FINAL PRESENTATION
ON
INDUSTRIAL TRAINING
Submitted by :
VARUN SHARMA 22104001
Under the guidance of
DR. VEERKARAN GOYAL
DR. AJAY KUMAR
INDUSTRY MENTOR
PROFESSOR, COLLEGE MENTOR
DEPARTMENT OF ELECTRICAL ENGINEERING
PUNJAB ENGINEERING COLLEGE
CHANDIGARH, 160012
INTRODUCTION TO COMPANY
• FOUNDED : 1999
• INDUSTRY: Power Electronics
• SPECIALITIES : Fully integrated in-house electronics research, design, and
manufacturing capabilities.
• KEY CLIENT : Indian Railways
• CORE FOCUS : Sustainable and Clean Energy Innovation
• LOCATION: Parwanoo, Himachal Pradesh
Page 2 of 67
TOOLS & SKILLS
• Code Composer Studio
• Texas Instruments DSPs TMS320F28379D, TMS320F280033,
TMS320F280137.
• Digital storage oscilloscope/DSO .
• Embedded C.
• Firmware Development
TMS320F28379D DSP
TMS320F28379D (Most General)
What is it?
• A high-performance digital signal processor (DSP) from TI’s C2000™ MCU series.
• Designed for the intensive math operations, like performing FFTs, executing control
loops, doing trigonometric operations using specialized hardware units like TMU,
FPU, CLA, VCU.
Specifications:
• Dual C28x CPUs with operating speeds upto 200MHz.
• Has modules like PWM, ADC, DAC, I2C, CMPSS, TRIP for different tasks.
• Floating-Point Unit (FPU) for high-precision float-to-float calculations.
• Dedicated hardware for trigonometric operations (TMU) to reduce CPU load.
• 16-bit ADCs for extremely accurate data acquisition.
• Communication Interfaces: CAN, SPI, UART, I2C, USB.
FIRMWARE DEVELOPMENT.
Embedded
Firmware development lies at the junction of the hardware C file. (.c
files)
and software development. It is defined as the software
which is directly fed to microcontrollers and acts as their Compiler
brain according to which the microcontrollers performs all the
operations. Few points about it are as: Object
files (.obj
• Firmware development at industrial level is mostly done files)
in the embedded C computer language.
Linker
• We code those algorithms which we want our DSP to Linked
perform in the C language in preferably different files files
while using different modules of DSP. (,out, .bin)
• Debugger.
Those different files are preprocessed, macros expanded
and compiled into corresponding .obj files by the Stored in the
flash
compiler. memory of
the DSP an
executes the
algos.
• Then the linker combines all those object
files or .obj files to form a single .bin file
or .elf file which is the final product of the
project
• The DSP Launchpad has its own debugger or
for a PCB, we can use a physical hardware or
TI Debugger. This debugger can be used to
load the .bin file into the DSP or the
microcontroller we are using and the
corresponding algorithm can be executed.
• Firmware development is used to program
several day-to-day where ever
microcontrollers are used like washing
machines, refrigerators, air conditioners and
is certainly called the brain of the
microcontrollers.
PROJECTS DISCUSSION I
Type-2 AC Charger: It is the simplest EV Charger that
can be used to charge both the three-phase and single-
phase vehicles user can start the charging by either
using the RFID or using remote charging option with the
help of the app.
• I have worked on the low level communication (LLC)
part, where I implemented the algorithm to detect the
state of EV charging and building strong
communication over CAN bus with the low level
controller (ESP32).
• Based on commands I receive from the local controller,
my task was to turn on and off the main relays and
Outer case of Type-2 AC Charger.
develop communication over the control pilot.
• Based on the maximum current per phase of 16A and
output voltage as 230V (Phase – Neutral), the power
rating of the charger is kept at 7.4kW.
About the PCB components
A PCB or printed circuit board is a flat board that
mechanically supports and electrically connects electronic
components using conductive tracks (traces), pads, and
other features etched from copper sheets and laminated
onto a non-conductive (insulating) substrate. The whole
PCB can be mostly divided into three parts:
• Control Card: This card include the microcontroller
that is handling all the control loops, using the sensor
outputs, executing the control algorithms actually is the Control Card
brain of the whole PCB. This charger use
TMS320F2800137 with 128kB flash.
• Base Card: This card is directly connected to the
control card using the interface pins. While the control
card contains a general microcontroller and signal
conditioning units, the base card contains the actual
working elements of the circuit to be designed like
capacitors, inductors, transformers, heat sinks, inputs,
outputs etc.
Base Card
About the PCB components
IOT Card: This component of the PCB used to get the
access to internet and sending live data to the data
servers and turning on/off leds like Wi-Fi present led, grid
present led. There are variety of microcontrollers used for
this purpose, the one we used for our case was the ESP32
microcontroller which has IOT capabilities like Wi-Fi,
Bluetooth, MQTT etc. The card is as shown in the diagram.
IOT Card.
Debuggers: Essentially, these are not the PCB
components, but are used to put the binary files
generated by the code editor as explained few slides
before. Both IOT card and control card where the code is
actually put into the microcontrollers, these debuggers
are used and are specific to the manufacturing company
of the DSP or the IOT supported microcontroller. The code
Debugger Probe (With JTAG)
is fed into the controller using interfaces using JTAG.
Actual Project Working
EVs are the future of sustainable energy. With the increase In the
number of the EV buyers, there is also a need to correspondingly
increase the number of EV charging stations as well as personal EV
chargers for charging those EVs. So for the reliable charging, the
international community has a well defined set of rules as defined
in IEC 61851. In the adjoining diagram, apart from three phase
outputs, there are also three more outlets which are specifically for
serving this cause. Before moving to them we need to know what
are the things we need to communicate for robust charging:
Charger Socket Diagram
• Charging State: It means whether socket is plugged in or not,
EVSE is able to supply energy or not, EV is in charging state or
EV (Electric EVSE (Electric
not and based on these, there is a set of six charging states. Vehicle) Vehicle Supply
Equipment)
• Maximum load current: The EVSE and car may not be of similar
power level, so the EVSE needs to effectively communicate the
maximum current EV can draw from it to avoid overload cases.
• Fault Detection: EVSE and EV must be able to communicate any
fault condition to each other to avoid any disorderness.
Solution to problems : CP-PE
communication
The parameters mentioned in the previous slide are
communicated using the control pilot (CP) outlet of the socket
with potential earth (PE) acting as common reference for EV
and EVSE. Means of communication of control pilot:
• DSP (TMS320F2800137) generates a PWM using its
dedicated and precise EPWM module. As per IEC, the PWM
frequency is fixed at 1kHz. This PWM generated pass
through the signal conditioning unit to give an output PWM
oscillating between the +12V and -12V levels. Because of Charger Socket Diagram
diode, car sees PWM between 0V and +12V. When not
connected the sensor detects high level as +12V or STATE A
as per IEC (International Electrotechnical Commission).
• As EVSE is plugged in, the resistor R3 activates and draws
power and the voltage sensed by EVSE (PE is shorted to
chassis) is 12* 9V (STATE B). Now EV takes it time to starts
it own charging process and as soon as it is ready it switches
the switch S2 ON and the resistor R2 comes in parallel with
R3 and the new voltage detected is 12* (STATE C or EV
charging) Control pilot communication circuit.
CP-PE in max load and fault handling
Now in the previous slide we were detecting state using the
high level of the PWM but we forgot very important parameter
of a PWM its DUTY CYCLE. The max load current is
communicated using the duty cycle of the PWM as follows:
Minimum Maximum Duty Cycle
Current (in A) Current (in A) (in %)
6 51 Iav / 0.6
51 80 (Iav / 2.5) +
64
• If EVSE detects any fault it lowers it duty cycle to 0 to
indicate faulted state and voltage sensed is -12V and EV will
immediately detach the socket and state is STATE F.
• Again if somehow the control pilot and potential earth shorts
the voltage sensed by the sensors will be 0V and this state is
called as STATE E.
PROJECTS DISCUSSION II
Alternator Battery Charger: It is used to charge the battery
of the rail wagons. It uses the kinetic energy of the axle of the
wheel to generate electric power using a PMSM (Permanent
Magnet Synchronous Machine) which is rectified using a Full-
Wave 3-Phase Rectifier and finally regulated using a buck
convertor inner-outer control loop and finally a 125V volt
output supply is used to charge the battery which later powers
the whole wagon.
• The maximum output current is rated at 6A and maximum
output voltage is at about 125V which makes its output
power stand at about 750W. Further it is designed for
maximum rpm of about 900rpm with maximum DC link
voltage of about 800V.
• It is primarily for the non-AC wagons, where the energy
About the project
Like mentioned during Type-2 AC Charger PCB
components. Alternator Battery Charger has also a:
• Control card with DSP TMS320F280033. Control
card for a PCB seldom changes in terms of the
signal conditioning circuits. Only DSP is chosen
according to the project. Current DSP has 256kB
flash memory to store code with clock frequency of
120MHz.
• Base card with buck convertor, rectifier and other Alternator Battery Charger, Base Card
required components
• IOT card with ESP32 for connecting to the Global
Positioning System (GPS) to measure the train
speed, location and other parameters and sending
the live values to the railways servers for real time
monitoring of the whole system.
• LCD module, for user to view the current voltage,
current, temperature of inductor core and copper
and heat sink temperature.
Control Card
Power flow diagram
As shown in the flowchart, the axle serves as
prime mover for the alternator. As the axle of the
train rotates, the PMSM generates three-phase
power at its output. Three-phase power is rectified
using the full-wave rectifier as shown in the
digram. The buck convertor control has been
programmed in such a way that software
implemented controller activates as soon as the Flow Chart of Alternator Battery Charger
DC link voltage at the output of the rectifier
reaches or crosses a level of 130V.
The reason for using the full-wave rectifier instead
of the half-wave rectifier is that output of the full-
wave rectifier produces 6-pulse ripple which
produces multiples of 300Hz noise at its output as
compared to multiples of 150Hz in the case of the
half-wave rectifier. Clearly the one produced using
the full-wave rectifier can be easily made noise- Schematic diagram
free using simple low-pass filter.
In DSO, I observed a noise of 300Hz because of
this full wave rectifier.
Buck Convertor Inner-Outer loop control
We have followed a hit and trial method approach for
the Kp and Ki tuning. For the low overshoot dynamic Kp
and Ki are programmed as follows:
• Before the buck convertor reaches its reference
values the Kp and Ki are 100x smaller than their
normal values to avoid the overshoot.
• As the reference voltage is reached once, Kp and Ki
are set to their normal values and the voltage is
strictly monitored.
• As the voltage crosses a range of (Vref-15V, Vref+15V),
the Kp and Ki values are increased 5x for quick
control of the voltage to their in-range values.
• To handle the no-load condition; as the battery is
removed or sudden no-load occurs due to some
reason, the output voltage overshoots. To prevent
this, as the voltage crosses Vref+25V, the controller
stops and does not start until voltage reaches
reference value.
Dynamic Saturation: Drawing of excessive current
leads to desynchronization of the PMSM. To prevent
this current saturation capping is used to make sure
that current never crosses maximum current at given
Experimental Setup
CCS Window
Graph of the desired
parameter.
Debugger
TMS320F28379D
DSP Launchpad
Debug Probe
References
1. Electro Waves Electronics, Official Website, Available:
https://electrowaveselectronics.com/.
2. Texas Instruments, Official Website, Available: https://www.ti.com/.
3. Texas Instruments, TMS320F2837xD Dual-Core Microcontrollers Technical
Reference Manual, SPRUHM8, Available: https://www.ti.com/lit/pdf/spruhm8.
4. Texas Instruments, TMS320F28379D Datasheet, Available:
https://www.ti.com/lit/gpn/tms320f28379d.
5. Texas Instruments, LAUNCHXL-F28379D LaunchPad Development Kit User
Guide, SPRT720, Available: https://www.ti.com/lit/pdf/sprt720.
6. Texas Instruments, F2837xD Microcontroller Workshop Manual, Available:
https://software-dl.ti.com/trainingTTO/trainingTTO_public_sw/c28x28379/
F2837xD_Microcontroller_MDW_2-0.pdf.
7. Keysight Technologies, Oscilloscopes, Available:
https://www.keysight.com/in/en/products/oscilloscopes.html.
