The Green Box
[pic]
Senior Design 2 Final Document
Summer/Fall 2009 Group #5 Members:
Brett Burleigh
Alec Calhoun
Eric Eiermann
Patrick Neely
[pic]
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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