Electrical Engineering 595 Capstone Design Team #4 Universal Power Box

Staff Gerry Callison, BSEE Maria Schlicht, BSEE Ethan Spafford, 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 Vanessa White, BSEE 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: gerrycallison@yahoo.com Phone: (414) 382-1208 Email: maschlicht@ra.rockwell.com Phone: (262) 332-0646 Email: espaff_@yahoo.com Phone: (262) 893-3015 Email: mrisic@hotmail.com Phone: (608) 212-7431 Email: vjwhite@uwm.edu

Weekly Availability Worksheet Gerry Callison Maria Schlicht Ethan Spafford Matt Risic Vanessa White Time 1: Monday nights Time 2: Friday any Time 3: Saturday any Time 1: Monday after 5p Time 2: Tue after 4p Time 3: Fridays after 4p Time 3: Fridays any Time 4: Sat any Time 1: Monday after 7 Time 2: Tues any Time 3: Thursday 1-6 Time 1: Monday after 5:30 Time 2: Fri after 5 Time 3: Saturday any 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 March April May Define Initial Design Component Selection Build Prototype Verification Refine Design Documentation

Time Line Summary Man Completion Hours Date Basic Product Definition Compilation/Definition of 2 2/4 Team Logistics/Operation Team Resources Allocation 1 2/15 Product Level Requirements 2 2/4 Standard/Performance Proto-Type Block Diagram Block Diagram with 2 2/5 Assignments and Interfaces Block Review Team T/A 1 2/18 Productization Develop Product Level 3 4/10 Verification and Requirement Plan Compilation/Development of MFG 4.5 4/30 Processes, Block Diagrams Design Plans for Testing Disposal 4 4/19 and Service

Time Line Summary Documentation Est.Man Completion Hours Date Proto-Typing Integrate BL Proto-Type into 2 4/24 Product Level Proto-type Testing of Fully Integrated 5 4/24 Proto-type Execution of PL Verification/Validation 2 4/30 Plan Compilation of Resource Expenditure 1 5/5 and Budget Chart Documentation Compilation of Individual 12.5 5/5 MSWord Reports Compilation of Final MSWord Report 1 5/10 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 0-120VAC. 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 user-defined 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 0%RH to 70%RH Block Cost <$20 Parts Count <30 Block Size <48cm2 Block Mass <95.5 grams Max Power Consumption <20W Operating Temperature Range 5C to 35C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 3 Years

Performance Requirements Power Control Input Voltage +3.3V (+/- 3%) Full Scale Output Voltage +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 0 to 70 %RH Block Cost <$6.00 Parts Count <30 Block Size <20cm2 Block Mass <100grams Max Power Consumption <3W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70%RH Reliability (MTBF) 5 Years Allocations Cost 15% Parts 15% Unique Parts 14% Power Cons. 20% Mass 5% Area PCB 12%

Performance Requirements Inverter-Rectifier Input Voltage 0-50Vdc, 0-120VAC Full Scale Output Voltage 0-50Vdc, 0-120VAC Inverter/Rectifier Life 5 Years % Error <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 0 to 70 %RH Block Cost <$4.00 Parts Count <20 Block Size <20cm2 Block Mass <60grams Max Power Consumption <3W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70%RH Reliability (MTBF) 5 Years Allocations Cost 10% Parts 10% Unique Parts 5% Power Cons. 20% Mass 3% Area PCB 7%

Performance Requirements DC/DC Converter Input Voltage 0-50Vdc, 0-120VAC Full Scale Output Voltage 0-50Vdc, 0-120VAC Inverter/Rectifier Life 5 Years % Error <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 0%RH to 70%RH Block Cost $10.00 Parts Count 4 Block Size 133 (H) x 111(W)x 48(D) mm Block Mass 284 grams Max Power Consumption 2.5 W max. (0.105 A @24Vdc) Operating Temperature Range 0˚ C to 55˚C Storage Temperature Range -20˚C to 85˚C Operating Humidity 5 to 95% at 0˚ to 55˚C Heat Dissipation 2.5W (8.5 BTU/Hour) Reliability (MTBF) 5 Years Allocations Cost 25 % Parts 5 % Unique Parts 5 % Power Cons. 5 % Mass 5 % Area PCB 5 %

Performance Requirements User Interface Input Voltage +24V (+/-5%) Full Scale Output Voltage +24V (+/-12%) User Interface Life 5 Years % Error 10% Display (type) Liquid Crystal Display (LCD) with LED Backlighting Display (size) 73mm (w) x 42mm (h) Certifications 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 0%RH to 70%RH Block Cost <$20 Parts Count <20 Block Size <40cm2 Max Power Consumption <2W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Reliability (MTBF) 2 Years Allocations Cost 5% Parts 10% Unique Parts 12% Power Cons. 1% Mass 2% Area PCB 5%

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 0%RH to 70%RH Block Cost <$20 Parts Count <20 Block Size <12cm2 Block Weight <500grams Max Power Consumption N/A Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Reliability (MTBF) 1Year Allocations Cost 10% Parts 10% Unique Parts 12% Power Cons. N/A Mass 10% Area PCB 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/Regulator-Sensors/MicroController/PowerFilter/etc DC input path: amplifier-voltage/regulator-sensors/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 0%RH to 70%RH Block Cost <$15 Parts Count <7 Block Size <40cm2 Block Weight <100grams Max Power Consumption <2W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Reliability (MTBF) 2 Years Allocations Cost 1% Parts 2% Unique Parts 2% Power Cons. 1% Mass 1% Area PCB 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 0%RH to 70%RH Block Cost <$2 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years Allocations Cost 5% Parts 12% Unique Parts 12% Power Cons. 10% Mass 7% Area PCB 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 0%RH to 70%RH Block Cost <$3 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years Allocations Cost 7% Parts 12% Unique Parts 13% Power Cons. 10% Mass 7% Area PCB 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 +12VDC AC Sensor Life 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 0%RH to 70%RH Block Cost <$3 Parts Count <24 Block Size <40 cm2 Block Mass <140 grams Max Power Consumption <3 W Operating Temperature Range 0C to 50C Storage Temperature Range 0C to 50C Operating Humidity 0-70% Reliability (MTBF) 2 Years Allocations Cost 7% Parts 12% Unique Parts 13% Power Cons. 10% Mass 7% Area PCB 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 +12VDC Internal Sensor Life 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