Fuel-Cell Powered DC Motor Controller - ECE Department Wiki

winetediousElectronics - Devices

Oct 7, 2013 (3 years and 8 months ago)


Cell Powered DC Motor Controller

Conceptual Design and Options Considered w/ Budget and Timeline

Group: SD0805

Travis Brost

Nicholas Bullinger

Gabriel Kainz


The ECE department currently has a proton exch
ange membrane (PEM), or
hydrogen, fuel cell. The purpose of this project is to build a motor controller that will
allow this fuel cell to power a 90 volt DC motor. We will utilize a DC to DC converter
that will step the voltage of the fuel cell from 24 t
o 90 volts. When completed, this
controller will be used for class and department tour demonstration in the ECE
department at NDSU. Client is the NDSU ECE department.

Pervious Work:

This project is a very standard design. Using pulse width modulation t
o vary the
duty cycle of the AC side of a DC to AC converter is a commonly utilized system. Once
we have the AC signal, it is a simple matter of stepping up the voltage using a
transformer and then using a diode bridge to rectify the signal. We have foun
d some
patents tha
t use very similar designs:
7321213 and
70278986. We found
others, but listing them would be very redundant. The main difference in most of the
circuits that we found is the method of delivering the pulses to the MOSFETs. We

be using a c

that has undoubtedly been used in this type of design before, but the
simplicity is what makes it attractive.

Design Options:


The main difference between the two different transistors is
that the IJBTs ope
rate at lower frequencies. A second difference is that we can get the
IJBT in a compact bridge form that will save us space. We will be using the MOSFETs
at the beginning of the project and switching to the IJBTs next semester will cause us to
have to ad
just our design somewhat and this could cause considerable time delays in our
project. We are not concerned about
saving space at this time, so again, the MOSFETs
will be our best option.


PIC 876. We chose the UCC 8895 because it required

hardware making it more se
lf contained and more reliable. Having a simpler circuit will
help us to cut down on troubleshooting and component cost.

For now we decided to use a

EE Ferrite Core.

This is a standard type of
transformer core that will
enable us to construct the transformer on site instead of
contracting the manufacturing out, thus lowering our budget.

The Diodes we used were RURP 3060 because they are standard high voltage
diodes and w
ill be

ed for us.

IRF 2113 drivers
. We wil

these drivers to interface between the controller
and the MOSFETs.

We have decided to use a plexi
glass type container

that will be 12” x 12” x 12”

instead of a metal container due to its cheaper and easier to work with while also giving a
view of
what is inside and how the H

Bridge was built.

The controller will

contain the rechargeable battery inside the container because
we will need a voltage source that can start the fuel cell up. A
s of now we have a 24V
power source that powers up the DC f
uel cell and is only need for about ten seconds and
then is no longer need to power the fuel cell

so to have rechargeable battery in the design
is a good option to make things more compact but will add additional weight to the

The battery mus
t be capable of delivering at least 6 amps at 24 VDC for 60
seconds. This has so far been the hardest component to find while keeping weight and
cost down.

We also are going to use heat sinks for the MOSFET’s and diodes because of the
high heat dissipa


See attached chart.


See attached
Gantt C


As we have a working motor and fuel cell, the only design is the controller and
any interface needed between the major components. The controller will include a DC to

AC converter, a step
up transformer, an AC to DC converter, and the pulse width
modulation control circuit.

Basic Block Diagram

Basic circuit for DC
AC conversion, step
up transformer and AC
DC conversion.

Travis Brost


Nicholas Bullinger


Gabriel Kainz


Advisor, Dr. Yuvarajan