3L MCU and Sensor Card

Project Info:

Main Project:
200 kW Inverter Project
Client:
Ario Metapower
Design Completion Date:
2022-12-28
Design Complexity:
The design comprised 104 unique components and a total of 1490 components.

Project Description:

The 3L MCU and Sensor Card is one of three boards that form the control stack of the inverter. It integrates a range of critical functions, including:

  • Linear and switching power supplies
  • Isolated (5 kV) high-voltage 3-phase AC and DC measurement interfaces
  • High-current sensor and temperature measurement inputs
  • Signal conditioning circuitry
  • Discrete digital logic safety systems
  • External interfaces for earth fault measurements

Electron Artz was tasked with evaluating and redesigning the schematics from the ground up — incorporating all required functionality, ensuring high analogue signal integrity, and validating the design of all subsystems.

The initial design met all performance and certification requirements without the need for any revisions.

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 3L MCU and Sensor 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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