Circuit Breaker Calibration · Objective • Design and create functioning circuit calibration unit...
Transcript of Circuit Breaker Calibration · Objective • Design and create functioning circuit calibration unit...
Circuit Breaker CalibrationPhilip Simonin (EE)
Kyle Weber (EE)Louis Leblanc (EE)
Tyler Lyon (EE)Advisor: Ali Gokirmak
Sponsor: Carling Technologies
Outline
1. Design objective and approach2. Hardware specification
1. Circuit Breakers2. PSoC3. Stepper Motor4. Pneumatic rig5. Relays6. Load bank
3. Circuit Design Diagram4. Alternative Design Possibilities5. Budget6. Timeline
Objective
• Design and create functioning circuit calibration unit• Comprised of pneumatic press, stepper motor,
PSoC, load bank, relays• Breakers of 5, 10, 15, or 20 Amperes must be
brought to proper trip point• PSoC will be the microcontroller
Problems To Address
Calibration currently done manually
Introduces unwanted human error
+/- 30% error
Effects manufacturing production
rate
Makes testing difficult for technicians
Our Solution
• Reduce margin of Error to +/- 10% (goal)
• Can be integratable into mass production
• More reliable product delivered to customer
• Simplified testing for engineers and
technicians
What is Being Calibrated?
• The spring attached to the actuation arm• Controls magnetic flux in the plunger• Alters current let-through and trip-point
Adjusts spring force onactuation arm
Applications
• Minimizes inaccuracies between products
• Allows engineers and technicians to test
products and achieve a repeatable
threshold
• Allows for testing of breakers before
shipment
• Modifiable for other product lines
• Can be applied to multiple poles potentially
Specifications
Circuit Breaker Specifications:
•A-Series Circuit Breakers• 5, 10, 15, 20A rated breakers• Max Voltage Current Rating: 80
VDC• Resistance values from Line to Load
Terminal• Single Pole• 10,000 ON/OFF operations @ 6 per
min.• Trip free
Breaker Architecture
Adjustment screw
Magnetic Sensing Coil
PSoC
• PSoC® 4 CY8CKIT-049 4200• C code programmable, via USB• Monitors current• Signals relays and stepper (bidirectional)• Conducts calibration adjustments• Automates system• Complete in 30 seconds or less
Top Design and Control
• Clock can be adjusted to speed of stepper motor
• ADC with follower input configuration from op-amp and protected by Zener.by Zener, looks for contact open/close
• Provisions for breaker in position are TBD
• Outputs kept at low level current and drive optocouplers and LEDs
PSoC Pinout
• Approximately 35 pins for I/O
• Data paths available
• Easy to program
PSoC MiniProg
• PSoC programmer via USB• 5 pin docking and programs in
seconds• Alternate ten pin or direct USB
available
Stepper Motor
Nema 11 Motor
• Step angle: 1.8°± 5% • Two Phase• Bidirectional
Holding
Torque
Current /
Phase
Voltage /
Phase
Phase
Resistance
Phase
Inductance
(1KHz)
0.6 Kg*cm 0.67 A 3.8 V 5.6 Ω± 10% 4.2 mH± 20%
Stepper Motor
Physical Dimensions:
• Bi-polar Microstepping Driver
• 2A/Phase Max
• 1.4-1.7A/Phase w/o Heatsink
• Max Motor Drive Voltage: 30V
• On-board 5V/3.3V Regulation
Motor Driver
opto
opto
opto
opto
opto
opto
opto
opto
a
bc
d
++
+ +
Pneumatic Press/Rig
• Pneumatic activated to contain breaker vertically (50 psi)
• Spring loaded compress for horizontalcontainment
Yellow: Stepper MotorRed: ArmatureBlue: Adjustment screwGreen: Horizontal SupportOrange: Connectors to breakerNot shown: Solenoid to interrupt trip
Power Relay
• Coil Voltage: 6-600V• Current Max: 40A• Response Time: 30 ms• Average Power Dissipation: 4 W
Optocoupler – 4N26
Input Parameters
Reverse Voltage 5 V
Forward Current 60 mA
Surge Current 3 A < 10µs
Power Dissipation 100 mW
Output
Collector Emitter Breakdown Voltage
70 V
Emitter Base Breakdown Voltage 7 V
Collector Current 50 mA (100 mA < 1ms)
Power Dissipation 150 mW
Load Bank
Taps:• One tap for 200% Current• Another for 115% Current
(for calibration)
Breaker Test Diagram
PSoC Operating
• Red – on for 10 seconds during200% load
• Clear LED – indicates activated relay, calibration commence
• Yellow – flashes indicatingpower to motor
• Green – Alive pin• Blue – Test done
Alternative Designs
• In place of the PSoC, use an Arduino, PLC or FPGA
• Construct our own mechanical unit in place of the rig provide by Carling Technologies
Budget
Quantity Item Model Specifics Cost
(1) Programming Unit for PSoC
CYPRESS – CY8CKIT-002 PSoC® MiniProg3 Program and Debug Kit
$82.43
(1) Stepper Motor Model – NEMA-17, product code: RB-Ada-138
$14.00
(1) Alternative Stepper Motor
Model NEMA-11, product code: 11HS12
$16.99
(1) USB oscilloscope From Analog Discovery, to be used with LabVIEW
$159.00
(1) Analog Parts Kit $49.99 (w/ academic discount)
Budget Continued
Quantity Item Model Specifics Cost
(1) NI Multisim & NI Ultiboard
NI Circuit Design Suite $9.95 (w/ academic discount)
(1) Analog Discovery BNC Adapter Board
$19.99
(1) BNC Oscilloscope Probes (pair)
$19.99
(1) Mini "Grabber" test hooks
$14.99
(1) Project Box + StickerSheet
$7.00
(2) Relay Schneider Electric/Magnecraft Model 119DBX-3
$37.70
Quantity Item Model Specifics Cost
(3) Signal Relays Kemet EE2-5NU-L, 3.75 V
$1.81
(3) Signal Relays Kemet EC2-12NU, 9 V $1.97
(6) Optocouplers Part number: 4N26 $0.59
Total: $484.61
Budget Continued
Timeline of Project
Questions?