Transcript Team4phase2(march31)

Electrical Engineering 595
Capstone Design Team #4
Universal Power Box
1
Project Abstract
With the immense selection of electrical
devices used in everyday lives, there can
be much need to convert between one
type of power source into another. The
Universal Power Box (UPB) will combine
many types of conversions into one
product.
Cost, reliability, accuracy and safety are
key aspects in the scope of this project.
2
Product Description
The user will attach a power source to the UPB, then enter a desired
output power type and level.
The UPB will sense the type of power the user is inputting.
The UPB utilizes a Flyback DC to DC converter and an H-bridge
inverter which doubles as a full-wave rectifier for power conversion.
The power converters are run by a microprocessor, which takes
input from a variety of feedback sensors. All converters are pulsewidth modulated.
An internal power supply, which draws from the power input by the
user, powers the UPB.
3
Product Feature Set
Desired Features of the UPB:
The UPB will be able to convert AC to DC, DC to AC,
and DC to DC.
The user will interact with the UPB through an LCD and
numeric keypad.
The UPB will draw its internal power supply from the
input power.
The UPB will have a Total Harmonic Distortion
sufficiently low for consumer electronics applications.
The UPB will have a weight, size, and durability that
allows it to be portable.
4
Target Market
This product is being developed for use
with consumer electronics in the North
American environment.
Common applications will include:


Creating 120 VAC from a car outlet (for both
14Vdc and 42Vdc systems).
Replacing consumer electronic AC to DC
adapters.
5
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
6
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
7
Team Logistics
Meetings: Held on a need basis, usually in the evenings
of weeknights. Tasks were primarily delegated to
individuals, to maximize productivity. On average, each
team member spent about 10 hours per week on the
project.
Decision making: Conesus/Majority vote.
Project duties:
 Webmaster: Matt Risic
 Archiver: Vanessa White
 Presentation Manager: Gerry Callison
 Report Manager: Ethan Spafford
 Graphics Manager: Maria Schlicht
8
Product Performance
Requirements
Input voltage ranges:


14-50Vdc
108-132VAC
Maximum input current: 7 amps
Output power: 75 watts
Output voltage ranges:


14-50Vdc
108-132VAC
Maximum output current: 5 amps
Total Harmonic Distortion < 5%
9
Product Standard Requirements
Operating Requirements






0-50 degrees Celsius
0-70% RH
Maximum product size 2000 cm^3
Maximum product mass 2kg
Maximum parts count 200
3 Years Component Life
10
Productization Aspects &
Requirements
Legal/Ethical Aspects & Requirements



Includes UL labels
Includes safety labels (liability protection)
All labels and user manual in English and Spanish
Safety/Health Aspects & Requirements


Includes proper shielding
Safety directions in product manual
11
Productization Aspects &
Requirements
Sustaining Aspects & Requirements


This product does not require field service
Design team will monitor field defects for
future versions
Reliability Aspects & Requirements


1 year warranty standard
Products which fail under warranty should be
returned for analysis.
12
Productization Aspects &
Requirements
Environmental Aspects & Requirements


Proper disposal: Recycled, NOT thrown in
general refuse
The following power and EMF tests should be
used:
IEC61000-3-2
IEC61000-3-3
IEC61000-4-6
IEC61000-4-11
EN61000-6-2
13
Block Diagram
Gerry
Matt
Maria
Ethan
Vanessa
14
Functional Block Description
Agenda
Microprocessor - Matt
User Interface - Maria
Power Conversion - Gerry
Internal power & Cooling - Ethan
Sensor & I/O - Vanessa
15
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
16
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
17
3 MODES OF OPERATION
AC to DC.
DC to DC.
DC to AC.
18
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.
19
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.
20
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.
21
TOP-LEVEL FUNCTIONALITY
REQUIREMENTS
The user can input 14-50Vdc or 24-120VAC 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.
22
Block Requirements
23
Power Control
Matt Risic
24
Power Control
Gerry
Matt
Maria
Ethan
Vanessa
25
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
Microprocessor will control the LCD display
based on user input from the keypad
Different scenarios will be performed based on
the power conversion being performed
26
Standard Requirements
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
<$15
<20
<48cm2
<95.5 grams
<20W
0C to 75C
0C to 75C
0-70%
3 Years
27
Performance Requirements
Control
Input Voltage
Full Scale Output Voltage
Minimum speed
Desired Memory
Programming Language
Number of Registers
+3.3V (+/- 3%)
+3.3V (+/- 3%)
1Mhz
1K SRAM
Assembly
32
28
Input/Output Voltages
Sensor
0-3.3V
Switch Driver
AC Sensor
3.3V
0-3.3 V
6V
Power Control
0.15 V
Control Power
0.65-2.2V
LCD Display
Cooling
0.15V
Keypad
29
Microprocessor Selection
Atmel ATMega169v
Microprocessor








Advanced RISC
Architecture
130 Instruction Set
C and Assembly Coding
32 x 8 General Purpose
Registers
16KB Programmable Flash
512 Bytes EEPROM
1KB SRAM
64 Pin Chip
30
Chip Size
31
32
CPU/ALU Timing Diagrams
33
SRAM Timing Diagram
34
Programming Examples
35
Memory Hierarchy
36
ATMega169v Operating Conditions
Operating voltage between 1.8-5.5V
Operating temperature between -40 to +85
degrees Celsius
Up to 1 MHz Clock Speed
Power Consumption



At 1MHz consumes 1.8V, 400uA
At 32 kHz consumes 1.8V, 20uA
Power-down Mode is 0.5uA at 1.8V
37
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.
38
Programming Software
AVR Studio 4.08
Integrated Coding,
Compiling and Debugging
Software
Configurable Memory
Support for C, Pascal,
BASIC and Assembly
Simulate Port Activity
Logging and Pin Input
39
Programming Software
AVR Studio 4 Service Pack
Adds support for the ATMega family
Builds upon the AVR Studio 4 software
Improved documentation and help
features
40
Programming Software
AVR LCD Visualizer
Create and modify
LCDs with editor
Debug and visualize
with AVR plug-in
Real run-time updates
41
LCD Flowchart
42
Block Component Cost
ATMega169v microprocessor - $10.81
STK500 Board - $79.00
STK502 Expansion Board - $99.00
AVR Studio 4.08 – FREE
AVR Studio 4 Service Pack – FREE
AVR LCD Visualizer - FREE
43
User Interface
Maria Schlicht
44
User Interface
Gerry
Matt
Maria
Ethan
Vanessa
45
User Interface
46
USER INTERFACE OVERVIEW
The user interface will contain a 12-key numeric keypad to enter the
voltage desired by the user. It will also contain a 16 x 2 LCD display.
Display Capacity of 25 segment and 4 Common Terminals
The inputs include:

The User can select three modes of operation
(AC–DC,DC-AC & DC-DC)

User can defined level/Type of power
The User will have access to review or modify terminal settings by
NUMERIC keys, navigate through the configuration screen.
Electrical Safety for User
47
USER INTERFACE IMPORTANCE
Changing settings take affect immediately
(without powering off the terminal)
User can reset the interface without having to
remove and then re-apply power or battery.
User friendly
48
USER INTERFACE STANDARDS REQUIREMENTS
Proto Cost
% Allocation
Production cost
% Allocation
Proto Parts Count
Unique Parts
Production Parts Count
Unique Parts
Max. Product Size (L x W in cm)
$53.35
35.1%
$20.00
5%
2
0
2
0
(7 x 2) LCD
(5 x 6.8) Keypad
Max. Product Weight (kg)
Max. Power Consumption (W)
Max. Operating Temp Range
(degrees °C)
Min. Operating Humanity Rage
(rh%)
Reliability and Life (MTBF in
yrs, %R 1 yr, %R 5yrs)
Disposal/Recycle/Maintenance
(# of recycles parts, Hazards)
0.50
0.800
Safety and Regulatory Standards
UL508C/CSA 22.2
0°C to 50°C
<95%, non-condensing
5 yrs, 1 yr at 2%, 5 yrs at 10%
European Standard, prEN13965-2
49
USER INTERFACE PERFORMANCE REQUIREMENTS
LCD Operating Values:
Logic Supply Voltage Range: 3.5-5.0V
LCD Supply Voltage Range: 2.6-3.35V
Input High Voltage VIH: 2.2-5.1V
Input Low Voltage VIL: 0.65V
Output High Voltage VOH: 2.3V
Output Low Voltage VOL: 0.5V
Max. Input Current IDD: 1.2mA
Temp. (Operating) TOPR: 0°C - 50°C
Temp. (Storage) TSTG: -10°C - 60°C
Viewable from 1 ft.
Keypad Operating Values:
Insulation Resistance:
> 1.01k at 500V
Max. Output Current IOUT:
5mA for .5 sec
Temp. (Operating) TOPR:
-30°C - 70 °C
Temp. (Storage) TSTG: 150°C
Contact Bounce:
< 10mS
Frequency:
65.1dB
50
USER INTERFACE BLOCK DIAGRAMS
51
USER INTERFACE PRODUCTIZATION REQUIREMENTS
User Interface Controls:

12-button keypad: Digits 0-9,
Pound sign, and Start key.
Safety Features:



Illuminated display indicates
voltage present
Temperature range as specified
by overall product
Components to be chosen to
comply with temperature
requirements
Hand Assembly:

Keypad and LCD display manually
assembled, all other components
can be automatically installed.
Societal/legal/Monetary Aspects:

Pushbuttons
(ergonomic & friendly)

Material Degradation

Rust and corrosion
Suitable for electrical
conditions

Disposability/Recycle ability:


Parts recyclable as PCB
assembly
Reliability:


Prototype: Length of project
Production:
1 yr @ 2%
5 yrs @ 10%
52
KEYPAD SCHEMATICS
53
Inverter-Rectifier
Gerry Callison
54
Inverter-Rectifier
Gerry
Matt
Maria
Ethan
Vanessa
55
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
Inverter- 2 phase pulse width modulated.
Rectifier- full wave, uncontrolled (meaning
voltage level is not adjusted in this converter).
56
Inverter/Rectifier Interfaces
From Power Control: 0/3.3Vdc binary
wave to drive PWM function.

Goes through IR2181 high/low driver.
To/from internal sensor: varying level of
DC, depends upon user command.
To/from filter: varying power, depending
on functionality.
57
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%
58
Performance Requirements
Inverter-Rectifier
Input Voltage
Full Scale Output Voltage
Maximum Input current
Maximum Output Current
Maximum Power Passed
Inverter/Rectifier Life
Amplitude Modulation Ratio
% Error
14-170Vdc, 108-132VAC
14-119Vdc, 108-132VAC
5 amps
5 amps
75 watts
5 years
.8
<10%
59
SO WHERE
DID THESE
NUMBERS
COME FROM
!?!?!?!
60
Input Voltage: 14-170 Vdc, 108-132 VAC
108 VAC: 120 VAC – 10% = 108 VAC
132 VAC: 120 VAC + 10% = 132 VAC
14 Vdc: Voltage of current automotive systems
170 Vdc:


To achieve 132VAC out with Ma = .8
Vdc max = V1 ÷ Ma = 132 ÷ .8 = 165 ~ 170 Vdc
61
Output Voltage: 14-85 Vdc, 108-132 VAC
108 VAC: 120 VAC – 10% = 108 VAC
132 VAC: 120 VAC + 10% = 132 VAC
14 Vdc: Voltage of current automotive systems
119 Vdc:
Vm  2 *Vrms  2 *132  187V
V fullwaveout 
2Vm


2 *187

 119V
62
Maximum Input Current = 5 amps
Maximum Output Current = 5 amps
Maximum Power Passed = 150 watts
Amplitude Modulation Index = .8
5 amps: Agreed upon by group
75 watts: Agreed upon by group
.8 Amplitude Modulation Index:


Forces to harmonics to higher frequencies,
where they are easily filtered
Causes Vin = 170 Vdc (V1 = Ma*Vdc), which
components can easily handle.
63
TOPOLOGY
64
A standard H-bridge topology was
used.
65
OPERATIONAL DIAGRAM
66
COMPONENT
SELECTION
67
POWER SWITCHES (MOSEFETS)
REQUIREMENTS (with error margins):




Vdss of at least 350 Volts
Current of at least 8 amps
Gate threshold voltage of 3.3 Volts
Switching Frequency of at least 100kHz
CHOSE: International Rectifier IRF740A
MOSFET, which exceeds all minimum
requirements.

IRF740A features built in diode to always allow for
current to flow from source to drain
68
MOSFET DRIVERS
REQUIREMENTS:



3.3 Volt logic level
Maximum high-side voltage of at least 350
Volts
Switching frequency of at least 100kHz
CHOSE: International Rectifier IR2181
high and low side driver, which exceeds all
minimum requirements.
69
DC to DC Converter
Gerry Callison
70
DC to DC Converter
Gerry
Matt
Maria
Ethan
Vanessa
71
DC to DC functionality
Unique Challenge: Because of multidirectional
flow of power, both ends needed to function as
inputs or outputs.
Solution: Dual ended flyback converter, which
share some parts.
A flyback converter can raise or lower DC
voltage to a sufficient gain.
Requires 2 IRFP350 MOSFETS.
This converter is where the voltage is adjusted
to user-commanded level.
72
DC to DC interfaces
From Power Control: 0-3.3Vdc binary signal
drives MOSFETs, manipulating output based
upon duty cycle of signal.
MOSFETs driven from power control through
IR2181 high and low side driver chip.
To/from DC sensor: Varying power, depending
upon functionality.
To/from internal sensor: Varying level of DC,
depending upon user command.
73
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%
74
Performance Requirements
DC/DC Converter
Input Voltage
Maximum Input Current
Full Scale Output Voltage
Maximum Output Current
Maximum Power Passed
Inverter/Rectifier Life
% Error
14-119Vdc
5 amps
14-170Vdc
7 amps
75 watts
5 Years
<10%
75
SO WHERE
DID THESE
NUMBERS
COME FROM
!?!?!?!
76
Input Voltage: 14-170 Vdc
14 Vdc: Voltage of current automotive systems
119 Vdc: Maximum output of Inverter/Rectifier
Output Voltage: 14-170 Vdc
14 Vdc: Voltage of current automotive systems
170 Vdc: Required by Inverter/Rectifier to
achieve 132 VAC
77
Maximum Input Current = 7 amps
Maximum Output Current = 5 amps
Maximum Power Passed = 75 watts
7 amps:



To achieve 14V to 170V conversion,
maximum voltage amplification = 12.2
75 watts ÷ 132 VAC = .57 amps at max
voltage
.57 amps * 12.2 = 7 amps
5 amps: Agreed upon by group
75 watts: Agreed upon by group
78
TOPOLOGY
79
Initially, a buck-boost topology was
planned, but it was ruled out due to
nonideal effects
80
A dual ended flyback topology was used
Vout
dutycycle N 2
 Vin
1  dutycycle N1
81
OPERATIONAL DIAGRAM
82
COMPONENT
SELECTION
83
PULSE TRANSFORMER(S)
REQUIREMENTS:


Turns Ratio of at least 8:1
ET constant of at least 350 V*uS
ET constant = pulse width*pulse magnitude
CHOSE: C&D Technologies 1003 (must
cascade 3 to achieve 8:1 turns ratio).


Turns Ratio = 2:1:1 (when cascaded = 8:1:1)
ET = 400 V*uS
84
POWER SWITCHES (MOSEFETS)
REQUIREMENTS (with error margins):




Vdss of at least 350 Volts
Current of at least 9 amps
Gate threshold voltage of 3.3 Volts
Switching Frequency of at least 100kHz
CHOSE: International Rectifier IRF740A
MOSFET, which exceeds all minimum
requirements.

IRF740A features built in diode to always allow for
current to flow from source to drain
85
MOSFET DRIVERS
REQUIREMENTS:



3.3 Volt logic level
Maximum high-side voltage of at least 400
Volts
Switching frequency of at least 100kHz
CHOSE: International Rectifier IR2181
high and low side driver, which exceeds all
minimum requirements.
86
Power
Ethan Spafford
87
Power
Gerry
Matt
Maria
Ethan
Vanessa
88
Standard Requirements
Power
Humidity Range
Block Cost
Parts Count
Block Size
Block Weight
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Reliability (MTBF)
0%RH to 70%RH
<$20
<28
<12cm2
<500grams
N/A
0C to 50C
0C to 50C
1Year
89
Performance Requirements
Power
Input Voltage
voltage input by user
Full Scale Output Voltage
+12Vdc (+/- 2%)
Control Power Life
2Years
Dual Power Supplies
Supply connects made to both DC I/O, AC I/O and 12V Battery
Switching circuit routes the user input voltage and disables output voltage
connection
AC Input path: Solid State Relay-Transformer-Rectifier-Solid State Relay voltage Regulator-Sensors/Micro-Controller/Cooling/etc
DC input path: Solid State Relay-Flyback Converter-Solid State RelayVoltage Regulator-sensors/microcontroller/Cooling/etc
Immediately after startup the AC or DC input will act as power supply to the
rest of the unit
90
Control Power Circuit
91
Input Power Select
Input Selected from Key
Pad – Signal sent from
PC
Inverting Schmitt Trigger
sends signals to solid
state relays and to
inverter to solid state
relays
PC Low Signal opens DC
PC High Signal opens
AC
92
DC Input
Flyback Converter
Converts Input DC
Voltage from 14-50V to
12.6V
Average Input current
between 75mA-270mA
VO
D
N2
 VS (
)(
)
1 D
N1
2
I LM
VO

VS DR
VO  VO
D
RCf
93
AC Input
Step Down Transformer Rectifier
Converts 120AC to 12.6Vdc

Transformer steps down
voltage from 170Vpk to 15Vpk
Rectifier



Vo,max = 13.6V
ΔV = 1.3
Vo,avg = 12.3V
VO ,max  VM  2VD
VO ,avg  VO ,max
VO 
V

2
VO ,max
2 fRC
94
Component Costs
Component







amount
Solid State Relays(low Voltage)
Solid State Relay(high Voltage)
AC Transformer
Fly-Back Transformer
1
Diodes/Resistors/Caps
Op amps
MOSFET
Total
3
≈$18.50
1
≈$21.00
1
≈$6.00
≈$6.00
18
≈$5.00
2
≈$1.50
1
≈$1.50
95
Temperature Control
AC Filter
Ethan Spafford
96
Temperature Control
AC Filter
Gerry
Matt
Maria
Ethan
Vanessa
97
Standard Requirements
Temperature Control & AC Filter
Humidity Range
Block Cost
Parts Count
Block Size
Block Weight
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Reliability (MTBF)
0%RH to 70%RH
<$15
<7
<40cm2
<100grams
<2W
0C to 50C
0C to 50C
2 Years
98
Performance Requirements
Temperature Control & AC Filter
Temperature Control







Input Voltage
+12V (+/- 2%)
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
AC Filter



Input Voltage
Full Scale Output Voltage
Filter Life
14-50Vdc or 120VAC
14-50Vdc or 120VAC
2 Years
99
AC Filter Circuit Diagrams
C 
2
LC
Single Low-Pass RLC
Filter
Use potentiometer

R obtained experimental
If necessary ladder
network or composite
filter can be easily added
ωc slightly higher so that
operating frequency is
below the “knee” of
attenuation (100Hz)
100
Component Costs
Component


amount
Inductors/Resistors/Caps
Fan/HeatSinks/TmaxIC
Total
18
6
≈$2.50
≈$15
101
Sensors
Vanessa White
102
Sensors Overview
Sensors provide electrical isolation from
input power to controller components
Measure voltage level of input – output a
reduced level signal to processor
Take advantage of on-board ADC in
processor
103
DC Sensor
Gerry
Matt
Maria
Ethan
Vanessa
104
DC Sensor Considerations
Maximum tolerable signal to processor
Nominal current expected for
measurement
Large input range makes determination of
nominal voltage for sensor input difficult –
may introduce large error
105
Standard Requirements
DC Sensor
Humidity Range
Block Cost (Production)
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
0%RH to 70%RH
<$10
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
106
Performance Requirements
DC Sensor
Input Voltage: 14-50VDC
Full Scale Output Signal Voltage (measured V to
processor): +3.3V (+/-10%)
Supply Voltage: +12V
Current Input: 10mA (nominal)
Current Consumption: < 50mA
Response Time : < 2ms
Accuracy @ 25C: < +/- 5%
Linearity: < 0.5%
107
DC Sensor Block Interfaces
From Input/Output: Receives input power (14-50VDC)
From Internal Power: Receives +12VDC power supply
To Controller: Passes voltage level signal (V measured,
0-3.3VDC)
Internal
Power +12V
14-50
VDC
DC Sensor
0-3.3V
Controller
108
Detail Design
DC Sensor
LEM Transducer – LV
20-P
R1 – Calculated
based on expected
voltage to be
measured and
nominal current of
10mA
109
AC Sensor
Gerry
Matt
Maria
Ethan
Vanessa
110
AC Sensor Considerations
AC input only
Nominal current expected for
measurement
Maximum tolerable signal to processor
111
Standard Requirements
AC Sensor
Humidity Range
Block Cost (Production)
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
0%RH to 70%RH
<$10
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
112
Performance Requirements
AC Sensor
Input Voltage: 120VAC (+/- 10%)
Output Signal Voltage (to processor): 3.3VDC
Supply Voltage: +12VDC
Current Input: 10mA (nom)
Current Consumption: < 50mA
Response Time : < 2ms
Accuracy @ 25C: < +/- 5%
Linearity: <0.5%
113
AC Sensor Block Interfaces
To/From Input/Output: Receives input power (nominally
120VAC)
From Internal Power: Receives +12VDC power supply
To Control: Passes voltage level signal (V measured, 03.3VDC)
Internal
Power +12V
120
VAC
AC Sensor
0-3.3V
Controller
114
Detail Design
AC Sensor
LEM Transducer – LV
20-P
R1 – Calculated
based on expected
voltage to be
measured and
nominal current of
10mA
115
Internal Sensor
Gerry
Matt
Maria
Ethan
Vanessa
116
Internal Sensor Overview
Monitors internal voltage between DC/DC
Converter and Inverter-Rectifier
Passes measured voltage level to
processor for verification of level within
tolerances and any corrections to be made
117
Internal Sensor Considerations
Bi-directional system – measures both DC
and AC levels
Response time for corrections
118
Standard Requirements
Internal Sensor
Humidity Range
Block Cost (production)
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
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
119
Performance Requirements
Internal Sensor
Input Voltage : 14-50VDC , 120VAC (+/-10%)
Full Scale Output Signal Voltage (to Processor):
+3.3VDC
Supply Voltage: +12VDC
Current Input: 10mA (nom)
Current Consumption: < 50mA
Response Time : < 2ms
Accuracy @ 25C: < +/- 5%
Linearity: <0.5%
120
Internal Sensor Block Interfaces
From Internal Power: Receives +12VDC power supply
To Power Control: Passes measured voltage level signal (0-3.3VDC)
To/From DC/DC Converter: Receives or sends internal DC power
(14-50VDC)
To/From Inverter-Rectifier: Receives or sends internal AC power
(nominally 120VAC)
Internal
Power +12V
0-3.3V
Controller
InverterRectifier
120 VAC
Internal
Sensor
14-50
VDC
DC-DC
Converter
121
Detail Design
Internal Sensor
LEM Transducer – LV 20P
R1 and R2– Calculated
based on expected
voltage to be measured
and nominal current of
10mA
122
I/O
Vanessa White
123
I/O Overview
Provides circuit protection for sensors and
electronic components of power
conversion blocks
Switching circuit prevents power flow into
electronic components until measured
voltage is determined acceptable
124
DC I/O Considerations
Polarity reversal of input voltage
Electrostatic discharge
Inrush current
Driving switch from controller
current/voltage
125
Standard Requirements
DC I/O
Humidity Range
Block Cost (Production)
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
0%RH to 70%RH
<$10
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
126
Performance Requirements
DC I/O
External Input Voltage: +14-50VDC
Full Scale Output Voltage: +50VDC
Control Voltage: 3.3VDC
Input/Load Current: < 10A
Switching Speed (Pickup/Dropout Time): < 3ms
Pickup Voltage: 4VDC (max)
Dropout Voltage: 1VDC (min)
127
DC I/O Block Interfaces
To/from Input/Output: Receives DC input power (1450VDC) or passes output power (14-50VDC)
From Controller: Receives digital signal based on
measured voltage (Vok)
To/from DC/DC Converter: Passes input power (1450VDC); passes output power to output
DC-DC
Converter
14-50
VDC
14-50
VDC
DC I/O
0/3.3V
Controller
128
Detail Design
DC I/O
• Solid State Relay –
current limiting and
switching for input power
flow
• BJT driver - drive current
to relay
• Capacitance – ESD
• Thermistor – current
limiting for sensors
129
AC I/O Considerations
AC input only, but can be DC or AC out,
depending on mode (DC-DC or DC-AC)
Out of range input voltage (European or
other supply voltage outside nominal
120VAC not permitted to pass)
Electrostatic discharge
Inrush current
130
Standard Requirements
AC I/O
Humidity Range
Block Cost (Production)
Parts Count
Block Size
Block Mass
Max Power Consumption
Operating Temperature Range
Storage Temperature Range
Operating Humidity
Reliability (MTBF)
0%RH to 70%RH
<$10
<24
<40 cm2
<140 grams
<3 W
0C to 50C
0C to 50C
0-70%
2 Years
131
Performance Requirements
AC I/O
External Input Voltage: 120VAC (+/- 10%)
Full Scale Output Voltage: 132VAC,+50VDC
Control Voltage: 3.3VDC
Input/Load Current :< 8A
Switching Speed (Pickup/Dropout Time): < 3ms
Pickup Voltage: 4VDC (max)
Dropout Voltage: 1VDC (min)
132
AC I/O Block Interfaces
To/From Input/Output: Receives input power (nominally
120VAC) or passes output power (nom. 120VAC or +1450VDC)
From Control: Receives digital signal based on
measured voltage (Vok)
To/From AC Filter : Passes input power (nominally
120VAC); passes output power to output
AC Filter
120
VAC
14-50
VDC /
120VAC
AC I/O
0/3.3V
Controller
133
Detail Design
AC I/O
• Solid State Relay –
current limiting and
switching for input power
flow
• BJT driver - drive current
to relay
• Capacitance – ESD
• Thermistor – current
limiting for sensors
134
Timeline
135
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
14
2/4
12
14
2/15
2/4
14
2/5
12
2/18
16
4/10
19
4/30
18
4/19
136
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
14
4/24
20
4/24
14
4/30
22
5/5
25
5/5
10
5/10
Documentation


Compilation of Individual
MSWord Reports
Compilation of Final MSWord Report
and PowerPoint Slide Show
137