Industrial Electronics

Assignment Title: ICA

In this coursework you will work through a series of exercises that will lead to the design of a power supply and you will demonstrate them through MATLAB simulations. Throughout the completion of these design and analysis exercises, you will develop skills in dealing with complex problems and providing effective solutions for such problems.

All information required for completion has been provided or covered in module laboratory sessions. You will be expected to perform independent research and further study as appropriate to aid completion. You should write a report based on the requirements of the attached brief and this should be an individual submission.

This ICA will assess the following Learning Outcomes as documented in the module specification and handbook:

Personal and Transferrable Skills
Identify and use appropriate analytical methods to evaluate industrial electronic systems.
Communicate effectively, using technical report writing skills and selection of appropriate information presentation methods.

Research, Knowledge, and Cognitive Skills
Produce a specification for an industrial electronic system or industrial electronic product.
Describe and explain the operation of simple industrial electronic systems.
Demonstrate an understanding of the operating principles of individual components that form an integrated system.

Professional Skills
Examine industrial electronic systems in a practical environment and describe their role within general engineering applications.

This module assesses the following AHEP4 (Accreditation of Higher Education Programmes) learning outcomes at ISCED (International Standard Classification of Education) level 6.

Research, Knowledge, and Cognitive Skills
Select and apply appropriate computational and analytical techniques to model complex problems, recognising the limitations of the techniques employed (C3).

Personal and Transferrable Skills Development
Evaluate the environmental and societal impact of solutions to complex problems and minimise adverse impacts (C7).
Use practical laboratory and workshop skills to investigate complex problems (C12).
Select and apply appropriate materials, equipment, engineering technologies and processes, recognising their limitations (C13).

Professional Skills, Values and Behaviours
Function effectively as an individual, and as a member or leader of a team (C16).

Introduction
Switching to Electric Vehicles (EV) can effectively contribute to sustainable mobility by making vehicles more energy efficient and reducing greenhouse gas emissions. This shift to electric power can lead to a cleaner environment overall. This assessment focusses on the design and simulation of a power supply system for a 50 kW Electric Vehicle Fast Charging System, incorporating various components and loads as shown in Figure 1.

Figure 1 - Overall System Diagram

The AC supply to the full wave rectifier is 230 V single phase AC at 50Hz.

The loads are as follows:
The output of DC-DC Converter 1 is to be 30 V to power the control system.
The output of DC-DC Converter 2 is to be 500 V to charge the batteries of an electric vehicle directly.

Deliverables and Assessment Criteria
The work to produce this circuit has been broken down into the following activities and these will form the basis for your report.
Complete all 5 activities.
Show all calculations and simulations clearly.
The requirements for each activity, explaining how you will be assessed, is described against each activity.

Activity 1: AC-DC conversion system design

You are required to design and simulate an AC-DC conversion system for a 50 kW EV Fast Charging System. The system is powered by a 230 V single phase AC supply at 50 Hz.
Rectifier Design
Design and simulate a full wave rectifier for this system. You may assume that:
The load resistance, R, is 3 ?.
The load inductance, L, is 50 mH.
The source resistance, RS, is 2 m?.
The source inductance, LS, is 60 µH.

Your design report should include the following:
Identification of key parameters for the selection of the diodes to be used and specifications for their values.
A simulation to validate the operation of the circuit, presented with appropriate graphs.
Explanation of your choice of filter components you would use to design a filter to smooth the rectified output.
A summary of the performance of this rectifier to include the form factor and efficiency, including comments on these values and their significance.

Activity 2: DC-DC Converter 1 Design

Design a DC-DC converter to provide a stable 30 V to power the control system with minimal voltage ripple. Since this circuit will supply the control system you should ensure the output voltage ripple does not exceed 5% of the output voltage.

Your design work should include:
Calculation of the DC input voltage based on the output of the rectifier.
Selection of appropriate values of the inductor L and Capacitor C.
Determination of a suitable switching frequency.
Justifications with design calculations and appropriate explanation.
Simulation of the circuit and presentation of the results to demonstrate its performance.
Description of any significant consideration for the selection of the components.

Activity 3: DC-DC Converter 2 Design

Design a DC-DC converter to provide a stable 500 V output for charging the batteries of an EV. The output voltage ripple must not exceed 10% of the output voltage.

Your design work should include:
Identification of the type of converter required.
Calculation of appropriate component values.
Determination of a suitable switching frequency.
Justifications with design calculations and appropriate explanation.
Simulation of the circuit and presentation of the results to demonstrate its performance.
Description of any significant considerations for the selection of the components.

Activity 4: Simulation of Entire System

Integrate the individual models you have created above and simulate the performance of the integrated system.
The nature of EV charging is that the amount of current delivered to the battery is regulated by the EV's onboard system. You should therefore investigate the behaviour of the charging system at a range of power settings, ranging from 10 kW to 50 kW.

You should provide results and commentary related to:
Evaluation of the overall efficiency of the system across the specified range of outputs.
Analysis of the harmonic content of the input current drawn from the supply.
Calculation of the power factor of the system.
Evaluation of the system based on the above and any other relevant factors you wish to consider, to include any recommendations for how the system could be improved.

Activity 5: Application of Embedded Systems in Industrial Electronics

Based on your design and simulation on the demonstration of the power electronic converters, answer the following questions:
Provide a general definition for embedded systems. Using an appropriate schematic, identify the core components of an embedded system linked to each other.
List and explain common types of embedded systems that are categorised based on their functional requirements.
Explain how an embedded system facilitates the implementation of the control unit of a power converter.

The report should include a title page, student name, student personal identifier, module code and date of submission.
You should try to present your report to a professional standard and make appropriate use of headings, diagrams, and tables.
Your report will be a formal document and should record all your workings and include appropriate artwork (including screen shots, computer-based simulation models etc).
Figures, tables, and artwork must be presentable, consistent in style and format, and include numbered captions with brief descriptive text.
Font: Arial, size 12, line spacing at 1.5.
Page numbers should be included in the footer of each page.
The report must not exceed 20 single A4 sides, excluding references and appendices.
Properly reference all sources you use.
Make sure all references are correctly presented - if in doubt please use the "Cite them Right" resource which is available via the University Library website (see the link in the last page).
You should ensure your work addresses all the requirements listed in the Assessment brief below.
Check through this document on a regular basis to ensure you have not missed any important information.
Do not include spurious or unnecessary content that is not listed below in the Assessment brief. You will be marked on material that is related to the deliverables.
Brevity and concise writing are something you should try and achieve in your report.