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Cal Poly SuPER Project: Progress Report and Plans


Cal Poly SuPER Project: Progress Report and Plans EE 563 Graduate Seminar October 6, 2006 James G. Harris, Professor EE Department and CPE Program – PowerPoint PPT presentation

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Title: Cal Poly SuPER Project: Progress Report and Plans

Cal Poly SuPER Project Progress Report and
  • EE 563 Graduate Seminar
  • October 6, 2006
  • James G. Harris, Professor
  • EE Department and CPE Program

Cal Poly SuPER Project Outline
  • Background rationale for project
  • Progress Report for Last Year AY 05-06
  • Plans for This Year AY 06-07
  • Conclusion and Invitation to Join Project

Background - Electrification
  • Electrification National Academy of
    Engineerings top engineering achievement for the
    20th Century
  • Estimated 1/3 of population (now, 6B) do not have
  • Significant proportion of remainder does not have
    reliable access to battery or grid
  • 18,000 occupied structures on Navajo Nation lack
    electrical power (2001 legislation)

Background - Significance
  • Impact of electrification significant
  • Transformation of Western world
  • Thomas Hughes Networks of Power
  • People who caused change
  • Social Impact standard of living
  • Recognized by National Renewable Energy
    Laboratory in late 1990s
  • Village Power Program
  • Development of microfinancing

Background Solar Insolation
  • Goal to provide electrical resources to people in
    underdeveloped countries
  • Leapfrog technology no need for 100 years of
  • Example of cell phone in Asia
  • Review of global insolation map
  • Poorest people (1-2 a day income)
  • Within plus or minus 30 degree of latitude
  • Highest values of solar insolation (minimum W
    hr/sq m/day)

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Background DC Power
  • Solar photovoltaic systems inherently DC
  • History of DC (Edison) versus AC (Westinghouse
    and Tesla) at end of 19th century
  • DC versus AC for generation, distribution, and
  • Initially, applied to lighting
  • Lighting today
  • 60W incandescent bulb and 20W compact fluorescent
    bulb lumens
  • Equivalent to 3W LED technology, and improving

Background DC power loads
  • Efficiency of electrical motors few horsepower
  • Permanent magnet DC motors
  • Electrical appliances
  • Computer 50W laptop (DC)
  • TVs, radios use DC power
  • RV 12V DC market kitchen appliances
  • Portable power tools battery powered (DC)
  • Computers wireless connection
  • Internet, phone (voice over IP), TV, radio,
  • Education MIT Media Lab 100 laptop project

Background Moores Law
  • Stand-alone solar photovoltaic system technology
    is mature, e.g., Sandia Handbook
  • Application of Moores Law to development of
    SuPER system
  • Solar cell development commercial and research
  • Estimate 5 per decade with base of 16 in 2005
  • Implies 25 efficiency in 2025
  • DARPA RFP 1000 units of 50 efficiency

Commercial Module Range
Laboratory Cells Histories of Silicon
Photovoltaic Module and Cell Efficiencies Ref.
Martin A. Green "Silicon Photovoltaic Modules A
Brief History of the First 50 Years" Prog.
Photovolt Res. Appl. 2005 13447455 (Published
online 18 April 2005 in Wiley InterScience
April Allderdice and John H. Rogers Renewable
Energy for Microenterprise National Renewable
Energy Laboratory November 2000
Antonio C. Jimenez, Tom Lawand Renewable Energy
for Rural Schools National Renewable Energy
Laboratory November 2000
Jonathan O.V. Touryan and Kenell J. Touryan
Renewable Energy for Sustainable Rural Village
Power Presented at the American Scientific
Affiliation Conference Arkansas August 1,
1999 National Renewable Energy Laboratory
Background Solar and DC Power
  • Conclusion
  • Solar photovoltaic is poised for leapfrog
  • Many development tools available
  • Expectation of future efficiencies
  • Sustainable power source
  • Digital control of standalone system
  • DC is power of future
  • Decentralized
  • Matched to source and loads

Background Overall Cal Poly SuPER System Goals
  • Design lifecycle of 20 years
  • Total Cost less than 500 for 1 sq m PV module
    including battery replacements
  • Mean time between failures (MTBF) 25 years
  • Mean time to repair (MTTR) 1 hour
  • Power depends on PV efficiency and battery
    storage capacity

Why? Broader Impact of SuPER Project
  • Provides family owned electrical power source
  • Only electrical power source for family
  • Increasing power resource with time
  • With financial business plan 2-3 per month for
    all electrical power needs
  • Decentralized, sustainable development of
    electrical power in poorest countries
  • SuPER system potential resource for raising
    standard of living of poorest to par with rest of

Background Five Year Plan for Development
  • Five years for completed design, development, and
    field testing
  • Includes business plan, documentation and
  • First three years for prototype development
  • Three generations at one year for each
  • Last two years for field testing
  • Establishing contacts overseas now

Progress Report Technical Description of SuPER
Prototype Development Phases
  • Phase 00 use of existing donated PV module
    (150W) PV system
  • Phase 0 cart mounted system
  • Phase 1 cart system with
  • Laptop computer with USB i/F to sensors
  • Linux OS
  • Cart for packaging
  • Phase 2 cart system performance testing/design
  • Phase 3 packaging/manufacturability goals
  • Port software/electronics to FPGA with
  • Phase 4 system testing/preliminary field testing

Summary -Progress Report AY 05-06
  • Cal Poly SuPER project lab established in 20-101
  • Development phases 00, 0 , and 1 planned
  • Phase 0 implemented resulting in 1 thesis and 3
    senior projects by end of Summer
  • BUS 454 (Spring 06) senior project team develops
    business/marketing plans 4 senior projects
  • Foundation provided for future development of
    phase 1 prototype

Eran Tal working with prototype SuPER System
June 2006
SuPER Development Team
Weekly Seminar Meeting in Power Senior Project
Room (20-101) SuPER Project Laboratory
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Cal Poly SuPER Project - Spring 2006
SUPER prototype cart with solar panel, battery,
instrumentation and control subsystems Members
present in photo (left to right) Eran Tal, Eric
Phillips, Gustavo Vasquez, Alexander Gee,
Jennifer Cao, Sam Muehleck, Dr. Jim Harris, Dr.
Taufik, Tyler Sheffield, Dr. Ali Shaban Members
missing Dr. Ahmad Nafisi, Robert Johnson
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Prototype SuPER System Cart protection and load
distribution 12V DC service panel with five load
circuits (four in service)
Prototype SuPER System Cart bottom shelf 12V DC
1/4HP motor load and 12V battery
Prototype SuPER System Cart top shelf view Laptop
computer, interface circuits, MX-60 controller
Prototype SuPER System Cart left side switchboard
enclosure Main switchboard (bottom) and PV
switchboard (top left)
Prototype SuPER System Cart right side view
Comparison of Open Loop and Phase 00 Systems
Plans for This Year AY 06-07
  • Recruit new Cal Poly Super Team
  • Initial meeting this past Wednesday
  • Develop and test the Phase 1 Prototype
  • All Cal Poly fabrication except for PV and
  • Continue effort initiated by BUS 454
  • Work with consumer community

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Plans Research Opportunities Available on Cal
Poly SuPER Project
  • Undergraduates and graduates EE, CPE
  • Graduate students provide leadership/thesis
  • Undergraduates work on senior project
  • Others invited
  • Design/development team environment
  • Weekly seminar meetings with faculty
  • Funds available to purchase materials and
    components for students

Plans Some Research Areas for Student Projects
  • Simulation of system with MatLab/Simulink
    digital control algorithms
  • DC-DC converter development PV to battery, DC
    output bus to LED lighting
  • Printed circuit board development PCBExpress
    on-line design and fabrication
  • Battery and ultra-capacitor technology
    electrical power storage research and modeling
  • Modeling of DC loads white LED lighting, DC
    motor, battery charging, refrigerator
  • Power distribution and protection NEC code

Plans Some Research Areas for Student Projects
  • Sensor data acquisition and processing voltage,
    current, temperature and sun insolation
  • System engineering PV input modeling and DC
    output load scenarios for testing
  • PV array modeling study of technology and
    maximum power point tracking algorithms
  • White light LED system development
  • DC motor characterization and load performance

Plans Interested in Participating?
  • Check out SuPER website http//
  • Announcement of opportunities
  • White Paper
  • Graduate Seminar Presentation
  • Senior Projects
  • Thesis
  • Visit with faculty involved
  • EE Jim Harris, Ahmad Nafisi, Ali Shaban, Taufik
  • OCOB Doug Cerf, Norm Borin

Cal Poly SuPER Senior Projects and Thesis
(available at SuPER website)
  • Thesis
  • Eran Tal, "SuPER System Prototype Design and
    Implementation", July 2006 (pdf file)
  • Senior Projects
  • Tyson DenHerder, "Design and Simulation of
    Photovoltaic SuPER System using Simulink", March
    2006 (pdf file)
  • Gustavo Vasquez Jr., "Data Acquisition and Sensor
    Circuits for the SuPER Project", June 2006 (pdf
  • BUS 454 Client Report Presentation - June 2006
    Student Team - Jessica Hickey, Richard Huskey,
    Heather McGinnis, Nick McMillan Faculty
    Supervisor -Dr. Lynn Metcalf (PowerPoint)
  • Alexander Gee, "Printed Circuit Board Design and
    Construction for hte SuPER Project", August 2006
    (pdf file)

  • 1. George Constable, Bob Somerville A Century of
    Innovation Twenty Engineering Achievements that
    Transformed our Lives National Academy of
    Engineering 2003 overview available at
  • 2. Jonathan O.V. Touryan, Kenell J. Touryan
    "Renewable Energy for
  • Sustainable Rural Village Power" Presented at
    the American Scientific Affiliation
  • Conference Arkansas August 1999, available from
    NREL as NREL/CP-720-26871
  • hybrid system for nrel village power program
  • 3. Begay-Campbell, Sandia National Laboratories
    "Sustainable Hybrid System Deployment with the
    Navajo Tribal Utility Authority" NCPV and Solar
    Program Review Meeting 2003 NREL/CD-520-33586
    Page 541 available at http//
    m/pdfs/33586073.pdf estimated date 2003,
    describes program resulting from "On November 5,
    2001, President Bush signed the Navajo Nation
    Electrification Demonstration Program (Section
    602, Public Law 106-511) into Law. This law
    directs the Secretary of Energy to establish a
    5-year program to assist the Navajo Nation in
    meeting its electricity needs for the estimated
    18,000 occupied structures on the Navajo Nation
    that lack electric power."
  • 4. Thomas P. Hughes Networks of Power
    Electrification in Western Society, 1880-1930
    Baltimore Johns Hopkins University Press, 1983
  • 5. Thomas P. Hughes American Genesis A Century
    of Invention and Technological Enthusiasm
    1870-1970 Penguin Books 1989
  • 6. David Nye Electrifying America Social
    Meanings of a New Technology, 1880-1940 MIT
    Press 1990

  • 7. Antonio C. Jimenez, Tom Lawand "Renewable
    Energy for Rural Schools" National Renewable
    Energy Laboratory November 2000
  • report from village power program at nrel
    covers all renewable sources
  • 8. April Allderdice, John H. Rogers Renewable
    Energy for Microenterprise NREL November 2000
    available from http//
  • microfinance introduction for renewable energy
    in underdevelopment countries
  • 9. Ulrich Stutenbaumer, Tesfaye Negash, Amensisa
    Abdi "Performance of small scale photovoltaic
    systems and their potential for rural
    electrification in Ethiopia" Renewable Energy
    18 (1999) pp 35-48
  • authored by locals, but dated example of
    early recognition of possibilities
  • 10. Sunwize Technologies http//
    insolation map available at
  • on-line catalog and interactive planning
    support global insolation map
  • 11. Evan Mills "The Specter of Fuel-Based
    Lighting" Science v. 308, 27 May 2005, pp
  • 12. E. Fred Schubert, Jong Kyu Kim "Solid-State
    Light Sources Getting Smart" Science v. 308, 27
    May 2005, pp 1274-1278
  • 13. Thurton, J.P. and Stafford, B "Successful
    Design of PV Power Systems for Solid-State
    Lighting Applications" Fourth International
    Conference on Solid State Lighting 3-6 August,
    2004, Denver. Colorado / Proc. of SPIE v. 5530
    2004 pp284-295
  • mainly lessons learned

  • 14. MIT Media Lab http//
  • 15. Sandia National Laboratories, Solar Programs
    and Technologies Department Southwest Technology
    Development Institute, New Mexico State
    University Daystar, Inc., Las Cruces, NM
    "Stand-Alone Photovoltaic Systems A Handbook of
    Recommended Design Practices" Sandia National
    Laboratories, SAND87-7023 Updated July 2003
  • revised handbook first published in 1988
  • 16. Kyocera Solar, Inc., Solar Electric Products
    Catalog , August 2005
  • available on web prices for small modules
  • 17. IEA PVPS International Energy Agency
    Implementing Agreement on Photovoltaic Power
    Systems Task 3 Use of Photovoltaic Power Systems
    in Stand-Alone and Island
  • Applications Report IEA PVPS T3-09 2002 "Use of
    appliances in Stand-Alone PV Power supply
    systems problems and solutions September 2002
  • dos and don'ts for design
  • 18. Alison Wilshaw, Lucy Southgate Rolf Oldach
    "Quality Management of Stand Alone PV Systems
    Recommended Practices" IEA Task 3,
  • another report of iea agreement
  • 19. Martin A. Green "Silicon Photovoltaic
    Modules A Brief History of the First
  • 50 Years" Prog. Photovolt Res. Appl. 2005
    13447455 (Published online 18 April 2005 in
    Wiley InterScience (
    DOI 10.1002/pip.612)
  • history and use of moore's law with darpa rfp
    also figure
  • 20. Defense Advanced Research Projects Agency
    (DARPA) BAA05-21 posted Feb. 25, 2005 RFPVery
    High Efficiency Solar Cell (VHESC) program
    announcement with deadline on 3/29/2005, which
    will be open at least a year from this date see

  • 21. H. Spanggaard, F.C. Krebs "A brief history
    of the development of organic and
  • polymeric photovoltaics" Solar Energy Materials
    Solar Cells 83 (2004) 125146
  • overview in context of inorganic (si) pv's)
  • 22. T. Givler, P. Lilienthal "Using HOMER
    Software, NRELs Micropower Optimization Model,
    to Explore the Role of Gen-sets in Small Solar
    Power Systems Case Study Sri Lanka" Technical
    Report NREL/TP-710-36774 May 2005.
  • 23. David L. King, Thomas D. Hund, William E.
    Boyson, Mark E. Ralph, Marlene Brown, Ron Orozco
    "Experimental Optimization of the FireFly. 600
    Photovoltaic Off-Grid System" Sandia National
    Laboratories, SAND2003-3493 October 2003
  • system and component test with ac inverter
    measurement parameters standards and codes
    identified, e.g., grounding
  • 24. R. Akkaya, A. A. Kulaksiz "A
    microcontroller-based stand-alone photovoltaic
    power system for residential appliances" Applied
    Energy 78 (2004) 419431 available at
  • microbased control, but focused on AC output

  • 25. Angel V. Peterchev, Seth R. Sanders
    "Digital Loss-Minimizing Multi-Mode Synchronous
    Buck Converter Control" 2004 35th Annual IEEE
    Power Electronics Specialists Conference Aachen,
    Germany, 2004
  • dc to dc for cell phone/computer using
    digital techniques
  • 26. Jason Hatashita, "Evaluation of a Network
    Co-processing Architecture Implemented in
    Programmable Hardware." EE MS Thesis, February
    2002 available at http//
  • 27. Homepage for Cal Poly Marketing Program
    see client application in lower right hand space
  • 28. EE 460/463/464 Senior Seminar/Senior Project
    Handbook available at
  • http//
  • 29. Muhammad H. Rashid Power Electronics
    Circuits, Devices and Applications(3rd Edition)
    Prentice-Hall 2004