Open Source, DIY-able, Portable Power Factor Correction System for Inductive Loads with ESP32 and ES

DESCRIPTION

My name Is Yusni Maulana, I'm a Mechatronics student in Politeknik Kota Malang Indonesia, I like to design PCB's. I have a big dream for the world, i mean the efficient world, i wanted to change a little bit of this world so it can be better a little bit

my method is to explaining about power factor to everyone around me and about how its affecting the electrical bills

this project intended to be DIY-able with single/double layer support in one design.


TECHNICAL DETAILS

this project is intended to monitors the values of an electrical system such as voltage, current, power and correcting the quality of the power factor.

The method to collect the data are using sensors which will be processed by microcontroller ESP32 and can be moitored by electronics devices which has wifi and browser.

Sensors which are used in this project are the current sensor non invasive clamp YHDC SCT-103-000 with 100A maximum current which i limit into 20A Peak to Peak (14,14 ARMS) by calculating the scale of the voltage output and giving a burden resistor. meanwhile the voltage reading are using ZMPT101B, then both signal are sampled and calculated the average value.

The processor is an ESP32 with dual core processor with 240Mhz maximum frequency.

The dynamic Capacitor Bank is separated. its using the ESP8266 whic control the relay to get desired capacitance value for variable load.


DIAGRAM BLOCK

block.PNG


MATERIALS



No.

Components

Specification

1

Voltage Sensor

ZMPT101B/1000V

2

Current Sensor

YHDC SCT-013-000

3

Monitor Microcontroller

ESP32

4

Capacitor

Total 145uF Combination with 1uF resolution

5

Driver Relay

Relay Module Arduino

6

Dynamic Capacitor Bank Controller

ESP8266

7

PCB

designed in autodesk eagle

8

Filament

3d printing material (PLA)

9

OP-AMP

LM358



Electronics Design

1. Current Sensor

    image.png

The Signal Conditioning Schematic


Calculating The Burden Resistor


image.png

final schematic


2. Voltage Sensor

1.      define the maximum RMS


Vmax = Vpeak ADC/2√2

then,

Vmax  = 3.3 /2√2 V

Vmax = 1.16V


2.      define the current limiting resistor

                        R  =          V/I

                        R  =          220/0.0003

                        R  =          733333.3

                        closest safe value is 820K


3.      define the Sampling resistor


                        R  = V/I

                        R  = Vmax/Vinmax * Rlimiting

                            Vmax                   =          1.16V

                            Vinmax                =          250V

                            Rlimiting              =          820KΩ

                               so:

                                    R  =          1.16/250*820000

                                    R  =          3804.8 Ω

3. offset shifting
image.png


4. total design off all

image.png5. the PCB

image.pngTOP

image.pngBottom


6. Capacitor Design

image.png


Mechanical Design

1. 3D PCB

  image.png

2. Top Case

image.png

3. Bottom Case

image.png

4. Front look

image.png

5. The Dynamic Capacitor Bank design

image.png

for the unreleased design and untested prototype

contact me at instagram @yusnimawl

or gmail: yus***m@gmail.co


I hope this project will be sponsored by PCBWay so i can finish it as soon as possible

my target is i will finish it at the end of december 2018.

at least PCBWAY will give a free prototyping and free shipping to Indonesia

thank you for giving me platform to share my project

i hope everyone will realize how power factor increasing our electrical bills




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Nov 11,2018
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