Transcript here. - Edge

Subsystem Design
Review
P16203
Andre Pelletreau, Kerry Oliviera, Jeremy Willman,
Vincent Stowbunenko, Kai Maslanka
Recap of Last Review
• Functional Decomposition
• Morphological Chart and Concept Generation
• Concept Selection
• Engineering Analysis
• System Architecture
• Feasibility Analysis
• Risk Assessment
• Test Plan
• Next 3 Weeks…
Agenda

System Architecture

Requirements Flow Down

Subsystem Interaction

Constant Current and Constant Voltage Loads

Thermal Analysis of Enclosure

Stress Analysis

UML Diagrams

RS-232 Proof of Concept

Stress Analysis for Enclosure

Design of Enclosure and Safety Shield

Air Flow Analysis

Preliminary BOM

Updated Test Plan

Next 7 Weeks…
Subsystem Interaction
Subsystem Engineering Requirements
Sub-System
ER
Physical
Enclosure
Data
Storage
Cooling
Feedback
Processing
Loads
Internal
Temperature
< 50 ˚C
Store
Test Data
Length of
test < 5
minutes
Output 2 –
Resistive
Load
AC voltage
accessibility
Output 1
– Active
Load
Establish
communication
with UUT
AC disengaged
when lid is open
Successfully
calibrate UUT
Pass/fail
indication
AC disengaged
when lid is
open
AC voltage
accessibility
Able to
withstand
UUT failure
Difficulty
to set up
/ lock in
AC disengaged
when lid is
open
Quick
(dis)connect
wires
Time to
set up < 1
minute
Transparent
Safety
Enclosure
Length of
test < 5
minutes
Tx and Rx
data to/from
UUT
Reason for
failure
Number of
test steps
under 5
Able to
withstand
UUT failure
AC voltage
not
accessible
Safety
1.5’ x
1.5’ x 1’
UUT on
indication
Internal
Temperature
< 50 ˚C
Test
Bench on
indication
AC voltage
accessibility
AC disengaged
when lid is
open
Transparent
safety
enclosure
Constant Voltage Load
Constant Current Load
Stress Analysis for Enclosure Metal
Thermal Analysis
UML Diagrams
UML Diagrams
UML Diagram Cont’d
UML Diagram Cont’d
RS-232 Proof of Concept
Autotransformer Mathematical
Proof of Concept
AC Inputs

Two autotransformers were needed to satisfy AC
input specifications

The outputs of the transformer will be controlled by
a relay

The relay will be controlled by the Arduino
Microcontroller

The Hammond Manufacturing Hard Wired 170 Series
autotransformer will step down 115 V to 85 V

E100E SOLA HD autotransformer will step from 120
V to 264 V with the added 24 V winding
Feasibility Analysis of Design
Enclosure Material Selection
Enclosure and Safety Shield
Enclosure and Safety Shield
Circuitry and Resistor Layout
Airflow Analysis
Airflow Analysis Cont’d
Preliminary Bill of Materials
Line Item
Part
Vendor
Manufacturer
Quantity
Price
1
6 ", 200 W Tubular Resistor
Farnell
Vishay
4
~40
2
Arduino Mega
SparkFun
Arduino/ATMEL
1
~$60
3
21 x 4 (characters) LCD
SparkFun
N/A
1
$18
4
E075E - Autotransformer (High Line)
Newark
Sola-HD
1
$51.55
5
168C - Autotransformer (Low Line)
Mouser
Hammond
1
$77.84
6
25 Ohm Tubular Resistor
Newark
Multicomp
2
$5.66
Test Plan

Are the physical measurements ≤ the required dimension?



Verify power turns off when Safety Shield is opened
Verify that the AC voltage is not accessible and is within the
enclosure.

Verify that the Safety Shield is transparent and that the UUT is
visible

Verify that the GUI states a failure and where in the test it
fails
Is there an indication that the UUT is on?

Is the safety enclosure transparent?
Verify there is an LED indicator that the UUT
Is there reason for failure feedback?


Verify from GUI that data is being shared and received
through the proper completion of the test
Has the UUT been successfully calibrated?


Verify GUI indicates communication has been made
Has data been transmitted and received to/from the UUT?

Is the AC voltage accessible?



Run stress tests and force tests on the base and the safety
shield to see how much heat and force each can withstand
Has communication with the UUT been established?

Does the AC disengage when lid is open?



Use a thermometer to measure
Verify that the GUI lists pass/fail after a test in complete
Is the enclosure able to withstand a failure of the UUT?

Are there indications of passing/failure of the test fixture?


Time the entire test starting from power supply board set up
finishing with the verification of entire unit test.
Is the Internal Temperature ≤ 50 Celsius?


Measure the physical dimensions of the enclosure
Is the length of the test ≤ 5 min?



Verify that there is an LED indicator that the UUT is powered
on, and a label saying ‘UUT Power On’
Is there an indication that the Test Bench is on?

Verify there is an LED indicator and a label saying ‘Test Bench
Power On,’ and verify that the LED is on
Test Plan Cont’d

Are the number of test steps less than 5?


Is there a quick (dis)connect?


Based on time to set up and the number of steps, verify that those
requirements are met, which will indicate ease of setup.
Is the test data being stored?


Time the setup of the enclosure
Is the set up difficult?


Verify the connect and disconnect time is less than 5 seconds for each.
Is the time to set up less than 1 minute?


Complete set up and verify that the number of steps is less than five per
each test (PS Board test, Controller Board Test, and Entire Unit Test)
Connect SD card and USB to computer to see if test data is being stored
Is the budget under $1500?

Yes/No
Next 7 Weeks…
• Detailed Design Activities
• Updated Test Plan
• Finalize detailed CAD
• Active Loads
• PCB Layout
• Final schematics
• Bill of Materials
• Code Algorithms
• Prototyping Activities
• Active Load – Constant Current
• Active Load – Constant Voltage
• RS232 Communications
• CNC of Enclosure Materials
• Risk Assessment
Questions/Concerns?