Battery Charging System for Toy Truck Capstone Design Project Spring 2007 AKA: Chain Saw

Kassie Shore Mark Noller Eric Fitch Josh Siehoff Team #4: Staff Kassie Shore Mark Noller Eric Fitch Josh Siehoff BSEE

Team #4: Expertise & Experience Expertise: Soldering, PLC Programming, Project Manager Experience: 4 Coop Semesters at B&S Expertise: Soldering, EMC Experience: 4 year at Harley Expertise: Soldering, Microcontroller, Elec/Mech Tech Experience: Military, Industrial Tech Expertise: Flying Planes Experience: Pilot Kassie Shore Mark Noller Eric Fitch Josh Siehoff

Team #4: Weekly Availability Worksheet Kassie Shore Mark Noller Eric Fitch Josh Siehoff 15-20 hrs/week 20 hrs/week 15 hrs/week

Team #4: Weekly Project Meeting Plan Weekly Meeting 1: UWM, Wednesday 5:00-6:30 PM Kassie, All, Discuss Roles and Project Ideas Weekly Meeting 2: UWM, Wednesday 5:00-6:30 PM Kassie, All, Needs for Project and Start Design Weekly Meeting 3: UWM, Wednesday 5:00-6:30 PM Kassie, All, Continue Design and Split up the Project Weekly Meeting 4: UWM, Wednesday 5:00-6:30 PM Kassie, All, TBD Weekly Meeting 5: UWM, Wednesday 5:00-6:30 PM Weekly Meeting 6: UWM, Wednesday 5:00-6:30 PM

Team #4: Total Resources 60 hrs/week $100-$1000+ pending sponsorship

Team #4: Decision Making Our team will make decisions by consensus. If we can not come to a consensus, we will seek our Lab Assistant. The last option in our decision making process will be the Professor/Lecturer.

Emergency Vehicle Early Warning System Control Unit Heads-Up Display Transmitter Receiver Power Source Power Source Product Description Alerts traffic to oncoming emergency vehicles. Control unit on emergency vehicles turns on when siren and lights are active. Receiver and heads-up display are automatic. Benefits Increases time for motor vehicle get out of the way. Decreases Emergency vehicles response time. Major External Electrical and User Interfaces Heads-up Display Power switches Mute/Activate button External Power Inputs and Outputs Uses 12 VDC vehicle power RF signal output/transmitter

Game Whistle Clock Synchronizer Whistle/Sensor Clock Control Transmitter Receiver Power Source Power Source Product Description Synchronizes the referee whistle and the scorers clock When the whistle is blown to stop play the clock will automatically stop When the whistle is blown to start play the clock will automatically stop Benefits Eliminates the human time delay Improves the integrity of the game. Major External Electrical and User Interfaces Whistle On/Off switch Clock control on scorer’s table External Power Inputs and Outputs Power source for whistle is 12VDC battery Power source for scorers station is 120VAC with set down transformers.

Electronic Fuel Tank Switching Unit Fuel Level Sensor Digital Screen Battery Tank Switching Unit Product Description This unit would switch between fuel tanks in a small general aviation aircraft based on a timer input from the user. In the event that a tank gets too low for safe operation, the unit would automatically switch tanks. Benefits This unit would alleviate some workload in the cockpit. The device would also eliminate errors in forgetting to switch tanks preventing fuel starvation. Major external electric & user interfaces The user interface would be a digital screen allowing the user to enter in the amount of time that they wanted to burn off of each tank. Thirty minutes would be entered if the user wanted to switch fuel tanks every half an hour. The electronic unit would have a manual override. External Power Inputs and Outputs Power would be supplied by the 12-volt system that is standard to small aircraft

Battery Charging System for Toy Truck Power Supply Control Inverter Inductive Coils Product Description Toy truck battery charger Slow trickle charge through induction connection Benefits Rechargeable battery more cost effective Eliminates the need for additional connections to charge battery Major External Electrical and User Interfaces LEDs display the amount of time the battery has been on charge. Inductive coils used for wireless charging. External Power Inputs and Outputs Power source on toy is the vehicle power Induction loops pass the current to the toy vehicle for charging the batter

Project Selection Project was selected because funding exists and completion is feasible. The scope of the project can be adjusted with minimal difficulty. The size of the project fits the team size and interests. The major risks are in dealing with batteries and antennas. The other projects were rejected due to lack of funding and inability to scope the project. The project was unanimously supported by the team.

Proposed Product Summary Battery Charging System for Toy Truck This battery charging system will allow the user to trickle charge without physical connections to the toy truck. Primary benefit is to charge without having to physically connect to the charging system. Other benefits: Shows the length of time the battery has been on charge. Quick, easy to use Low maintenance Intended application is to charge the battery on the truck for extended use. The truck becomes fully automatic without having to connect up to the charging system. The induction charging system is an unique idea. Automotive/Entertainment/Promotional Industries

Vehicle Battery Charger Power Supply Inverter Induction Loops Vehicle Connection Control w/LED Display

Block Diagram Description Block Name Owner Brief Description Of Block Function Power Interfaces Digital Analog 1 Power supply Kassie Converts residential 120VAC power to required voltage needed to power the charging circuit and its components. In: 120V AC Out: 12 VDC In: None Out: None 2 Inverter Josh Converts the input of 12VDC from the power supply to 12VAC at a given frequency in order to put the power through the coils. In: 12VDC Out: 12 VAC In: 125Khz 5VDC Out: Variable VAC control signal 3 Control Eric Regulates outgoing power to the toy vehicle depending on mode of operation and current battery state. In: 12 VDC Out: 5VDC, 125Khz 5VDC In: Variable AC control signal 4 Induction loops Mark Transfer power from stationary unit to toy vehicle and rectify to DC voltage without having a physical wire connection. In: 12 VAC

Requirements System – Standard Requirements Market Material Cost: $100 Manufacturing Cost: $50 Power Energy Source: AC Voltage Range: 102VAC – 132VAC Power: 1200W Mechanical Energy Source Connector: NEMA 5-15 Environmental Min Oper Ambient Temp Range: 0 – 50C Min Oper Ambient Humidity Range: 0 – 85% Min Storage Ambient Temp Rang: -20 – 70C Min Storage Ambient Humidity Range: 0 – 90%

Requirements System – Standard Requirements Cont. Safety Must comply with Part 15 of the FCC Rules regarding radio frequency devices Manufacturing Part count is undetermined Life Cycle Service Strategy Repair at factory Product disposal Return to manufacturer

Requirements System – Performance Requirements User Inputs Input: Push Button User Indicators & Displays Indicator 1: Information Indicator 1 type: Binary Binary Indicator Technology: LEDs Operation Modes Power Modes: On, Off, Standby Function Modes: Charging Safety Power Signal Ground Fault Max: 6 mAmps Power Signal GF Max Trip Time: 16 msecs

Block 1 – Power Supply Owner - Kassie Power Signals Input: AC Nominal Voltage: 120V , Range: 10.2V – 13.2V Nominal Frequency: 60Hz, Range: 57Hz – 63Hz Maximum Current: 10A Output: DC Nominal Voltage: 12V, Range: 11.60V – 12.60V V ripple: 0.2V Maximum Current: 20A Digital Signals N/A Analog Signals

Block 2 – Inverter Owner - Josh Power Signals Input: DC Nominal Voltage: 12V , Range: 10.2V – 13.2V Maximum Current: 20A Output: AC Nominal Voltage: 24V, Range: 0V – 48V Maximum Current: 10A Nominal Frequency: 400 Hz, Range: 100-500Hz Digital Signals Input Frequency Input Nominal Frequency: 400Hz, Range: 100-500Hz 5V Logic Voltage Analog Signals Output Frequency Control Nominal Frequency: 60Hz, Range: 51-66Hz Voltage Max Amplitude: 14.5V

Block 3 – Control Owner - Eric Power Signals Input: DC Nominal Voltage: 12V , Range: 11.0V – 14.5V Nominal Frequency: N/A Maximum Current: 1A Digital Signals Output: DC (frequency control) Nominal Voltage: 5V, Range 2.4V- 5.5V Nominal Frequency:400hz Pulse (control signal) DC (LED Display) Nominal Voltage:5V. Range 2.4V-5.5V Maximum Current 100mA Analog Signals Nominal Voltage: 12V , Range 11.0V – 14.5V Maximum current: 1.0A

Block 4 – Inductive Loops Owner - Mark Power Signals Input: AC Nominal Voltage: 24V , Range: 0V – 48V Nominal Frequency: 400Hz, Range: 100Hz – 500Hz Maximum Current:10 A Output: DC Nominal Voltage: 13.8V, Range: 13.0V – 14.0V V ripple: .2V Maximum Current:30 A

Patents US PN 6,972,543 Series resonant inductive charging circuit December 6, 2005 US PN 5,694,023 Control and termination of a battery charging process December 2, 1997 US PN 6,940,257 Battery charger September 6, 2005

Ethical or Societal Issues One issue that we have to address is to prevent too much current from entering the battery on the toy car during the charging process. Another issue that we have to address is to make sure there is sufficient shielding around the coils.