Fuse Demonstrator Document - 123

Proven Engineering Ltd.

FUSE DEMONSTRATOR DOCUMENT - 123

Application of Micro-controller to Wind Turbine System

Abstract Proven Engineering Products Ltd. is a mechanical engineering company with facilities for machining, welding and plastics formation specialising in renewable energy sources. The objective of the project was to improve the human interface and control features of the well established wind turbine system for off grid power supplies with micro-controller technology. The introduction of microcontroller technology will enable a gain in market share and the knowledge transferred into the company to allow further development and new products. The applications for wind turbine system are in remote houses and farms, telecommunication sites, etc. both in the UK and world-wide for the generation of off grid power. The renewable energy market is growing, and in order to sustain growth and competitiveness, Proven needs to make its wind turbine system more user friendly; more capable and adaptable, and to provide customisable features for the growing market. Our present system is not customisable and requires costly factory set up procedures of many potentiometers and other discrete components. The user has a tendency to modify the settings in the field which most often require the unit to be returned for calibration. With the micro-controller controlled system set up procedures for the user to operate can be included and Proven expect to gain market share by supporting extra features. There is also an emerging market from the industrial sector that demands extra features from such equipment that must be customisable from installation to installation. This can only be done by the use of electronics more advanced than discrete components. This represents a major leap in technology for Proven Engineering Ltd. who are a mainly mechanical engineering company. There are two main types of wind power systems. The first is a simple system which supplies a simple load for water heating for example. In the second more complex system the wind turbine charges a bank of batteries whose dc voltage can then be converted into domestic 230V ac power. Presently the present system requires two systems, however, with the microcontroller system both types can be incorporated on the same board and even integrated to work together where appropriate. A user interface via a keyboard and LCD status display is included in the new microcontroller system. The existing system provides only very crude load control with difficult to use and adjust analogue monitoring circuits. There is no friendly user interface either for the input of information or for display. The cost of the experiment was ECU 47k and was scheduled to last for 14 months. The duration of the actual project was 18 months, Several issues contributed to this delay which including the illness of the main engineer on the project and some technical issues with the project. The payback period is estimated to be within two years assuming the sales increase as shown in section 4 and the ROI is estimated to be 400% within a five year period. However, the
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microelectronics unit only represents 5% of the selling price of the completed wind turbine system and the relationship between this project and increased sales is complex. Since it is a part of a system in a developing new market - the project will both increase sales due to better functionality and user benefits and making it easier to produce in the increasing production needs. As can be seen from the figures below in 17, we expect to double our sales next year and increase thereafter - based on actual orders and enquires - so increasing both turnover and profitability. There were many lessons learned during the project, with perhaps overcoming the fear of new technology with help and support being the greatest; and the choice of micro-controller that best suited the expertise of Proven and the application. There are perhaps lessons to be learned for the microcontroller industry as well - more work needs to be done to enable small non-electronics companies like Proven to easily assimilate and use microcontroller technology in their products. Another major lesson was the need for detailed planning at the start of the project and accurate monitoring throughout the duration of the project. There are several routes to economic benefit from the project. Reduction of overall system cost. When an integrated inverter module is included there will be a significant ( ECU2500 )reduction in system cost so making sales easier in a capital cost sensitive market. This will also allow in house manufacture of more of the system rather than import from the USA. Reduction of circuit board stocks. Presently two very different boards are used with different assembly and set up needs. The microcontroller system will have only one board for all functions. Combined with the increase in sales this will for the first time allow sub contract board manufacture in economic batches so cutting costs and improving quality.

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1. Company Name and Address Proven Engineering Products Ltd. Moorfield Industrial Estate Kilmarnock Ayrshire KA2 0BA UK Telephone: Fax: E-mail: +44 (0) 1563 543 020 +44 (0) 1563 539 119 gproven@enterprise.net

2. Company Size The company comprises 12 full time employees and 5 part time. There are three people within the company who have some electronics expertise, this is focused upon simple power electronics with some analogue design. The people involved in the project were Gordon Proven who has a mechanical engineering background but some expertise in discrete analogue electronics. Richard Curtis and Richard Caldow both of whom had a small amount of expertise in digital electronics using 74C and CD4000 series CMOS. 3. Company business description Proven Engineering Ltd is a small independent multi-discipline company with facilities in house for machining, welding, plastics forming, permanent magnet generator construction and basic electronics. Provens main business is in mechanical engineering, manufacturing metal products but we have developed expertise in process control and automation and have developed our own wind turbines using our novel design of turbine blades. Proven manufactures and installs the wind turbine systems which include all the metal work, wind turbine blades, battery and inverter and controller. Only the batteries and inverter are bought in from a third party. These systems are mini power stations for use in remote locations such as houses, farms, remote phone systems, remote water pumps, etc. They require their own power control and management system and it is this that the project concentrates upon. These systems are bought individually by the users. 4. Company Markets and competitive position at the start of the project Proven is operating in a growing World market. We have 90% of the UK market in our size range; and a growing World reputation for wind turbines which are tough and reliable. We have only a few competent world competitors - Bergey of the USA being the most significant. More competitors are emerging and the market is simultaneously expanding rapidly. To stay competitive we have to provide better functionality - especially in Hybrid systems (e.g. Wind Solar Hydro combinations) and lower costs. Without the FUSE project the Proven controller would be seen to be less attractive when compared to our competitors. This would limit the long term growth of the company and without the new controller sales

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would less quickly.

Proven Wind Turbine and Renewable Energy Sales

Year Number of Units Sales Value ,000s
92 1 5 93 16 72 94 10 52 95 14 84 96 22 175 97 30 217 98 44 330 99 95 855

900 800 700 600 500 400 300 200 100 0 92 93 94 95 Year Sales Value ,000s Number of Units 97 98 99

Year

96

Value for 98 extrapolated from first 9 months Value for 99 based on order book and known sales in pipeline. Gordon Proven

To convert to ECU the above figures should be multiplied by 1.5. Proven Engineering has been designing and building special machines and automatic control systems since 1980, and developing small wind turbines (600W to 6000W) since 1981. The Wind turbines have been on the market since 1992 and there are now over 150 systems installed world-wide. These are mainly in the UK but with several installed in the Falkland Islands (over 20 turbines) and South Africa. Other machines have been sent to sites including; Eire, Ethiopia, New Zealand, USA and Japan. During these early years the Wind turbine systems have been adapted to improve customer needs using feedback from existing customers. The main market to date has been from domestic users but there is a growing demand from the industrial field. An example of this is the increasing need for more mobile phone transmitters. These transmitters are being installed in more remote sites as the phone companies strive to increase the service areas. It is frequently impractical to bring mains power to these sites and as they are often exposed hill top locations they are ideal for using wind generated power. Other industrial situations include radio links for conventional telephone systems where the terrain prohibits the use of cables. The domestic market tends to be cost sensitive and the industrial sector is looking for reliability and how the system will function within their existing equipment. The industrial sector often requires the inclusion of certain specifications

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and system operation which may be slightly different than normal. The present equipment is therefore ruled out of this latter market since it is of fixed operation and not easily customisable. It is believed that market share can be gained by the inclusion of more features since customer feedback suggests that it is the features that can tip the balance from a non sale to a sale. This year two of the major UK mobile phone companies have opted for Bergey (USA) wind turbines - in preference to Proven due, we think, to us not being quite ready with our technology for that market. We are expecting to install a test system with one of the other companies (One to One) in the next few weeks. The introduction of the microcontroller based system will allow us to become competitive with Bergey. 5. Product to be improved and its industrial sectors The product to be improved is a wind turbine system controller. Below is shown the PCBs of the existing controller with the sixteen adjustable potentiometers.

Figure 1 shows a block diagram of the existing system. The three phase output of the wind turbine1 is rectified to give a dc voltage which is then used to charge a battery bank. The analogue circuitry monitors the battery bank and, as this becomes fully charged, switches in a load to divert power from the wind turbine, therefore controlling the amount of charge into the battery bank. In periods of time when there has been little wind or when the demand for power has been high then the batteries will become discharged. In this case a backup power source is usually available. This is often an engine driven generator. In many cases the generator will be automatically started before damage to the batteries through overdischarge occurs. The power stored in the batteries can be used directly (e.g. to provide heat through a resistive heating element) or the dc voltage can be converted into a mains ac voltage by means of an inverter.

The output voltage of the Windturbine is low voltage three phase. The magnitude depends on the system battery configuration voltage which is normally 12, 24 or 48 V for battery systems and 120 V or 240 V heating

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Wind Turbine 3ph LV out Rectifier Charge Control Contactors Analogue Control Circuit Backup Generator

Proven Engineering Ltd.

Battery Store

Inverter

230Vac Out

Contactors DC Divert Loads

Relays AC Divert Loads

Figure 1

Block diagram of existing system

The wind turbine system can be used for any low power application where mains electricity is not available such as remote houses, farms, telecommunication sites and third world applications. Many customers with an existing electricity supply and a good wind resource install a system to offset the amount of conventional power used. This has both environmental and economic arguments. The electronics within the present system are realised by analogue designs using discrete components and adjusted by means of 16 potentiometers which have to be set separately for each board produced. This setting is time consuming and requires the use of a bench power supply which can be accurately set to the required switching levels. This makes it difficult to accurately adjust the switching levels in the field and virtually impossible for customer adjustment. However end users have wanted to adjust the levels and attempts have resulted in the need to return the control board for factory resetting. System information is shown to the user via a series of board mounted LEDs and two analogue moving coil meters. These LEDs indicate the state of the contactor and relay switching signals, the meters show battery voltage and charging current. There are several reasons to innovate these are: To be able to compete with our competitors and improve our market share. To be able to reduce assembly and setup costs. To reduce cost of the electronics and to contain all the electronics on one board. To provide digital user control eliminating the use of potentiometers as stated above. To enhance the product by improving the existing functions and features. To make the unit more user friendly by providing a comprehensive user display and input keypad allowing extra features. Using a micro controller with an analogue to digital converter will allow the switching levels to be set in software and the inclusion of a LCD display will allow more system information

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including power etc. to be displayed accurately and replace the two moving coil meters thus reducing the production cost. 6. Description of the technical product improvements
LCD Display

Power Supply
EEPROM

Serial Interface

Key Pad

Real Time Clock PWM signal for proportional load control Generator Start Load Switching

Oscillator Analogue Signals (Battery Voltage, Current) PIC 16C74 Analogue Processing

Output Drivers

Figure 2

Block Diagram of Improved Product

A diagram of the improved system is shown in Figure 2.

Photograph of the microcontroller WT controller with keyboard and LCD display in final prototype form.

hardware and software

6.1

Structure

of

The structure of the software of the improved product is shown in Figure 3. Each of the software modules interface to a central main programme core. This structure allows individual

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modules to be customised and improved with out modification to the main programme or structure.
Keyboard PWM Output LCD Display

EEPROM

I2C

Main Program

Generator Logic

External link Power Clock, etc. Signal Processing

Digital Outputs

Voltage Current

Figure 3 Program Structure The targeted aims for the new product were met and have resulted in a significant improvement in the control electronics of the wind turbine. The equipment is now much more user friendly by the inclusion of the keypad and the LCD display. With a basic keypad some user control of the system is possible. This includes the adjustment of the switching levels from the factory set values. These levels will be shown on the display. This adjustment will allow the user to safely fine tune their system to give the best performance; but by limiting the access for adjustment by the microcontroller potentially damaging adjustment is not allowed. The main effect for Proven, however, by the use of the keypad is the reduced test and setup time in the factory for the wind turbine controller thus reducing manufacturing costs. The method of charge regulation has been improved with more control over the divert loads. The present controller switches in a series of fixed loads. It is preferable for the divert load to be gradually increased or decreased, this has been achieved by the use of a single element with PWM power control. This smoother control is better for the health of the batteries. At present each divert load step is controlled by a separate transistor drive and relay. Hence the cost of the electronics has been reduced, fewer components are used so the control electronics now fit on one board reducing the inventory costs and increasing the systems reliability. Extra outputs have been made available to allow extra features to be added in future models. One such feature is the ability to start and stop a backup generator another is a switched output to provid a warning of low battery condition.

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7. Choices and rationale for the selected technologies, tools and methodologies Several technologies were considered that could be used to upgrade the Wind Turbine System. The main areas of consideration were the effectiveness of the technology chosen, the cost of the technology compared to the predicted sales volumes and the application of the technology to future product development within the company. Although the unit is not particularly price sensitive it must always be borne in mind that the typical customer of this equipment is buying to a budget and hence price considerations are important. The customer must always see value for money and any price increase must be matched to the extra features provided. Advice was taken from Paisley University who conducted a feasibility study into the available technologies, such as discrete devices, FPGAs, ASICs and micro-controllers. Discrete The product could continue to be developed using discrete devices, but there is a very limited scope for improvement. This methodology would greatly increase the component count and so result on a much larger and costly PCB. The increased component count also affects the final reliability of the product. One of the main problems with the discrete system is the difficulty in adjusting the potentiometers which set the switching and hysteresis levels. Expanded displays can not be achieved using discrete components considered essential for the improved device. New features could also not be handled without a complete redesign of the system. PLCs which are easy to program were also considered but were deemed to be too expensive for this equipment. A PLC controlled wind turbine system has already been built by Proven, but it was found that the cost was very high, a typical PLC with analogue inputs, costing almost 1,000 ECUs. This design was too costly for the domestic user Although extremely versatile in industrial control applications attempts to use PLCs in the past for wind turbine control applications have not be favourable. Several external components such as a display module would have to be included in the system further raising the cost of the finished unit. Features such as PWM control would also need to added. The power requirements of the devices also need to be considered. We need a system with minimal power consumption especially in the smaller systems as every watt used by the controller needs to be produced by the wind turbine. PLC tend to assume that there is a mains power supply available.

FPGA products are suitable for handling concurrent tasks quickly which is not a requirement of the Wind Turbine System. Additionally, several supporting devices would be required to complement the FPGAs lack of in-built peripherals which would lead to a high unit cost. Since a real time clock is used in the system a communications protocol would have to be developed which not best suited to FPGAs. There would be a steep learning curve associated with the implementation of this technology in this application resulting in an excessively long time to market. ASIC products were examined, but ruled out due to both the high tooling costs and high unit costs for the volumes considered. Risks are also unacceptably high presenting a very steep learning curve for this technology.

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Micro-controllers Although micro-controllers are relatively slow devices in comparison with FPGAs, they function best in a serial application environment, such as the Wind Turbine System. The micro-controllers have in-built peripherals and are available from a wide family of compatible devices they also have dedicated serial bus I/Os allowing interface to a wide range of serial peripherals e.g. memory, real time clocks etc.. Moreover, the unit costs are low and the perceived implementation speed is higher than with other technologies. The Paisley University feasibility study also concurred that the micro-controller would be the most suitable technology for this application.

Several micro controller families were initially considered and development began using the Thompson ST6 family. This family met all the hardware needs required for the planned product. These included analogue inputs, on chip EEPROM for user parameter storage and a PWM feature. Another major benefit seen was the availability of a high level graphical programming aid called Realiser. This allowed the required design to be entered in a schematic form and then a complete programming code file is generated ready for downloading to a specified Thompson micro controller. Proven were concerned that knowledge transfer should take place but being a small company it was only possible to dedicate one employee to the main programming aspects of the project. As the knowledge gained would be lost if that employee left the company, the deciding factor to choose the Thompson ST6 was that it could be programmed easily by the use of the Realiser software package, and so any of the engineers in the company could easily acquire the knowledge needed to use and maintain the system.. It was also felt that code changes after a length of time would be easier if they were made to a schematic rather than following thorough a program listing. This program listing possibly originating from another person. To produce a programming file from the Realiser the user simply draws the required system from a library of logic functions, timers, counters, etc., and indicates which pins of the micro controller are connected to the various inputs and outputs of the schematic. The software allows the circuit to be simulated and tested with a range of virtual instruments and at the press of a button produces the required programming file. Using this software package meant that in a very short time a first micro controller board was built which replicated all the functions of the existing controller. One of these early ST6 based boards was incorporated into a wind turbine system and installed in a customer application. This controller has been working without a problem since being installed. However, it was discovered that it is very difficult to represent some of the required functions in a schematic format, for example initialisation of the LCD display but only once when the program began. At this time in the project Paisley University (the TTN) was attended for a course in LCD displays. This was the first formal training undertaken. On the course the Microchip PIC family was introduced. The instruction set for these microcontrollers was fairly simple to learn and it was discovered that there was a wealth of information from the manufacturers and also many third party sources. Following the course it was decided to focus the design on the PIC microcontroller family.

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As the micro-controllers form a significant part of the control PCB, which was designed and made in-house using the layout package EasyPC, initial testing was carried out after the PCB had been populated and assembled. This included basic functionality testing by means of a small test rig at an electrostatic-free workstation. Final testing was carried out on the fully assembled unit operating in a diagnostic test sequence 8. Expertise and experience in microelectronics of the company and the staff allocated to the project The electronics expertise with Proven Engineering at the start of the project was limited to the design and assembly of discrete circuits and some expertise in the programming of PLCs. Three Proven staff were allocated to the project - Two with Mechanical Engineering degrees and one with an Electrical HNC. All have experience in the Renewable Energy Field and are familiar with the requirements for the Control system. Although discrete analogue electronic controls had been developed and used over several years there was no-one in Proven with the appropriate knowledge or experience to enable a move into Microcontroller technology with the complex real time feedback control systems needed for effective system control and stability. Several attempts to assimilate and master micro processor technology had been made in the past but without result. 9. Workplan and rationale

The work plan and effort in person days together with estimated costs is shown below. The first table below indicates the effort and costs, both planned and actual and the other the schedule that was planned in the original Technical Annex before the start of the Application Experiment. Due to illness and some design changes the project needed to be extended by four months, this is reflected in the extra time spent on the management and design of the wind turbine system.

Estimated
Activity Management Training Specification Design Evaluation Effort in person days 39 20 34 56 85

Actual Costs kECUs

6.0 8.5 6.4 10.7 16.0 Effort in person days 45 23 44 94 96

Costs kECUs
8.7 8.0 5.7 12.3 12.5

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The original workplan is shown below. Activities

Management Project Management Specification Functional Spec. System Spec. Technical Spec. Training Micro-controller Training Design System Level Sub system Level Evaluation Prototype Production Test set up Functional Test Prototype Test Field Test

Month
1 2 3 4 5 6 7 8 9 10 11 12 13 14

X X

X X X

X X X X X X X X X

X X X X

X X X X X

X X X X X X X X X X X X X

Approval was sought and authorised for the experiment to be extended by 4 months due to illness and the extra time needed to improve the operation of some software algorithms discovered during the field test stage of the project. This added two months to the project between months 7 and 8 and months 10 and 11 of the original schedule shown above. 9.1 Management Management time was allocated throughout the project. The time spent was not only the regular management of the project but also time allocated to the monthly monitoring meetings and the preparation of the monthly reports. An extra 6 days were spent on the management of the project over that planned due to the time extension. 9.2 Specification The specification of the product was scheduled during the first three months of the project and a specification was completed in this time frame. The initial plan was to use the ST6 micro-controller from Thompson, the main reason being the associated Realiser software package that allowed the design to be entered in a schematic form to produce the correct coding. This micro-controller was chosen since it was felt that this would provide a simple learning curve for micro-controller technology and contained many in-built peripherals. However, the Realiser software was limited in the functions it could produce and as a result of the training undertaken at the University of Paisley a major change was made to the specification. It was decided to use PIC micro-controllers for all of the design. This is explained more fully in the design section. As a result of this change extra time was expended on the specification in month 8 and 9 extending the specification period by 10 days. 9.3 Training The University of Paisley provided formal training and some design assistance on the use and

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operation PIC micro-controllers. The training, tailored to Provens needs, focused upon the programming and features of PIC micro-controllers since this was the now chosen microcontroller to be used in the wind turbine project. Three Proven staff attended the Paisley training programs. The training comprised of one two day course and two three day courses early in the project. The two day course was an introduction to developing PIC based micro-controller products. The two three day courses focused upon driving LCD modules by the micro-controller and the serial bus operation of the PIC Micro-controllers. Informal training was undertaken separately by extensive use of published literature and data CD Roms. Arizona Microchip, the manufacturers of PIC micro-controllers also have a comprehensive web site containing many worked examples of typical programme modules. We also had contact with two other FUSE project teams to discuss issues and ask advice. 9.4 Design The design section of the project was extended due to several reasons the primary one being the change from the SGS Thompson Microprocessor to the Arizona Microchip PIC microcontroller. The changes to the specification have resulted in what we believe to be a much better product. Also during the actual field tests ( as opposed to simulated testing ) it was found that some of the control algorithms were not able to cope with the constantly varying input from the wind generator. These had to be refined and added to the time. Time was also spent upon the analysis of an inverter module. This activity although extending the time spent on the design phase of the project, has enabled us to gain valuable knowledge of inverter technology and operation allowing the accurate specification and purchase a commercial inverter that meets the requirements of the wind turbine operation. The load control has been refined so that in place of the regulating inverter module the microcontroller now uses its Pulse Width Modulating functions to control a pulsed DC system. This is integrated into the system rather than being a separate controller as previously envisaged giving much greater control of the loads. This was not in the original specification but was included as our knowledge increased regarding the features and operation of microcontrollers. The printed circuit boards were manufactured in-house using single sided copper board to reduce the costs. It is planned to have these professionally made for the production machines. The costs of the design exceeded the original estimate due to the change in microcontroller. Some cost were, however, saved since the design of the inverter module were not persued. 9.5 Evaluation and Testing As shown in the software programme structure the wind turbine controller was developed in a modular fashion. As each module was designed and the software developed the hardware and software of the module was thoroughly tested and correct operation verified. On the bench with test equipment it is possible to simulate instantaneous operation but in real life the wind which drives the turbine is never constant and hence the controller is dealing with a constantly varying input that is impossible to simulate with bench instruments.

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Throughout the duration of the project, development has continued using two prototype boards. One of these has been used with the emulator for bench testing. The other has been installed within a wind turbine system at the Proven Engineering factory. This has allowed ongoing testing with a real system as soon as a new section of code or circuit has been completed. The testing of the code has been completed with the watchdog feature of the micro-controller inhibited enabling all faults and software problems to be monitored by disallowing the micro-controller to enter its reset routines if a fault is detected. During this extended testing in real wind conditions as described the software algorithms had to be fine tuned to cope with the constantly variation of the wind. These tests could not be done on the bench and are necessary since the welfare of people and the successful operation of remote repeater stations need to operate with minimum maintenance because of their remoteness. Evaluation time of the product approximated the time planned in the original proposal. 10. Subcontractor information University of Paisley, High Street, Paisley, PA1 2BE, Scotland Phone (44) 141 848 3419 The University of Paisley was chosen as the training subcontractor because of its closeness to Provens premises (only 30 Km from Provens premises) and for its ability to tailor courses to the specific companys needs. The costs were also competitive. All thses matters regarding the content of the courses and the costs were discussed and a contract written and signed covering all the relevant points before the training commenced. The training focused upon the programming and features of PIC micro-controllers since this was the chosen micro-controller to be used in the wind turbine project. The training comprised of one two day course and two three day courses early in the project. The two day course was an introduction to developing PIC based micro-controller products. The two three day courses focused upon driving LCD modules by the micro-controller and the serial bus operation of the PIC Micro-controllers. Design assistance was also provided by the University of Paisley. EMC Compliance Services 15 Hal Road Nemphlar Lanarkshire ML11 9JE This subcontractor was used for design assistance and advised Proven on our design with reference to compliance to EMC regulations. The circuit and its operation were reviewed by EMC Compliance Services for problems who

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advised on minor changes in PCB layout etc. No formal testing for EMC compliance was performed since this will be done on the completed unit. No charge was made for this EMC design advice. 11. Barriers perceived by the company in the first use of the micro-controller technology The main barrier perceived by Proven was the knowledge barrier. The electronics experience in-house was only concerned with simple discrete circuits. There was no knowledge of digital electronics and hence how to develop a development schedule for a micro-controller. However, Proven knew that the knowledge of digital electronics would enable them to produce products to serve many different applications related to renewable energy and so felt that to subcontract the design would be the wrong thing for them. The initial choice of micro-controller was influenced by this gap in knowledge since we felt that we should use the simplest method of data entry and this seemed to be provided by the ST Realiser system. This micro-controller also had a number of built in features not available with other products, although able to be added using external components utilising the serial bus. Since Proven sells the wind turbines in very low volumes it is difficult to use contractors for the electronic assembly. A subcontractor minimum assembly run could provide the electronics for well over a years production causing cash flow problems. The result is that subcontractors for assembly can not be used and Proven must acquire these skills of assembly and microcontroller development. There was also a financial barrier which prevented Proven launching into the unknown, however, we did believe that we needed to make a leap in technology to keep our products up to date. If this did not happen then Proven would be more reliant upon their metal work skills, this would hamper growth of the company and make our products less competitive in a rapidly developing market. 12. Steps taken to overcome the barriers and arrive at an improved product We at Proven knew that the wind turbine system had to be improved to enable our market share to grow and to be able to provide features to ensure its long term sales. Several years ago we approached the Department of Applied Physics at the University of Strathclyde who conducted a feasibility study concluding that the microprocessor technology could be used in an improved wind turbine. Several years later we heard about the FUSE programme through advertising by the TTN and we contacted Paisley who did another feasibility study. Because of the great advances in micro-controller technology Paisley we were convinced that microcontroller technology was the most suitable for the wind turbine project. Several other technology options were considered. The structured approach taken in developing the Fuse proposal which included the detailed project plan gave us further confidence that we could complete the project and its detailed approach allowed a costed plan to be developed. Within this plan the ROI and payback period for the investment were also calculated. This further gave us confidence that the

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project should be completed using microcontroller technology. A training was also developed which not only included formal training and design assistance but also included the use of the Web for information and access to other independent experts who could go into more detailed training on the specification and design of high current equipment. The financial support that the Fuse programme provided was very important and this removed the financial barrier although we now see that we will be able to recover the cost of the development relatively easily with the increased volume and selling price of the wind turbine with the extra features. Throughout the project we also found networking with other First Users useful in giving us insights into others experiences etc. 13. Knowledge and experience acquired The main area of experience gained is in managing a complex project involving microcontroller technology at the core. The training courses were of great help in acquiring the technical skills quickly. We now have the capability to specify and design micro-controller projects using the knowledge we have gained from this FUSE project. This has already been shown by our first replication project using a micro-controller. This is an automatic start for a diesel generator which is incorporated into a micro hydro power installation. The involvement with the electronic peripherals including LCD displays, keyboards, memory and serial busses has generally updated electronic skills. Whilst sourcing these parts from technical catalogues and journals other equipment and information was discovered which has been useful in other areas. The above training and experience equips us to define and develop microelectronic projects for the future growth of the company. Our design skills have been enhanced through our attempt to design the inverter and a better working knowledge of power electronics has been gained including the use of IGBTs. Although the final use of power electronics in the project has been limited to the PWM switched load, the early experiments and investigations into IGBTs has led to these devices being used as a replacement for MOSFETs in the Proven Wind Turbine heating controller. The IGBTs are considerably less expensive than the previous devices used and have proved over a 12 month period to be greatly more reliable increasing our competitive position. Through the use of the PCB layout package EasyPC we are now able to manufacture our own PCBs. This package, EasyPC by Number One Systems Ltd., is only a simple design package but it has enabled Proven to develop our own prototype boards saving development costs. We do plan for the final production unit to have the board professionally made by a local PCB supplier. The manufacturing contract is being developed and training and experience the FUSE project has given us in dealing with subcontractors gives us confidence to use such subcontractors.

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Most gratifying to Proven was the fact that we have been able to complete this project using totally new technology to us with the training and design assistance suggested in the original plan. 14. Lessons learned Many lessons were learned throughout the execution of this project. A surprising number from going down paths that did not go anywhere but introduced us to other aspects of electronics that was beneficial to the overall project and to our present products providing greater reliability e.g. the use of IBGTs. The instruction set for these micro-controllers (PIC) was fairly simple to learn and it was discovered that there was a wealth of information from the manufacturers and also many third party sources. Microchip provide a CD-ROM with comprehensive device information and large library of applications and examples which has proved a great help and is recommended for all users. They also provide a good telephone technical help line. This helped us, with training, to use assembly language programming of microcontrollers. Micro-controller technology, with the correct guidance, can be adopted by companies who have little electronic engineering knowledge; but a great deal of time and expertise had to be acquired before we could achieve the complex control systems we needed. The time required for software development should not be underestimated, sources of good examples of coding can be found by using the Internet. The knowledge on how to use a micro can be fairly quickly obtained but coding can take a lot of time. There are discussion groups where solutions to frequently encountered problems can be found. These are published on Bulletin Boards where examples of code are also posted. Good early planning is essential to make the best use of the micro controllers features, but of course until the capabilities are well known this is not always possible, this is where early design assistance and training is most useful. Care and consideration is necessary in the selection of the function of each I/O pin to optimise the function and minimise coding changes. An example of this was the use of two I/O pins for the inclusion of a watch crystal so that time counts of several seconds could be achieved. Using the internal microcontroller clock it became difficult to set a counter to measure times of more than fractions of seconds. From application notes it was seen that with the addition of a watch crystal one of the internal timers could be set to measure periods of several seconds. This crystal required the sacrifice of two particular I/O pins. These pins were being used for other purposes and therefore the code had to changed. At this point in time all the I/O allocation was reviewed and changes were made in several sections. These changes were possible as the final hardware layout was not fixed. If we had been at the stage where a hardware layout had been finalised then we may not have been able to use the timer controlled by a second crystal. A software fix could have been made but would not have been the simplest solution. The above example was the result of continuous learning and not just down to poor initial

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planning. On the more complex micro controllers there are so many inbuilt features and functions that it is difficult for a first user to incorporate them into the initial design. As time passes something may be discovered in an application note which has a beneficial effect on other parts of the project. With the knowledge gained this situation should not occur in any future new products. Towards the end of the project the engineer associated with the software of the project left the company. This was a big blow since we had invested a large amount of training in him. We can not stop anyone leaving the company to go to another job but we could have written into his contract that a proportion of training costs should be repaid if should he leave within a certain time of completion of courses. This repaid money could then be used to enable training for replacement engineers, thus providing a saving on our costs. A major lesson was the finding that the Realizer software that was provided with the ST6 microcontroller was not adequate for the total projects needs. By taking advice and attending training courses the fact that the project could be completed using the PIC family of microcontrollers was established. A great benefit which speeded up the design and development process was the purchase of a PIC emulator. Without it written code had to be loaded into the PIC16C74 available in EPROM style so each modification required UV erasing. This process is slow and although emulators are relatively expensive the time saved in not having to erase EPROMs and being able to debug code while it is running in real time while running the hardware makes them invaluable. Programme changes can be made in seconds compared to up to half an hour without it. It had originally been planned that at the outcome of the project we would have developed an integrated inverter module controlled by the system microcontroller. From the reading of text books on the subject of power electronics this looked perfectly feasible. However as time passed it was discovered that this area of electronics was not quite so easy to put into practice. Further reading of manufacturers data sheets and technical journals led us to the conclusion that physical layout of the circuits is critical for reliable operation. This physical layout appears to be of such importance that some suppliers of power electronic devices will freely issue a printed circuit board design to incorporate into the users own design. Careful consideration needs to be given to track layout, interconnecting wires and placement of the switching devices on heatsinks. The above problems and the need for very expensive test and safety equipment necessary for the high currents and voltages of the inverter caused us to rethink our strategy. This led us to make the decision that this area of electronics was something best left to those with specialist training and equipment. The knowledge and experience gained while investigating inverter design has not been wasted since it has allowed us to define our requirements accurately and has allowed us to find a local company who currently manufacture a suitable product. They are willing to work with Proven to produce a modified version to meet our particular needs. 15. Resulting product and its industrialisation and internal replication

The prototype is currently made up of two separate single sided PCB boards made in house by Proven. For the production unit these two boards will be combined into one PCB

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produced by a local PCB manufacturer. The boards will have extra ground planes for reduced noise and more layers to assist in the PCB assembly. The microcontroller based board, built in batches of 50 100 by the subcontractor, actually contains more components and will be slightly more expensive in component cost than the existing board in the Wind Turbine Controller. However, the use of a specialised subcontractor will result in a cost reduction of about ECU25 per board (out of ECU90) and a good increase in quality as well as functionality compared to the present board which is made and assembled in house. Reliability will be greatly enhanced by the removal of the potentiometers and having the controls set digitally by the microcontroller programme. The final product will be fitted into the existing switchgear cabinet. The industrialisation cost is confined to the cabinet modifications only since the microcontroller replaces existing electronics. The total cost of these modifications will be less than ECU500. There will also be an added cost of reprinting brochures to include the extra features of the system. The cost of this, for the first run, is estimated to be 600 ECU. This work will be complete early in 1999 and the first Wind Turbine with the new microcontroller board is expected to be shipped during Quarter 2 of 1999 six months after the completion of the FUSE project. Our ability to offer a many function controller which efficiently takes control of the entire local power management gives us a better capability than almost all of our competitors. This can open up new applications such as: control of Diesel Generators and with the use of ancillary inputs can operate Solar PV etc.. The system also gives historic information useful to the user and to Proven. Since the complete control of the system makes life much easier for the end user we expect our competitive position to improve as the market matures. Using the micro-controller as the core of the equipment it is possible to include features for individual users but since this will only involve the software no changes to the hardware will be necessary. It is also planned to investigate further features that would be desirable to have to enable the development of a range of related products that could be offered at an enhanced price structure. The knowledge gained of using microprocessors will not only be of use to this project. Many other applications have already been identified. The controller has been designed with some element of flexibility to allow for a degree of customisation should a customer require. Examples of special needs requested in the past include: An extra input to generator start signal that prevents the generator starting at the normal low battery level. Generator only allowed to start before the batteries reach a level where damage will occur. This feature was specified for an Ecology monitoring project where the exhaust fumes from the generator engine would affect data readings. A system that provided power in a youth hostel needed to shut down low priority loads as the batteries became low. Visitors to the hostel do not always realise that the amount of electric power was limited when there was no output from the wind turbine. If too many lights were left on and the stored power became low then the lights would be made unavailable. Power was still available to the warden and for the fire alarm system.

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The above features could all be incorporated by using spare inputs with some software changes. Previously they would have to be added in using separate control boards based on analogue and digital discrete circuits. It is not planned to customise every system but, by including some general purpose input/output lines, special needs can be met by software change only. The first new project using microprocessors has already been completed. This is an add on control to an existing hydro turbine installation. The control utilises routines written for the fuse project to activate and monitor a specially converter diesel generator. The development is underway for a hydro turbine using the power of a stream instead of the wind to provide power. The controllers of the two systems are very similar and this range of equipment will use the hardware and several software routines developed for the wind turbine.

16.

Economic impact and improvement in competitive position

This project associated with the FUSE scheme was a small component in a large system. The FUSE Project does not result in a less costly product but it provides Proven with a greatly enhanced competitive position. As can be seen from the table below sales have been steadily increasing. The average cost of the whole system is approximately ECU12000 with the microcontroller electronics consuming approximately ECU200. Without the use of microcontroller microelectronics Proven would not be able to compete effectively with their competitors, this would result in declining sales culminating in Proven Engineering going out of business. The FUSE project was crucial to the survival of the company. Year Units Sales value (ECU 000) 1995 14 122 1996 22 263 1997 30 325 1998 44 495 1999 95 1382 2000 135 1600 2001 180 2600

It is very difficult to calculate the ROI since the cost of the electronics within the FUSE project is so small when compared to the selling cost of the overall system. There is a general increase in renewable energy sales and the increased functionality of the micro-controller system will help to reinforce extra sales which are projected to be over 200 units by the year 2002. The payback period is estimated to be within two years assuming the sales increase as shown above and the ROI is estimated to be 400% within a five year period. However, the microelectronics unit only represents only 2% of the selling price of the completed wind turbine system and the relationship between this project and increased sales is complex. Since it is a part of a system in a developing new market - the project will both increase sales due to better functionality and user benefits and making it easier to produce in the increasing production needs. Due to its adaptability the micro-controller system can also be used for our newly developed micro-hydro turbines. The rapid boom in mobile phone users and the requirement for greater coverage in more rural areas will also increase sales.
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17.

Target audience for dissemination throughout Europe

Proven Engineering is a small company which has extensive knowledge of their specialised technology and in building machines concerned with this technology. Although Proven had used electronics in the past their electronics expertise was limited and restricted to discrete electronics and very simply PCBs. The four digit Prodcom for Proven is 3110, Electric Motors, Generators and Transformers and this demonstrator document would be of interest to companies within this code who plan to use microelectronics to control their systems. However, the target audience for this type of project covers much more than those companies in this code. This demonstration document therefore should be aimed at a target audience of companies in all industrial sectors producing instrumentation equipment and in particular as described in Prodcom code 3320, Instruments and Appliances for measuring, checking, testing etc.. The demonstrator document should be targeted to companies who tend to be small in size and who utilise poor methodology in defining and executing projects, often resulting in overruns in both time and cost. The document also has relevance to companies who are starting from a low electronics expertise base and wish to improve their product. However, it also shows how a company not involved with microelectronics can use the technology to their advantage to stay competitive and in business. The target audience for this project is therefore very large. The project has particular relevance to companies involved in renewable energy projects such as the generation of electricity by means of wind or water power. Proven Engineering are members of the British Wind Energy Authority and members of the Small Wind Energy Committee within this organisation and plan to discuss the project with them to show the benefits of electronics. Targeting similar bodies throughout Europe would further expand the target audience.

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17.1 Post Script Unfortunately Richard Curtis - the main staff participant in the programming part of project has decided to go back to England and leave Proven. Although this will no doubt disseminate the benefits of FUSE in general terms and his new company will benefit, Proven have to relearn some of the training in PICs and train another engineer. This re-inforces the original aim - and the reason for using the ST6 and Realizer - to find an easily useable microcontroller system which could be used on a casual basis by any nonexpert engineer ( much as PLC systems have become).

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