Transcript Team4phase1

Electrical Engineering 595
Capstone Design Team #4
Universal Power Box
Staff
Gerry Callison, BSEE


Expertise: Power Systems,
Digital Design, Presentation
Experience: 3 years experience
at Johnsons Controls
Maria Schlicht, BSEE


Expertise: Micro controllers,
PLCs, Project Management,
Technical Writing, Language Skills
Experience: 8 years experience
at Rockwell Automation
Ethan Spafford, BSEE

Expertise: RF, Circuit Design,
Optical Communication, PSpice
Software
Staff
Matt Risic, BSEE/BSCS


Expertise: High Level
Programming, Assembly,
Computer Networks, Computer
Organization
Experience: Two summers
interning at Philips Advance
Transformer
Vanessa White, BSEE


Expertise: Digital Design, Micro
controllers, PLC Logic
Experience: One year experience
at Harley Davidson
Contact Info
Gerry Callison
Maria Schlicht
Ethan Spafford
Matt Risic
Vanessa White
Phone: (414) 510-1218
Email: [email protected]
Phone: (414) 382-1208
Email: [email protected]
Phone: (262) 332-0646
Email: [email protected]
Phone: (262) 893-3015
Email: [email protected]
Phone: (608) 212-7431
Email: [email protected]
Weekly Availability Worksheet
Gerry Callison
Maria Schlicht
Ethan Spafford
Matt Risic
Vanessa White
Time 1: Monday nights
Time 3: Saturday any
Time 1: Monday after 5p
Time 3: Fridays after 4p
Time 1: Monday after 5p
Time 3: Fridays any
Time 1: Monday after 7
Time 3: Thursday 1-6
Time 1: Monday after 5:30
Time 3: Saturday any
Time 2: Friday any
Time 2: Tue after 4p
Time 2: Tue after 4p
Time 4: Sat any
Time 2: Tues any
Time 2: Fri after 5
Time 4: Sunday any
Weekly Project Meeting Plan
Weekly Meeting 1:
3rd Floor Lab, Monday 5-7 PM
Owner: Gerry Callison
Weekly Meeting 2:
3rd Floor Lab, Tues 12-2 PM
Owner: Matt Risic
Weekly Meeting 3:
3rd Floor Lab, Friday 12-2 PM
Owner: Ethan Spafford
Weekly Meeting 4:
3rd Floor Lab, Sat 12-2 PM
Owner: Maria Schlicht
Total Resources Estimate
400 Manhours, approximately 80 per member
$300 or key part availability for material and
prototyping
Information Media Roles
Website URL and Web master: Matt Risic
Project Archiver: Vanesssa White
Presentation Mgr: Gerry Callison
Report Mgrs: Maria Schlicht/Ethan Spafford
Project Selection
•
Best fit for scope of project and component
availability
Fullest use of skills and experience of team
•
Major risks
•
Electrical Safety
Electronic Overload
Physical Durability
•
•
•
Other projects rejected for lack of variety in tasks
and their limited scope
Decision unanimously supported by team
Selection Process
– Majority vote after input from faculty advisors
Timeline
February
Define
Initial Design
Component
Selection
Build Prototype
Verification
Refine
Design
Documentation
March
April
May
Time Line Summary
Basic Product Definition

Compilation/Definition of
Team Logistics/Operation

Team Resources Allocation

Product Level Requirements
Standard/Performance
Proto-Type Block Diagram

Block Diagram with
Assignments and Interfaces

Block Review Team T/A
Productization

Develop Product Level
Verification and Requirement Plan

Compilation/Development of MFG
Processes, Block Diagrams

Design Plans for Testing Disposal
and Service
Man
Hours
Completion
Date
2
2/4
1
2
2/15
2/4
2
2/5
1
2/18
3
4/10
4.5
4/30
4
4/19
Time Line Summary
Est.Man Completion
Hours
Date
Proto-Typing

Integrate BL Proto-Type into
Product Level Proto-type

Testing of Fully Integrated
Proto-type

Execution of PL Verification/Validation
Plan

Compilation of Resource Expenditure
and Budget Chart
2
4/24
5
4/24
2
4/30
1
5/5
12.5
5/5
1
5/10
Documentation


Compilation of Individual
MSWord Reports
Compilation of Final MSWord Report
and PowerPoint Slide Show
Product Definition: User
Requirements
•
•
•
•
•
•
Product: Universal Power Box
Industry Family: Consumer Electronics
Useful to eliminate the multitude of power adapters
needed for many electronic devices so that they may
be powered by any battery or standard wall plug
regardless of the type of power required by the
device
Intended for use in home electronics devices
The UPB will deliver power with simplicity!
Many different power adapters available, but none
known that combine AC-DC, DC-AC, and DC-DC in
one product
Refined Block Diagram
Gerry
Matt
Maria
Ethan
Vanessa
3 MODES OF OPERATION
AC to DC.
DC to DC.
DC to AC.
AC to DC operation overview
AC voltage applied to I/O AC.
Uncontrolled Inverter/Rectifier converts
AC to DC.
Buck-Boost converter adjusts output DC
voltage to user-defined level.
DC to DC operation overview
User inputs DC to I/O DC.
Buck-boost converter adjusts DC to user
defined level of DC.
Inverter/Rectifier switches configure to
pass through output DC without altering it.
DC to AC operation overview
User inputs DC through I/O DC.
Buck-boost converter adjusts level of DC
necessary for proper AC output.
Inverter/Rectifier runs PWM switching to
output AC.
TOP-LEVEL FUNCTIONALITY
REQUIREMENTS
The user can input 0-50Vdc or 0-120VAC to get out 0-50Vdc or 0120VAC.
Separate adapter cables will allow for various power supplies to be
connected to the UPB
The UPB will sense the level/type of input power, then output a userdefined level/type of power.
The UPB will be able to output 150 Watts of power.
The UPB will be able to output 5 Amps of current.
Block Requirements
Power Control
Matt Risic
Power Control
Gerry
Matt
Maria
Ethan
Vanessa
Block Purpose
The Power Control is the center of the
Universal Power Box
The programming is responsible for
converting input waves into necessary
output voltage waves.
This will vary from mode of operation.
ATMega88 Microprocessor
Uses RISC Architecture
131 Instruction Set
C and Assembly Coding
32 x 8 General Purpose Registers
8KB Programmable Flash
512 Bytes EEPROM
1KB SRAM
28 Pin Chip
ATMega88 Operating Conditions
Operating voltage between 1.8-5.5V
Operating temperature between -40 to +85
degrees Celsius
0-6 MHz @ 1.8-5.5V, 0-12MHz @ 2.7-5.5V
At 1MHz consumes 1.8V, 240uA
At 32 kHz consumes 1.8V, 15uA
Power-down Mode is 0.1uA at 1.8V
Microprocessor Selection
Selected over other considerations
because of best benefits per cost ratio.
Available locally or over Internet
Dependable and respectable
manufacturer.
Manuals, examples and tutorials readily
available.
AVR Studio 4
Integrated Coding,
Compiling and Debugging
Software
Configurable Memory
Support for C, Pascal,
BASIC and Assembly
Simulator Port Activity
Logging and Pin Input
Standard Requirements
Power Control
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
0%RH to 70%RH
<$20
<30
<48cm2
<95.5 grams
<20W
5C to 35C
0C to 50C
0-70%
3 Years
Performance Requirements
Power Control
Input Voltage
Full Scale Output Voltage
+3.3V (+/- 3%)
+5V (+/- 3%)
Interfaces with User Interface, Control Power, Switch Driver, AC
Sensor and Internal Sensor
Inverter-Rectifier
Gerry Callison
Inverter-Rectifier
Gerry
Matt
Maria
Ethan
Vanessa
Inverter/Rectifier functionality
H-bridge topology- allows for one circuit to
function as inverter or rectifier.
H-bridge topology features four power-electronic
switches.

IRF740A- MOSFET, 400V, 10A, Vgth=2-4V
Inverter- 2 phase pulse width modulated.
Rectifier- full wave, uncontrolled (meaning
voltage level is not adjusted in this converter).
Inverter/Rectifier Interfaces
From Power Control: 0/3.3Vdc binary
wave to drive PWM function.
MOSFET can be driven directly from
Power Control (no driver needed).
To/from internal sensor: varying level of
DC, depends upon user command.
To/from filter: varying power, depending
on functionality.
Standard Requirements
Inverter-Rectifier
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0 to 70 %RH
<$6.00
<30
<20cm2
<100grams
<3W
0C to 50C
0C to 50C
0-70%RH
5 Years
15%
15%
14%
20%
5%
12%
Performance Requirements
Inverter-Rectifier
Input Voltage
Full Scale Output Voltage
Inverter/Rectifier Life
% Error
0-50Vdc, 0-120VAC
0-50Vdc, 0-120VAC
5 Years
<10%
DC to DC Converter
Gerry Callison
DC to DC Converter
Gerry
Matt
Maria
Ethan
Vanessa
DC to DC functionality
Unique Challenge: Because of multidirectional
flow of power, both ends needed to function as
inputs or outputs.
Solution: Dual Buck-Boost converters, which
share some parts.
A buck-boost converter can raise or lower DC
voltage.
Requires 2 IRF740A MOSFETS.
This converter is where the voltage is adjusted
to user-commanded level.
DC to DC interfaces
From Power Control: 0-3.3Vdc binary signal
drives MOSFETs, manipulating output based
upon duty cycle of signal.
MOSFETs driven directly from power control.
To/from DC sensor: Varying power, depending
upon functionality.
To/from internal sensor: Varying level of DC,
depending upon user command.
Standard Requirements
DC to DC Converter
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0 to 70 %RH
<$4.00
<20
<20cm2
<60grams
<3W
0C to 50C
0C to 50C
0-70%RH
5 Years
10%
10%
5%
20%
3%
7%
Performance Requirements
DC/DC Converter
Input Voltage
Full Scale Output Voltage
Inverter/Rectifier Life
% Error
0-50Vdc, 0-120VAC
0-50Vdc, 0-120VAC
5 Years
<10%
User Interface
Maria Schlicht
User Interface
Gerry
Matt
Maria
Ethan
Vanessa
User Interface
User Interface Overview
The User can select three modes of
operation (AC–DC,DC-AC & DC-DC)
User can defined level/Type of power
The User can access to review or modify
terminal settings by using the up and down
arrows keys, navigate through the
configuration screen.
Electrical Safety for User
User Interface Importance
Changing settings take affect immediately
(without powering off the terminal)
User can reset the user interface without
having to remove and then re-apply power
or battery.
User friendly
Standard Requirements
User Interface
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Heat Dissipation
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0%RH to 70%RH
$10.00
4
133 (H) x 111(W)x 48(D) mm
284 grams
2.5 W max. (0.105 A @24Vdc)
0˚ C to 55˚C
-20˚C to 85˚C
5 to 95% at 0˚ to 55˚C
2.5W (8.5 BTU/Hour)
5 Years
25 %
5%
5%
5%
5%
5%
Performance Requirements
User Interface
Input Voltage
Full Scale Output Voltage
User Interface Life
% Error
Display (type)
Display (size)
Certifications
+24V (+/-5%)
+24V (+/-12%)
5 Years
10%
Liquid Crystal
Display (LCD) with LED Backlighting
73mm (w) x 42mm (h)
UL
CE marked for all applicable
CSA (c-UL Class I Div 2 Hazardous)
AC Filter
Ethan Spafford
AC Filter
Gerry
Matt
Maria
Ethan
Vanessa
Standard Requirements
AC Filter
Humidity Range
Block Cost
Parts Count
Block Size
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
5%
10%
12%
1%
2%
5%
0%RH to 70%RH
<$20
<20
<40cm2
<2W
0C to 50C
0C to 50C
2 Years
Performance Requirements
AC Filter
Input Voltage
0-50Vdc or 0-120VAC
Full Scale Output Voltage
0-50Vdc or 0-120VAC
Filter Life
2 Years
Forces non-linear load to draw sinusoid current
Couple with passive filters to remove noise from APF and harmonics
from INV/RECT
Acts in both directions:
-AC input – creates cleaner voltage for Rectifier
-AC output – forces non–linear load to draw sinusoid
Disadvantages:
-May drastically increase cost as well as complexity of controller
programming
-Passive filter designs made in parallel in event APF becomes
overly complex.
Control Power
Ethan Spafford
Control Power
Gerry
Matt
Maria
Ethan
Vanessa
Standard Requirements
Control Power
Humidity Range
Block Cost
Parts Count
Block Size
Block Weight
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Reliability (MTBF)
Allocations

Cost

Parts

Unique Parts

Power Cons.

Mass

Area PCB
0%RH to 70%RH
<$20
<20
<12cm2
<500grams
N/A
0C to 50C
0C to 50C
1Year
10%
10%
12%
N/A
10%
5%
Performance Requirements
Control Power
Input Voltage
voltage input by user
Full Scale Output Voltage
+3.3Vdc (+/- 2%)

Additonal voltage levels may be needed as sensors are determined.
Control Power Life
2Years
Dual Power Suppies
Supply connects made to both DC I/O and AC I/O
Switching circuit routes the user input voltage and disables output voltage
connection
AC Input path: transformer-rectifier-voltage/RegulatorSensors/MicroController/PowerFilter/etc
DC input path: amplifier-voltage/regulatorsensors/microcontroller/powerfilter/etc
If battery becomes necessary
Immediately after startup the AC or DC input will act as power supply to the
rest of the unit as well as the battery charger.
Temperature Control
Ethan Spafford
Temperature Control
Gerry
Matt
Maria
Ethan
Vanessa
Standard Requirements
Temperature Control
Humidity Range
Block Cost
Parts Count
Block Size
Block Weight
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0%RH to 70%RH
<$15
<7
<40cm2
<100grams
<2W
0C to 50C
0C to 50C
2 Years
1%
2%
2%
1%
1%
1%
Performance Requirements
Temperature Control
Input Voltage
+5V (+/- 5%)
Temp Cont Life
2Years
Fan and Heat sinks
PCB designed for ideal heat dissipation
Temperature warning and shut down
When Tmax reached warning light notifies user to turn off unit
Unit shuts itself off when Tmax is reached
Sensors
Vanessa White
Input Sensors Overview
Provide electrical isolation from input
power to electronic components
Measure voltage level of input – output a
reduced level signal to processor
DC Sensor
Gerry
Matt
Maria
Ethan
Vanessa
DC Sensor Considerations
Polarity reversal of input voltage
Maximum tolerable signal to processor
Large input range makes determination of
nominal voltage for calculating input
resistance difficult – may introduce large
error
DC Sensor Block Interfaces
To/from Input/Output: Receives or passes
input/output power (0-50VDC)
From Control Power: Receives +12VDC power
supply
To Power Control: Passes voltage level signal
(0-5VDC)
To/from DC/DC Converter: Passes input power
(0-50VDC) after processor determines it is within
acceptable limits; passes output power to output
Standard Requirements
DC Sensor
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0%RH to 70%RH
<$2
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
5%
12%
12%
10%
7%
10%
Performance Requirements
DC Sensor
Input Voltage
0-50VDC
Full Scale Output Signal Voltage (to processor)
+5V (+/-10%)
Full Scale Output Voltage (to DC/DC converter)
+50V
Supply Voltage
+12V
Current Consumption
< 20mA
DC Sensor Life
2 Years
AC Sensor
Gerry
Matt
Maria
Ethan
Vanessa
AC Sensor Considerations
Out of range input voltage (European or
other supply voltage outside nominal
120VAC not permitted to pass)
Input power surges or dips (response
time)
Takes advantage of on-board ADC in
processor
AC Sensor Block Interfaces
To/From Input/Output:Receives or passes
input/output power (nominally 120VAC)
From Control Power: Receives +12VDC power
supply
To Power Control :Passes voltage level signal
(0-5VAC)
To/From AC Filter : Passes input power
(nominally 120VAC) after processor determines
it is within acceptable limits; passes output
power to output
Standard Requirements
AC Sensor
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0%RH to 70%RH
<$3
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
7%
12%
13%
10%
7%
10%
Performance Requirements
AC Sensor
Input Voltage
120VAC (+/- 10%)
Full Scale Output Signal Voltage (to processor)
5VAC,+5VDC
(+/- 5%)
Full Scale Output Voltage (to Inverter-Rectifier)
120VAC
Supply Voltage
AC Sensor Life
+12VDC
2 Years
Internal Sensor
Gerry
Matt
Maria
Ethan
Vanessa
Internal Sensor Overview
Monitors internal voltage between DC/DC
Converter and Inverter-Rectifier
Passes reduced voltage level to processor
for verification of level within tolerances
and any corrections to be made
Internal Sensor Considerations
Bi-directional system – measures both DC
and AC levels
Response time for corrections
Internal Sensor Block Interfaces
From Control Power: Receives +12VDC power
supply
To Power Control: Passes voltage level signal
(0-5VAC or 0-5VDC)
To/From DC/DC Converter: Receives or sends
internal DC power (0-50VDC)
To/From Inverter-Rectifier: Receives or sends
internal AC power (nominally 120VAC)
Standard Requirements
Internal Sensor
Humidity Range
Block Cost
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
Allocations






Cost
Parts
Unique Parts
Power Cons.
Mass
Area PCB
0%RH to 70%RH
<$3
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
7%
12%
13%
10%
7%
10%
Performance Requirements
Internal Sensor
Input Voltage
0-50VDC ,
0-120VAC (+/-10%)
Full Scale Output Signal Voltage (to Processor)
5VAC, +5VDC
(+/-5%)
Full Scale Output Voltage (to Inverter-Rectifier or
DC/DC Converter)
0-50VDC , 0-120VAC
Supply Voltage
Internal Sensor Life
+12VDC
2 Years
Power Consumption by Block
Control Power <20W
Inverter-Rectifier <3W
User Interface 2.5W
AC Filter <1W
DC/DC Converter <3W
DC Sensor <3W
Internal Sensor <3W
AC Sensor <3W
Cooling <1W
Control Power <10W
Total Power: <49.5W