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The biennial national electric competition is approaching, how is everyone preparing? Darwin has invited previous national first-place winners to share the modules needed for different competition topics. The first issue focuses on the preparation for power-related competition topics, explained by the veteran contestants from the 2019 and 2021 national competitions, Hui Yujiao from Xi’an University of Electronic Science and Technology.——
Below is the organized transcript of the video:
Regarding the preparation experience for power-related topics, Darwin also released a video previously (Preparing for the Electric Competition: Knowledge Reserve/Topic Analysis/MCU Learning), which everyone can refer to, as it systematically introduces the preparation work before the competition.This video focuses on the modules needed for power-related topics and the considerations for module design.
Module Preparation: Before the competition, we can prepare some auxiliary power modules, power supply modules, inverter modules, and minimum system boards for microcontrollers to save a lot of time during the competition.
Auxiliary power is needed for all competition topics, as it can power the system’s measurement and control circuits. However, the supply voltage for power topics is usually higher, and the voltage range is quite broad, so we need to prepare several auxiliary power modules with different operating voltage ranges.
Next, I will introduce the auxiliary power modules we prepared previously.
The image below shows the PCB of the buck power module, which can be soldered with different power chips to adapt to various input voltage ranges. For example, soldering the SY8401 can support a maximum input voltage of 55V, while the SY8120 can support up to 18V.
The image below shows the low-voltage synchronous rectification auxiliary power module based on SY8088, mainly used for voltage conversion below 5.5V.
The image below shows the boost auxiliary power module SX1308:
The boost auxiliary power is designed based on SX1308, which can boost when the input voltage is low, providing power for gate drivers and other circuits.
Since the electric competition projects are mainly based on perforated boards, the input and output interfaces of these auxiliary power supplies can use 2.54mm pin headers, making it easier to solder on perforated boards.
In addition, we can also prepare some ready-made power modules, such as 220V power modules, isolated DC-DC power modules, etc., for emergencies. For example, during the 2020 electric competition, we used a 220V power module modified into a high-voltage DC-DC auxiliary power module to power the system control circuit.
☞ Power Supply Modules:
Power supply modules serve as the main power circuit of the power system, which is a key focus of power topics and the most complex and challenging part of the design. When designing power supply modules, it is essential to consider the input and output voltage and current ranges, device heat dissipation, module efficiency, functionality, and extensibility. I recommend prioritizing external synchronous rectification solutions for switching devices, allowing flexible selection of suitable MOSFETs based on the competition requirements.
Here, I will use the LM5117 synchronous rectification buck power supply module as an example to introduce our design.
On this PCB, we have brought out almost all the control pins of the LM5117 to pin headers, allowing jumper caps to select the operating mode of the LM5117 or use a microcontroller for control. Additionally, we have reserved a voltage adjustment interface for the microcontroller, which can control the output voltage of the module through its DAC function.
In addition to the dedicated power controller-designed power modules, we have also designed a bidirectional DC-DC module that can be directly driven by a microcontroller’s PWM. For example, this is a bidirectional DC-DC module, operating from left to right as a Buck module and from right to left as a Boost module. We have also integrated voltage and current sampling circuits for input and output on this module. I used two of these bidirectional power modules in the 2021 electric competition and achieved a national first-place result.
☞ Inverter Modules:
DC-AC is also a key focus of the electric competition, so we need to prepare inverter modules, such as this three-phase inverter module we prepared, which can achieve three-phase DC-AC conversion. To create a single-phase inverter, we only need to solder two of the half-bridge circuits. This module also integrates three-phase AC current and voltage sampling functions.
We have previously conducted a step-by-step teaching sharing on the design of this module for a 2017 electric competition topic. If you are interested, you can check it out: Step-by-step guide to the electric competition real questions: 01 Hardware schematic/PCB design; 02 Soldering/writing STM32 code/tuning PID immersive; 03 Testing methods/steps Experimental results are perfect (open-source software and hardware).
☞ Minimum System Boards for Microcontrollers:
Some electric competition topics will specify the use of TI processors, so remember to apply for or purchase some TI boards on their official website.Common minimum system boards can be directly purchased on certain platforms, which are sufficient for most topics.Of course, if you have the resources, you can also design your own minimum system board.We have also designed some minimum system boards, and the main difference from mainstream minimum system boards is that we use switching power supplies instead of LDOs, which can support a wider input power voltage range, with lower energy loss and stronger load capacity.The ADC reference voltage source for the microcontroller uses a dedicated voltage reference chip, providing more accurate and reliable measurements.
☞ Other Modules:
In addition to the modules mentioned above, we have also prepared some other PCB modules, such as an active balancing module for lithium batteries using ETA3000, a lithium battery charging module using IP2312, a DAPLINK downloader, and an adapter board for SMD to DIP conversion.
PCB Design Considerations:
After introducing the modules we prepared, I would like to summarize some considerations for module preparation:
1) When designing modules, sufficient interfaces need to be reserved, including input, output, testing, and control interfaces.
2) Functional and extensible considerations need to be fully taken into account, reserving circuits for various functions. They can be omitted, but they cannot be absent.
3) Consider the compatibility with perforated boards. During the competition, most teams may not have time to design and prototype PCBs, so they will use perforated boards for soldering and typically connect various circuit modules with perforated boards.
Finally, keep an eye on the release of the competition component list. A few weeks before the competition, the recommended instruments and components list will be published. After obtaining the list, analyze its content carefully and prepare the modules and PCBs that may be needed. For example, in the 2019 electric competition, by analyzing the list, we speculated that there might be topics related to wireless charging cars, so we temporarily prepared a PCB for a wireless charging car, which indeed came in handy during the competition, saving us a lot of time.
That concludes my sharing today. I hope it is useful for everyone. Finally, I wish everyone success in the national competition year! Keep it up!
END
Recommended Reading for Electric Competition
2022 Electric Competition:
List Interpretation + Signal Topic Special Session >>>
Various Ways to Play with Hula Hoops (Measurement and Control Topic Proposition Predictions and Preparation Suggestions)
How to Prepare in the Last 8 Days? Detailed Interpretation and Tips for Each Category
Reference Ideas for A and E Topics
Reference Ideas for A and C Topics
C Topic: Multi-Car Intelligent Following System Based on TI MCU and High-Efficiency Power Control Chips
F Topic: 4 Days and 3 Nights of Electric Competition | Worth It! Give It Your All for F Topic
A Topic: No Physical Objects, No Electric Competition! A Topic Wireless Charging Electric Car Wins the TI Cup (2022)
C Topic: Direct Hit on the Electric Competition | Repeatedly Tearing Down and Rebuilding! What to Do in 6 Days and 5 Nights? (Complete Guide)
2021 Electric Competition Work Analysis:
A Topic National First: How to Achieve Small Errors and Wide Bandwidth in Signal Topic FFT? Sequential Sampling is the Trick
C Topic National First: Can Two DC-DC Conversions Secure the C Topic?
D Topic National First: 3 Jetson Nanos Make Node Data Processing Fly, Awesome!
E Topic National Second: Is the High-Frequency Topic Complex? AM Modulation Easily Achieves Digital and Analog Mixed Transceivers
F Topic National First: Dual K210 + OpenMV Support, Strongest Tracking, Recognition Without Pause
G Topic National Second: The Aircraft Scheme Using Optical Flow is Inferior! This High-Precision Indoor Positioning Scheme is Worth Having
J Topic TI Cup: 6 Types of Waveform Recognition Measurement, Multiple Fitting Algorithms, Top the TI Cup
K Topic National First: LED Stable Adjustable Desk Lamp is Enough with STC8 Microcontroller
Power Topic Special Session, Summary of Prediction Key Points >>>
Control Topic Special Session, Summary of Prediction Key Points >>>
Preparing for the Electric Competition: Knowledge Reserve/Training Cases/Topic Analysis/MCU Learning
The Ultimate Sprint for the Electric Competition: Analysis of Key Points from Previous (Power) Real Questions! What to Do in 4 Days and 3 Nights?
1. 2020 TI Cup Electric Competition Response Ideas Reference
2. 2020 National Electric Competition (Provincial Competition) Topic Predictions
2019 National Competition Topic Analysis Summary: Click to View
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