Ahmed zahran power electronics projects portfolio

AHMED ZAHRAN

Ahmed Zahran eng.ahmed.zahran2010@gmail.com

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

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.


Modular Multi-Level converter – design phase


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.

Circuit design, PCB layout, 3D circuit view, Components soldering, DSP MATLAB
software, CANalyzier interface software, Commissioning for the setup.


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).


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).
Circuit design, PCB layout, 3D circuit view, Components soldering, DSP MATLAB
software, CANalyzier interface software, Commissioning for the setup.


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.

Circuit design, PCB layout, 3D circuit view, Components soldering, DSPIC33F C
coding, part of the Labview software, Commissioning for the setup.

Flow Meter Board Labview block diagram

TEST

HALL
EFFECT



1

3

5

7

2

4

6

8

SOLENOID 1
ON / OFF



PRESSURE SENSOR 1

TEMP

DEPASSIVATION
ON / OFF



ACCELERATION SENSOR

PRESSURE



BAR

X-AXIS

TEMP

K

Y-AXIS
Z-AXIS

PRESSURE SENSOR 2

PRESSURE
TEMP


BAR
K

BATTERY

VOLTAGE

V

CURRENT

A


Flow Meter Board Labview block diagram

CHARTS

SCAN TIME
EEPROM DATA

SEC

SCANNER

SAMPLES

SAMPLES



PRESSURE 1 SENSOR

VOLTAGE,
CURRENT

PRESSURE,
TEMP.

BATTERY

TIME



ACCELERATION SENSOR

X-AXIS, Y-AXIS,
Z-AXIS



TIME


TIME


PRESSURE 2 SENSOR

BOARD TEMPERATURE

1

3

5

7

2

4

6

8

DEPASSIVATION
ON / OFF

TEMP

HALL
EFFECT

PRESSURE, TEMP

SOLENOID 1
ON / OFF

TIME


TIME

Flow Meter Board Block Diagram

POWER SUPPLY
UNIT

SOLENOID UNIT
Solenoid drive (20V,1A)
Solenoid current sensing

Buck converter 10VDC/1A and 3.3VDC/1A
Battery current sensing
Voltage current sensing
DE passivation circuit

CONTROL UNIT
BOARD TEMP. UNIT

ACCELEROMETER
UNIT

DSP, EEPROM, Voltage reference, Clock
oscillator, RS485 interface

X.Y and Z directions sensing

RTD board temperature circuit

HALL EFFECT
SENSORS UNIT
Eight hall effect sensors interface


PRESSURE SENSOR
UNIT
Two pressure sensing interface circuits
Sensor Temperature measurement

Flow Meter Board


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.

Circuit design, PCB layout, Components soldering, DSP TMS320F28335 MATLAB
software for open loop and Commissioning for the setup.


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) .

Circuit design, PCB layout, 3D circuit view and Components soldering.


VOLTAGE AND CURRENT TRANSDUCERS


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.
Circuit design, PCB layout, 3D circuit view, Components soldering, acrylic

enclosure design, setup harness, Matlab code by using TMS320F28335
EZdsp board


Five Phase Inverter


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).

Circuit design, PCB layout, 3D circuit view, Components soldering, Matlab code by
using TMS320F28335 EZdsp board


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.

Circuit design, PCB layout, 3D circuit view, Components soldering, Matlab code by
using TMS320F28335 EZdsp board


Single 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.

Circuit design, PCB layout, 3D circuit view and Components soldering.


MOSFET/IGBT GATE DRIVEs


Three Phase Low Pass Filter


Thank You


Ahmed zahran power electronics projects portfolio

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