EE Senior Design I
EE Senior Design I ECE 480
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This 46 page Class Notes was uploaded by Fredy Okuneva on Thursday October 22, 2015. The Class Notes belongs to ECE 480 at University of Idaho taught by Brian Johnson in Fall. Since its upload, it has received 25 views. For similar materials see /class/227722/ece-480-university-of-idaho in ELECTRICAL AND COMPUTER ENGINEERING at University of Idaho.
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Date Created: 10/22/15
Improved Control Algorithm for Infrared Paper Dryers ECE 480 Senior Design Review Tuesday April 5 2005 Michael Frost Matthew Harvey Kellin LangGillming Instructor Brian Johnson Technical Advisor Joe Law Sponsor Compact Engineering Ltd Presentation Outline Background In ated IR Drying Firing Comouer Design Demmtm on ofCormpt DOC Schware Skmnctbn IR Dryer Model Mn Vui ca on Schedule Budget NSIZOOS Background Infrared Dryers Increasingly vital Two primary reasons for this increase provide more controllable and precise drying may be inserted into existing paper machines increasing production speed Two types Electric Natural Gas 452005 Background Compact Engineering Ltd Based in Thinsk England Designs and Manufactures Electrical IR dryers Provide their own cordrol systems Mandacture thei own lamps Po atch Mill in Lewiston Idaho has installed Compact dryers 452005 Background Potlatch Installation Power Quality Problems Total Harmonic Distortion THD Crest Factor CF 0 Machine Shutdowns current spikes exceed rated currents of supply transformers roughly once every 46 weeks last 24 hours approximately 20000hr in lost production 452005 Presentation Outline 811de c Maud IR Balm Fm ComoIIer Design Demmtm on Concept DOC Schware Simuhtbn IR Dryer Model Design chca on Schedule Budget NSIZOOS Infrared Drying Paper Drying Overview Calendar Stack Fluw Spreada DryEr semun 1 HEFEUX Press Semun imw lee W igmmm L Figure 1 Paper Drying System 452005 Infrared Drying Electric Infrared Dryers Composed of heating elements tungsten laments generate 520 kWm2 healing energy per element Physical Orientation 700 parallel elements leld in dlrectlon of paper flow grouped in zones of 10 elements 452005 Infrared Drying Moisture Pro ling Paper moisture level measured perpendicular to direction of paper ow Power level in each dryer zone based on moiS the pro le Figure 2 Moisture Pro le 4 52005 Infrared Drying Control System Power computer ang Conmle r gt Heating um angsrgna smv thsnms Figure 3 Infrared Drying System Overview Marstuve p we 452005 Infrared Drying Control System Dignat ampms a annedian 7 Rsoas Dignat ampms a may 2cm inpmsra Digitat 4 mm as Firing Cnnlrnller Gm drivers Dignat input Dignat rnpmsra Figure 4 Firing Controller Interface 452005 Infrared Drying Control Algorithm Bit Fire Zone power levels are achieved by controlling the number of half cycles SCR generated of conduction per set timing period Each zone power level is determined based on the moisture pro le All zones operate with the same conduction pattern given the same power level 452005 IR Drying Present Control Algorithm Present Firmg Scheme I 2 2 l 1 3333 I 18333 3139H3333U339 U Figure 5 Odd Number of Cycles 452005 IR Drying Present Control Algorithm mmquot Mama arm I 3 2 r 1mm 1 33 Emu m Am a Figure 6 Even Number of Cycles 452005 IR Drying Present Control Algorithm 39 As shown by gures these types of waveforms cause large instantaneous current spikes These current levels exceed the ratings of the supply transformers feeding the dryer units Transformer relays shut off Disconnects dryers and other machines fed by transformers SHUTS DOWN PAPER PRODUCTION 452005 Presentation Outline Background Infrared IR Drying Flrhg Controller Dulyn Demmtm on of Cement DOC Somme Sknulatlon IR Dryer Model Design Vul ca on Schedule Budget NSIZOOS Design Objectives New control algomhm and related hardware 9 rephce present ring oomro ev Cannot Filing Card 4152005 Design Objectives Reduce THD and CF to acceptable levels Meet IEEE 519 and lEC 100032 EN standards Maintain present drying performance Ability to independently control 96 zones Compatibility with present systems Physical connectivity Electrical data compatibility Documentation of design 452005 Design Proposed Control Algorithm 1 1 Prop as e d Firing Scheme i 7 05 i L i I 3333 439 1 r B H 3333 I El Figure 7 Distribution of Cycles 452005 641 Design Proposed Control Algorithm Example of Proposed Control Algorithm Znne r4 ml rer cycle Example of Present Control Algorithm Znne 1sz per cycle In 452005 Design Proposed Control Algorithm Matrix calculated based only on CHANGES in recommended power levels nmnou 1 nmnou a Znne Znne mm w cycle mm per ml nmnou 2 Iteration 3 No change in recommended power levels for zones 3 and 4 Znne mm w WEI Design Controller Speci cations In Figure 4 the interface of the controller was shown The controller must be industrial grade Several IIO pins to monitor the state of the system Possibly need AID to measure supply Possibly external memory to store control matrix Serial to Parallel device to control zones to minimize needed output pins 452005 Design Methods Characterization of Lamps Dermnstration of Comp Software Simulation Big Modal Prototyping Veri cation 452005 Design Lamp Characterization Dryer Heating Elements Lamps Tungsten Resistance varies greatly over temperature range Contributes to current spikes during lamp startup Present control algorithm only considers lamp survivability Implements phase back control but only to extent that lamp is protected Doesn t consider current spikes due to lamp inrush 452005 Design Lamp Characterization Experimentally obtain relationship between lamp temperature and resistance Create software models to predict the temperature and resistance of lamps for a given applied voltage Dr Law has already done this for the 5kW Compact Lamps We will repeat this procedure for standard 100 W light bulbs Allow testin to be done using the 70bulb scaled mode 452005 Presentation Outline Backgromd Inflated IR Drying NSIZOOS Demonstration of Concept DOC Purpose Demonstrate ability to control lamp zones in simpli ed single phase 120 VAC case Work out obstacles before tackling the full size model 452005 DOC Circuit Schematic E commAc cumAc v W Bu 3 Am RanPm NM was M2 mamurva ax mcmrm mnwump m mnvl umv DOC Controller Use PC16F747 ZOMHz clock 7168 bytes field programmable ash 36 HO pins 1410bitAD Represents Firing Controller VWI control only 3 lamps MII use only halfcycle control 452005 DOC Power Level Input v Slide PotentiometerPQ1OGOSBND 0 10k Simulate recommended power levels output by the Power Computer Analog voltage acmss resistors convened to digital word by PIC AID 450005 DOC Phase Monitoring Unit For actual Compact design this provides zero orossing detection Hope to get from Compact If Compact doesn t provide us with one Build circuit Change scope of project 452005 DOC AC Switching Solid State Relay Crydom CXZ4OD5R Characteristics of antiparallel SCR39s Random turnon zero crossing tum off 12280 VAC 0065 Arms output 250 Apk for 1 cycle surge current handling 01 msec turn onloff time 452005 DOC Lamps 100W incandescent bulbs Tungsten filament Using these lamps because Compact s are cost prohibitive 452005 DOC Miscellaneous parts Wall TransformerT312P1 3PND 120 VAC to 5 VDC P13 connector for wall transforrnerCP016 ND Resistors 10k carbon lm 14WP10KBACT ND 4 X 2 X 112 Plywood 120V AC cleat receptacle 14 gauge 3 wire Romex 452005 Presentation Outline Biekumund In ated IR Drying Firing Cormaeroulgn Demmm Cement DOC 80me Simul lon IR Dryu Mada Dulgn ValMn Schedulelaudget 45000 Software Simulation Use Matlab code developed by Dr Joe Law to simulate various algorithms Chose algorithm that minimizes CF and THD to implement in hardware 452005 IR Dryer Model 7O Bulbs to represent 70 zones Digital Controller to control ring of lamps Single switch to simulate error occurrences Single switch to Breaker Status 452005 Veri cation Test procedures Use Harmonic analyzer to verify THD and CF Use oscilloscope to verify timing and output nput signal levels are compatible Simulate system errors Use oscilloscope to compare power output of present and new 452005 Presentation Outline Backgromd In ated IR Drying Fm Comouer Mn Demmtm on Concept DOC Schware Simuhtbn IR Dryer Model Design Ved ca on Schedule Ended NSIZOOS Schedule M m mu M1 WNW H mm Man mm Man m Man wins w Newquot u 452005 Budget Projected A Personnel Name Cost Subtotal Matthew R Harvey 350 hrs 25111 8 8750 Kellin M LangGillming 350 hrs 25M 3 8750 Michael R Fmst 350 hrs 25hr 8750 Total 26250 452005 Budget Projected B Eguipment Sugglies 452005 Item Lamps and xtures for Model Army Manning Hardware and Structure for Model Array Controller and Associated Development Tools Thyristors Heat Sinks Gate Drivers etc Printed Circuit Boards Presentations and Documenta om Cost 1000 5 300 1000 5 3000 S 300 am 5 5700 Budget To Date gm nagKey 53044 Moocow Building Sum m To 6636 50005 Presentation Outline Background In ated IR Drying Firing Comouer Design Demmtm on ofCormpt DOC Schware Skmnctbn IR Dryer Model Mn Vui ca on Schedule Budget NSIZOOS Current Progress Building small scaled model Characterization of lamps Developing ring algorithm 452005 Acknowledgements Joe Law 39 Jerry Spencer 452005
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