Project Report for TI Analog Design Contest 2009

Microprocessor controlled Electronic Load Control for Micro Hydro Power Plants

Submitted by: Ankit Agarwal Anubhav Gupta Shailesh K. Dubey IIT DELHI

Abstract
This report discusses the design of a microcontroller based Electronic Load Controller for standalone applications in Pico/Micro-hydro power generating stations. The design includes a multimeter based voltage sensor that senses the voltage across the load, a microcontroller MSP430 which generates a pulse width modulated wave as per the error in voltage at any instant and a rectifier circuit that is connected to across a dump load and is switched by the PWM wave generated by the microcontroller. The main goal of the project was to design a cheap control system which would facilitate the installation of the large number of proposed Pico-Hydro Power Stations across India which has not been possible until now due to the lack of a cheap and robust control system.

Contents
Abstract ......................................................................................................................................................... 2 Contents ........................................................................................................................................................ 3 List of Figures ................................................................................................................................................ 4 Acknowledgements....................................................................................................................................... 5 Original Proposal ........................................................................................................................................... 6 Introduction to the problem ......................................................................................................................... 7 Theoretical Background ................................................................................................................................ 9 Introduction .............................................................................................................................................. 9 Remarks .................................................................................................................................................. 11 Literature survey ......................................................................................................................................... 12 Hardware Design Overview ........................................................................................................................ 14 ICL7106 based Multimeter unit for Voltage Sensing .............................................................................. 14 Analog Multiplexers MPC508 ................................................................................................................. 15 Operational Amplifier - LM224 ............................................................................................................... 17 MSP430F1611 ......................................................................................................................................... 18 IGBT Gate Driver TLP250 ...................................................................................................................... 19 IGBT - GT60M303 .................................................................................................................................... 19 Software Design Overview .......................................................................................................................... 20 Microcontroller code .................................................................................................................................. 21 Simulation ................................................................................................................................................... 25 Case 1: Load is either On or Off. No intermediate Value........................................................................ 27 Case 2: The Load Value doubles after sometime.................................................................................... 28 Observations ............................................................................................................................................... 30 Implementation .......................................................................................................................................... 31 Voltage Sensing: An Innovative approach .............................................................................................. 31 Use of Analog Multiplexers ..................................................................................................................... 31 Reference changing in ICs ...................................................................................................................... 31 Components Used ................................................................................................................................... 32 PCB Designing ............................................................................................................................................. 33 Chassis Design ............................................................................................................................................. 37 3

Future Work ................................................................................................................................................ 39 Bill of Material............................................................................................................................................. 40 References .................................................................................................................................................. 41

List of Figures
Fig 1. A Rough Sketch of the System ............................................................................................................. 8 Fig 2. System Description ............................................................................................................................ 10 Fig 3. In-Phase signal from multimeter ....................................................................................................... 14 Fig 4. Out-of-Phase signal from multimeter ............................................................................................... 15 Fig 5. Multimeter Chip used as Voltage Sensor .......................................................................................... 15 Fig 6. Analog Multiplexer circuit ................................................................................................................. 16 Fig 7. XOR gate circuit ................................................................................................................................. 16 Fig 8. Difference Amplifier .......................................................................................................................... 17 Fig 9. Non-inverting Amplifier ..................................................................................................................... 18 Fig 10. MSP430 Development board with JTAG programmer .................................................................... 18 Fig 11. Opto-coupler Circuit ........................................................................................................................ 19 Fig 12. Snubber Circuitt ............................................................................................................................... 19 Fig 13. Simulink Circuit Diagram ................................................................................................................. 25 Fig 14. PI controller and PWM generation.................................................................................................. 26 Fig 15. Case 1:Terminal Voltage Across SEIG .............................................................................................. 27 Fig 16. Case 1: Dump Load voltage ............................................................................................................. 27 Fig 17. Case 1:Dump Load Current.............................................................................................................. 27 Fig 18. Case 1:Dump Load Power................................................................................................................ 28 Fig 19. Case 2:Terminal Voltage Across SEIG .............................................................................................. 28 Fig 20. Case 2: Dump Load voltage ............................................................................................................. 28 Fig 21. Case 2: Dump Load Current ............................................................................................................. 29 Fig 22. Case 2: Dump Load Power ............................................................................................................... 29 Fig 23. Case 2: Load Power ......................................................................................................................... 29 Fig 24. Case 2: Total Power ......................................................................................................................... 29 Fig 25. Schematic for PCB........................................................................................................................... 34 Fig 26. PCB Frontside .................................................................................................................................. 35 Fig 27. PCB Backside.................................................................................................................................... 36 Fig 28. Solidwork model .............................................................................................................................. 38 Fig 29. Photographs of Product .................................................................................................................. 42

Acknowledgements

We would like to express our sincere gratitude to Prof. S.S.Murthy, Prof. G.Bhuvneshwari and Research Scholar Sarsing Gao for their overwhelming, continuous and unfailing support, guidance and help, which have been invaluable during the course of this project. Their knowledge, insight and constant motivation at each step of the project has been instrumental in its completion.

Ankit Agarwal Anubhav Gupta Shailesh K. Dubey

Original Proposal
Name of the University: IIT-Delhi, New Delhi, India Department: Deptt. Of Electrical Engineering Details of the Students Name Ankit Agarwal Anubhav Gupta Shailesh Kr. Dubey Details of the Faculty Advisor Name Dr. S.S.Murthy Email ssmurthy@ee.iitd.ac.in Contact Number
+91-011-26591063

Email ankitag9@gmail.com anubhavgupta.iitd@gmail.com shailesh.k.d@gmail.com

Mobile Number +91-9911490709 +91-9911727943 +91-9999248650

Title Of the Project: Microprocessor controlled Electronic Load Control for Micro Hydro Power Plants. Brief Summary: This project involves the controlling of redirection of surplus power to a dumper load for micro-hydro power plants. The task involves the switching of dumper circuit according to power consumed by main load. We will use voltage and current sensors, amplifiers, IGBT switch, comparator, clocks and timers. All these will be controlled through microprocessor for which we will use TI MSP430.

Introduction to the problem

Traditionally, synchronous generators were used for power generation, but the use of induction generators is picking up fast these days. The increasing rate of the depletion of conventional energy sources has given rise to an increased emphasis on renewable energy sources such as wind, pico/mini/micro-hydro, etc. because of their relative advantageous features. In renewable energy applications of low and medium power (up to 100 kW), the induction generator offers considerable advantages which include manufacturing, maintenance and operational simplicity, brushless and rugged construction, lower unit cost, good dynamic response, self-protection against faults, ability to generate power at varying speed and trouble free operation for many years. Owing to the self-excited induction generator (SEIG) does not need an external power supply and its related equipment, such as field breaker, rheostat, and automatic voltage regulator to produce the excitation magnetic field it is a good candidate for wind, biogas, and hydro powered electricity generation especially in remote and isolated areas. These advantages facilitate induction generator operation in stand-alone/isolated mode for supplying local load and in grid mode. In remote locations or hilly areas, electrical energy can be obtained from local resources at less cost compared to grid connection. Such areas are characterized by sparsely distributed population with electric loads of single phase. The single-phase power supply is preferred over the three-phase in order to render the distribution system simple and cost effective. The SEIG has a major drawback of poor voltage regulation. The generated voltage depends upon the speed, capacitance, load current, and power factor of the load. Input power remains constant with unregulated micro-hydro turbine, but output power is not constant due to changing the load requirement of consumer load. In order to keep SEIG output power constant, a dump load is connected in parallel with the consumer load such that the total generated power is held constant. The amount of power to be supplied to the dump load is decided by the Electronic Load Controller (ELC).

Fig 1. A Rough Sketch of the System

Theoretical Background
Introduction
Single-phase induction motors can be used as single phase Self Excited Induction Generators for single-phase power generation. But this involves problems in determining the size and arrangement of capacitors required to achieve excitation without overloading the windings. In addition, single-phase induction motors are only available for relatively small power outputs. However, three-phase induction machines have relatively higher efficiency and lower cost than an equivalent-sized single-phase machine. It is possible and feasible to use a three-phase induction motor as a single-phase generator with only 10 to 20% power de-rating. It thus is the preferred approach for providing a singlephase supply. A three-phase squirrel-cage induction motor is connected in delta connection and excitation capacitors are connected in what is called a C-2C configuration. For a purely resistive load, if the current of the C-valued capacitor is equal to root three times of current in a resistive load, then a C-2C-connected generator behaves as a balanced three-phase machine. Excitation capacitance has to provide required voltage on load at the operating speed for the given induction machine operating as a SEIG. The amount of capacitor excitation at no load and rated load may be determined iteratively. The equivalent circuit parameters may be obtained from an open-circuit and blocked-rotor test. Performance of the SEIG depends on its magnetizing characteristics. The magnetizing characteristics of these machines are obtained from the synchronous-speed test. The SEIG has a major drawback of poor voltage regulation. The generated voltage depends upon the speed, capacitance, load current, and power factor of the load. Input power remains constant with unregulated micro-hydro turbine, but output power is not constant due to changing the load requirement of consumer load. In order to keep SEIG output power constant, a dump load is connected in parallel with the consumer load such that the total generated power is held constant. Thus the SEIG feeds two loads in parallel, such that the total power is constant; that is, Pout = Pc + Pd; where Pout is the generated power of the generator (which must be kept constant), Pc is the consumer load power, and Pd is the dump-load power. This dump-load power (Pd) may be used for non-priority loads such as heating, battery charging, cooking, etc. The amount of dump-load power is controlled by the IGBT chopper. The duty
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cycle of the gate pulse of the IGBT gives the average conduction period of the chopper and, hence, the amount of power in the dump loads. A variable mark-space ratio chopping approach has been adopted for the IGBT chopper because it produces a variable unity power-factor load with just a single ballast or dump load. The output power of the SEIG is kept constant by the ELC.

Fig 2. System Description

The figure shows a schematic diagram of the SEIG-ELC system. It comprises of a three phase delta connected squirrel-cage induction machine driven by a constant power prime mover. The values of the excitation capacitances are determined so as to result in rated terminal voltage at rated load. The consumer load and the control unit are connected in parallel across the generator terminals of the induction machine.

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The Electronic Load Controller Unit primarily consists of : a multimeter based voltage sensor that senses the voltage across the load, and gives out a digital output on the LCD display, a series of analog multiplexers, opto-isolators and XOR gates to decode the the readings of the seven segment display of the LCD, a microcontroller MSP430 which interprets the readings corresponding to a sequence of the seven segment display, finds the error in the voltage and generates a pulse width modulated wave as per the error in voltage at any instant, and an IGBT based uncontrolled rectifier circuit which is connected to a series resistive dump load and is switched by the PWM wave generated by the microcontroller.

Remarks
The design involves multiple facets of electrical engineering like power electronics, control systems, and digital systems. The control algorithm (described in section 3) was modified rigorously to get the optimal control scheme for each case. The overall system presented an opportunity to explore various aspects of hardware design in the electrical engineering field and led to an increased array of knowledge and experience.

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Literature survey
New Load Controller for Single-phase Self Excited Induction Generator - D. K. Palwalia and S. P. Singh This article presents the digital design and implementation of a new digital signal processorbased load controller to regulate the voltage and frequency of a single-phase self-excited induction generator, suitable for stand-alone operation with an unregulated turbine and constant excitation. The prototype model of a single-phase self-excited induction generator is developed such that the load on the self-excited induction generator remains constant despite the changes in the consumer load. A sinusoidal pulse-width-modulated AC chopper control technique is implemented toregulate the random consumer load so as to maintain a constant load on the generator. The proposed load controller for this self-excited induction generator system can feed the stand-alone loads with an enhanced quality power supply. The transient behavior of the developed digital signal processor-based load controller with the self-excited induction generator system at different operating conditions, such as application and removal of static (resistive and reactive) and dynamic (single-phase induction motor) loads, is investigated to demonstrate the capabilities of the proposed controller. Digital Signal Processor-based Controller Design and implementation for Self Excited Induction Generator - D. K. Palwalia and S. P. Singh This article presents the design and implementation of a digital signal processor (DSP)-based induction generator controller (IGC) to regulate the voltage and frequency of a single-phase selfexcited induction generator (SEIG), which employs a three-phase squirrel-cage induction machine that is suitable for the stand-alone power mode and employing an unregulated turbine, such as micro-hydro power generation. A three-phase induction machine can be used to generate single-phase supply at constant voltage and frequency if the electrical load is constantly maintained at its terminals. A prototype model of a single-phase SEIG is developed, such that the load on the SEIG remains constant despite a change in the consumer load. The transient behavior of the developed DSP-based SEIGIGC system at different operating conditions, such as application and removal of static (resistive and reactive) and dynamic (single phase induction motor) load, is investigated to demonstrate the capabilities of the proposed IGC.

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An Electronic Voltage and Frequency Controller for Single-Phase SEIG for Pico Hydro Applications - Prof. S.S. Murthy and Prof. Bhim Singh This paper presents the design, implementation and control of an electronic load controller (ELC) to regulate and frequency of single-phase self-excited induction generator (SEIG) for constant power applications such as uncontrolled turbine in pico-hydro power generation. An electronic load controller is developed for maintaining constant voltage frequency of SEIG with variable consumer loads driven uncontrolled water turbine. The transient behavior of SEIG-ELC system at different operating conditions such as application and removal of resistive and reactive (0.8 PF) loads and starting of a single-phase induction motor as dynamic load is investigated to demonstrate the capability of proposed ELC. Extensive tests are conducted on the developed prototype of SEIG-ELC system.

A Single Phase Self-Excited Induction Generator with Voltage and Frequency Regulation for use in a Remote Area Power Supply L.Robinson and D.G.Holmes Micro-hydro generator schemes are an attractive choice for electricity generation in remote locations or underdeveloped communities where a grid supply is not available. Since such systems must be low cost, reliable, and robust to minimise maintenance requirements, the use of a standard squirrel cage induction motor is appealing either three phase or single phase depending on power ratings and availability. The principles of generation using induction motors are well established, and self generation is readily achieved by connecting excitation capacitors in parallel with the motor, to form a resonant LC circuit. However, control of the output voltage and frequency is not possible if fixed excitation capacitors are used. This paper presents a method of controlling a self-exciting single phase induction motor, where the shunt capacitance connected across the machine is varied to regulate the output voltage magnitude, while the output frequency is regulated by using a triac to vary the power fed to a resistive dump load. The paper reviews self excitation principles for a single phase induction motor, develops the voltage and frequency regulation concepts, presents the design of the microprocessor based regulation system, and then concludes with experimental results that verify the systems operation.

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Hardware Design Overview

The hardware design offered a number of challenges. For example the choice for the voltage sensing unit that would decrease the cost of the equipment considerably and at the same time work in tandem with the rest of the control unit without any problems was a tricky one. Similarly the synchronizing of the various chips in the voltage decoding unit was also a sensitive issue. The following is the description of the hardware components and the reasons they were preferred to their counterparts.

ICL7106 based Multimeter unit for Voltage Sensing

This is the USP of our project since it cuts down on the cost of manufacturing by a huge factor when compared to traditional Hall-Effect based sensors which measure instantaneous voltages. An ordinary multimeter readily gives the RMS value of the AC voltage. The multimeter uses a fairly simple resistive-capacitive circuit along with the chip ICL7106 or ICL7109 for all analog to digital conversions. This also saves us the pains of writing a separate code to calculate the RMS value from the instantaneous voltage sensors and thus increases the idle time of the microcontroller which can be utilized for other productive uses. The outputs from ICL7106 are uniform square wave trains with high value of 9 volts and low value of 4 volts, whose phase determines whether a particular segment of the seven segment display is on or off. These wave trains are compared for phase with the clock wave train of this multimeter.

Fig 3. In-Phase signal from multimeter

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Fig 4. Out-of-Phase signal from multimeter

Fig 5. Multimeter Chip used as Voltage Sensor

Analog Multiplexers MPC508

These are needed to obtain wave trains from the ICL7106 one by one. We use three 8X1 multiplexers since there are three 7-segments (unit, tens and hundredth place). All the three receive the same inputs from the microcontroller so that the corresponding segments of each place are isolated to be fed to the microcontroller. The Microcontroller sends signals to MUX and the corresponding signal goes to the XOR gate.

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Fig 6. Analog Multiplexer circuit

4-channel Logic XOR gate - SN74LS86

The wave trains from ICL7106 are XORed with the clock wave train to find the state of a particular segment on the display. Since we have at the most 3 waves at hand at any instant a single 4 channel XOR gate suffices. Since the Signal from the Multimeter and Multiplexer are both square waves oscillating between 4V and 9V, we have changed the ground voltage of XOR gate to 5V and Vcc to 10 V. The output we get is 5V or 10V depending whether the particular segment is displayed or not.

Fig 7. XOR gate circuit

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Operational Amplifier - LM224

Before the isolated wave train can be sent to the microcontroller, it needs to be deamplified to the voltage levels which can be fed to the microcontroller. This circuit is created using Operational amplifiers. We are using two LM224 ICs and in total 6 opamps. As there are three 7-segments and 3 Multiplexers so 3 are being used in difference amplifier configuration to subtract 5V from the output of XOR gate. Output of the difference amplifier is Vout=Rf/Rin*(V2-V1). In our case Vout=20/33*(V1-5) where V1 is either 5V or 10V.

Fig 8. Difference Amplifier

Second configuration we are using is that of non-inverting amplifier. The control signals for the MUX should be greater than 5V but the microcontroller provides 3.3V signal. So these signals had to be amplified before they can be fed to the control signals of MPC508. In non inverting case Vout=Vin(1+R2/R1) In our case Vout=3.3(1+20/33)=5.3V

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Fig 9. Non-inverting Amplifier

MSP430F1611
MSP430 is a low power consuming series of Microcontrollers. With up to 8MHz clock speed it provides sufficient processing power needed in this project. MSP430F1611 has 48KB Flash and 10 KB RAM which is required to store the PI controllers Kp and Ki Matrices.

Fig 10. MSP430 Development board with JTAG programmer

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IGBT Gate Driver TLP250

The PWM output from the microcontroller is not enough for driving the IGBT switch being used to switch the rectifier circuit feeding the dump load. We also need the microcontroller circuit to be completely isolated from the rectifier circuit where large currents and voltages are being dealt with. This is achieved by the use of the driver chip TLP250 which contains an inbuilt opto-coupler for electrical isolation.

Fig 11. Opto-coupler Circuit

IGBT - GT60M303
The IGBT should be such that it can withstand continuous operation of the dump load circuit, withstand the spikes if any despite the snubber circuit and have a suited switching frequency. IGBT GT60M303 fulfilled all the above conditions.

Fig 12. Snubber Circuitt

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Software Design Overview

The microcontroller is programmed using IARWorkbench. The crux of the software driving this ELC is a fuzzy-logic PI controller which is explained below. Traditionally in all the ELCs a standard value for Kp and Ki is used which gives the best control for most of the scenarios. But during testing it was found that such a scheme is not very robust. So in this ELC a special type of PI controller is implemented which uses different values of Kp and Ki based on the current operating conditions and the error signals. Since numerous such combinations are possible a fuzzy-logic scheme is implemented for the purpose which gives very good performance and at the same time keeps our memory requirements low. The fuzzylogic matrices have been developed through extensive testing and they are being continually improved. The results of this scheme are very promising over existing designs. The basic working of the software is as follows: On initiation, control signals are sent to multiplexers and corresponding state of each segment is read. A simple algorithm retrieves the voltage from these states. The fuzzy PI controller is turned on as soon as the voltage reaches RMS steady state voltage. The voltage reading is updated every one-third of a second and sent to the PI controller.\ The output of the controller is compared with a high frequency triangular wave (generated through algorithm) and PWM signal for the IGBT is generated. This signal is sent to the IGBT driver.

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Microcontroller code
#include <msp430x16x.h> //defining the variables to be used in program unsigned int i,zero,ten,hundred,ab4; float wave,piout1,piout2,kp,ki,error1,error2,sampletime; int value(int k) //defining the values for various inputs { switch(k){ case 0x0066: return 0; case 0x0020: return 1; case 0x0065: return 2; case 0x0061: return 3; case 0x0023: return 4; case 0x0043: return 5; case 0x0047: return 6; case 0x0060: return 7; case 0x0067: return 8; case 0x0063: return 9; default: return 10; } }

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void delay_ms(int n){ //a delay function for(int a=0;a<n;a++) for(int m=0;m<2000;m++){ } } int calculatevoltage() { for (int j=0;j<7;j++) { if(j!=2&&j!=3) { P2OUT=j<<3; delay_ms(20); if(P2IN&BIT0) zero|=1<<(6-j); if(P2IN&BIT1) ten|=1<<(6-j); if(P2IN&BIT2) hundred|=1<<(6-j); } } zero=value(zero); ten=value(ten); hundred=value(hundred); return (hundred*100+ten*10+zero); }
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void main(void) { piout1=0; error1=0; kp=0.8; ki=8.5; sampletime=0.333; WDTCTL = WDTPW+WDTHOLD; P1DIR=0x01; P1OUT=0x00; P2DIR=0x38; P2OUT=0x00; CCTL0 = OUTMOD_4; CCR0 = 127; TACTL = TASSEL_1 + MC_1; i=0; piout2=1.2; while(1!=0){ if(i%10000==0) { zero=0x00; ten=0x00; hundred=0x00; error2=calculatevoltage(); error2=error2-230;//230 is the reference volatge
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// Stop watchdog timer

// CCR0 toggle mode

// ACLK, upmode

wave=TAR*(.078125)-5; piout2=kp*(error2-error1)+ki*sampletime*error1; if(piout2>=wave) P1OUT|=0x01; else P1OUT|=0x00; error1=error2; piout1=piout2; i++; } else { wave=TAR*(.078125)-5; if(piout2>=wave) P1OUT=0x01; else P1OUT=0x00; i++; } } }

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Simulation
We are using a 7.5kW star connected SEIG for this simulation. Here we are connecting a resistive load of 3kW. We are using a saw wave to produce the required PWM wave. First we let the voltage build up to its rated value and then at time t=1.9s we switch on the rectifier circuit. PI controller is also switched on at this instant. The main load is switched on at time t=2.8s and then switched off at t=3.4s.

Fig 13. Simulink Circuit Diagram

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Fig 14. PI controller and PWM generation

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Case 1: Load is either On or Off. No intermediate Value

Fig 15. Case 1:Terminal Voltage Across SEIG

Fig 16. Case 1: Dump Load voltage

Fig 17. Case 1:Dump Load Current

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Fig 18. Case 1:Dump Load Power

Case 2: The Load Value doubles after sometime.

Fig 19. Case 2:Terminal Voltage Across SEIG

Fig 20. Case 2: Dump Load voltage

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Fig 21. Case 2: Dump Load Current

Fig 22. Case 2: Dump Load Power

Fig 23. Case 2: Load Power

Fig 24. Case 2: Total Power

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Observations
As seen from above curves the on/off operation of the main load is pretty smooth and the user voltage profile is within permissible limits. The temporary rise in terminal voltage when the main load is switched off is around 20V which comes back to rated voltage within milliseconds. Also the power consumed in dump load varies very nicely with the consumption in the main load. The total power derived from the generator is almost constant with variations within acceptable limits. In second case it is visible that at half load the half of the power is consumed in dump load thus maintaining the voltage regulation.

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Implementation
Implementation Details Voltage Sensing: An Innovative approach
Traditionally in such applications hall-effect voltage sensors (for e.g. Lem LV100-250) have been used. Though such sensors provide excellent accuracy and dynamic response but they cost around $75 which is considerably high when we need to develop an ELC for a pico/micro-hydro power plant for which the induction generator itself costs around $200. Clearly the cost of the traditional sensors in this case is unacceptable. Also, since such sensors measure instantaneous voltage therefore we need to compute RMS in a processor in order to run the PI Controller. This increases the cost of the processor used. Therefore, we thought of a completely new approach to sense voltage. We are using an off the shelf multimeter based on ICL7106/7109 which costs around only $2.5. Additionally we dont need to do RMS calculation externally as these ICs already measure that. Therefore our processing requirements are considerably less and an MSP430, which is much cheaper than the traditionally used DSPs in such applications, is more than sufficient for us. The only problem with these ICs is that of isolation but we have optocouplers to take care of that.

Use of Analog Multiplexers

ICL7106 gives output in a form so as to drive an LCD. Therefore, we had to decode the voltage reading from ICL7106 by decoding the 7-segment that it generates. In order to keep the number of inputs to microcontroller minimum we used a 8:1 analog demultiplexer (details at the end of section) for each digit in the voltage reading. The microcontroller sends the control signal (a 3 digit BCD) to each of the demultiplexers in order to get the required segment output from each. Therefore number of connections to/from microcontroller was reduced from 21 to 6 (for sensing purpose).

Reference changing in ICs

We are using many ICs in our project (the exact details are at the end of this section). Naturally different ICs have different operation voltages and we were facing a challenge to minimize the no. of different supply voltages. Now a particular case was when we were demultiplexing output from ICL7106. Before this output could be sent to microcontroller it had to be XORed with an output from ICL7106 itself but in order for
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that XOR to be successful the 7486 which operates at 5V had to be operated at 10V. Therefore, the ground of 7486 was brought at 5V with respect to system ground and then 10V was given at Vcc. This 5V was obtained easily from 10V by using a 7805 voltage regulator. The sensed input voltage is fed to ADC input of MSP430. The sensed voltage is compared with a reference voltage signal which is hardcoded in the microcontroller and is taken as proportional to the rated terminal voltage of the SEIG and may be altered as and when required. The error output decides the increase or decrease of the pulse width. The error is compared with a very high frequency triangular wave and the corresponding output is fed to the PI Controller section of the code in microcontroller. The PI controller is turned on only after an initial voltage of around 230V has been achieved after the start so that the initial errors when the voltage is rising do not interfere with the integral part of the controller. The output of the PI controller section is the required PWM signal for switching the IGBT to regulate the dump load. The PWM output is then given to the IGBT chopper through an opto-isolation and pulse driver circuit.

Components Used
TI components: 1. 2. 3. 4. MSP430F1611 Microcontroller MPC508 Analog Multiplexer LM224A - Operational Amplifier SN74LS86 4-channel Logic XOR gate

Other Components: 1. 2. 3. 4. 6N136 Optocoupler ICL7106 based off the shelf voltage sensor 7805, 7810, 7815, 7824, 7833 Voltage Regulators Toshiba GT60M303 - IGBT

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PCB Designing
We used DipTrace software from Novarm for designing our PCB. Most of the components used were available in it so designing the circuit was easier. We had to design a special connector for making a connection between multimeter and our PCB. The dimensions of that connector were 18mmX3mm. It had a total of 30 pins. The gap between the pins was too small for connecting a work-strip so we used a Zebra Connector for this purpose. The Schematic and the PCB layout are displayed below.

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Fig 25. Schematic for PCB

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Fig 26. PCB Frontside

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Fig 27. PCB Backside

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Chassis Design
To make the connections between the PCB and the Multimeter and the PCB and the LCD screen we designed the chassis to hold these three things together tightly. The body was designed using Solidworks and was then fabricated using the Rapid Prototyping facility in IIT. These are some of the views of the model.

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Fig 28. Solidwork model

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Future Work
Initial testing was done by powering the ELC using a DC power supply. Powering through an SMPS based Adapter drawing voltage from the very same generating unit which is being controlled burns down the voltage regulators. So we need to resolve the issue of the power supply to the ELC unit. We are thinking of using a rectifier circuit and converting the AC being generated to give power to our circuit. For emergency backup we can integrate a battery pack which can power the ELC for some time. After completing this we proceed to the final testing on SEIG. This would involve the changes in code to get better and faster results for all kinds of loads. The next task would be to make it industry ready with the improvements in the already designed casing for the Voltage sensing unit and the encasing of the rest of the component units. This step will also include improvements to be made in the design based on the recommendations from the industry.

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Bill of Material Part No./ IC Name

MSP430F1611 MPC508 SN74LS86 LM224A ICL7106 UA7805 UA7810 UA7815 UA7824 TLP250 R1 R2 GT60M303

Manufacturer
Texas Instruments Texas Instruments Texas Instruments Texas Instruments Intersil Texas Instruments Texas Instruments Texas Instruments Texas Instruments Toshiba Toshiba

Description
Microcontroller Analog Multiplexer XOR gate Operational Amplifier A/D converter Voltage regulator Voltage regulator Voltage regulator Voltage regulator IGBT Gate Driver 10 K resistor SMD 33 K resistor SMD IGBT

Quantity
1` 3 1 2 1 1 1 1 1 1 16 8 1

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References
1. D. K. Palwalia, S. P. Singh, New Load Controller for Single-phase Self-excited Induction Generator, Electric Power Components and Systems, Volume 37, Issue 6 June 2009 , pages 658 - 67 2. D. K. Palwalia, S. P. Singh, Digital Signal Processor-based Controller Design and implementation for Self Excited Induction Generator, Electric Power Components and Systems, Volume 36, Issue 10 October 2008 , pages 1130 - 1140 3. S.S. Murthy, Bhim Singh. An Electronic Voltage and Frequency Controller for SinglePhase SEIG for Pico Hydro Applications, IEEE PEDS 2005 4. L.Robinso, D.G.Holmes, A Single Phase Self-Excited Induction Generator with Voltage and Frequency Regulation for use in a Remote Area Power Supply 5. Power Electronics Circuits, Devices and Applications, M.H.Rashid, Prentice Hall 6. Electric Machinery and Transformers, Bhag S. Guru, Hiziroglu 7. www.ti.com 8. www.embeddedrelated.com

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Fig 29. Photographs of Product

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