dimembermatt commented 2 months ago

What are the overarching goals and requirements for this project?

Given some design specifications, we want to

find the optimal topology and components needed to build a converter that is:
- maximally efficient
- both broadly and
- at maximum power transfer (the peak operating point)
- maintains the desired safety factor
- is within the specified input/output voltage/current ripple and
- is effectively stable during open and closed loop operation
visualize aspects of the optimal converter, including:
- steady state operation, which involves input/output voltage mappings of:
- duty cycle
- current transfer
- power transfer
- losses across each component
- temperature rise across each component
- voltage and current ripple
- efficiency
- stability and time to settle within some statistical distribution
- transient modeling of voltage and current nodes in response to some dynamic change.
create a digital twin of a physical converter, that allows us to:
- pair with different source/sink models
- interface with higher level control models and
- generate realistic dynamic simulations that can prove long duration efficiency and operation.

Based on the overarching goals, we have the following requirements:

We shall be able to define requirements and operating specifications of the system, including:
- the input and output model type and scope
- the maximum acceptable input and output voltage and current ripple of the converter
- the minimum acceptable stability of the converter
- the minimum allowable safety factor of the converter
- the maximum allowable cost and size budget of the converter
We shall be able to provide a comprehensive and standardized set of components used in converter design, including the following:
- FETs
- schottky diodes
- capacitors
- inductors (cores + shape)
We shall be able to select and design a converter from the following (but not exhaustive) list of topologies:
- DC-DC converters
- direct converter
  - asynchronous/synchronous buck/boost converter
  - four switch buck-boost converter
- CCM and DCM operation
- PFM operation
- interleaved converters

Indirect DC-DC converters, DC-AC inverters, and AC-AC transformers are not within the scope of this project.

For each converter topology, we shall be able to identify a linear pathway for selecting components while minimizing the number of constraining variables.
For each viable converter design (topology + components), we shall be able to generate estimated performance data in regards to the following attributes:
- switching frequency
- switch loss (switching versus conduction)
- inductor loss (ripple versus conduction)
- capacitor loss (ripple versus conduction)
- switch temperature rise
- inductor temperature rise
- capacitor temperature rise
- duty cycle
- noise stability
- component cost
- component area
For each viable converter design, we shall be able to assign a score or rank dependent on the estimated performance data, in particular:
- total efficiency
- total cost
- total complexity (number of parts, distributors, etc)
For each selected converter design, we shall be able to visualize its steady state and dynamic operation, including:
- input/output maps of current, power transfer, efficiency, dead time, duty cycle
- small signal stability analysis
- large signal stability analysis
- impulse response analysis

Sources:

dimembermatt commented 2 months ago

Breakdown of SW project

Modularization of the pipeline

specs package

Package specifying what our general design constraints should look like.

what is our expected input source model?
what is our expected output sink model?
what is our maximum allowable inp/out ripple?
what is our minimum allowable safety factor?
what is our target input/output ranges?
(opt) what is our target power transfer?
additional constraints
- components that should not be used
- maximum allowable cost
- maximum number of parts distributors
- etc

source and sink package

Package specifying the types of sources and sinks that are connected to the converter, and how they behave at various operating regims.

topology package

Package specifying the types of topologies that can be implemented, as well as how to (1) linearly solve for a solution and (2) relevant optimization parameters.

The topology package executes relevant component subpackages and simulation subpackages.

List of converter topologies:

async boost converter
sync boost converter
...

component package

Package specifying the various components that can be used in the converters, and how to extract relevant parameters from each of them.

capacitors
inductors
FETs
diodes

simulation package

Package specifying the types of simulations that can and should be performed for the topology, including:

thermal simulation of components
steady state efficiency
small signal stability
large signal stability
etc

graphics package

Package specifying the types of output graphics that can and should be generated for the topology, including:

input vs output maps
etc

Optimization of the pipeline

Using some combination of the following to improve optimization and simulation time:

numba
cython
multiprocess
etc

Expand component selection

Expand the existing CSVs to encompass required components. Generate scraping scripts or automation scripts to extract relevant properties.

If this requires narrowing manufacturers then so be it.

dimembermatt commented 1 month ago

specs package

Package specifying what our general design constraints should look like.

what is our expected input source model?
what is our expected output sink model?
what is our maximum allowable inp/out ripple?
what is our minimum allowable safety factor?
what is our target input/output ranges?
(opt) what is our target power transfer?
additional constraints
- components that should not be used
- maximum allowable cost
- maximum number of parts distributors
- etc

{
    # OK
    "NAME": "Broad range MPPT",
    "AUTHORS": ["Matthew Yu", "Jacob Pustilnik"],
    "DESCRIPTION": "MPPT Boost Converter v0.3.0",
    "DATE_DESIGNED": "05/23/24",

    # TO MODIFY
    "DESIGN": {
        "input_source": {
            "source_model_type": "solar_cell", <- specify different types of models
            "cell_type": "Maxeon Gen III Bin Le1",
            "num_cells": 111,
            "r_sh": 40,
            "r_s": 0.0035,

            # converter specs           <- move to separate group
            "inp_ripple (V)": 1.0,
            "user_v_range": [20, 72]
        },
        "output_sink": {
            "sink_model_type": "battery",
            "battery_type": "INR21700-M50LT",
            "num_cells": 32,

            # converter specs           <- move to separate group
            "out_ripple (V)": 1.0,
            "user_v_range": [80, 125]
        },
        "safety_factor": 1.2
    }
}

source and sink packages

-> generic models for the following

solar cell
batteries
resistive
capacitive
inductive
combination of the last three
power supply

should generate a graphical and textual representation of the below ->

component packages

mosfets
- can't particularly change atp
- ideally we build a test rig and buy all the components and have standardized test methodology like LTT
inductors
- can't particularly change atp
capacitors
- would like to hold both electrolytic, mlcc, film
- need to find out relevant spec to make components comparable
- would like scripts to scrape from selected manufacturers
- e.g. TDK
- consider a vds filtered FOM
schottky
- V_DS
- I_D
- leakage
- R_DS
- R_JB
- R_JC
- T_J_MAX
- P_D

-> optional: end of design creation

get all the distributors and costs for component for all components
select for cheapest distributor
tally up total design cost
generate spreadsheet of items to buy

dimembermatt / MPPT-Design

Define scope of SW optimization and simulation pipeline #16

Modularization of the pipeline

specs package

source and sink package

topology package

component package

simulation package

graphics package

Optimization of the pipeline

Expand component selection

specs package

source and sink packages

component packages