318-595 Spring 2005, Team #4 Atomic Clock Receiver

Team Staff Atomic Clock Receiver Atomic Clock Receiver Expertise: 318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Team Staff Michelle Hecyk - BSEE Expertise: PLD, Project Mgmt, Technical Writing Experience: 1 Co-op @ GE Cons & Industrial 2 Co-ops + 1.5 years @ GE Supply Jonathan West - BSEE Expertise: Microwave, VLSI, 6σ, Assembly Experience: 3 Co-ops @ GE Healthcare Ned Storer - BSEE Expertise: Communication, PCB layout Experience: 1.5 years intern @ Wells Mfg 2 Co-ops @ Pentair Water Harrison Chiu - BSEE Expertise: Software Simulation/Testing Experience: Software QA @ JCI for 8mo

Team Dynamics Atomic Clock Receiver Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Team Dynamics 500 Available Man-Hours Project funding provided by Pentair Water Treatment Chose project because it will give us industry experience developing a product for a company given desired product specifications and target cost. Decisions made by consensus Established team website to ease file sharing/storage and communication Regular meetings Monday evenings and Sunday afternoons Responsibilities assigned as follows: Jonathan West: Assembly & Proto Mgr, Archive Web Mgr Ned Storer: Project Integrator Harrison Chiu: PCB Layout Mgr Michelle Hecyk: Report & Presentation Mgr

Product Purpose Atomic Clock Receiver Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Product Purpose The purpose of this device is to provide an accurate time signal to an external device upon request. Current applications require manual intervention to re-program correct time after loss of power. This project aims to eliminate the manual intervention, leading to a decrease in product maintenance cost.

Product Functions Atomic Clock Receiver Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Product Functions Accurate time will be maintained internally by periodically syncing the on-board clock with an atomic clock by means of the NIST radio station: WWVB. A time request from the host system will be fulfilled instantaneously providing date and time (accurate to the second) in military format. Device will be AC powered with battery back-up and run independently of any host system it is connected to. Time output in RS232 format

318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Product Features Manual Sync Option allows user to update system time on request Optional external serial interface System monitor

Project Level Performance Requirements 318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Performance Requirements Operation Modes Power Modes: ON, Battery ON Functional Modes: AutoSync, ManualSync, Time Send Safety Power Sig 1 Current Lim Max: .5A Power Sig 2 Current Lim Max: .5A Max Potential of User Surface: 0V Environmental Operating Temp Range: 0 to 40°C Storage Temp Range: -10 to 50°C Operating Humidity Range: 0-90% Storage Humidity Range: 0-100% Operating Altitude Range: 0 – 4300 Meters Storage Altitude Range: 0 - 14000 Meters Max Storage Duration: 5 Years

Project Level Performance Requirements 318-595 Spring 2005, Team #4 Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Performance Requirements Interfaces Connector 1 Type or Style: DB-9 Connector 1 Min Total Contacts: 3 Connector 1 Gender: Male Connector 2 Type or Style: Grounded Wall Plug Connector 2 Min Total Contacts: 3 Connector 2 Gender: Male Mechanical Max Product Volume: 500cm3 Max Shipping Container Vol: 525cm3 Max Product Mass: 1kg Max Printed Circuit Boards: 1 Max Total PCB Area: 155cm2 Energy Source 1 Conn: Battery Harness Energy Source 2 Conn: Grounded Wall Plug Maximum Shock Force: 50G Maximum Shock Repetitions: 30

Project Level Standard Requirements 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Standard Requirements Power Source 1: 4AA Batteries Connection: Temporary Min Oper Voltage Range: 5.9V - 6.1V Max Output Current: 1mA Consumption: 2500mAh Source 2: 120VAC Connection: Permanent Min Oper Voltage Range: 102V – 132V Frequency Range: 57Hz – 63Hz Max Output Current: 500mA Max Total Power: 2W Output: Nominal Voltage: 3.3VDC Operating Range: 3.1V – 3.5V Max Voltage Ripple: 2.5% Electrical Transfer Performances Min-Max Voltage Gain: 60 - 80 Min SNR: 10dB Max THD: 5% Max Noise: 100 nV/thz Max Error Voltage: 0.25V Max Delay: 1 Sec

Project Level Standard Requirements 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Standard Requirements Manufacturing Maximum Total Parts Count: 75 Maximum Unique Parts Count (Product): 35 Maximum Parts & Material Cost: $4.00 Maximum Mfg Assembly/Test Cost: $1.00 Life Cycle Estimated Max Production Lifetime: 5 Years Service Strategy: Dispose Product Life, Reliability in MTBF: 5 Years Full Warranty Period: 1 Year Product Disposal: Landfill

Project Level Standard Requirements 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Standard Requirements Health & Safety Compliant with the following standards: IEC 60950-1: IT equipment - Safety - Part 1: General Req. UL 1270: Radio Receivers, Audio Systems, and Accessories ISO9001:2000 Quality Management Systems-Requirements EMC Standards EN 61000 - General EMC Standard EN 61204-3:2001 - Low Voltage Power Supplies DC Output. (Part 3: Electromagnetic compatibility)

318-595 Spring 2005, Team #4 Atomic Clock Receiver Block Diagram

Project Level Prototyping 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Prototyping Block Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Component Types of Connectors Signal Receiving 11.43 1.27 N/A Surface Mount Wire PCB Traces Filter 5.72 PCB Outsourced Micro-controller 6.45 Power 45 12.5 Power Cable User Interface 7.62 Serial (DB9)

Basic Business Case Atomic Clock Receiver Average Selling Price: $15 318-595 Spring 2005, Team #4 Atomic Clock Receiver Basic Business Case Average Selling Price: $15 Annual Sales Volume: 10,000 Per Unit Cost (Parts/Materials): $4 Per Unit Cost (Assembly/Mfg): $1 Total Development Cost: Engineering ($150/hour X 500 hours) $75,000 Material $ 1,000 $76,000 Annual Sales: $150,000 Per Unit CM: $10 CM%: 66% Annual CM$: $99,000 ROI : 1.3 years

Project Level TASK-RESOURCE ESTIMATE SUMMARY 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level TASK-RESOURCE ESTIMATE SUMMARY Using the Project Task Spread Sheet: Resources available for this project = 500 hours Resources estimated for this project = 383 hours

Project Level Gantt Chart 318-595 Spring 2005, Team #4 Atomic Clock Receiver Project Level Gantt Chart

Block 1 Signal Receiving 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block 1 Signal Receiving Ned Storer

LOCATION ON BLOCK DIAGRAM 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING LOCATION ON BLOCK DIAGRAM

318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING DESCRIPTION This block is responsible for receiving, matching, and amplifying the WWVB signal. It is the first block in the overall block diagram.

PERFORMANCE REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING PERFORMANCE REQUIREMENTS Environmental: Operating Voltage Range: 2.8V – 3.5VDC Operating Temp Range: 0 to 40 C Storage Temp Range: -10 to 50 C Operating Humidity Range: 0 to 90% Storage Humidity Range: 0 to 100% Operating Altitude Range: 0 to 4300 meters Storage Altitude Range: 0 to 14000 meters Electrical Interfaces: Power Input: Passive and 3.3VDC nominal input Minimum Signal Strength: 50uV/m Input Frequency: 60 kHz Bandwidth: 59.65 kHz – 60.35 kHz Mounting: Surface Mount style on PCB Power Modes: On/Off

ANALOG/RF ELECTRICAL INTERFACE SIGNALS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING ANALOG/RF ELECTRICAL INTERFACE SIGNALS Input (Antenna): Minimum Signal 50uV/m Output (Amplifier): 10mVpAC to 30mVpAC

POWER ELECTRICAL INTERFACE SIGNALS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING POWER ELECTRICAL INTERFACE SIGNALS Antenna: Passive Device Amplifier: 1.1VDC to 5.0VDC

PROTOTYPING PLAN 1) select parts 2) order parts 3) connect parts 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING PROTOTYPING PLAN 1) select parts 2) order parts 3) connect parts 4) use a spectrum analyzer to confirm part selection

Task-Resource Estimate Summary 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING Task-Resource Estimate Summary Resources available for Block 1: 100 hrs Estimated man-hours required for Block 1: 85 hrs

Block Architecture Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 1 – SIGNAL RECEIVING Block Architecture

Key Components Antenna Receiver IC Crystal Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING Key Components Antenna Resonant Frequency 60 kHz (WWVB) Pre-tuned Commercially Available / Low Cost Small Receiver IC Works at 60 kHz Low Power Consumption 3.3VDC Supply Voltage Crystal Oscillate at 60 kHz

Design Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 1 – SIGNAL RECEIVING Design

Nominal Value Functionality 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING Nominal Value Functionality Simulation Data Not Available Antenna Nominal Frequency 60 kHz (± 300 Hz) Bandwidth < 700 Hz Receiver IC Sensitive to 0.5μVRMS/m Operating Voltage 1.10-3.60VDC Minimum Output Current 5µA Minimum Output Voltage 20mVP Maximum Power Dissipation 100mW Operating Temperature -20ºC - 70ºC Crystal 60 kHz (± 30 PPM) Operating Temperature -10ºC - 60ºC

Passive Component Properties 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 1 – SIGNAL RECEIVING Passive Component Properties Only capacitors will be used No breakdown voltage Voltage rating 16V and 25V Tolerance ±10% 0805 package will be used for both prototyping and final product

Bill of Materials Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 1 – SIGNAL RECEIVING Bill of Materials

Block 2 Filtering Jonathan West Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block 2 Filtering Jonathan West

Bandpass Filter Atomic Clock Receiver High Q Required 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING DESCRIPTION AND LOCATION Bandpass Filter High Q Required Centered at 60kHz Active Filter

BLOCK DIAGRAM Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 2 – FILTERING BLOCK DIAGRAM

PERFORMANCE REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING PERFORMANCE REQUIREMENTS Power Modes: On/Off (controlled by uC) Electrical Interface: Input signal strength: 10mV – 30mV Input Frequency: 1kHz – 100kHz Output Signal Strength: 0.5V – 3V Output Frequency: 59200Hz – 60800Hz User Input: Filter tuning control Potentiometer (Dial) User Indicator: Type: LED Description: Indicates whether filter is properly tuned

PERFORMANCE REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING PERFORMANCE REQUIREMENTS Electrical Transfer Performance: Min/Max Volt. Gain: 35-45 dB Min SNR: 20dB Max Noise: Max Error Voltage: 0.2V Power: Energy Source: 3.3V nominal (3.1-3.5)V Consumption: ~50mW

STANDARD REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING STANDARD REQUIREMENTS Life Cycle: Lifetime: 5 Years Service Strategy: Dispose/Replace MTBF: 5 Years Disposal: Landfill Market: Annual Volume: 10,000 Material Cost: $0.80 Manufacturing Cost: $0.10 Manufacturing: Max Part Count: 25 Unique Parts: 10

STANDARD REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING STANDARD REQUIREMENTS Environmental: Temp: 0-40 C Operating -10-50 C Storage Humidity: 0-90 %RH Max Storage Length: 5 years Mechanical: Area: 2.25 in2 # PCB: 1 Energy Source Connecter: PCB Trace

ELECTRICAL INTERFACE SIGNALS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING ELECTRICAL INTERFACE SIGNALS

Block Prototyping Plan Template 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Block Prototyping Plan Template Block Name Block Area (in2) Total PCB Area (in2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Signal Receiving 4.5 .5 N/A Surface Mount Wire PCB Traces Filter 2.25 PCB Outsourced Microcontroller 1 Power 8 Power Cable User Interface 3 Serial (DB9)

Block Prototyping Plan 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Block Prototyping Plan Procure and Test all parts Test block 2 on breadboard Combine block 1 and 2 and test on breadboard Capture waveforms after each test Correct any problems and then order PCBs

TASK-RESOURCE ESTIMATE SUMMARY 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING TASK-RESOURCE ESTIMATE SUMMARY Material Costs: $15.00 Man Hours: 130.6

GANTT CHART Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 2 – FILTERING GANTT CHART

Block 2: Block Diagram Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Block 2: Block Diagram

Filter Schematic Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 2 – FILTERING Filter Schematic

Delyiannis-Friend Transfer Function 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Delyiannis-Friend Transfer Function Of the Form:

Delyiannis-Friend Design Calculations 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Delyiannis-Friend Design Calculations Let Ho=10 and C=1nF

Stage 1 Frequency Response 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Stage 1 Frequency Response

Stage 2 Design Calculations 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Stage 2 Design Calculations

Stage 2 Frequency Response 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Stage 2 Frequency Response

Overall Gain vs Frequency Response 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Overall Gain vs Frequency Response

Phase vs Frequency Response 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Phase vs Frequency Response

Passive Components Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 2 – FILTERING Passive Components

Monte Carlo Gain Analysis 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Monte Carlo Gain Analysis

Monte Carlo Gain Analysis 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Monte Carlo Gain Analysis

Monte Carlo Phase Analysis 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Monte Carlo Phase Analysis

Active Filter DFM Input Impedance: 4kΩ Output Impedance (@60kHz): 0.3Ω 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Active Filter DFM Input Impedance: 4kΩ Output Impedance (@60kHz): 0.3Ω Op-Amp Characteristics Slew Rate: 10V/uV Offset Voltage: 0.85mV (+/-6) Input Bias Current: 50pA Input Resistance: 1000MΩ

318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 2 – FILTERING Voltage Reference Goal: Provide stable reference voltage for the A/D converter Input Voltage: 3.3V (nominal) Output Voltage 2.5V (+/- 1%) National Semiconductor: LM4040

BOM Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 2 – FILTERING BOM This block will consume approximately 60mm2 of our PCB.

Block 3 Microcontroller 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block 3 Microcontroller Harry Chiu

LOCATION ON BLOCK DIAGRAM 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller LOCATION ON BLOCK DIAGRAM

DESCRIPTION Atomic Clock Receiver Keeps time accurate to the second 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller DESCRIPTION Keeps time accurate to the second A/D converter Control of receiver, listen for requests from unit, control output and user input Signal processing Serial output

PERFORMANCE REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller PERFORMANCE REQUIREMENTS Power: Energy Sources: 3.3V DC Max Total Current: 780uA Environmental: Max Operating Temp Range: 0 - 40 °C Max Operating Humidity Range: 0 - 90% Max Storage Temp Range: -10 – 50 °C Max Storage Humidity Range: 0 – 100% Max Storage Duration: 5 Years Inputs: Keeps time within a second Catches analog signal in 2 min Signal process incoming data < 1sec Outputs: Fulfills request in 5 minutes

STANDARD REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller STANDARD REQUIREMENTS Manufacturing: Maximum Total Parts Count: 5 Maximum Unique Parts Count: 3 Maximum Parts & Material Cost: $7 Maximum Mfg Assembly/Test Cost: $2 Physical: Max Total PCB Area: 6.45cm2 Etch connections Safety: Primary EMC Standards: EN61204-3

Microcontroller Signal 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller Microcontroller Signal

BLOCK DIAGRAM OF BLOCK Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller BLOCK DIAGRAM OF BLOCK

PROTOTYPING PLAN Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 3 – Microcontroller PROTOTYPING PLAN Block Name Block Area (cm2) Total PCB Area (cm2) Substrate Type Comp Attachment Socketed Components Types of Connectors Microcontroller 6.4 Breadboard Surface Mount PCB Traces Wire Support Circuits .5

TASK-RESOURCE ESTIMATE SUMMARY 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller TASK-RESOURCE ESTIMATE SUMMARY Using the Project Task Spread Sheet: Resources available for this block = 100 hours Resources estimated for this block = 93.5 hours

Package Selection Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 3 – Microcontroller Package Selection This physical selection (SOIC) was chosen over (SSOP), (PDIP), (QFN) do to simplicity, availability, cost, and ease of attachment.

Oscillator Design Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 3 – Microcontroller Oscillator Design

Bill of Materials Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 3 – Microcontroller Bill of Materials

Block 4 - Power Michelle Hecyk Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block 4 - Power Michelle Hecyk

BLOCK 4 – POWER LOCATION ON BLOCK DIAGRAM 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power BLOCK 4 – POWER LOCATION ON BLOCK DIAGRAM

DESCRIPTION Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power DESCRIPTION Provides DC voltage to all necessary components Converts 120VAC to 3.3VDC Plugs into any standard wall outlet Provides battery back-up in case of power failure Output voltage regulated to ensure maximum performance

PERFORMANCE REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power PERFORMANCE REQUIREMENTS Energy Source 1 – AC Supply: Energy Source 2 – 4AA Battery Supply: Connection: Permanent Connection Type: 3 Conductor Standard Plug Battery Chemistry: Alkaline Battery Std Size: AA Battery Capacity: >2500mAh Minimum Battery Life: Continuous use: 48 Hours In standby: 1 Year Power Outputs: Max Output Voltage Range: 3.1V – 3.5VDC Nominal Voltage: 3.3V Nominal Current Output: 800uA

STANDARD REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power STANDARD REQUIREMENTS Mechanical: Max Block Volume: 35cm2 Max Total PCB Area: 20cm2 Energy Source 1 Connector: Wire (Battery Harness) Energy Source 2 Connector: 3 Conductor Standard Wall Plug Manufacturing: Max Total Parts Count: 15 Max Unique Parts Count: 8 Max Parts & Material Cost: $3 Max Mfg Assembly/Test Cost: $1

STANDARD REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power STANDARD REQUIREMENTS Safety: Primary Safety Standards: IEC60950: IT equipment - Safety - Part 1: General Req. Primary EMC Standards: EN61204-3: Low Voltage Power Supplies DC Output (Part 3: Electromagnetic compatibility) Environmental: Min Operating Temp Range: 0 - 40 °C Min Operating Humidity Range: 0 - 90% Min Storage Temp Range: -10 – 50 °C Min Storage Humidity Range: 0 – 100% Max Storage Duration: 5 Years

ELECTRICAL INTERFACE SIGNALS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power ELECTRICAL INTERFACE SIGNALS

PROTOTYPING PLAN Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 4 – Power PROTOTYPING PLAN Block Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors AC to DC Converter 10.2 N/A External Wall Unit Plug Wire Battery Backup 18 PCB Outsourced Surface Mount PCB Traces Source Switching Circuit 8.5 6.5 Voltage Regulator

TASK-RESOURCE ESTIMATE SUMMARY 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power TASK-RESOURCE ESTIMATE SUMMARY Using the Project Task Spread Sheet: Resources available for this block = 100 hours Resources estimated for this block = 92.5 hours

BLOCK DIAGRAM OF BLOCK Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power BLOCK DIAGRAM OF BLOCK

AC/DC Converter Block Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block Minimum Value Calculations: Incoming AC voltage: 102-132V Main Feeder Block Regulator requires minimum 4.3VDC for operation Bridge rectifier must be able to supply at least 4.4VDC with 102V AC input We can find the required transformer secondary voltage using the following calculation: To keep standard component values we will use 5VAC or N1=24

AC/DC Converter Block Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block Maximum Value Calculations: Incoming AC voltage: 102-132V Main Feeder Block Regulator maximum input voltage is 20V Bridge rectifier must not supply more than 20VDC with 132VAC input Using N1=24 we find the following: Over-current Protection Calculations: To keep standard component values we will use a 1A fuse

AC/DC Converter Block Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block Rectifier Calculations: Diode Specs - PIV (Peak Inverse Voltage) rating of 2.828 x Vsec is desirable 14V is not a standard value so we will use minimum of 35V @ 1A Output Filter Capacitor Calculations: Maximum ripple: 2.5% Vripple=7.77V x 0.025 =.194Vrms Vripple=2.828 x .194V = .549V Time interval for charge pulse: t=1/(2*f)=1/(2*60)=8.3mS To keep standard component values we will use a 6800uF capacitor

Main Feeder Block Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Main Feeder Block Provides 3.3VDC Vcc signal to all blocks Input Voltage Min: 4.3V Output Voltage Range: 3.22 – 3.38VDC Typical Output Voltage Noise: 20uVrms* *when Cout=10uF and Cbyp=.01uF Min Ripple Rejection: 50dB Max ripple rejection accomplished with .01uF bypass capacitor

Main Feeder Block Back-up Supply Switch: When Vin<Vbatt: 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Main Feeder Block Back-up Supply Switch: When Vin<Vbatt: Vcc switches to battery signal Sends BATTERY ON signal to PIC Controller for low power operation (optional) Vout(min)= Vbatt-.2 Iout(max) = 40mA

Battery Supply Block House and regulate back-up battery voltage 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Battery Supply Block House and regulate back-up battery voltage (4AA Alkaline Batteries) Provides 3.3VDC signal to Main Feeder Block Input Voltage Min: 4.3V Output Voltage Range: 3.22 – 3.38VDC Typical Output Voltage Noise: 20uVrms* *when Cout=10uF and Cbyp=.01uF Min Ripple Rejection: 50dB

Battery Supply Block Battery Life Calculations: Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Battery Supply Block Battery Life Calculations: With loss of AC Power MAX6363 communicates change to battery power to the micro-controller. Using a standard 2500mAh battery we obtain the following results for battery life: BLOCK TYPICAL MAX Signal Receiving 50uA 100uA PIC 500uA 780uA User Int 150uA 300uA Filtering 700uA 1.1mA TOTAL 1.4mA 2.28mA CURRENT DRAW PER BLOCK

Applicable Worst Case Analysis Plan (See DFM Analysis Guide) 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Power Block DFM Plan V or I Regulation Pulse Response & Delay Max Offset Voltage Noise and/or Ripple C Specs C Tol Input Voltage Range Power Semi Package Power Semi J Temp Over Current Protect Battery Back-up Voltage Regulator IC Main Power Voltage Regulator IC Output Voltage Ripple Xfmr Diode Bridge Battery Back-up Switch IC Task 10 Task 9 Task 8 Task 7 Task 6 Task 5 Task 4 Task 3 Task 2 Task 1 Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Sub Circuit Type

Power Block Passive Discrete Specifications 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Power Block Passive Discrete Specifications Component Nominal or Max Value Tolerance Around Nominal Maximum Working Voltage Composition Dielectric or Form Pkg Voltage Regulators Output Capacitor 10uF +/- 20% 10V Alum Electrolytic SMT Bypass Capacitor .01uF +/- 10% 100V Ceramic Input Capacitor 1uF 50V Battery Back-up Switch Decoupling Capacitors .1uF 35V Tantalum Rectifier/Filter Filter Capacitor 6800uF 25V Axial

Atomic Clock Receiver Bill of Materials (1) 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Bill of Materials (1)

Block Bill of Materials (2) 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Block Bill of Materials (2)

Manual Manufacturing Processes 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Manual Manufacturing Processes Manual Solder: Voltage Regulator 1 Voltage Regulator 2 Battery Holder Manual Placement: 4AA Batteries in Battery Holder Insert Fuse in Power cable inlet Connect power cable

Power Block Test Process 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Power Block Test Process Test 1 Primary Power Verification Action 1: Apply 102VAC Verify: Output voltage 3.1 - 3.5 VDC Action 2: Apply 132VAC Verify: Output voltage 3.1 – 3.5 VDC Test 2 Battery Power Verification Action 1: Step 1-Apply 120VAC for 10 seconds Step 2-Remove AC Power Action 2: Apply 120VAC

Block 5 User Interface Harry Chiu 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block 5 User Interface Harry Chiu

LOCATION ON BLOCK DIAGRAM 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface LOCATION ON BLOCK DIAGRAM

DESCRIPTION Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface DESCRIPTION Increase incoming serial signal to output in RS232 @ -12V to 12V Provide user with a “sync on command” option Provide a microcontroller reset Provide real-time operation status to user

PERFORMANCE REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface PERFORMANCE REQUIREMENTS Environmental: Max Operating Temp Range: 0 - 40 °C Max Operating Humidity Range: 0 - 90% Max Storage Temp Range: -10 – 50°C Max Storage Humidity Range: 0 – 100% Max Storage Duration: 5 Years Safety: Primary EMC Standard: EN61204-3 Inputs: Serial output from the microcontroller Outputs: RS232 compliant signal Power: Energy Sources: 3.3V DC Max Total Current: 0.3mA

STANDARD REQUIREMENTS 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface STANDARD REQUIREMENTS Manufacturing Maximum Total Parts Count (Block):10 Maximum Unique Parts Count (Block):5 Maximum Parts & Material Cost: $10 Maximum Mfg Assembly/Test Cost: $2 Physical: Max Total PCB Area: 3.22cm2 Etched PCB wiring

UI Signal Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 5 – User Interface UI Signal

BLOCK DIAGRAM OF BLOCK Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface BLOCK DIAGRAM OF BLOCK

PROTOTYPING PLAN Atomic Clock Receiver 318-595 Spring 2005, Team #4 BLOCK 5 – User Interface PROTOTYPING PLAN Block Name Block Area (cm2) Total PCB Area (cm2) Substrate Type Comp Attachment Socketed Components Types of Connectors RS232 6.4 Breadboard Surface Mount PCB Traces Wire LED & Switches 1 n/a DB9 1.2 Support Circuits .5

TASK-RESOURCE ESTIMATE SUMMARY 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface TASK-RESOURCE ESTIMATE SUMMARY Using the Project Task Spread Sheet: Resources available for this block = 100 hours Resources estimated for this block = 103.5 hours

User Interface RS232 chip Capacitors Atomic Clock Receiver 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface User Interface RS232 chip Capacitors Capacitor tie to gnd for V+ & V- Capacitors to make the charge pumps function

Case Selection Atomic Clock Receiver Prototype case 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface Case Selection Prototype case A custom case can be made after final diamentions are found to minimize cost. Gives a decent size case to start with for reasonabl price Uses AA but a custom made case can be had with AAA Allows for drilling and modification to case.

Micro-controller and User Interface Block BOM 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 5 – User Interface Micro-controller and User Interface Block BOM