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Energy Storage
Designed an ultra capacitor test card and test system for 100% test quality control and statistical monitoring in a rugged industrial production line. The system can test 32 capacitors at one time in less than 48 seconds. The results are sent to a PC for real time analysis of the production line flow and stored in a Windows database application. It identifies short circuit and open circuit capacitors as well as those capacitors that fall below certain minimum requirements for capacitance, equivalent series resistance (ESR) and leakage. Plots of data are available as characteristic curves for each capacitor (individually or 32 combined), normal distribution curve for all tests, power supply voltage monitoring, and temperature monitoring. The card features measurement accuracy of 0.000125V; handles peak surge currents of 40A; is equipped with 16 bit self-calibrating ADCs; small high quality MOSFETs; a RISC micro-controller, and capacitive touch button manual control. I am a co-inventor of a capacitor-screening patent for this test system.
Developed charge balancing cards for 2700 Farad capacitors used in multiple cell banks for high current powercache applications. Balancing was user enabled with a very low quiescent current of 26uA and a maximum drive current of .5A. Typical units provided 1.6KWm to 2.3KWm (Kilo-Watt-minutes) of power for telecom, medical, industrial and other industries that require high reliability bridge power. Involved concept development, electronic circuit design, system engineering, schematics, printed circuit card (PCB) layout, test and integration.
Designed a card to combine two 5 Farad ultracapacitors into one package (PC5-5) with integral active balancing circuit. Then combined these cards into a panel of 195 cards with stiffener for mass production. Involved concept development, electronic circuit design, schematics and printed circuit card (PCB) layout.
Designed a card to combine two 5 Farad ultracapacitors into one package (PC5-5) with integral passive balancing circuit. Then combined these cards into a panel of 195 cards with stiffener for mass production. Involved concept development, electronic circuit design, schematics and printed circuit card (PCB) layout.
Designed three 26 cell over voltage protection and balancing cards for 2700 Farad ultracapacitors (PC2500). Two of which were bus cards that routed the signals from the cells. Involved reverse engineering, redesign, electronic circuit design, schematics and printed circuit card (PCB) layout.
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