Interface Card

Project Info:

Main Project:
200 kW Inverter Project
Client:
Ario MetaPower
Design Completion Date:
2022-12-28
Design Complexity:
The design comprised 100 unique components and a total of 718 components.

Project Description:

The Interface Card is one of three boards that form the control stack of the inverter. It includes:

  • Linear and switching power supplies
  • Analogue-to-Digital Converters (ADCs) with precision voltage reference
  • Interfaces to the main IGBTs of the inverter core
  • Control interfaces for cooling fans
  • Various isolated (5 kV) high-voltage external interfaces

Electron Artz was tasked with evaluating and redesigning the schematics from the ground up — incorporating all required functionality and ensuring robust design across all subsystems.

The initial design performed as expected and passed certification without requiring any revisions.

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Main Project:

Ario MetaPower approached Electron Artz for design assistance with the electronic hardware of their 200kW inverter. Electron Artz was tasked with reviewing, redesigning, and adding new functionality to two of the three boards in the inverter control stack. Additionally, we were commissioned to design two entirely new boards for the inverter from the ground up.

The Interface Card was one of the two boards that were reviewed & redesigned.

Gallery:

Three inverters packaged in a customer's shipping container almost ready to go
Three inverters packaged in a customer's shipping container almost ready to go
Earth Fault Protection Card in an assembled inverter and the inverter stack at the top left.
Earth Fault Protection Card in an assembled inverter and the inverter stack at the top left.
Assembled inverter, without enclosure, ready for initial testing with the Earth Fault Protection Card to the center right
Assembled inverter, without enclosure, ready for initial testing with the Earth Fault Protection Card to the center right
MetaEdge Expansion Board being used to control and test an inverter setup for a customer
MetaEdge Expansion Board being used to control and test an inverter setup for a customer
Testing of the three inverters packaged in a customer's shipping container
Testing of the three inverters packaged in a customer's shipping container
Inverter assembly area and three inverters packaged in a customer's shipping container
Inverter assembly area and three inverters packaged in a customer's shipping container
Assembled inverter, without enclosure, ready for initial testing
Assembled inverter, without enclosure, ready for initial testing
Two assembled inverters being packaged and tested within a shipping container
Two assembled inverters being packaged and tested within a shipping container
Assembled inverter, without enclosure, showing the Inverter Stack on top of the inverter and the Earth Fault Protection Card to the right
Assembled inverter, without enclosure, showing the Inverter Stack on top of the inverter and the Earth Fault Protection Card to the right
Assembled inverter, without enclosure, showing the Inverter Stack front and center and the Earth Fault Protection Card to the right
Assembled inverter, without enclosure, showing the Inverter Stack front and center and the Earth Fault Protection Card to the right
Inverter stack being repurposed in the High Power AC Remote Syncronous Contactor
Inverter stack being repurposed in the High Power AC Remote Syncronous Contactor
Full view of the Gate Drivers, Snubber Cards, bus bars and Inverter Stack being repurposed in the High Power AC Remote Syncronous Contactor
Full view of the Gate Drivers, Snubber Cards, bus bars and Inverter Stack being repurposed in the High Power AC Remote Syncronous Contactor
Inverter Stack being repurposed in the High Power AC Remote Syncronous Contactor
Inverter Stack being repurposed in the High Power AC Remote Syncronous Contactor
New client warehouse. Inverter assembly and testing area.
New client warehouse. Inverter assembly and testing area.
New client warehouse. Battery assembly on the left and inverter assembly and testing on the right.
New client warehouse. Battery assembly on the left and inverter assembly and testing on the right.
New client warehouse. Inverter assembly and testing area.
New client warehouse. Inverter assembly and testing area.
New client warehouse. Battery assembly on the left and inverter assembly and testing on the right.
New client warehouse. Battery assembly on the left and inverter assembly and testing on the right.
Inverter "Stack" testing
Inverter "Stack" testing
Earth Fault Protection Card in system earth leakage testing
Earth Fault Protection Card in system earth leakage testing

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