The International

2003 Future Energy Challenge

A student competition sponsored by the

Institute of Electrical and Electronics Engineers (IEEE) - Power Electronics Society, Industry Applications Society, and Power Engineering Society

by the U.S. Department of Energy and the U.S. Department of Defense

and other sponsors

Request for Proposals Initial posting April 15, 2002. Revised based on comments, and updated April 19, 2002 Updates to topic (c), April 25, 2002. Final updates (minor corrections) May 2,2002.

Additional specification elements added or edited after July 15, 2002.

Full Proposal Deadline: May 31, 2002

Summary of changes after July 15, 2002 (no changes were made between May 2 and July 15, 2002):

Topic (c) is no longer active because of limited proposal submissions. A version of this topic will be present in the 2005 FEC.

Firmer dates have been listed for the final competition events and the February workshop.

Clarification to output requirements for topic (a) has been provided.

Additional clarification to output requirements for topic (a) added, November 2002.

Summary of changes, April 15 through final posting on May 2:

Topic (c) included in detail.

Topic (a) minor revisions to the target mass (increased to 30 kg) and to provide a consistent volume limit (88.5 L). The minimum efficiency is now 90%, although scoring will be arranged so that there are extra benefits to achieving the prior target of 94%.

Clarifications added in certain places such as the output power specification for topic (a) and the input power sources for topic (c).

Two sponsors (FTC and the Grainger Center) have been added.

Teams should plan to submit an electronic version (PDF format) of their proposal with the printed copies. Electronic versions will help to expedite the review process.

Summary of Competition and Proposal Requirements

General Information

Competition Title: 2003 International Future Energy Challenge student Competition

Topic areas: (a) Fuel cell energy conversion, (b) Single-phase adjustable-speed motors, and (c) Low-cost power for developing nations.

Period of Competition: August 1, 2002 to July 31, 2003

Challenge Award

At least US$10,000 (and up to US$50,000, based on sponsorship) will be awarded for highest score among entries meeting all minimum requirements, as confirmed through reports and hardware tests.

Program Awards (actual number depends on availability)

Best in specific topic areas (engineering design, reports, and others): expected levels are $3,000 to $5,000 each. The final amounts are subject to the recommendations of the judges.

Intellectual Property and Use of Prize Money

The Future Energy Challenge does not restrict the use or protection of inventions or other intellectual property produced by participating teams. There are no special licenses or rights required by the sponsors. However, the Final Test Events that begin May 19, 2003 will include public disclosure of each team’s technology. Teams interested in securing protection for their inventions should be aware of this date when making arrangements.

The prizes provided to schools are intended to benefit the team members and student team design project activities. There is a Letter of Support required for submission with the proposal, and it should outline the plans of the school in the event that a prize is received.

Outside Support

Individual schools should solicit project funding from NASEO, utilities, manufacturers, government agencies, or other sources. There is no limitation for the sources of project funding.

Eligibility Information:

• Eligible schools must: Have an accredited or similarly officially recognized engineering program (through the Accreditation Board for Engineering Technology (ABET) or equivalent); Be a college or university with engineering curricula leading to a full first degree or higher; Have the support of the school's administration; Establish a team of student engineers with an identified faculty advisor; Demonstrate the necessary faculty and financial support commitments; and Demonstrate a strong commitment to undergraduate engineering education through their proposal.
• Team Eligibility Limit: Each team is limited to one topic area, although each school can elect to support more than one team, at its discretion.

To confirm eligibility, potential participating schools must submit a Letter of Support together with a Preliminary Team Information Form when they submit the proposal.

How to Participate: Participation is on a proposal basis. Those schools that have submitted a Letter of Intent must submit a proposal no later than May 31, 2002. Proposals will be judged by a distinguished panel of volunteer experts from the IEEE and from industry. Schools with successful proposals will be notified by August 1, 2002. Student teams will then carry out the work and prepare hardware prototypes and reports. Preliminary reports are due March 15, 2003. The reports will be judged by a similar expert panel. The panel will select a small group of teams as Finalists. These teams will be invited to a competition event that will begin May 18, 2003. A Final Report will be due at the competition event. The team achieving the best overall results that meet all the requirements will receive a Challenge Award of no less than US$10,000 (and up to US$50,000 based on sponsorship levels). The best results in individual categories, including engineering design, engineering report quality, innovation, and other categories to be determined, will win special monetary prizes of approximately $3,000 to $5,000 each.

Please be aware that each of the three topic areas of the 2003 Future Energy Challenge will be judged separately, against a separate specification set. Each team proposal must address a single topic area.

Judging Panels

Experts from IEEE Power Electronics Society, Industry Applications Society, Power Engineering Society(and others to be announced), and representatives from manufacturers, national labs, independent test labs, utilities, and R&D engineers.

Judging

Student team project results will be judged based on cost effectiveness, performance, quality of the prototype and other results, engineering reports, adherence to rules and deadlines, innovation, future promise, and related criteria. Each aspect of judging will be scored according to a point list and Test Protocol published in the 2003 Future Energy Challenge Rules.

Proposals

Proposals will be judged on the quality of plans, the likelihood that a team will be successful in meeting the Future Energy Challenge objectives, technical and production feasibility and degree of innovation. Other key criteria are evidence of the school's commitment, capability, experience, and resources to implement their design over the one-year span of the competition. Commitment to excellence in undergraduate education is important, and acceptable proposals will involve undergraduate students as the primary team members. Interdisciplinary teams are encouraged. Graduate students are not excluded, but the impact on undergraduate education is a critical judging criterion. Proposals are limited to 12 double-spaced pages total, including all diagrams, attachments, and appendixes. Schools that are invited to participate in 2003 Future Energy Challenge are expected to adhere to the basic plans described in their proposals. Approval of the competition organizers must be sought for significant changes in plans or engineering designs. Only one proposal per topic will be considered for any school, but each topic requires a separate proposal and team. Eleven copies of the proposals are due, to be received by May 31, 2002, at the mailing address provided below.

A. Proposal Objectives

Respondents should express their ideas and plans relevant to their interested topic area. The project should include the construction and operation of a complete hardware prototype. The proposal must address both technical and organizational issues for each phase of the prototype’s development and testing. It must contain a realistic project budget, along with a plan to secure the necessary funding. The educational goals, including any course credit provided for work related to 2003 Future Energy Challenge, and how the project relates to other efforts within the school and at the regional or national level should be addressed. A Letter of Support from an official of the school confirming a commitment to participate in the competition, and stating the type(s) and level of support for the team's participation in the competition should be attached, and is not counted toward the 12-page limit. Refer to the attachments at the end of this document for a sample.

B. Administrative Considerations and Limitations

This section describes the limitations placed on the proposal. Compliance is mandatory.

Language Proposals must be written in English.

Length Proposals are limited to 12 single-sided double-spaced pages of text, figures, and appendixes. The page size must be 8.5" x 11" or A4 and the font size must be no smaller than 10 point. Margins should be at least 25 mm. The Preliminary Team Information form (Attachment 1 in this RFP), support letters from the school, government entities, or private sector organizations will not count in the proposal length.

Authors Proposals are to be prepared by the student team in collaboration with the faculty advisors.

Signatures Proposals must be signed by all authors of the proposal and the faculty advisor.

Letter of Support Proposals must be accompanied by a letter of support from an appropriate Dean, Department Chair, or other authorized school official. The letter must confirm the school’s commitment to participate. It must also state the type(s) and value of support from the institution. School support should match the value of cash and in-kind support from the team's principal sponsors. Additional letters of support from other team sponsors are optional. A sample is provided as Attachment 2.

Preliminary Team Data Submit one copy of the Preliminary Team Information form (Attachment 1) with the proposal, then an updated copy with the preliminary report to the address below. This form does not count in the 12 page limit.

Due Date All proposals must be received at the address below by close of business on May 31, 2002 for full consideration.

Number of Copies Ten bound copies and one unbound copy of the proposal must be sent to:

Robert Myers Phone: (310) 446-8280

Administrative Secretary Fax: (310) 446-8390

IEEE Power Electronics Society E-mail: bob.myers@ieee.org

IEEE Industry Applications Society

799 North Beverly Glen

Los Angeles, CA 90077

We would also prefer to have an electronic copy, in PDF format, delivered on floppy disk (IBM format) or CD with the proposal copies.

For Information

Non-technical or administrative questions should be directed to Mr. Robert Myers, bob.myers@ieee.org. Technical questions should be directed to the Future Energy Challenge Organizing Committee. The Chair is Prof. Jo Howze, Texas A&M University, howze@ee.tamu.edu. The Vice-Chair is Prof. Fang Peng, Michigan State University, fzpeng@egr.msu.edu. The competition website is http://www.energychallenge.org; this final version of this RFP will be posted on the website.

Time Schedule

April 8, 2002 - schools submit letter of intent

April 15, 2002 - Request for Proposals (RFP) sent (electronically) to schools that provide a Letter of Intent

April 15-30, 2002 – RFP is available for comments and questions from potential teams, and subject to editing in response to comments. (Final official RFP posted May 2, 2002.)

May 31, 2002 - proposals due

August 1, 2002 - schools informed of acceptance into competition

February 9-13, 2003 - Future Energy Challenge Workshop will be held during the IEEE Applied Power Electronics Conference, Miami Beach, Florida, USA. See http://www.apec-conf.org for conference information

March 15, 2003 - preliminary reports due

April 15, 2003 - finalists notified

May 18, 2003 – final competition: reception in Morgantown, WV for topic (a) participants

May 19-22, 2003 – final competition events for topic (a). Final reports due.

May 21-24, 2003 – final competition events for topic (b). Final reports due.

July, 2003 - awards ceremony at 2003 PES general meeting

Competition Description

Scope: An international student competition for innovation, conservation, and effective use of electrical energy. The competition is open to college and university student teams from recognized engineering programs in any location. Participation is on a proposal basis.

Introduction: In 2001, the U.S. Department of Energy (DOE), in partnership with the National Association of State Energy Officials (NASEO), the Institute of Electrical and Electronics Engineers (IEEE), the Department of Defense (DOD) and other sponsors, organized the first Future Energy Challenge competition. The objective was to build prototype, low-cost inverters to support fuel cell power systems. This competition was originally open to schools in North America with accredited engineering programs. The 2001 Future Energy Challenge focused on the emerging field of distributed electricity generation systems, seeking to dramatically improve the design and reduce the cost of dc-ac inverters and interface systems for use in distributed generation systems. The objectives were to design elegant, manufacturable systems that would reduce the costs of commercial interface systems by at least 50% and, thereby, accelerate the deployment of distributed generation systems in homes and buildings. The 2001 Challenge was a success, and is now the first in a biannual series of energy-based student team design competitions.

To continue and expand the 2001 success, the 2003 Future Energy Challenge has been organized as a worldwide student competition. The theme of the 2003 Future Energy Challenge is "Energy Challenge in the Home." The objective is to introduce engineering design innovations that can demonstrate dramatic reductions in residential electricity consumption from utility sources or that can lead to the best use of electricity in newly connected homes in developing nations. The innovations should be low in cost, and should have broad potential for the future.

Topics and Descriptions: The competition addresses three broad topic areas: (a) fuel cell energy conversion, (b) single-phase adjustable-speed motors, and (c) low-cost power for developing nations, respectively described as follows:

a) Energy processing to support the use of solid-oxide fuel cells to provide non-utility and ultra-clean residential electricity. The US Department of Energy and Department of Defense have agreed to provide prize money for substantial cost reductions in inverter technology for such sources. The target cost is less than US$40/kW for a 10 kW inverter interface system (not including an electric grid interface nor the battery). The hardware prototypes judged as best will be tested in a fuel cell system at the DOE National Energy Technology Laboratory. The school with the most cost-effective design and that can meet or exceed the aggressive cost target, and that provides a fully functional prototype, will be awarded with a large prize.

b) Innovations in motors and motor drive systems that produce deep cuts in losses and costs for home (appliance) use, or that could replace “universal motor” brush machines in residential applications. For example, use three-phase motors and motor drives that operate from single-phase power, reduce appliance in-rush currents associated with motor starting, and enhance motor efficiency across a wide load range are of interest. Target hardware costs are US$40 for a combination motor and motor controller that can operate from a single-phase residential source, deliver rated shaft load of 3/4 HP (or 500 W) at 1500 RPM, exhibit a useful speed control range of at least 150 RPM to 5000 RPM, and provide power efficiency of at least 70% for loads ranging from 50 W to 500 W at a specified speed. The hardware prototypes judged as best will be tested at a DOE or DOD National Laboratory. The school with the most cost-effective design and that can meet or exceed the aggressive cost target, and that provides a fully functional prototype, will be awarded with a large prize.

c) Efficient, cost-effective electrification for homes in developing nations. This involves low-cost local energy sources, and emphasizes innovations to allow small amounts of power to make significant impacts on standards of living. The target system addresses ways to produce and use a power-limited 100 W source. The objectives are to prepare a cost-effective low energy source, and to improve the quality of life in the most effective manner for a household if just a small power level is available. The system involves the design of small, low-cost, self-contained solar, wind, or other non-fuel power systems (plus any energy storage), capable of delivering 100 W over several hours at costs in the range of US$0.10/kWhr to US$0.20/kWhr when amortized over a required ten-year life. The system should provide for prioritized control of three different domestic loads. Entries and prototypes will be judged with the assistance of the Construction Engineering Research Laboratory, U.S. Department of Defense, or through arrangements with government or scientific facilities in other nations.

Detailed Description, Proposal Preparation and Specifications of Each Topic

Request for Proposals – Topic (a) Fuel cell energy conversion

The main goal of the Fuel Cell Inverter Challenge is to develop low-cost power processing systems that support the commercialization of a solid-oxide fuel cell (SOFC) power generation system to provide non-utility and ultra-clean residential electricity. For residential applications, the 5 kW SOFC is supplemented with a 5 kW battery set to meet extended-duration power-demand periods exceeding 5 kW and short-duration transient high power loads. Thus the target inverter rating is 10 kW. The US Department of Energy and Department of Defense have agreed to provide prize money for substantial cost reductions in inverter technology for such sources. The competition runs under the auspices of the IEEE Power Electronics Society, the IEEE Industrial Applications Society, The IEEE Power Engineering Society and the IEEE Industrial Electronics Society.

The target cost of a stand-alone, i.e. non-utility linked, 10 kW power processing unit should be less than US$40/kW for the inverter interface system when produced at large quantities. Emphasis is also placed on high-energy efficiency as this has direct impact of size and cost of the SOFC system and overall system fuel efficiency. The hardware prototypes judged as best will be tested first in a fuel cell emulator and subsequently in a fuel cell system at the DOE National Energy Technology Laboratory. The fuel cell system will be provided by Fuel Cell Technologies, Ltd. The school with the most cost-effective design, which meets or exceeds the aggressive cost target, and provides a fully functional prototype, will be awarded with a large prize. In the event that multiple designs meet the specification requirements, and are judged to be comparable on a cost basis, the Challenge Award will be given to the design with the best energy efficiency.

Vision

Encourage the development of technologies to reduce the cost of inverters (power processors) that are designed for domestic energy sources.

Incorporate practicality, potential manufacturability, and affordability into the competition assessment process.

Demonstrate technical progress toward and potential of advanced technologies that may help achieve the goals of this competition.

Improve engineering education and foster practical learning through the development of innovative team-based engineering solutions to complex technical problems.

Goals

Construct an inverter that will:

Reduce the manufacturing cost to less than $40/kW per unit;

Achieve maximum efficiency;

Achieve minimal size and weight requirements;

Minimize cooling requirements; and,

Develop a power processing system which realizes acceptability of fuel cell energy systems in the areas of performance (in steady state and under dynamic conditions), reliability and safety.

Inverter Specifications

The inverter proposed will be judged against a set of objectives, requirements and characteristics given below. The inverter design concept should target a 10 kW (peak) residential power generation system with 5 kW from an SOFC and 5 kW from a battery set. During overload the system draws 5 kW from fuel cell and 5 kW from battery for max. 1 min. To cope with the slow dynamic response of the fuel cell, the 48 V battery pack is also used as a secondary energy source to supply transient loads. A 48 V battery pack as described in the following minimum requirements will be provided at the competition test site. Student teams may elect and propose to provide this 5 kW of supplemental power by some other means. If a team elects to do so, then the team will be responsible for providing their own supplemental 5 kW power source in time to support testing at the competition test site. The fuel cell needs auxiliary power to run its internal circuits, such as balance-of-plant and control sub-systems. This load is 1 kW and has to be managed by the inverter as well. The target design requirements for the 10 kW system given below are minimums that need to be reached to win the Challenge Award of $50,000. Design concepts must be validated with working prototypes. Scoring will be set up such that improvements beyond the minimums are beneficial to the team, with significant weight on energy efficiency. More detail will be published in the official 2003 Future Energy Challenge Rules.

Design Item	Minimum Target Requirement 10 kW System
1. Manufacturing cost	Less than US$40/kW for the 10 kW design in high-volume production.
2. Complete package size	A convenient shape with volume less than 88.5 dm^3 (88.5 L).
3. Complete package weight	Mass less than 30 kg, not including energy source (SOFC) or auxiliary energy storage batteries^1.
4. Output power capability – nominal Output power capability – overload Current limit (short circuit)	5 kW continuous, total (5 kW continuous @ displacement factor 0.7, leading or lagging, max. from each phase) 10 kW overload for 1 minute (half of input from fuel cell and half from battery^1 supply) @ d.f. 0.7 (lead or lag). 5 kW @ 0.7 d.f. max. from each phase. Notice that the phase maximum requirements are the same under continuous and overload conditions. Unit shall shut down if the output current exceeds 110 % of maximum rated value. Teams may select either to continue supplying current or to shut down for currents >100% and <110%.
5. Auxiliary power feed for fuel cell control unit	Unit shall provide an additional NEMA 5-15R outlet to supply 120 Vac/60 Hz for the fuel cell control unit. The load will not exceed 1 kVA, and the displacement factor will not be less than 0.7. This outlet can be connected to either of the output phases, or can be separate at the team’s discretion. This load is counted as part of the total inverter output load for testing purposes. Unit shall provide a connection to supply 48 V dc, +/- 2.5%, for the fuel cell control unit. The load will not exceed 300 W. This 48 V auxiliary supply will be used in conjunction with the fuel cell, and electrically the low side is connected to the negative terminal of the fuel cell. There is no requirement for electrical isolation with respect to the fuel cell, provided the common connection is supported. Total power supplied to these additional outputs is included in the 5 kW continuous and 10 kW overload maximum output.
6. Phase(s)	Split single-phase, for US domestic ac supply with standard NEMA 5-15R receptacles for loads "2 degrees for balanced loads between phases. Please provide at least four outlets per phase to support tests up to 5 kW per phase.
7. Output voltage	120 V/240 V nominal (split-phase).
8. Output frequency	60 Hz ± 0.1 Hz.
9. Output voltage harmonic quality	Output voltage total harmonic distortion (THD): less than 5% when supplying a standard nonlinear test load (Test Considerations to be provided later).
10. Output voltage regulation quality	Output voltage tolerance no wider than ±6% over the full allowed line voltage and temperature range, from no-load to full-load.
11. Input source (SOFC)	22-41 VDC, 29 VDC nominal, 275 A max. from fuel cell.
12. Maximum input current ripple	3% rms of rated current
13. Battery auxiliary power^1	48 V dc nom. +10%-20%, with nominal rating of 500 Whr. Battery can be used as a temporary energy source (5kW peak equivalent at the output, 1 min.) as well as for control power. Charging and charge management must be provided, such that charge is unchanged at the end of a 24 hour test sequence.
14. Overall energy efficiency	Higher than 90% for 5.0 kW resistive load with minimal efficiency degradation up to peak power and down to minimum power. Additional scoring points will be awarded for efficiencies higher than 90%.
15. Protection	Over current, over voltage, short circuit, over temperature, and under voltage. No damage caused by output short circuit. The inverter must shut down if the input voltage dips below the minimum input. IEEE Std. 929 is a useful reference.
16. Electromagnetic interference	Per FCC 18 Class A -- industrial requirements for conducted and radiated EMI.
17. Safety	The final rules will contain detailed safety information. No live electrical elements are to be exposed when the unit is fully configured. The system is intended for safe, routine use in a home or small business by non-technical customers. Industry safety standards will be required, such as UL 1741-2000.
18. Grid and source interaction	None. The inverter is intended as a stand-alone unit for remote power or backup power.
19. Communication interface	Control communication between fuel cell and inverter is through RS232—see Table 1, below. Standard commercial software to be provided by the team to the test lab for acquiring any inverter internal data and recording it via a conventional spreadsheet.
20. Environment	Suitable for indoor or outdoor installation in domestic applications.
21. Storage temperature range	-20 to 85 °C
22. Operating ambient temperature range	0 to 40 °C
23. Other ambient	Humidity less than or equal to 95% up to 25 °C Less than or equal to 75% at temp. above 25 °C up to 40 °C
24. Enclosure type (suggested)	NEMA 1
25. Cooling	Air cooled
26. Shipping environment	Can be shipped by conventional air or truck freight.
27. Acoustic noise	No louder than conventional domestic refrigerator. Less than 50 dBA sound level measured 1.5 m from the unit.
28. Lifetime	The system should function for at least sixteen years with routine maintenance when subjected to normal use in a 20°C to 40°C ambient environment.
29. Technical report	Design, simulation, experiment results, lifetime analysis, and cost study.
30. Auxiliary power availability	The fuel cell system requires both the dc and ac auxiliary power (see item 5 above) fully functional before it can begin to operate. The power conversion system can bring the dc and ac auxiliaries up in either order, but the fuel cell system will not begin to work until both are powered up and available. (Notice that this will require power to be drawn from the battery pack as the fuel cell comes up.)
31. Control power	The power conversion system must draw all its power from either the fuel cell of the battery pack. This does not preclude the use of small internal batteries for nonvolatile memory or similar functions, but the conversion system should meet the sixteen year lifetime without requiring change of any extra internal source. (Notice that the battery pack is assumed to be connected continuously when the conversion system is to be in operation.)
32. Galvanic isolation	Galvanic isolation of the system is not a specific requirement, because the fuel cell system can “float” electrically, but it is encouraged. It is a requirement that the common neutral point of the ac output phases be available for external bonding to earth ground.

Notes: 1. A 48 V battery pack as described in the following minimum requirements will be provided at the competition test site. Students may elect and propose to provide this 5 kW of supplemental power by some other means. If a team elects to do so, then the team will be responsible for providing their own supplemental 5 kW power source in time to support testing at the competition test site.

Please note that each unit should be equipped with at least nine NEMA 5-15R receptacles: four for each output phase and one additional for the required fuel cell support power.

Final Competition Prototype Testing

A detailed test protocol will be presented to the teams prior to the competition. The teams can expect two stages of testing. The first being a preliminary test on a DC power supply (fuel cell simulator), and if the inverter passes, then is evaluated on the SOFC fuel cell system. Prototypes should be fully functional and meet the minimum requirements. In Spring 2003, submitted reports and other materials will be evaluated by the judges. A small group of teams will be selected as Finalists, and some support for travel to a Final Competition at the National Energy Technology Laboratory in Morgantown, West Virginia may be available. At the site, prototypes will be tested against the requirements to help validate the system design and the team’s concepts. Testing will first be performed using dc power supplies, i.e. fuel cell simulator, and finally with a working SOFC prototype from Fuel Cell Technologies, Ltd. Guidance on competition prototype test considerations will be provided at a later date.

Table 1. Communication to fuel cell controller

RS 232	The following signals are required to the fuel cell controller computer via the RS 232 link:
1) DC Fuel Cell Voltage NOTE: the Fuel Cell voltage cannot be below VFC min (Fuel Cell minimum voltage)
2) DC Fuel Cell Current
3) DC Battery Voltage
4) DC Battery Current
5) DC Link Voltage
6) AC Voltage
7) AC Current
8) KVA Output Total from Inverter
9) kW Output Real Power From Inverter
10) Run
11) PCU (or inverter) Fault
12) “ Slew rate ” : - to deal with fast step load changes, energy is initially drawn from the batteries. A configurable slew rate will be transmitted from the Fuel Cell controls to the inverter. This rate will quantify the rate at which the inverter transfers the load from the batteries back to the Fuel Cell (Amps / Sec). This is required because the Fuel Cell needs a period of time to adjust the Fuel and Air Flow rates as the Fuel Cell output current increases. NOTE: the rate of change of Fuel Cell Output Current < slew rate.
System Diagnostic on LEDs		- Run, Fault
Operators		- AC Line Breaker, DC Fuse Links
Discrete TTL Control Signal from Fuel Cell Controller		1. Enable Inverter (AUX Bus comes alive and power is at output) 2. Enable Grid Connect Mode 3. Enable Stand Alone Mode 4. Enable Battery Charging 5. Enable Battery Equalize charging
Software Protocol		RS 232, RS 485, TBD (Vendor Specific for prototype)

Requirements Intent

The requirements are intended to provide guidance rather than an exhaustive list of requirements. All teams are encouraged to develop novel solutions and test a wide range of ideas. The long-term purpose is to develop cost-effective technologies with high-energy efficiency that will bring alternative energy such as solid-oxide fuel cells to homes and businesses. Judges will be encouraged to consider the spirit, innovation, and future promise of each team’s work when reviewing entries. For designs of comparable high-production volume cost estimates, the design with better energy efficiency will be judged to be superior.

Design Restrictions

In general, any electrical, electronic, energy, mechanical, or other component may be used in the system design. Keep in mind the cost and efficiency considerations and the intended safe use in domestic applications. These factors will limit the feasible range of component choices.

Fuel Cell Simulator

Fuel Cell Technology, Ltd. will provide a fuel cell simulator for initial test and evaluation of inverters during the competition test period. The simulator provides both steady-state and dynamic behavior to model a 5 kW SOFC prototype design.

Solid-Oxide Fuel Cell Power Generation System

Fuel Cell Technology, Ltd. will provide a 5 kW solid-oxide fuel cell power generator for use during the competition test period.

Funding Sources

DOE and DOD provide the Challenge Award, publicity, and any related activities.

IEEE and other sponsors provide Program Awards.

FTC, in conjunction with NETL, will support the final testing events.

Individual schools should solicit project funding from NASEO, utilities, manufacturers, and NSF. There is no limitation for the sources of project funding.

References

National Electrical Code (NEC) 1999 (or NFPA 70)

MIL-STD-498A, Software Requirements Specification (SRS) DI-IPSC-81433

UL 1741 “Static Inverters and Charge Controllers for use in Photovoltaic Power Systems”

Information Sources

The US Dept. of Energy Solid State Energy Conversion Alliance (SECA) program was established to encourage the development of environmentally friendly solid-oxide fuel cell modules for use with commonly available fossil fuels at low cost. A cost goal of $400/kW within 10 years was set for developer of solid-oxide fuel cell power generation systems. Information on the SECA program and participants can be obtain at

http://www.seca.doe.gov/. Details on the requirements for the developers under the SECA program can also be found in solicitation DE-PS26-00NT40854 at http://www.netl.doe.gov/business/solicit/index.html.

The National Energy Technology Laboratory Strategic Center for Natural Gas provides access to fuel cell project information and reports at Gas Processing & End Use

Fuel Cells Reference Shelf via http://www.netl.doe.gov/scng/enduse/fc_refshlf.html.

Fuel Cell Technology, Ltd. is developing SOFC power generation systems with Siemens Westinghouse Power Corporation, Stationary Fuel Cell Division. Information on Fuel Cell Technology, Ltd .can be obtained at http://www.fct.ca/. Information on Siemens Westinghouse Power Corporation solid oxide fuel cells can be found at http://www.siemenswestinghouse.com/en/index.cfm.

M. B. Gunes, “Investigation of a Fuel Cell Base Total Energy System for Residential Applications”, MS Thesis, Virginia Polytechnic Institute, VA, April 30, 2001. This report provides an analysis of a residential proton exchange membrane (PEM) fuel cell power generation system with supplemental battery power.

Request for Proposals – Topic (b) Single-phase adjustable-speed motor

Topic Description

The information provided in the following is for the single-phase adjustable-speed motor topic. The objective is innovations in motors and motor drive systems that produce deep cuts in losses and costs for home (appliance) use, or that could replace “universal motor” brush machines in residential applications. For example, use three-phase motors and motor drives that operate from single-phase power, reduce appliance in-rush currents associated with motor starting, and enhance motor efficiency across a wide load range are of interest.

Target hardware costs are US$40 for a combination motor and motor controller that can operate from a single-phase residential source, deliver rated shaft load of 3/4 HP (or 500 W) at 1500 RPM, exhibit a useful speed control range of at least 150 RPM to 5000 RPM, and provide power efficiency of at least 70% for loads ranging from 50 W to 500 W at a specified speed. The hardware prototypes judged as best will be tested at a DOE or DOD National Laboratory. The school with the most cost-effective design and that can meet or exceed the aggressive cost target, and that provides a fully functional prototype, will be awarded with a large prize. Substantial funding for this topic is provided by the IEEE Power Electronics Society, the IEEE Industry Applications Society, the IEEE Power Engineering Society, and the Grainger Center for Electric Machinery and Electromechanics at the University of Illinois. Total prize money will depend on the number of schools engaged in this topic, and is expected to exceed US$25,000.

Vision

Encourage the development of technologies to bring dramatic improvements to low-cost single-phase motor systems for home use.

Incorporate practicality, potential manufacturability, and affordability into the competition assessment process.

Demonstrate technical progress toward and potential of advanced technologies that may help achieve the goals of this competition.

Improve engineering education and foster practical learning through the development of innovative team-based engineering solutions to complex technical problems.

Goal

Construct an adjustable speed motor system that will:

reduce the manufacturing cost to less than US$40 for a 500 W unit;

achieve maximum efficiency and operating requirements; and,

maintain acceptability in the areas of performance, reliability and safety.

Motor System Specifications

The motor system proposed will be judged against a set of objective specifications based on the example design targets shown below. The design concept is a 500 W motor system, and teams are asked to construct a complete hardware prototype to demonstrate their accomplishments. The target design requirements for the system given below are minimums that need to be reached to win the Challenge Award. Design concepts are expected to be validated with working prototypes. Scoring will be set up such that improvements beyond the minimums are beneficial to the team.

Design Concept/Function	Minimum Target Requirement
1. Manufacturing cost	No more than US$40 when scaled to high-volume production (approximately 1 million units/year).
2. Complete package size	A convenient shape with volume less than 4 L. (Motor maximum dimensions are given below.)
3. Complete package weight	Mass less than 8 kg for the complete system.
4. Output power capability and speed range	500 W continuous shaft output power at a nominal speed of 1500 RPM, and also at higher speeds up to 5000 RPM. Continuous output torque of at least 3.18 N-m at speeds from 150 RPM to 1500 RPM.
5. Input source	Single-phase source at 50 Hz or 60 Hz. Teams may select either to design for nominal 120 V at these frequencies or for nominal 220 V at these frequencies.
6. Overall energy efficiency	Higher than 70% for shaft loads ranging from 50 W to 500 W. Efficiency will be tested at a nominal speed of 1500 RPM.
7. Power factor	Power factor measured at the electrical input should be at least 80% when tested under a 500 W shaft load at 1500 RPM. Current waveform should conform to requirements in IEC1000-3-2 standards.
8. Safety	The system is intended for safe use in a home appliance or household HVAC system.
9. Speed control	Speed is to be controlled from start to the full 5000 RPM with a linear 0-10 V analog signal, referenced to the unit case. Except for starting, no testing will be performed below 150 RPM.
9. Speed regulation and accuracy	The actual operating speed should remain within ±5% of the voltage command setting (2 V/1000 RPM) from no-load to full-load.
10. Acoustic noise	Low noise. Less than 50 dBA sound level measured 0.5 m from the unit.
11. Electrical noise	Able to meet FCC Class A—industrial requirements for conducted and radiated EMI.
12. Protection	Self-protection against continuous stall conditions, over temperature, or loss of input source with no damage caused by any of these (up to the maximum storage temperature).
13. Environment	Open drip proof motor construction is acceptable. Ambient temperature -20°C to +40°C. Suitable for indoor or outdoor domestic applications.
14. Lifetime	The system should function for at least ten years with no maintenance needs when subjected to normal use in a 20°C to 30°C ambient environment.
15. Technical report	Design, simulation, experiment results, lifetime analysis, and cost study.

Additional Hardware Specifications
1. Inrush and starting current	Operating current shall not exceed 150% of nominal full-load current under any conditions, including power-on inrush and motor starts.
2. Phases and motor phasing	The input power source is single phase. There are no restrictions on the motor technology or motor phase count as long as the system operates from single-phase power.
3. Motor dimensions	The motor itself must be no larger than NEMA Frame Size #48. Radius from shaft center to mounting points not to exceed three inches or 76.2 mm. Overall length (not including shaft extension) not to exceed 7.75 inches or 197 mm.
4. Coupling and mount	Motor is to be provided with a footed or cradle mount with base holes corresponding to NEMA Frame #48 (width spacing 108 mm or 4.25 in, length spacing 70 mm or 2.75 in), located 76.2 mm (3 in) below the shaft center. Motor shaft diameter is to be 0.50 in (12.7 mm), or the team can provide a suitable adapter to achieve this diameter. The shaft should extend at least 38 mm beyond the motor case.
5. Safety	The final rules will contain detailed safety information. No live electrical elements are to be exposed when the system is fully configured.
6. Connection	The complete unit is to be provided with an IEC 320 input connection, with a clear label stating the voltage requirement.
7. Storage temperature range	-20 to 60°C
8. Bearings	Any choice of bearings is acceptable, provided no lubrication or maintenance will be needed during a ten-year normal duty operating life.
9. Handling	The unit must be robust enough for normal handling by a technician with no special training.
10. Shipping environment	Can be shipped by conventional air freight or truck freight.
11. Displays and data	No displays or data capability are required, although a digital display of running speed is encouraged. A control dial with markings is required, as stated above.
12. Command signal	Access to the speed control voltage signal is to be provided either through a conventional BNC jack or a pair of screw terminals. The input should be protected against accidental polarity reversal. The speed must return to zero if no signal is connected.
13. Switch	The unit must include an on/off switch. When the switch is off, the input power must not exceed 1 W.
Prototype Test Considerations
1. Inspections	All prototypes of approved Finalist teams must pass safety inspection prior to operation. All prototypes must function correctly during a 15-minute initial operation check before proceeding.
2. Test energy source: voltage	Prototypes will be tested with available power consistent with the selected voltage rating. Either 50 Hz or 60 Hz may be used.
3. Test duration	An automated load sequencing operation will be tested for up to 24 hr continuous.
4. Typical operation tests	Tests for steady-state performance, protection, robustness to stalls, acoustic noise, electromagnetic noise may be conducted.
5. Source interface tests	Tests for transient loads may be conducted, within the allowed torque, speed, and power range.

Specification Intent

The specifications are intended to provide guidance rather than an exhaustive list of requirements. All teams are encouraged to develop novel solutions and test a wide range of ideas. The long-term purpose is to develop cost-effective technologies that will bring major advances in motors for homes. Judges will be encouraged to consider the spirit, innovation, and future promise of each team’s work when reviewing entries.

Design Restrictions

In general, any electrical, electronic, energy, mechanical, or other component may be used and any motor technology is permitted. Keep in mind the cost considerations and the intended safe use in domestic applications. Both factors will limit the feasible range of component choices.

Funding Sources

IEEE and the Grainger Center for Electric Machinery and Electromechanics at the University of Illinois provide the Challenge Award.

IEEE and other sponsors provide Program Awards.

Tentatively, DOD will support the final testing events.

Individual schools should solicit project funding from NASEO, utilities, manufacturers, and NSF. There is no limitation for the sources of project funding.

Request for Proposals – Topic (c) low-cost power for developing nations

Topic Description

The information provided in the following is for the low-cost energy for developing nations topic. The objective of this topic is to encourage innovations to enhance electrical energy availability in developing nations, and to encourage ideas that have substantial impact on quality of life.

Target total hardware and operating costs are US$850 for a complete energy supply system with a nominal output power of 100 W. Over ten years of use, this will represent energy costs in the range of US$0.10 to US$0.20 per kilowatt-hour. The hardware prototypes judged as best will be tested at a DOE or DOD National Laboratory, or in collaboration with national facilities in countries of participating teams. The school with the most cost-effective design and that can meet or exceed the aggressive cost target, and that provides a fully functional prototype, will be awarded with a large prize. Substantial funding for this topic is provided by the IEEE Power Electronics Society, the IEEE Industry Applications Society, and the IEEE Power Engineering Society. Total prize money will depend on the number of schools engaged in this topic, and is expected to exceed US$25,000.

Vision

Encourage the development of technologies to bring dramatic improvements to alternative energy systems for homes in the developing world.

Incorporate practicality, potential manufacturability, and affordability into the competition assessment process.

Address lifestyle impacts of electrification at modest power levels, and focus on those loads most likely to improve quality of life.

Demonstrate technical progress toward and potential of advanced technologies that may help achieve the goals of this competition.

Improve engineering education and foster practical learning through the development of innovative team-based engineering solutions to complex technical problems.

Goal

Construct an energy supply system that will:

reduce the manufacturing and operating costs of alternative energy systems into the range of US$0.10 to US$0.20 per kilowatt-hour;

provide load flexibility to bring significant lifestyle enhancements to remote areas in the developing world;

provide reliability necessary for effective operation over many years of household use; and,

maintain acceptability in the areas of performance and safety.

Specifications – Topic (c) low-cost power for developing nations

Design Concept/Function	Minimum Target Requirement
1. Manufacturing and operating cost	Combined cost of manufacture, operation, maintenance, and installation, amortized over ten year life, not to exceed US$850. This represents US$0.10 to $0.20 per kW-hr over the life of the system. It assumes high-volume production (approximately 200 000 units/year).
2. Complete package size and weight	No special restrictions, except that the system must allow assembly by a single individual with no special training and with hand tools.
3. Input energy source	Any “non-fuel” energy source, including photovoltaic, solar thermal, wind generation, or water-driven generation. The widest possible application is of interest.
4. Output power capability	Electrical output must provide a minimum of 100 W for at least 6 hrs per day, a minimum of 50 W for at least 12 hrs per day, and a minimum of 25 W for at least 18 hrs per day.
5. Output specifications	Teams may select any one of four output configurations: 12 V dc (+-5%), 48 V dc (+-5%), single-phase 120 V ac 60 Hz (voltage +-10%, frequency +-2%), or single-phase 220 V ac 50 Hz (voltage +-10%, frequency +-2%), or the electric utility configuration available in the team’s home country. Please choose only one, but it is required that loads suitable for the chosen source be used.
6. Energy storage	There are no restrictions on the nature or type of any energy storage elements used to meet the requirements. Possibilities include, but are not limited to, batteries, water tanks, masses or springs, capacitors, thermal storage, or other means. Any energy storage used must be included in the cost and reliability analysis.
7. Weather	The output energy requirements must be met during typical weather conditions. The team may select weather conditions at a typical site in their home country as the basis for the design. Operation during severe weather is not required. Any weather-related de-rating must be described in the Final Report.
8. Safety	The system is intended for home use by untrained people, and should be inherently safe.
9. Loads	Tests are based on a small refrigeration load, lighting loads (such as compact fluorescent), and communications loads (TV/radio). Each team is encouraged to propose additional loads that they believe will provide substantial life enhancements, such as water pumps or purification systems, but must demonstrate that the loads can be addressed within the available energy. Loads are not included in the cost or reliability analysis.
10. Load priority	Loads must be provided with a priority setting that allows automatic control of energy delivery where it is most needed. At least three loads should be supported in this way. This can be provided within the energy unit, for example, by providing three separate power outlets, each with an internal priority setting.
11. Protection	Self-protection must be provided against short circuits or other output faults.
12. Environment	Suitable for outdoor installation. Ambient temperature -20°C to +50°C.
13. Lifetime	The system should function for at least ten years with any maintenance needs included in the cost analysis when subjected to normal use.
14. Technical report	Design, simulation, experimental results, lifetime analysis, and cost study. The report must include reliability and cost analysis to demonstrate that the design can meet the ten-year lifetime requirement and the life-cycle cost objectives.

Additional Hardware Specifications and Test Considerations
1. Safety	The final rules will contain detailed safety information. No live electrical elements are to be exposed when the system is fully configured.
2. Storage temperature range	-20 to 60°C
3. Handling	The unit must be robust enough for normal assembly and handling by a technician with no special training.
4. Shipping environment	Can be shipped by conventional air freight or truck freight. Multiple packages and assembly in a kit form are permitted.
5. Displays and data	No displays or data capability are required, although some general indication of the available power at any given moment is encouraged.
13. Switch	The unit must include an on/off switch. When the switch is off, no power is delivered to any load.
14. Inspections	All prototypes of approved Finalist teams must pass safety inspection prior to operation. All prototypes must function correctly during a 15-minute initial operation check before proceeding.
15. Test energy sources	An outdoor environment will be available for solar and wind testing (mirrors will be used if necessary to produce insolation consistent with tropical latitutes). A fan will be available if needed to simulate normal winds, and a water source with a pressure of 100 psi and a flow rate of up to 10 L/min will be available for testing of water-powered units.
16. Test duration	An automated load sequencing operation will be tested for up to 24 hr continuous. The units will be tested at power levels consistent with the “Output power capability” specification above.
17. Typical operation tests	Tests for steady-state performance, protection, interaction with loads, and the priority system may be conducted.

Additional Scoring

Teams are encouraged to analyze the manufacture and utility of their design. Technical reports that include manufacturing plans based on facilities in developing nations will receive extra merit during judging. Designs best suited for use in a wide range of locations will also receive extra merit. In the event that multiple teams are able to meet all the target specifications, the designs with the best promise for wide application and reports that address manufacturing plans in developing nations will be favored.

Specification Intent

The specifications are intended to provide guidance rather than an exhaustive list of requirements. All teams are encouraged to develop novel solutions and test a wide range of ideas. The long-term purpose is to develop cost-effective technologies that will bring major advances in energy sources for homes in developing nations. Judges will be encouraged to consider the spirit, innovation, and future promise of each team’s work when reviewing entries.

Design Restrictions

In general, any electrical, electronic, energy, mechanical, or other component may be used and any technology is permitted. Keep in mind the cost considerations and the intended safe use in domestic applications. These factors will limit the feasible range of component choices.

Funding Sources

IEEE provides the Challenge Award.

IEEE and other sponsors provide Program Awards.

Tentatively, DOD will support the final testing events.

Individual schools should solicit project funding from local or national sources. There is no limitation for the sources of project funding.

Attachment 1

2003 Future Energy challenge Preliminary Team Information Form Topic – XXXX

Submit with Proposal

Name of University:

DATE:

Corresponding Address (please include name):

TELPHONE:

FAX:

EMAIL:

Faculty Advisor(s):

Name Department E-Mail

_________________________ _________________________ ____________________

_________________________ _________________________ ____________________

_________________________ _________________________ ____________________

PRELIMINARY Team Members:

Name Major Field of Study Degree and

Expected Graduation Date

_______________________ ____________________________________ ________________

_______________________ ____________________________________ ________________

_______________________ ____________________________________ ________________

_______________________ ____________________________________ ________________

_______________________ ____________________________________ ________________

_______________________ ____________________________________ ________________

ATTACHMENT II

SAMPLE LETTER OF SUPPORT

[The letter below is a typical sample, and should not simply be copied. Please send a letter with similar content on your University letterhead.]

Robert Myers

Administrative Secretary

IEEE Power Electronics Society

IEEE Industry Applications Society

799 North Beverly Glen

Los Angeles, CA 90077

Dear Mr. Myers,

Our university has organized a student team to participate in the 2003 Future Energy Challenge. Our proposal for the ( ) topic is enclosed. A Preliminary Team Participation Form is attached, listing our contact person, the faculty advisor(s), and some of the students who plan to be involved. The team will keep an eye on the Energy Challenge web site for detailed rules and other information. We understand that we will be notified whether we have been accepted to participate by August 1, 2002. If we are accepted, we agree to have our student team perform the design tasks and prepare the reports and hardware prototypes required for the competition. Our school is prepared to support the team with the following resources:

· A final year project course, XXX, has been authorized to provide engineering students across several disciplines with the opportunity to include this project in their curricula. Laboratory space has been arranged for this course.

· A faculty advisor, Prof. YYY, has been identified, and has been formally assigned to teach the project course and to advise the student team as a portion of her regular duties.

· A graduate student assistant has been identified to help manage the student team and to supervise direct laboratory activity. This student is supported with a Teaching Assistantship, which represents a funding commitment of our university of approximately ( ).

· The student team will be provided with an appropriate level of technician and machine shop support to assist them with package preparation and assembly. This assistance represents a funding commitment of approximately ( ), and we consider this as a matching commitment for any in-kind support received from external sponsors.

· In addition, we will provide limited funds to help secure special parts and equipment, with a total commitment of up to ( ).

· The student team will be encouraged to secure outside sponsorship. Our university strongly supports all these efforts, and will match any outside cash support 1:1 up to an additional total of ( ).

In the event that our school receives prizes from the competition, we are committed to using approximately ( )% of this money for scholarships for the student team members. The remainder of the funds will be added to our Team Design Program fund, which supports this and similar projects through sponsorship matching, travel funds for participation in competition events, and other direct costs of large team design projects. In the event that our team creates new inventions in the topic area, our university also provides the possibility of assisting with organization of a start-up company.

We understand the importance of student team projects in the engineering curriculum, and look forward to our participation in the 2003 Future Energy Challenge.

Sincerely,

(Head of Department, Dean of Engineering or similar school official)