Team #6: Transistor/Diode Curve Tracer Brian Gallert John Edwards Karl Silge BSEE

Team #6: Expertise & Experience Brian Gallert John Edwards Karl Silge Expertise: Electronics, Power Systems Experience: 3 Co-op Semesters @ GE Consumer/Industrial Expertise: Solar/Renewable Energy, Controls, electrical test equipment Experience: USAF, Tektronix, Northrop (Testing and Repair) Expertise: Electromagnetics, Electronics Experience: 5 years @ Bucyrus as ME

Transistor/Diode Curve Tracer Description Trace electrical characteristics for Any two terminal device Resistors Diodes BJTs NPN PNP FETs JFET MOSFET User Interface for customized analysis

Transistor/Diode Curve Tracer Features User Interface Select base current increment Switch between two different devices under test Functions Collector Voltage sweep 0-30 VDC High range to view breakdown characteristics

Transistor/Diode Curve Tracer External Interfaces PNP, NPN, diode plug in Curve Tracer User input settings Current Range Voltage Range Device Type Oscilloscope 120 VAC outlet

Transistor/Diode Curve Tracer Internal Block Diagram of Curve Tracer Digital Functions Analog Functions microprocessor Current Source Signal Processing User Interface Power Supply John Karl Brian

System – Perf Reqs: Mechanical Characteristics of user interface Toggle Switches Rotary dials BNC male coaxial cable to oscilloscope Operation modes ON/OFF Testing for: two terminal devices three terminal devices Safety Current limiting of 150 mA to user Fuse for instantaneous trip time Max potential of user surfaces of 30V

System – Perf Reqs: Electrical Interfaces Signal Type Analog Signal Direction Input Basic Analog Characteristics 120 VAC 150mA 60Hz 25 W

System - Std Reqs: Env & Safety Min Operating Temp Range Min Operating Humidity Range Min Operating Alt or Press Range Min Storage Temp Range Min Storage Humidity Range Min Storage Alt or Press Range Max Storage Duration 10Co - 50Co 10 – 70 Rh% Sea level – 4000m 0 – 80 Rh% 3 Years

System - Std Reqs: Power Interfaces Energy Source List Source Connection List Min Operating Voltage Range Max Power Consumption Max Energy Consumption 120 VAC Temporary 102V – 132V 25 Watts Total 7500 Watt-Hours/Yr

System - Std Reqs: Mechanical Max Volume Max weight Electrical I/F Connector(s) Max # of PC Boards Max PCB Circuit Area 10” x 8” x 3” = 240 in3 10 lbs BNC connectors 5 80 in2

Basic Business Case Estimate the Average Product Selling Price (ASP$): $400 Estimate the Product Annual Sales Volume: 2500 Estimate the Per Unit Cost of all Parts and Materials using the above annual volume assumption: $100 Estimate the Per Unit Cost of all the Assembly, Test and Mfg using the above annual volume assumption: $120 Estimate the Total Development Cost in $ incl Labor+Material: $60,000 Calculate the Annual Sales $ = $400 x 2500 = $1M Calculate the Per Unit CM$ = $400 – $245 = $155 Calculate the CM% = $155/$400 = 38.75% Calculate the Annual CM$ = 38.75% X $1M = $387,500 Calculate the ROI Time in Years = $60,000 /$387,500 = .155 years

System - Std Reqs: Safety Safety Standards Adhered to Canadian Stds. Association CSA 1010.1:1992 CSA 22.2 :950 Underwriters Labs UL 3111-1:1994 UL 61010B-1:2003 UL 1950

EMC Standards Adhered to System - Std Reqs: EMC EMC Standards Adhered to EN61000-6-2 (Level C) IEC61000-4-2 (ESD immunity) IEC61000-4-5 (Surge immunity) IEC61000-4-11 (Voltage dips, short interruptions, variations)

Team 6: Team members with assigned blocks Brian Gallert User Interface Microprocessor Karl Silge Power Supply John Edwards Analog Devices Current Generator Signal Processing

User Interface Digital Functions Analog Functions Power Supply Brian microprocessor Current Source Signal Processing User Interface Power Supply Brian

User Interface Description Functions Toggle Switches On/Off Select between devices Left or Right BJT or FET P-channel or N-channel Rotary Dials Collector Voltage range 0-30 Base Current or Gate Voltage increments five different increments all by log scale 5 different series resistances to limit collector current Possible Features Rotary dial to adjust collector current DIP switch to select number of base current steps

User Interface Perf Requirements User Inputs Base Current or Gate Voltage Increment Rotary dial Five different increment options Device Type Four different device options Polarity of Device Collector Voltage range Series current limiting resistor Operational Modes ON/OFF LED indicator

User Interface Std Requirements Power 5 VDC source Min 4.5 Max 5.5 Connection Permanent Power consumed 2 W Size 475 cm3 95cm2 PCB

User Interface Power Interface

User Interface Digital Interface

User Interface Block Diagram 120 VAC To System ON/OFF Push Button 5 VDC Polarity Switch Base Current/ Gate Voltage Rotary Dial Left/Right Switch Device Rotary Dial To System To Microprocessor Collector Volts Rotary Dial Current scaling Rotary Dial Series Res. Rotary Dial # of Steps Rotary Dial

User Interface Task-Resource Estimate Prototype Time of assembly and testing – 15 hours Completed by April 30 Total Estimates Total Material Estimated $41 Total Manpower Estimated 37.3

User Interface Prototyping Plan Block Area 180 cm2 Total PCB Area 90 cm2 PCB Substrate Type Pre-perforated fiberglass Component Attachment Type Direct Solder Socketed Components Solid wire solder connection Types of Connectors AMP connector

Microprocessor Digital Functions Analog Functions Power Supply Brian Current Source Signal Processing User Interface Power Supply Brian

Microprocessor Description PIC16F876 with external clock Functions Decode user interface inputs Time the base current increments to voltage sweeps Change base current to gate voltage when testing a FET vs. a BJT Change increments on Base Current to User input

Microprocessor Perf Requirements User Inputs Base Current Increment Rotary dial Five different increment options Device Type Three different device options Operational Modes ON/OFF LED indicator

Microprocessor Std Requirements Power 5 VDC source Min 4.5 Max 5.5 Connection Permanent Power consumed 2 W Size 475 cm3 95 cm2 PCB

Microprocessor Power Interface

Microprocessor Digital Interface

Microprocessor Analog Interface

Microprocessor Block Diagram 5 V Base Current/ Gate Voltage Rotary Dial To Counter PIC 16F876 To Vref polarity Device Rotary Dial NPN or PNP Voltage or Current Current scaling Rotary Dial To IC scaling To Current Source # of Steps Rotary Dial From User Interface Clock

Microprocessor Prototyping Plan Block Area 90 cm2 Total PCB Area PCB Substrate Type Etched fiberglass Component Attachment Type ZIF Socket Socketed Components Processor Type of Connector AMP

Microprocessor Task-Resource Estimate Prototype Time of assembly and testing – 25 hours Completed by April 30 Total Estimates Total Material Estimated $21 Total Manpower Estimated 48.3

Power Supply Digital Functions Analog Functions Power Supply Karl microprocessor Current Source Signal Processing User Interface Power Supply Karl

Power Supply Description Characteristics Input – 120 VAC Outputs 5 VDC +15 VDC -15 VDC Full Rectified Wave 30 V peak to zero Features Isolation transformer Voltage Regulation to 10%

Power Supply Perf Requirements User Inputs Push Button ON/OFF Red LED Indicator for ON/OFF Operational Modes and Features 10% Voltage Regulation

Power Supply Std Requirements 120 VAC source Min 102 Max 132 Connection Temporary (only during use) Power consumed 20 W Size 475 cm3 95 cm2 PCB

Power Supply Power Interface

Power Supply Block Diagram collector xfmr +15V op amps xfmr regulator -15V xfmr regulator +5V digital bridges

Power Supply Prototyping Plan Block Area 90 cm2 Total PCB Area PCB Substrate Type Etched fiberglass Component Attachment Type Direct Solder Socketed Components Solid wire solder connection Types of Connectors AMP connections

Power Supply Task-Resource Estimate Prototype Time of assembly and testing – 30 hours Completed by April 28 Total Estimates Total Material Estimated $150 Total Manpower Estimated 112

Analog Devices Digital Functions Analog Functions Power Supply John microprocessor Current Source Signal Processing User Interface Power Supply John

Analog Devices Description Functions Base Current Source for BJTs Gate Voltage Source for FETs Scales and filters signals to oscilloscope Features BNC connectors to oscilloscope High SNR above 50 dB

Analog Devices Perf Requirements User Inputs Toggle Switch for polarity for N-channel P-channel Five position rotary dial for Base current increments on log scale starting at 10uA Gate voltage increments on log scale Operational Modes and Features BJTs or FETs High SNR of 50 dB BNC connectors for direct connection to oscilloscope

Analog Devices Std Requirements Power +/-15 V DC for op amps +5V DC Connections Permanent Power consumed 1 W Size 475 cm3 95 cm2 PCB

Analog Devices Power Interface

Analog Devices Digital Interface

Analog Devices Analog Interface

Analog Devices Block Diagram Voltage Source VC Polarity SW From Micro Current Limiting Resistance VC X Counter L/R SW To Oscilloscope Scaling and Current Conversion Op Amp Left D.U.T. Right D.U.T. D to A Converter IC Y Vref

Analog Devices Prototyping Plan Block Area 90 cm2 Total PCB Area PCB Substrate Type Etched Fiberglass Component Attachment Type Direct Solder Socketed Components Solid wire solder connection Types of Connectors AMP connections

Analog Devices Task-Resource Estimate Prototype Time of assembly and testing – 40 hours Completed by April 28 Total Estimates Total Material Estimated $60 Total Manpower Estimated 116.1

Overall High Level Package Description External Enclosure Plastic Box 10” by 7.5” by 3” Connections Plug Type B 2 male BNC connectors Internal Four PCBs each 2.5” by 6” Total of 15 sq inches of board space

Team Resource Capability vs. Project Resource Estimations Team Capabilities $350 400 Man-hours Resource Estimations $282 428.7 Man-hours Percentages used Dollars 80.5% Man-hours 107.2%

Overall Program Plan Gantt Chart