The UPS Team 5

Team 5: Staff Michael Myers BSEE Fernando Muñoz Jesus Lopez Adam Bitter Jake Koturbo BSEE

Team 5: Expertise & Experience Michael Myers Fernando Muñoz Jesus Lopez Adam Bitter Jake Kotrba Expertise: Power and Electromagnetics Experience: Kimberly-Clark, General Motors Expertise: Power, Motors Experience: Airforce electrician Expertise: Controls, Power Experience: We energies, Gossen Corporation Expertise: Controls Experience: N/A Expertise: Power, Motors Experience: Chicago-Kenosha Building Developement

Team 5: Contact Info Michael Myers Fernando Muñoz Jesus Lopez Adam Bitter Jake Kotrba Phone 1: 414-688-8367 414-229-3216 Email: doctechlabs@yahoo.com Phone 1: 414-793-7832 414-761-1244 Email: fmunoz@uwm.edu Phone 1: 414-248-1364 414-383-8548 Email: jesusl@uwm.edu Phone 1: 262-388-1132 262-338-6532 Email: albitter@uwm.edu Phone 1: 414-229-3049 414-229-3216 Email: jkotrba@uwm.edu

Team 5: Weekly Availability Worksheet Michael Myers Fernando Muñoz Jesus Lopez Adam Bitter Jake Kotrba Time 1 (all members): Monday, 8:00 AM – 10:00 PM Time 2 (all members): Wednesday, 8:00 AM – 10:00 PM Time 3 (all members): Friday, evening, as needed

Team 5: Weekly Project Meeting Plan Weekly Meeting 1: - EMS 202, Monday 8-10 AM Owner: Jesus Lopez Expected Attendees: all members Purpose: Project integration, review and set weekly goals Weekly Meeting 2: - EMS 202, Monday 8-10 AM, Wednesday 8-10 AM Owner: Mike Myers Purpose: Project procedures adjustments Weekly Meeting 3: - EMS 202, Monday 8-10 AM, Friday 5-until PM Owner: Adam Bitter Purpose: Weekly goals wrap up Note: Meeting Owners Send Weekly Email Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

Team 5: Total Resources 560 Man-hours Cost - $500.00

Team #: Decision Making Decisions will be taken based on a majority vote

Roles to Define & Assign Project Integrator: Jake Kotrba, Owns weekly progress reports to TA. Logistics and communication of team meetings. Develops and Tracks overall project plan. Integrates Block design plans. Tracks expenditures. Owns project level verification and validation plan, capture and documentation of results. Presentation Mgr: Jesus Lopez, Owns master MS Powerpoint slide set for team including formats, logos, fonts, colors, header/footer, backgrounds, rev control, submission of master floppy or CD for P1-P4 and Final Presentation. Report Mgr: Adam Bitter, Owns master MS Word document for team including revision control, formats, logos, fonts, colors, header/footer, table of contents, submission of master floppy or CD for Final report. Archive Web Mgr: Jake Kotrba, Owns weekly backup of all electronic material generated that week. Backup for Presentation Mgr and Report Mgr. Management of any team Web site resources. Assembly & Proto Mgr: Michael Myers, Owns overall assembly level definitions, basic assembly drawings, master prototype & product parts lists, collection of block parts lists, procurement of proto components. Overall prototype mechanical and electrical assembly PCB Layout Mgr: Fernando Muñoz, Owns overall PCB layout, Block to PCB mapping, PCB tools, PCB design drawings, PCB procurement, PCB assembly including special tools, soldering, wire-wrapping, drilling, and gluing.

+ + + + + Vac Sensor Jake AC Switch Jesus Main Switch Jesus Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Project Proposal Uninterruptible Power Supply (UPS) and surge protector. Supply uninterruptible power to computers, refrigerators, furnaces or other wanted appliances. There is a competitive market for this product. Targeted towards residential applications and small businesses.

Selection Process This product was selected because the sufficient number of blocks it yields, even work distribution and team experience with power. Risks include electrocution, sleep deprivation and damage to load device. Other projects were rejected because of their complexity and marketing requirements. This was a unanimously supported project. We decided on this project based on input from the instructor and time restrictions.

Performance Requirements Input AC Voltage: 105-132 V Input AC Current: max 15 A Input AC Frequency: 60Hz +/- 3Hz Output AC Voltage: 105-132 V Output AC Current: max 15 A Output AC Frequency: 60Hz +/- 3Hz Battery Size: 12V Automotive Battery Battery Life: 1 Hour Digital Functions: User display refreshed every 1/10 sec, monitoring and display input AC User Interface: 7 segment LCD, push pad Power Mode: Always on Sensory: Current, Voltage and Frequency Mounting: Feet Plug: Type B

Standard Requirements Operating Range: -15 -- 50ºC Max Operating Relative Humidity: 95% Operating Pressure Range: 1 atm +/- 15% Max Storage Duration: 10 years Energy Sources: AC, automotive battery Source connections: AC utility and DC battery Power Consumption: 5200 Watt hours per year Max Volume: 40000 cm3 Max Weight: 14 kg

Safety Requirements Primary Safety Standards IEEE C62.41-1991 Surge Protective Devices Standards UL 1449 Transient Voltage Surge Suppressors IEC 60095-1 Lead-Acid Starter Batteries Primary EMC Standards EN 50065-1:2001 Signaling on low-voltage electrical installations in the frequency range 3 kHz to 148,5 kHz ICES-003 Interference Causing Equipment

Business Case Average Selling Price: $80 Product Annual Sales Volume: 15,000 Per Unit Cost of all Parts and Materials: $30 Per Unit Cost of all the Assembly, Test and Mfg: $30 Total Development Cost: $75,000 Annual Sales: $1,200,000 Per Unit CM: $20 CM%: 25% Annual CM: $300,000 ROI Time: 0.25 years

+ + + + + Vac Sensor Jake AC Switch Jesus Main Switch Jesus Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Block Level Description

Name: Michael Myers Major: Electrical engineering Team 5: UPS Assignment: block 1 Block 1: Inverter

Inverter Once the power fluctuates outside the boundaries a control switch will allow the inverter power to transfer to the circuit.

+ + + AC Vac Sensor Jake Charging Switch Jesus Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Power Inverter The job of this inverter is to transfer 12Vdc to 120Vac. This device will always be on Control switch will allow inverter power to flow

Inverter Performance Requirements Input: Analog (nominal) 12Vdc 30Adc Output: Analog (nominal) 120Vac 60Hz 15Amps(maximum)

Inverter Standard Requirements Operating Voltage: Max 5.25Vdc Min 4.75Vdc Operating Temperature: Max 50 C Min -15 C Humidity: Max 95% r.h.

Analog and digital interfacing – N/A Inverter Signal Table Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current   Nominal Min Max Power1 VCC +12 DC- Power Input 12.0V 10.2 13.2V DC N/A 5.00% 0.1V 18A Power2 VCC -15V AC- Power Output 120.0V 102V 132.0V AC 57 63 0.25V 15.00A Analog and digital interfacing – N/A

Prototyping Plan Inverter 700 Fiber Glass Solder Yes Flat Pins Block Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Inverter 700 Fiber Glass Solder Yes Flat Pins

Block Diagram Inverter Block Battery (12Vdc) DC-AC To 12Vac Transformer To 120Vac Switch (120Vac)

Resource Estimate 14.9% of the Material Estimate Estimated 149 hrs.

Name: Fernando Muñoz Major: Electrical engineering Team 5: UPS Assignment: Power Block Block 2a: Charger (Rectifier) Block 2b: Battery Jjkjk

+ + + Vac Sensor Jake Charging Switch Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Power Inputs and Outputs Transformer Input : 120 VAC / 20Amp Transformer Output / Rectifier Input : 15.7 VAC (Step Down) Rectifier Output #1 : 14.3 VDC Rectifier Output #2 : 5 VDC

Power Electrical Interface Signals Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current   Nominal Min Max Power-1 AC Input AC Power Input 120V 102V 132V 60Hz 57Hz 63Hz 15.00% N/A 15A Power-2 VCC +14.3V DC Power Output 14.3V 12.15V 15.73V DC 1.00% 0.01V 35A Power-3 VCC +14.3V 2A

Block diagram of Power Supply System 120 VAC Main Input Transformer Rectification Smoothing Regulation 14.3 / 5 VDC Regulated output 14.3 VDC With Ripple 15.7 VAC 14.3 VDC

5 VDC Power Regulated System

Full-Wave Rectifier Bridge Rectifier is used so four diodes are arranged so that both the positive and negative parts of the AC waveform are converted to DC.

Since output voltage out of the Rectifier still varies between 0V and -1.4V a smoothing capacitor is required so when the voltage increases in the first half of the voltage peaks, the capacitor charges up. Then while the voltage decreases to zero in the second half of the peaks the capacitor releases stored energy to keep output voltage as constant as possible. After the smoothing process we regulate the rectifier output in order to get rid of Voltage Ripple, so we can get a more stable, accurate, known voltage for the circuit.

Charge Types Trickle Charge : Constantly supplies the battery with 14.3 VDC at 2 Amps. Quick Charge : When the battery is completely drained and commercial power is restored, the sensors will allow a much quicker charge of 14.3 VDC at 35 Amps charge the battery at a faster rate.

Main Purpose Keep a constant charge in the battery so when commercial power is lost, the device to which the UPS is connected to stays on for about a half hour or until the battery drains completely. Provide 5 VDC logic to the CPU which power s all essential controls and sensors.

Prototyping Plan Block Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Power 700 Copper Solder No B type plug Flat Pins

Resource Estimate 24.8% of the Material Estimate Estimated 73 hrs.

Name: Jesus Lopez Major: Electrical engineering Team 5: UPS Assignment: blocks 3 and 6 Block 3: Switching Gear Block 6: Display

Standard Requirements Temperature range: 150 C Max -15 C Min Operation humidity Range: 95 % Max Rh Intended aplication: home office

Performance Requirements Signal Interfaces (digital) +5 Vdc logic control LED display Signal Interfaces (analog) +10%/-15% 120 Vac 60 Hz +/- 3 Hz

Switching Gear The mechanical switching for this project will be effectuated by a double pole double throw relay. Power source switch. Charging switch. Note: other switches may be needed for different. Blocks.

+ + + AC Vac Sensor Jake Charging Switch Jesus Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Main Switch The job of this switch is to select the power source to be used, AC or DC. This switch selects AC power during normal operation. The mechanism for this switch is controlled by a direct input from the micro-controller, which either closes or opens the switch.

Main Switch Nominal Ratings Control Input : 5 Vdc Input: 120 Vac Output: 20 A

Main Switch Signal Table Power Signals   Type Direction Voltage Nominal Voltage Range Freq Freq Range % V-Reg Max V-Ripple Current Min Power1 VCC +5 DC Power Input 5.0V 4.75V 5.25V 5.00% 0.1V 1.2A Power1 AC AC Power 120V 102V 132V 60Hz 57Hz 63Hz 15.00% N/A 1.0A Power2 AC Output Power3 AC

Charging Switch The job of this switch is to allow for a high battery charging mode. This switch is regularly open and is closed only when the battery charge is very low. The control for this switch is a direct input from the micro-controller, which either closes or opens the charging switch.

Charging Switch Nominal Ratings Control Input : 5 Vdc Input: 120 Vac Output: 40 A

Charging Switch Signal Table Power Signals   Type Direction Voltage Nominal Voltage Range Freq Freq Range % V-Reg Max V-Ripple Current Min Power1 VCC +5 DC Power Input 5.0V 4.75V 5.25V 5.00% 0.1V 1.2A Power2 AC AC Power 120V 102V 132V 60Hz 57Hz 63Hz 15.00% N/A 1.0A Power3 AC

Display The display for the UPS will present the following basic features: On/Off manual power switch. On/Off LED. AC/DC LED. Fast/Slow charging mode. Remaining power indicator. Note: other features will be considered if time yields an. opportunity.

+ + + AC Vac Sensor Jake Charging Switch Power Source Switch Load Display Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Display Nominal Ratings Input: 8-bit digital signal Output: LED on/off state

Display Signal Table Power Signals Type Direction Voltage Nominal   Type Direction Voltage Nominal Voltage Range Freq Freq Range % V-Reg Max V-Ripple Current Min Power1 VCC +5 (switch) DC Power Input 5.0V 4.75V 5.25V DC N/A 5.00% 0.1V 1.2A 8-bit channel Digital

Display is meant to be basic, but complete Display is meant to be basic, but complete. An LED display chip will represent the battery life.

Block 3 & 4 Prototyping Plan Template Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Main Switch 35 700 N/A Spade connector Charging Switch Display 100 Fiber glass Solder 8-wire ribbon Easy disconnect connector

Switch Resource Estimate 10.8 % of the material estimate Estimated 80 hrs. Display Resource Estimate Estimated 30 hrs.

End of UPS blocks 3 and 4 !!!

Name: Adam Bitter Major: Electrical engineering Team 5: UPS Assignment: CPU

+ + + AC Vac Sensor Jake Charging Switch Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

CPU The CPU will do the following things: Read in a utility (AC) voltage signal Read in a battery voltage signal Read in a battery current signal Control the switching of the power source switch Control the switching of the charging switch Output a battery life signal to the display

CPU The CPU will switch to the battery when the voltage read in is below 105 V When the battery is run dead the CPU will switch on the fast charger for a certain period of time

CPU The CPU will send a signal to the display indicating the life of the battery based on the battery voltage level If necessary it will also be able to send more outputs to the display

CPU Performance Requirements Input: AC voltage: 8 bits, 5V DC DC voltage: 8 bits, 5V DC DC current: 8 bits, 5V DC Output: Display: 8 bits, 5V DC Charging Switch: 1 bit, 5V DC Power Switch: 1 bit, 5V DC

CPU Standard Requirements Operating Voltage: Max 5.25Vdc Min 4.75Vdc Operating Temperature: Max 50 C Min -15 C Humidity: Max 95% r.h.

CPU Power Interface Type Direction Voltage Nominal Voltage Range Frequency Nominal Frequency Range % V-Reg. V-Ripple Current Min Max DC Power Input 5.0V 4.75V 5.25V 5% 0.2V 1.5A

CPU Digital Interface Digital Signals Type Direction Input Structure Technology Logic Voltage Characteristics Vh Min Ih Max Vl Max Il Min Vac Sensor 8-bits Digital Input Standard TTL 5V 3.00V 1.0mA 2.2V 10uA Vdc Sensor 8-bits Idc Sensor 8-bits Switch 1-bit Output 3.25V 0.5mA 1.8V 0.1mA Battery 8-bits Power 2-bits

Block 5 Prototyping Plan Template Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors CPU 100 12 Copper solder Yes Ribbon Cable

Resource Estimate 12.9% of the Material Estimate Estimated 47.4 hrs.

Name: Jake Koturbo Major: Electrical engineering Team 5: UPS Assignment: block 6 Block 6: Sensors : Vac Vdc Idc

+ + + AC Vac Sensor Jake Charging Switch Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Purpose: It’s how the CPU interfaces with the input and output power.

Advantages of Using Sensors Upper and lower limit can be adjusted with a small change in the CPU’s programming. Example: Quick charger is turned on and off based on battery input current. Qcharger on when I>1.9A Qcharger off when I<1.5A

Sensor Performance Requirements Input: Analog (nominal) 120Vac 5Vdc 15Adc Output: Digital (nominal) 8-bits (5V logic)

Output continued… Directly interface with only the CPU All sensor outputs will supply the eight bit signal to the CPU. All sensors will use A/D converters and therefore use 5volt.

Sensor Standard Requirements Operating Voltage: Max 5.25Vdc Min 4.75Vdc Operating Temperature: Max 50 C Min -15 C Humidity: Max 95% r.h.

Sensor Power Interface Type Direction Voltage Nominal Voltage Range Frequency Nominal Frequency Range % V-Reg. V-Ripple Current Min Max DC Power Input 5.0V 4.75V 5.25V 5% 0.2V 0.5A

Sensor Analog Interface Analog Signal Type Direction Coupling Voltage Amplitude Maximium Impedence Frequency Range Leakage Max Min Max Vac Analog Input Xfmr 132V 5k 20k 63Hz 500uA Vdc 14.3V 1Hz Idc 5.25V

Sensor Digital Interface Digital Signals Type Direction Input Structure Technology Logic Voltage Output Characteristics Voh Min Ioh Max Vol Max Iol Min Vac 8-bits Digital Output Standard TTL 5V 3.25V 0.5mA 1.8V 0.1mA Vdc 8-bits Idc 8-bits

Convert to a proportional 0-5Vdc analog signal Simplified Sensor Analog Signal CPU Convert to a proportional 0-5Vdc analog signal ADC Vcc~5V

Vac Sensor Measure the input voltage from the commercial supply. Produce an eight bit output. Signal is monitored by the CPU to initilize the use of the inverter.

Placement of the Vac Sensor AC power AC power CPU

Vdc Sensor Measure the battery voltage. Produce an eight bit output directed to the CPU. Used to determine emergency CPU shutdown (when battery runs too low). Used in conjunction with the Idc sensor to estimate battery expectancy.

Placement of the Vdc Sensor Quick Charger Trickle Charger Inverter Vdc and Idc Sensors Battery

Idc Sensor Measure the input and output battery current. Produce an eight bit output directed to the CPU. Used to engage or disengage the Quick charger. Used in conjunction with the Vdc sensor to estimate battery expectancy.

Placement of the Idc Sensor Quick Charger Trickle Charger Inverter Vdc and Idc Sensors Battery

Block Prototyping Plan Template Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Sensors 120 700 Fiber Glass Wire Wrap N/A Spade connector, Cupper bus, easy disconnect

Resource Estimate 22% of the Material Estimate Estimated 50 hrs.

End Block Level Description Begin Product Level Description

All Blocks will be packaged into a shelf like orientation Prototype UPS Shelf All Blocks will be packaged into a shelf like orientation

Block Level Plan Man Hours Materials $ Inverter Block 1 149 81 Power 73 135 Switches Block 3 80 59 Display Block 4 30 CPU Block 5 47.4 70 Sensors Block 6 49.7 120

Estimated vs Available Total Manpower hours: estimated- 560 available- 528 Total material cost: estimated- $560 actual- $571

Plan Summary Man hours: previously 560 hrs. Now 528 Budget: previously 500 dollars. Now, estimated at 575 dollars. Increase the budget by 12 dollars per person. Man hour distribution percentage: 25 System design task 25 Detailed design task 10 Verification 40 Documentation

GANTT Chart Time Line

Chronological Obstacles Can’t begin to construct prototype until all parts have been obtained. Can’t obtain all parts until part list has been compiled. Can’t test the whole project as a hole until everyone gets their blocks put together and debugged. Can’t test the whole project until all safety standards and regulations have been met.