The Green Box - UCF Department of EECS



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Senior Design 2 Final Document

Summer/Fall 2009 Group #5 Members:

Brett Burleigh

Alec Calhoun

Eric Eiermann

Patrick Neely

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Table of Contents

Table of Contents ii

Table of Contents ii

Table of Contents ii

Table of Contents ii

1 Executive Summary 1

2 Definition 2

Motivation 2

Goals and Objectives 3

Input 1: Solar Power 3

Input 2: Wind Power 3

Input 3: Human Power 4

Output 1: DC Power 4

Output 2: AC Power 4

Simultaneous Operation 4

Efficiency 5

Ease and Intuitiveness of Use 5

Low Noise 5

Portability 5

Modularity/Compatibility 6

Enclosure/Housing 6

User Display 6

3 Requirements 7

Green Power Inputs 7

AC/DC Outputs 7

Power Storage 8

User Display 8

Physical Requirements 9

4 Research 10

Hardware 10

Generators 10

Batteries 12

Charging Systems 17

Solar-Cell Arrays 23

Wind Power Mechanism 29

Human Power Mechanism 33

Green Box Housing 38

Message Display 40

Power Inverters 43

Exhaust Fan 48

Microcontrollers 48

Power Factor Correction 53

Full Wave Rectifiers 62

Voltage Regulation 66

Software 73

Microcontroller 73

5 Design 74

Batteries 74

Charging Systems 78

Solar-Cell Arrays 85

Human Power Mechanism and Generator 90

Wind Power Mechanism 99

Message Display 102

Power Inverters 102

Green Box Housing and Power Outlets 104

6 Design Summary 106

7 Testing 118

Introduction to Testing 118

Power Generation Testing 118

Human Power Mechanism 118

Wind Power Generator 119

Solar-Cell Array 121

Total System 123

Power Storage Testing 123

Power Output Testing 124

Device Protection Testing 126

Software and Message Display Testing 126

8 Administrative 128

Milestones 128

Budget & Ultimate Ownership 129

Conclusion and Project Summary 130

9 Appendices I

Bibliography I

Image Permissions VIII

List of Figures

Figure 4.1.2A Advantages and Disadvantages of an Absorbed Glass Mat, Deep Cycle Lead-Acid Battery 15

Figure 4.1.2B AGM Battery Life Cycles vs. Depth of Discharge 16

Figure 4.1.3A Absorbed Glass Mat VRLA 20

Figure 4.1.3B Charge Controller Maximum Power Point Calculation 23

Figure 4.1.4A Photovoltaic Energy Production 26

Figure 4.1.4B I-V Curve 28

Figure 4.1.4C Solar Radiation in the United States 29

Figure 4.1.5A Example of a Small Horizontal-Axis Wind Turbine 30

Figure 4.1.5B Example of a Small Vertical-Axis Wind Turbine 31

Figure 4.1.5C Wind Resources in the United States 33

Figure 4.1.6A Typical Roller System Configuration 34

Figure 4.1.6B Typical Pulley System Configuration 36

Figure 4.1.6C Stamina InStride Cycle XL 37

Figure 4.1.6D Weslo Pursuit 4.0 Exercise Bike 38

Figure 4.1.6E Isokinetics Deluxe Pedal Exerciser 38

Figure 4.1.7A Polycarbonate Casing Possibility 39

Figure 4.1.8A Typical Alphanumeric LCD Display 41

Figure 4.1.8B Typical Graphic LCD Display 42

Figure 4.1.8C Assortment of LED Light Bar Indicators 43

Figure 4.1.9A XPower Inverter 300 45

Figure 4.1.9B PROWatt SW 600 45

Figure 4.1.9C DC/AC Inverter Schematic 46

Figure 4.1.9D Switching Circuit for DC/AC Inverter 47

Figure 4.1.11A Possible Microcontroller Configuration 52

Figure 4.1.12A Graph of In Phase Load 54

Figure 4.1.12B Passive Power Factor Control 55

Figure 4.1.12C Active Power Factor Control 56

Figure 4.1.12D T. I. UC2854A PFC Controller IC 57

Figure 4.1.12E UC28019A Block Diagram 59

Figure 4.1.12F TI UC28070 60

Figure 4.1.12G Block Diagram for an FAN4800I 61

Figure 4.1.13A Bridge Rectifier with Reservoir Capacitor 65

Figure 4.1.13B Unfiltered Output of Bridge Rectifier 65

Figure 4.1.13C Filtered Output of Bridge Rectifier 65

Figure 4.1.14A Linear Regulator 68

Figure 4.1.14B Linear Regulator with Emitter Follower 68

Figure 4.1.14C Step-down (Buck) Converter Schematic 70

Figure 4.1.14D Step-up (Boost) Converter Schematic 71

Figure 4.1.14E Buck-Boost Converter Schematic 71

Figure 5.1A Maximum Daily Energy Production 74

Figure 5.1B Realistic/Average Daily Energy Production 75

Figure 5.1C AGM Battery Specifications 77

Figure 5.1D Typical Warning Label 78

Figure 5.2A Maximum Daily Energy Production 79

Figure 5.2C Xantrex C-35 3-Stage Charge Controller Specifications 80

Figure 5.2D Voltage Regulator Circuit 84

Figure 5.2E Xantrax 3-Stage Charge Controller-(C35) 85

Figure 5.3A Monocrystalline and Polycrystalline Solar Panel Details(Averages) 87

Figure 5.3B One-Axis Solar Tracker 89

Figure 5.4A Leeson DC Electric Motor Model CM31D17NZ26D 92

Figure 5.4B Leeson DC Electric Motor Model C4D17NK9D 92

Figure 5.4C Stationary Bike Pedaling Speed Trial 94

Figure 5.4D MagneTrainer ER 96

Figure 5.5A Talco Electronics “Air Breeze Land” 200W Turbine 100

Figure 5.5B Wind Speed vs. Power Output Chart for Sunforce Products Model 44444 400W Wind Turbine System 101

Figure 5.7A Possible DC/AC Inverter for use in The Green Box 103

Figure 5.8A Pelican 1610 Large Case 105

Figure 5.1A Maximum Daily Power Production 106

Figure 6C Advantages and Disadvantages of an Absorbed Glass Mat, Deep Cycle Lead-Acid Battery 107

Figure 6D Absorbed Glass Mat VRLA 108

Figure 6E AGM Battery Life Cycles vs. Depth of Discharge 108

Figure 6F AGM Battery Specifications 109

Figure 6G Xantrax 3-Stage Charge Controller – (C35) 109

Figure 6H Monocrystalline and Polycrystalline Solar Panel Details 110

Figure 6I Solar Radiation in the United States 111

Figure 6J One-Axis Solar Tracker 112

Figure 6K Example of a Small Horizontal-Axis Wind Turbine 112

Figure 6M Wind Speed vs. Power Output Chart for Sunforce Products Model 44444 400W Wind Turbine System 113

Figure 6N Wind Resources in the United States 114

Figure 6P The Green Box's Human Power Assembly 115

Figure 6Q Voltage Regulator Circuit & Oscilloscope Output 116

Figure 6R Possible DC/AC Inverter for use in The Green Box 116

Figure 6S Typical Alphanumeric LCD Display 117

Figure 6T The Green Box (Complete System) 117

Figure 7.3A Charge Test Chart 124

Figure 7.4A Output Testing at Battery Terminal Voltage of 12.5 V (>80% charge) 125

Figure 7.4B Output Testing at Battery Terminal Voltage of 11.7 V ( actually building a three input generator with solar, wind and human power

> supplies. We've decided to use a small stationary bike for the human

> power portion and I was hoping to receive permission for use of the

> referenced images as examples of different ways to drive the generator.

>

> Thank you again,

>

> Eric Eiermann

>

>

>

> --- On Fri, 7/31/09, brad@

> wrote:

>

>

> From: brad@

> Subject: Re: Use of images

> To: "Eric Eiermann"

> Date: Friday, July 31, 2009, 10:17 AM

>

>

> What kind of engineering student are you? EE? ME?

>

> What is the title of the project? Did you build a bike generator?

>

> Brad

>

>

>> Brad,

>>

>> I am an engineering student at the University of Central Florida and am

>> working on my senior design project. I would like to request permission

>> to use two images from your website in my report. I will, of course,

>> site

>> your company and website as the owner of the images and list the images

>> as

>> copyright protected. The images are the roller and belt

>> examples located

>> at the following link:

Re: Use of images - Yahoo! Mail Page 1 of 2

... 8/3/2009

>>

>>

20human%20put%20out

>>

>> Thank you in advance,

>>

>> Eric Eiermann

Generators:

FW: FW: - Ask Leeson Friday, July 31, 2009 4:12 PM

"Nikki Hernandez"

ericeiermann@

Eric,

Thanks for checking with us. You may use the information for your report.

Regards,

Nikki Hernandez

From: Cindy.Perez-Rondeau@ [mailto:Cindy.Perez-Rondeau@]

Sent: Thursday, July 30, 2009 4:31 PM

To: Nikki Hernandez

Subject: Re: FW: - Ask Leeson

Hello Nikki,

Thanks for forwarding that on to me. It is not a problem for him to use the logo or the photos, etc., in his report.

It's when people don't ask permission that we usually end up with issues.

From: leeson.noreply@ [mailto:leeson.noreply@]

Sent: Wednesday, July 29, 2009 7:11 PM

To: nikki@

Subject: - Ask Leeson

Below is the result of Ask Leeson. It was submitted by

Eric Eiermann(ericeiermann@) on 07/29/2009 18:11:16

Message

To whom it may concern, I am an engineering student at the University of Central Florida and am working on my senior design project. I would like

to request permission to use an image of a product from your website in my report. I will, of course, site your company and website as the owner of

the images and list the images as copyright protected. The image is of the SUB-FHP Low Voltage Motors and the page

Power Inverter:

use of images Saturday, July 25, 2009 6:44 PM

"Eric Eiermann"

customerservice@

To whom it may concern,

I am an engineering student at the University of Central Florida and am working on my senior design project. I

would like to request permission to use images of two of your products from your website in my report. I will, of

course, site your company and website as the owner of the images and list the images as copyright protected.

The pages containing the images are as follows:





Thank you in advance,

Eric Eiermann

Exercise Bikes:

 Question about MagneTrainer Re: Use of image Friday, July 31, 2009 8:23 AM

"Eric Eiermann"

magneTrainer@

To whom it may concern,

I am an engineering student at the University of Central Florida and am working on my senior design project. I

would like to request permission to use an image of a product from your website in my report. I will, of course,

site your company and website as the owner of the images and list the images as copyright protected. The

product is the MagneTrainer ER and the page containing the images is as follows:



Thank you in advance,

Eric Eiermann

Use of image Tuesday, July 28, 2009 7:02 PM

"Eric Eiermann"

info@

To whom it may concern,

I am an engineering student at the University of Central Florida and am working on my senior design project. I

would like to request permission to use an image of a product from your website in my report. I will, of course,

site your company and website as the owner of the images and list the images as copyright protected. The

product is the Isokinetics Deluxe Pedal Exerciser and the page containing the images is as follows:



Thank you in advance,

Eric Eiermann

Housing Section

------------------------------------------------------------------------------------------------------------

To: Pelican Cases Services

From: BurleighB1@

Date: August 4, 2009 2:35PM EST

RE: Use of Pelican 1610 Case Photo

To whom it may concern:

My name is Brett Burleigh and I am representing a group of students from the University of Central Florida currently taking Senior Design. We are currently exploring the use of a picture of your Pelican 1610 case. The referenced picture is attached. This project is for educational use only and no commercial interests will be pursued.

If permission for use is granted, please email me back at burleighb1@. If you have any questions, I am available all day at (904)-219-4795.

Thank you for your time. I hope to hear from you soon.

Very respectfully,

Brett H. Burleigh

University of Central Florida College of Electrical Engineering

Group 5 - The Green Box

Email: burleighb1@

Mobile: (904)-219-4795

-----------------------

|Advantages |Disadvantages |

|Less Hazards from Battery Acid |Expensive |

|Long Cycle Life |Sophisticated Charger Required |

|Fast Recharge Rate |Extremely Heavy |

|Low Internal Resistance |Thermal Runaway |

|Efficient Power Storage (99%) |Inferior Cold Cranking Amps |

|Slow Self-Discharge Rate | |

|Spillproof/Leakproof | |

|Maintenance Free | |

|Install in any Orientation | |

|Approved for Air/Ground Transport | |

|Efficient in High Temperatures | |

|Durable | |

|Vibration Resistant | |

|Popular is Solar and Wind Systems | |

|Advantages |Disadvantages |

|Less Hazards from Battery Acid |Expensive |

|Long Cycle Life |Sophisticated Charger Required |

|Fast Recharge Rate |Extremely Heavy |

|Low Internal Resistance |Thermal Runaway |

|Efficient Power Storage (99%) |Inferior Cold Cranking Amps |

|Slow Self-Discharge Rate | |

|Spillproof/Leakproof | |

|Maintenance Free | |

|Install in any Orientation | |

|Approved for Air/Ground Transport | |

|Efficient in High Temperatures | |

|Durable | |

|Vibration Resistant | |

|Popular is Solar and Wind Systems | |

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