Industrial-Grade 3-Phase Inverter Design

Embedded Hardware & Firmware Expert Needed for Industrial 3-Phase Pure Sine Wave Inverter
Project Overview:
I am seeking an experienced Power Electronics and Embedded Systems Engineer to design the hardware and firmware for an Industrial-Grade 3-Phase Pure Sine Wave Inverter. The project involves designing multiple PCBs (MCU Motherboard, IGBT Driver, Thyristor Driver, and Sensing Interface) and developing robust firmware for system control, monitoring, and HMI integration.
1. Hardware Specifications & PCB Requirements:
You will be responsible for designing the following industrial-grade PCBs:
• MCU Motherboard: Based on Texas Instruments (TI) or Microchip architecture. Must handle PWM modulation and system logic.
• IGBT Driver PCB (3-Phase): Industrial grade, optimized for Infineon or Fuji IGBT modules.
• Thyristor Driver PCB (3-Phase): For Static Switch control.
• AC/DC Sensing & Interface PCB:
• 3-Phase AC Voltage and Current monitoring for the Bypass Input.
• 3-Phase AC Voltage and Current monitoring for the Inverter Output.
Power Ratings:
• DC Input: 110 Vdc to 390 Vdc.
• AC Output: 130 Vac to 220 Vac (3-Phase).
2. MCU I/O & Interface Requirements:
• Analog/Digital Inputs:
• 3-Phase AC Voltage inputs (Bypass & Inverter Output) for grid synchronization.
• 6 channels of AC Current input.
• DC Voltage input.
• Trip Zone digital input.
Communication Ports: 2x RS232 and 2x RS485 for serial communication, software monitoring, and data analysis.
3. Firmware & Control Logic:
• Inverter Startup Conditions: The MCU must initiate the 3-Phase PWM only when:
• The manual "ON" push button is pressed.
• DC Input Voltage > 195 Vdc.
• Inverter Output Voltage is 230 Vac (±10%).
• Inverter Output Frequency is 50 Hz (±5%).
• No active alarms from GPIO (Overload, High Temperature, Short Circuit).
• No High DC Current detected from the current transducer.
Operational Logic:
• PWM is manually controlled via On/Off push buttons.
• The system must support Inverter Output Voltage adjustment.
• The MCU must continuously monitor all statuses and automatically shut down the inverter if any abnormal conditions arise.
• Non-Volatile Memory: The MCU must retain programmed firmware after power down and log data for any failure events.
4. Static Switch & Interlock Function:
• The Inverter Static Switch should turn ON only after a 10-second continuous "healthy" status check where:
• All 3 PWM modulations and waveforms are correct.
• Output Voltage is 230 Vac (±10%) and Frequency is 50 Hz (±5%).
• No overload alarms are present.
Fail-Safe Interlock: If any of the above conditions fail, the Inverter Static Switch must turn OFF immediately, and the Bypass Static Switch must turn ON instantly. These two switches must be electronically interlocked.
5. HMI & Display Integration:
• Hardware: 4x20 LCD display communicating via I2C, integrated with a 6-button keypad shield (Up, Down, Enter, On, Off, Mode).
• UI Navigation (5 Pages):
1. System Input & Output Data
• System DC Status & Temperature
• System Function Status
• System Alarm Status
• System Alarm Logs
6. Final Project Deliverables:
Upon completion, the freelancer must provide full ownership and transfer of the following:
1. Hardware Files: Complete Circuit Diagrams/Schematics, Gerber files, and BOMs for all 4 boards (MCU, IGBT Driver, Static Switch Driver, AC & DC Interface).
2. Software Files: Fully commented firmware source code for the MCU.
Application Requirements:
To be considered for this project, please provide:
• A brief cover letter outlining your approach to this project.
• Portfolio examples or case studies of past projects specifically related to 3-phase inverters, IGBT/Thyristor drivers, and industrial power electronics.