1 Introduction

At present, the wind solar complementary system is developing rapidly, and there are many kinds of wind solar complementary controllers, but it can really achieve economy. There are not many systems with reliability and safety. One of the main reasons is that there is no good control system. The wind solar complementary lighting controller works in the outdoor environment and is the core of the wind solar complementary system. It has high technical requirements for the controller. On the premise of meeting the use function, the control should be intelligent. Reliability. Long life. Good stability.

After the battery is full, the conventional photovoltaic controller will start the open circuit protection mode and disconnect the charging circuit between the solar panel and the battery to protect the battery. However, for the wind solar complementary lighting system, when the battery is overcharged, the fan cannot be directly protected from open circuit. Generally, the unloader is used to brake the fan.

Through in-depth study of the problems existing in the engineering application of wind solar complementary lighting system, combined with many years of practical experience, this paper puts forward a design method of wind solar complementary LED lighting controller based on new substrate packaging, which adopts novel circuit and special circuit packaging to well solve the brake failure of the existing wind solar complementary lighting system, The reliability of wind solar complementary lighting system is improved.

2 system composition

As shown in Figure 1, the wind solar complementary lighting system is composed of wind turbines. Solar panels. Battery. Controller and unloader are composed of five parts.

Design of wind solar complementary LED lighting controller based on substrate packaging

In the whole system, the functions of the controller mainly include battery charge and discharge management, led on-off and full power / half power control. Charging and unloading control of fan. Protection of system software and hardware, etc.

3 system design

3.1 controller principle

The wind solar complementary controller is divided into control circuit and power circuit according to functional modules, as shown in Figure 2.

Design of wind solar complementary LED lighting controller based on substrate packaging

The control circuit includes MCU. AD conversion circuit. Display key circuit. 10 drive circuit. Hardware protection circuit and interface circuit; Battery collected by power circuit board. The voltage and current signals of solar panels and LED lamps are sent to the AD conversion circuit through the interface circuit. The AD conversion circuit converts the signal into a signal that can be recognized by the single chip microcomputer and sends it to the single chip microcomputer. The single chip microcomputer processes the converted results, and then gives the control command and sends it to the display key circuit and IO drive circuit; The power circuit includes the battery circuit. Solar panel circuit. LED lamp circuit. Wind turbine generator circuit. Unloading comparison circuit. Fan unloading circuit and interface circuit, external equipment battery. The solar panel and LED lights are respectively connected to the battery circuit. The voltage signal output from the solar panel circuit and LED lamp circuit through the wind turbine circuit is sent to the unloading comparison circuit, which compares and sends a control command to the fan unloading circuit.

3.2 conventional unloading control method

In the wind solar complementary lighting system, when the battery is overcharged or the wind speed is too high, the fan needs to be braked. The common protection and control method is to collect the fan output voltage through the controller AD conversion circuit, and judge whether the fan is unloaded or not through the single limit comparison circuit.

As shown in Figure 3, vcc-wind.gnd-wind are the output terminals of the fan after rectification, lm393d is the comparison chip, and pin 2 is the input reference voltage terminal of the comparator. Pin 3 inputs the fan input voltage to pin 3 through the voltage dividing resistor r23.r24. TVs is voltage stabilizing. Anti shock diode, CIO is filter capacitor. By comparing the rectified voltage of the fan to generate the gated model, gate shutdown outputs high and low levels to control whether to unload.

Design of wind solar complementary LED lighting controller based on substrate packaging

As shown in Figure 3, the single limit comparator is very sensitive. Ideally, when the input voltage of the comparator reaches the reference voltage, the comparator switches the output state. However, in practice, the randomness of wind energy is large, the generated voltage is intermittent, and the switching characteristics of the comparator are nonlinear, which will lead to the complex switching state of the comparator and poor anti-interference ability.

At this time, the MOS switch tube controlling the unloading of the fan is in the on and semi on state, and the MOS is easy to burn out, resulting in damage to the controller.

3.3 new unloading control method

As shown in Figure 4, according to the poor anti-interference ability of the single limit comparator in Figure 3, we introduce the hysteresis comparison circuit. The output characteristics of the circuit are fed back to pin 3 through output pin 1, and the unloading function is switched between the two threshold points in this interval. It will not switch the working state frequently, which improves the stability of the comparator, so it has a certain anti-interference ability. Where 12V is the supply voltage of the comparator, RML is the pull-up resistance at the output end, r23.r25 is the voltage dividing resistance, and pin 2 is the reference voltage.

Through long-term test and engineering application, the unloading pre judgment system using hysteretic comparison circuit can improve the protection of internal switching components of the controller, improve the stability of unloading performance, and meet the requirements of practical engineering application.

Design of wind solar complementary LED lighting controller based on substrate packaging

4 substrate packaging technology

Fed to pin 3, the output characteristics of the circuit are in two threshold intervals, and the unloading function is switched between the two threshold points in this interval. It will not switch the working state frequently, which improves the stability of the comparator, so it has a certain anti-interference ability. Where 12V is the supply voltage of the comparator, RML is the pull-up resistance at the output end, r23.r25 is the voltage dividing resistance, and pin 2 is the reference voltage.

Through long-term test and engineering application, the unloading pre judgment system using hysteretic comparison circuit can improve the protection of internal switching components of the controller, improve the stability of unloading performance, and meet the requirements of practical engineering application.

In the wind solar complementary lighting system, through solar panels. During the charging process of the battery, the wind turbine generator will produce a large amount of energy conversion, and part of the energy is consumed through the heat energy, which brings great risks to the stability of the system circuit. Especially in the hot summer, when the outdoor temperature reaches 40 degrees, a large amount of heat will be generated when the controller performs electric energy conversion or the fan is unloaded. If the heat cannot be dissipated in time, The electronic components inside the controller will change their characteristics with the rise of temperature, resulting in the burning of the controller.

Through the controller circuit design specification, the aluminum substrate packaging circuit board is designed independently. Its unique metal aluminum plate has good thermal conductivity. Electrical insulation and machinability. It can quickly dissipate the heat lost due to excessive power of the controller when the wind speed is large, and can withstand the impact of high current and high temperature cycle, so that the wind solar complementary controller has high reliability. Low cost. Low power consumption.

Design of wind solar complementary LED lighting controller based on substrate packaging

As shown in Figure 5, the outside of the controller is mainly composed of housing 1, aluminum substrate 2 and radiator 3. Aluminum substrate 2 is located at the bottom of housing 1, and radiator 3 is closely bonded with aluminum substrate 2. The contact surface between the aluminum substrate 2 and the radiator 3 is coated with thermal conductive silicone grease, which can withstand the impact of high current and high temperature. The controller power circuit is directly welded on the aluminum substrate, which is connected with the radiator to facilitate heat dissipation.

Through long-term test and engineering application, the wind solar complementary controller encapsulated with aluminum substrate has 10 times the heat dissipation performance of the general controller, which can quickly dissipate heat and protect the controller.

5 Conclusion

Through the new substrate packaging technology and the access function of intelligent unloading module, the wind solar complementary LED lighting controller with new substrate packaging solves the damage caused by over speed of wind turbine generator. On the one hand, this scheme solves the over speed braking of wind turbine generator. Rapid heat dissipation, on the other hand, also improves the reliability and power quality of wind and solar power supply.

At the same time, the control system can realize the control of power flow, so as to achieve a certain degree of peak shaving and valley filling, which not only alleviates the contradiction of power consumption, but also improves the power supply structure of the power grid.

Responsible editor; zl

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