ahmed zahran power electronics projects portfolio
DESCRIPTION
My power electronics projects (circuit design, PCB layout, components assembly, 3D circuit view, enclosure design and embedded programing)TRANSCRIPT
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
Modular Multi-Level converter
Description
Three phase five levels inverter up to 1000V ,10 A transformer less converter.
Circuits
Power Inverter Arm board; consists of 8 IGBT (4 cell) with the required cooling
(heat sink and fans) and stacking connectors.
Capacitor Banks board; consists of four capacitors groups (each group consists of
four capacitors 680uF, 400V).
Gate Drive board; consists of 8 fiber optics gate drives and one Arm input current
measurement.
Capacitors Voltage measurement board; consists of 4 voltage measurements circuits
with high isolation level (5Kv isolation level).
Phase control board; consists of 16 fiber optics transmitters with the required
current drivers, dead time generation circuit for each leg signals and low-pass filter
for the phase measurement signals.
My role in the project
Circuit design, PCB layout, 3D circuit view, soldering, DSP MATLAB software,
CANalyzier interface software, Commissioning for the setup.
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
High Voltage Generation
Description
High Voltage Pulse generator for water treatment. It generates pulses by 1000V
amplitude for 2.5 µsec duration and frequency of 50 Hz from DC supply of 12VDC to
kills microbes in the water. The control is based on TMS320F28335 EZdsp board.
Circuits
• Main power board; consists of (boost converter, buck converter and two three
stages voltage multiplayer).
• LV control board; consists of (2 gate drive circuits +/- 15V 2.5A and four voltage
measurement circuits with 5KV isolation level).
• HV control board; consists of one gate drive circuit +/- 15V 2.5A with 5KV
isolation level.
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, DSP MATLAB
software, CANalyzier interface software, Commissioning for the setup.
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
Plug in Inverter Modules
Description
It contains of common power electronics circuits used in voltage source inverters up to 7
phases. The main benefits is the simplicity of connection where there is no need for any
wires (power or control)
Circuits
• Main Inverter Leg control board; it is 4 layers board consists of two gate drives
(+15V,2.5A) with 5KV isolation voltage, measurement for (Output current and DC
link voltage and current) and collection for all of the analog and PWM signals in
single connector.
• Auxiliary Inverter Leg control board; it is 4 layers board consists of two
gate drives (+15V,2.5A) with 5KV isolation voltage, , output current
measurement and three DIP switches to select the channel for the PWM
signals and current signal for the auxiliary inverter leg.
• Main/Auxiliary Inverter Leg; consists of two IGBTs with the required
cooling (heat sink and two fans). The rate for the leg is (400V/20A or
800V/10A).
• 400V Capacitor bank board; consists of array of parallel capacitors (total
4700uF).
Ahmed Zahran [email protected]
Plug in Inverter Modules
Description
• 800V Capacitor bank board; consists of array of parallel and series
capacitors (total 2700uF).
• Three phase Bridge rectifier board; is working up to 800V/10A or
400V/20A with the required cooling (heat sink and two fans).
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, DSP MATLAB
software, CANalyzier interface software, Commissioning for the setup.
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
Flow Meter Board
Description
Flow meter board is for down hole applications. The board has the capability to work
up to 125 C. The board records the measurements in the down hole and store them in
the EEPROM, after that we take the readings by using RS485 interface and make some
analysis on the computer using Labview software. I made two revisions one of them 2
layers and the other one 6 layers.
Main features
• Battery voltage and current
measurement.
• Solenoid drive (10VDC and 1A).
• Two Pressure sensors interface with
temperature measurement for
calibration and 10VDC power supply.
• Acceleration measurement in X,Y and
Z directions.
• EEPROM memory to store the data.
• RS485 serial interface for PC
interface.
• External I2C for another board or
device interface.
• External SPI for another board or
device interface.
• De-passivation circuit for Li-on
battery.
• 8 Hall effect sensors interface.
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, DSPIC33F C
coding, part of the Labview software, Commissioning for the setup.
Ahmed Zahran [email protected]
Flow Meter Board Labview block diagram
Ahmed Zahran [email protected]
1 SOLENOID 1
ON / OFF
DEPASSIVATION
ON / OFF
TEST
PRESSURE SENSOR 1
PRESSURE BAR
TEMP K
PRESSURE SENSOR 2
PRESSURE BAR
TEMP K
BATTERY
VOLTAGE V
CURRENT A
ACCELERATION SENSOR
X-AXIS
Y-AXIS
Z-AXIS
TEMP
2
3
4
5
6
7
8
HALL
EFFECT
Flow Meter Board Labview block diagram
Ahmed Zahran [email protected]
SOLENOID 1
ON / OFF
EEPROM DATA SCANNER
CHARTS
ACCELERATION SENSOR
X-A
XIS
, Y
-AX
IS,
Z-A
XIS
TIME
BOARD TEMPERATURE
TE
MP
TIME
PRESSURE 1 SENSOR
PR
ES
SU
RE
,
TE
MP
.
TIME
PRESSURE 2 SENSOR P
RE
SS
UR
E, T
EM
P
TIME
BATTERY
VO
LT
AG
E,
CU
RR
EN
T
TIME
DEPASSIVATION
ON / OFF
SCAN TIME SEC
SAMPLES
SAMPLES
1
2
3
4
5
6
7
8
HALL
EFFECT
Flow Meter Board Block Diagram
Ahmed Zahran [email protected]
CONTROL UNIT
DSP, EEPROM, Voltage reference, Clock
oscillator, RS485 interface
POWER SUPPLY
UNIT
Buck converter 10VDC/1A and 3.3VDC/1A
Battery current sensing
Voltage current sensing
DE passivation circuit
SOLENOID UNIT
Solenoid drive (20V,1A)
Solenoid current sensing
ACCELEROMETER
UNIT
X.Y and Z directions sensing
PRESSURE SENSOR
UNIT
Two pressure sensing interface circuits
Sensor Temperature measurement
BOARD TEMP. UNIT
RTD board temperature circuit
HALL EFFECT
SENSORS UNIT
Eight hall effect sensors interface
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
High Voltage Generation
Description
It is working as single stage DC/AC converter. It converts the voltage from
100VDC to 220VAC 50Hz base on boost circuit by single stage and the out is
pure sign wave.
Circuits
• Main power boards; 3 boards each one consists of boost converter.
• Control boards; 3 boards each one consists of 2 gate drive circuits +/- 15V 2.5A
with 1KV isolation level.
My role in the project
Circuit design, PCB layout, Components soldering, DSP TMS320F28335 MATLAB
software for open loop and Commissioning for the setup.
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
VOLTAGE AND CURRENT TRANSDUCERS
Description
• Voltage transducer boards for power inverter applications which have high common
mode rejection and high isolation voltage based on opto-isolation and another based
on hall effect .Main components (LV20-P LEM transducers and HCPL7800 avago
transducers).
• Current transducer boards for power inverter applications which have high common
mode rejection and high isolation voltage based on opto-isolation and another based
on hall effect .Main components (LTSR-25 LEM transducers, HCPL7800 avago
transducers and ACPL-79A avago transducers and ACS716) .
My role in the project
Circuit design, PCB layout, 3D circuit view and Components soldering.
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
Five Phase Inverter
Description
It is five phase voltage source inverter for five phase induction machines driving
applications. The inverter has been put in acrylic enclosure to achieve a degree of
simplicity in using. It contains all required measurement signals.
Circuits
• Ten IGBT gate drive ±2.5A, 15V, with its isolated power supply with supply under
voltage protection and isolation voltage of 2.5KV.
• Four output current measurement boards.
• DC link voltage measurement.
• Five IGBT Leg inverter boards with the requirement cooling.
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, acrylic
enclosure design, setup harness, Matlab code by using TMS320F28335
EZdsp board
Ahmed Zahran [email protected]
Three Phase Inverter
Description
It is three phase voltage source inverter based on IRAMY20UP60B power intelligent
module for three phase machines driving applications. The setup contains all required
measurements and easy to connect.
Circuits
• Driving three phase loads up to 400V 10A.
• Short circuit protection.
• High isolation level for all analog and digital control signals.
• Contains measurement for (two output currents, DC link current and DC link
voltage).
• Very simple to connect (single connector for control signals and power terminals).
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, Matlab code by
using TMS320F28335 EZdsp board
Ahmed Zahran [email protected]
Three Phase Inverter
Main features
• Driving three phase loads up to 400V 10A.
• Six IGBT gate drive ±2.5A, 15V, with its isolated power supply with supply under
voltage protection and isolation voltage of 2.5KV.
• Two output current measurement boards.
• Three IGBT Leg inverter boards with the requirement cooling.
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, Matlab code by
using TMS320F28335 EZdsp board
Ahmed Zahran [email protected]
Three Phase Inverter
Main features
• Driving three phase loads up to 400V 10A.
• Six IGBT gate drive ±2.5A, 15V, with its isolated power supply with supply under
voltage protection and isolation voltage of 2.5KV.
• Two output current measurement boards.
• Three IGBT Leg inverter boards with the requirement cooling.
My role in the project
Circuit design, PCB layout, 3D circuit view, Components soldering, Matlab code by
using TMS320F28335 EZdsp board
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
Three Phase Inverter
Circuits
• ±2.5A, 15V, 200KHz MOSFET/IGBT gate drive with its isolated power supply
with supply under voltage protection and isolation voltage of 5KV.
• ±2.5A, 15V, 200KHz MOSFET/IGBT gate drive with its isolated power supply
with supply under voltage protection and miler effect protection and isolation
voltage of 5KV.
• ±2.5A, 15V/-15V, 200KHz IGBT gate drive with its isolated power supply with
supply under voltage protection, miler effect protection and isolation voltage of
5KV.
• ±2.5A, 15V/-15V, 200KHz IGBT gate drive with its isolated power supply with
supply under voltage protection, miler effect protection, IGBT short circuit
protection and isolation voltage of 5KV.
• ±8A, 15V/-15V, 200KHz IGBT gate drive with its isolated power supply with
supply under voltage protection, miler effect protection, IGBT short circuit
protection and isolation voltage of 5KV.
My role in the project
Circuit design, PCB layout, 3D circuit view and Components soldering.
Ahmed Zahran [email protected]
Modular Multilevel Converter
High Voltage generation
Plug in Inverter Modules
Flow meter board
Three phase boost inverter
Voltage and Current transducers
Inverters single/three/five phases
MOSFET/IGBT Gate Drives Cards
Three phase filters
Ahmed Zahran [email protected]
Overview
