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- | ====== NinjaSCC Hardware ====== | + | ====== NinjaSCC Hardware |
- | # Design Specifications | + | {{: |
- | Desired NinjaSCC Specs to have a guideline during design phase. | ||
- | | Symbol | + | Desired NinjaSCC Specs to have a common frame of reference during design and |
- | |: | + | documentation phase. |
- | | V< | + | |
- | | V< | + | |
- | | I< | + | |
- | | P< | + | |
- | | V< | + | |
- | | I< | + | |
- | | OVP | Overvoltage Protection | + | |
- | | OTP | Overtemperature Protection | | 125 | | °C | | + | |
- | | MPP< | + | |
- | | PM< | + | |
+ | ===== Electrical ===== | ||
- | ### Input | + | ==== PV Input ==== |
- | | Parameter | + | ^ |
- | |: | + | | |
- | | Input Configuration | + | | |
- | | Max. Input Voltage | + | | |
- | | Max. Input Current | + | | |
- | | Cont. Input Current | + | | - | Panel/Cell Configuration |
- | ### Battery | + | ==== Battery |
- | | Parameter | + | ^ Symbol |
- | |: | + | | |
- | | Output Configuration | + | | |
- | | Max. Input Current | + | | |
- | | Cont. Input Current | + | | |
- | ### Load Output | + | NinjaSCC will by default fall into a 12V system. Any other check, charge, |
+ | equalize and float setpoints can easily be overriden in software to leave | ||
+ | more headroom for all kinds of use-cases and many battery types like lead-acid, | ||
+ | gel,agm and lithium battery packs in the 12V to 36V range. | ||
- | | Parameter | + | Output Current/ |
- | |: | + | increase battery lifetime and allow RF sensitive devices, like remote |
- | | Cont. Output Current | 10 | A | | + | SDRs, to be powered by NinjaSCC as well. |
- | ## Environment | + | ==== Load ==== |
- | | Parameter | + | ^ Symbol |
- | |: | + | | |
- | | Min. Temperature | + | | |
- | | Max. Temperature | + | |
+ | ==== Efficiency ==== | ||
- | When the optimal operating condition falls into a narrow window | + | ^ Symbol |
- | that Vin and Vout are within about ±2% of each other, the panel mode is engaged to take the advantage | + | | BK-MPP< |
- | of the almost lossless energy harvest feature. In panel mode as shown in Figure 6, Q5A/B remains ON | + | | BST-MPP< |
- | while the DC/DC converter shuts down, establishing a direct link between the PV panel output and the | + | | TR< |
- | string. | + | |
- | When the panel mode is not the optimal operating condition, the MPPT/PM controller will turn-off PM | + | ==== ADC ==== |
- | switches and engage the DC/DC converter for maximum power tracking. In a conventional Buck-and- | + | |
- | Boost converter, switching of the diagonal switches is synchronized. Namely Q1 and Q3 are turned on | + | |
- | and off at the same time. So are Q2 and Q4. | + | |
- | NinjaSCC has four operating modes: | + | 10-bit ARef 5V (Arduino) |
+ | 12-bit ARef 5V (4 channel external ADC via I2C) | ||
- | * Buck-Only (BK) | + | ===== Environment ===== |
- | * Boost-Only | + | |
- | * Buck-Boost-Interleaved | + | ^ Symbol |
- | * Bypass | + | | |
+ | | | ||
+ | | | ||
+ | |||
+ | ===== PCB ===== | ||
+ | |||
+ | ^ | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | | ||
+ | | Substrate HQ | P96/ | ||
+ | | Substrate MQ | | ||
+ | | Substrate LQ | FR4 | | ||
+ | |||
+ | ===== Protection ===== | ||
+ | |||
+ | ==== Electrical ==== | ||
+ | |||
+ | | ||
+ | * Over-Voltage [HW+SW] | ||
+ | * Over-Current [HW+SW] | ||
+ | * Adjustable Current Limiter [HW+SW] | ||
+ | * LVD (Low-Voltage Disconnect of Load) [SW] | ||
+ | * UVLO (Under-Voltage Lock-Out) [HW] | ||
+ | * Uncontrolled Back-Channel DC GND return (High-Side Load Switch) [HW] | ||
+ | * Electromagnetic and Lightning induced extraneous Voltage Transients [HW] | ||
+ | * Local ESD [HW] | ||
+ | |||
+ | ==== Environmental ==== | ||
+ | |||
+ | * Battery Temperature Monitoring | ||
+ | * PV Panel Temperature Monitoring | ||
+ | * PCB Temperature Monitoring | ||
+ | * Over-Temperature controlled Shutdown | ||
+ | * Fan-Control | ||
+ | * Assembly PU-Coating | ||
+ | |||
+ | ===== Modes of Operation ===== | ||
Based on real-time assessment of the operating conditions, NinjaSCC dynamically | Based on real-time assessment of the operating conditions, NinjaSCC dynamically | ||
determines the optimal operating mode in order to track the maximum power point | determines the optimal operating mode in order to track the maximum power point | ||
- | of the PV panel, keeping overall conversion efficiency close to 100%. | + | of the PV panel, keeping overall conversion efficiency close to 99%. |
+ | |||
+ | * MPP Tracking Buck-Only (BK) | ||
+ | * MPP Tracking Boost-Only (BST) | ||
+ | * MPP Tracking Buck-Boost-Interleaved (BB) | ||
+ | * Transit (TR) | ||
+ | |||
+ | ===== Controller ===== | ||
+ | |||
+ | Since Arduinos have been around for a while and have a very broad | ||
+ | spectrum of documentation, | ||
+ | AVR ATMega32U4 8-Bit Microcontroller (with built-in USB support so that | ||
+ | we can [[https:// | ||
+ | chosen as the main controller in a fully Arduino-Micro compatible | ||
+ | configuration, | ||
+ | This way, NinjaSCC can be used and flashed over USB like any other | ||
+ | Arduino-Micro board. | ||
+ | |||
+ | ===== Dedicated USB Charging Port (DCP) ===== | ||
+ | |||
+ | As other USB power sources, like most wall warts and auto adapters, | ||
+ | NinjSCC does not enumerate the USB output port. Charging can begin | ||
+ | immediately, | ||
+ | in the supplementary USB Battery Charging Specification, | ||
+ | 4/15/2009 (BC1.1). | ||
+ | |||
+ | * Supply 5V up to 1.5A | ||
+ | * DCP mode identified by a short between D+ to D- | ||
+ | * Short-Circuit, | ||
+ | * Shares EN pin with Load Switch to maintain LVD ability by default, | ||
+ | but can be selected with a solder bridge/0R | ||
+ | |||
+ | ===== Monitoring & Metrics ===== | ||
+ | Constantly monitor and collect all relevant system metrics and operating | ||
+ | parameters and deliver a high-resolution, | ||
+ | over USB to be live-viewed and/or shipped into a metrics storage engine | ||
+ | like [[https:// | ||
+ | real-time, remote system awareness, gather long-term data to optimize | ||
+ | the system even further and have a means to analyze/ | ||
+ | operating conditions which might lead to failure like: Battery temperatures | ||
+ | that are consistently above ambient may indicate high ripple, overcharging | ||
+ | or internal cell shorting. | ||
- | Generally, when the PV panel’s Vmpp is lower than about 98% of Vout defined in Equation 2, the | + | ===== Remote Control ===== |
- | controller will run the converter in the BK mode. Figure 7a shows the equivalent circuit of BK mode, where | + | |
- | only Q1 and Q2 are switching, while Q3 remains OFF and Q4 stays ON. | + | |
- | When the PV panel’s Vmpp is greater than about 102% of the output voltage defined in Equation 2, the | + | |
- | controller will run the converter in the BST mode. Figure 7b shows the equivalent circuit of BST mode. | + | |
- | Only Q3 and Q4 are switching, while Q2 remains OFF and Q1 stays ON. | + | |
+ | Any DC/DC regulation parameter can be overriden in software by remote | ||
+ | controlling NinjaSCC over USB, so playing and experimenting on a live, | ||
+ | working converter with instant metric feedback will be a great opportunity | ||
+ | to study its behaviour while changing parameters and operating modes | ||
+ | manually. And of course, a fun and hands-on learning assistance while | ||
+ | teaching buck/boost technology to others. | ||
+ | ===== Resilience ===== | ||
- | ## Protection | + | Designed in a built-to-last approach, almost all components have been |
+ | selected in a range between automotive qualified and up to | ||
+ | aerospace/ | ||
+ | because this way the focus gets back where it should belong: On the | ||
+ | product and the component quality it is made of. With attention to detail | ||
+ | and without undue compromise. | ||
- | ### ESD | + | To further decrease the chance of total system failure, most important |
+ | system blocks and components have been set up n+1 redundant, wherever | ||
+ | possible and reasonable. | ||
- | Input/ | + | NinjaSCC must withstand |
- | are available | + | providing power to the camera you’ve put out there for over a year, |
+ | to make a movie about glacier calving or you are in a remote desert at | ||
+ | +55°C ambient temperature and need power to operate your water pump. | ||
+ | When you’re truely off-grid, this is the device that must not fail | ||
+ | (or at last reasonably max out the chance that it does), because murphy | ||
+ | dictates: it usually does so at the worst possible point in time. | ||
First concept: | First concept: |