The Control Boards

Smpc-three Overview

Application Functionality

Energysat has designed the Smpc-three  with the main objective of simplifying the project of a huge range of products as data acquisition, precision instruments, converters, AVR´s, VSC´s, Cycloconverters, medium power SMPS, motor controls, smart grid, control systems,  UPS and other applications.

The heart of the board is the 60Mips DSP.  A Microcontroller with 12 PWM generators that can be directly applied to command  UPS, motor inverter systems with great flexibility. Those PWM generators can be set to work in pairs or isolated, enabling the use in many applications. When working in pairs, they present a controlled dead time.  That is very important in the control of power converter bridges, not only avoiding unwanted saturation overlap between the same arm switches (BIPOLAR, MOSFET or IGBT transistors) but simplifying the reduction of distortion in 3 levels inverters and additionally controlling and avoiding unwanted DC load components.

The Smpc-three board are entirely parameterized by external software that has a friendly graphical interface, therefore simplifying the process.

For Developers, the board is equipped with a JTAG that can be connected directly to the Codewarrior, creating a pleasant development environment and simplifying the development process.

The current work is an UPS application project employing those elements (Smpc-three board and the DSP56F8346 ). It is equipped with a series of advanced features as unit power factor due to its new PFC topology, totally DSP controlled, redundancy through tests of non consistency, remote management, remote adjustments, remote maintenance, monitoring and others.
 

Benefits of the Solution.

This UPS System presents many features that can simplify the Time To Market process. The first is the application of a control system, where all the problems of EMI/EMC have been solved in order to avoid noise problems that is one of the most often headache creators of the job.

All wiring in the system is done by Flat Cables to avoid human errors. Only the power part and short thin control wiring are made by single conductors. For this purpose the cards are placed near their working places and interconnected by flat cables. With 60 MIPS operation and a broad range of instructions (such as MAC multipliers), it has became possible to implement functions that have never been seen in any other systems of its class.

Why should I use the SMPC-three Board?

On a higher level project , in the same way that EnergySat has chosen The 60Mips Microcontroller as the heart of SMPC-three card project due its features, the SMPC-three card is the right choice for UPS manufacturers to use it as the UPS central control. There are some benefits in using it:

Optimized Time to market, due to the fact that all electronic controls are included in SMPC-three board, For other UPS projects, Galvanic Line Isolated UPS through High frequency converter, Non Line Isolated bridges UPS (Industrial Type) and Battery adaptor converters (An Improvement of the present UPS enabling the use of the UPS with any number of battery cells), please refer to the Smpc-three board optional manual.

Cost savings: Human resources like IT professionals, Power Electronics Engineering, Testing Engineering needs are considerably reduced.

Computer tested equipment where human intervention is not necessary. That software is available for factory usage..

Logistics: Flexible System, therefore reducing the BOM.

Warehouse optimization due to a single control card use for a broad range of UPS Systems.

Remote Management facilities, with several software versions for each application.

Size: only one very small card is responsible for the control of the whole UPS System.

Updates: The system can be updated remotely on the fly, with a very short interruption in order to assure its modernization all the time.

High Flexibility - It's adaptable to any system configurations, by the board parameterization through external PC software, "Ups monitor factory".

High reliability - The system is based upon Digital Signal Processing with the lowest number of circuits possible, presenting high MTBF (Mean Time Between Failures) and due to its modularity, it presents low MTTR (Mean Time to Repair).

High Precision - all the measurements made by SMPC-three present high precision, and have been made in their adequate forms, as the TRUE-RMS in AC measurements and control (Voltages and Currents), and average values for DC signals, are all made in real-time and implemented using DSP digital filters.

Parallelism. The parallelism can be done in two ways: Master-slave (Parallel passive) topologies, where You employ only one control and several power systems in parallel. This system is usefull for obtaining high power equipment, from paralleled small power modules. Parallel redundant (Parallel Active) topologies, where all equipments are paralleled for higher powers or implementation of very high reliability systems. EnergySat has a trully parallel redundant system, without any critical node in the reliability tree. No parallelism board is needed (whose employment entirely degenerates the reliability). In our case the parallelism is done through a pseudo CAN bus in combination with fiber optics system, in order to prevent critical concentration nodes.

A third parallelism system employ active-reactive power technology with real time current regulation, that  locks the phase of the inverter with a fixed line. This is useful in systems of parallelism with the mains for bilateral power flow in smart grid systems.

Connectivity - Connectivity is quite simple when using SMPC-three, it has built-in RS232 or RS485, and external ETHERNET and FAST-ETHERNET modules, implementing all the most important INTERNET layer application protocols: HTTP, TELNET, SNMP and SMTP. And EnergySat can provide you with a great range of softwares and even implementing special customized applications.

    There are two versions of the Smpc-three board: The first is with fiber optical ports, for high voltage inverters, preventing noise from the main bridge or an additional isolation between power and control. The second one is with electrical ports with connectors installed in the same space occupied by the fiber optical ports. If needed we can send the boards without any output port, that can be installed at the moment of production.

    Normally we supply all boards needed for an application, power supplies, signal conditioning boards, gate drivers, transfer switch gate drivers, display and keyboard but we can agree other solutions as needed.