Subsystem Design Review P16203 Andre Pelletreau, Kerry Oliviera, Jeremy Willman, Vincent Stowbunenko, Kai Maslanka

Recap of Last Review Functional Decomposition Morphological Chart and Concept Generation Concept Selection Engineering Analysis System Architecture Feasibility Analysis Risk Assessment Test Plan Next 3 Weeks…

Agenda  System Architecture  Requirements Flow Down  Subsystem Interaction  Constant Current and Constant Voltage Loads  Thermal Analysis of Enclosure  Stress Analysis  UML Diagrams  RS-232 Proof of Concept  Stress Analysis for Enclosure  Design of Enclosure and Safety Shield  Air Flow Analysis  Preliminary BOM  Updated Test Plan  Next 7 Weeks…

Subsystem Interaction

Subsystem Engineering Requirements Sub-System ER Physical Enclosure Transparent Safety Enclosure AC disengaged when lid is open AC voltage not accessible Able to withstand UUT failure 1.5’ x 1.5’ x 1’ Quick (dis)connect wires Difficulty to set up / lock in Time to set up < 1 minute Loads Length of test < 5 minutes Output 1 – Active Load Output 2 – Resistive Load Data Storage Store Test Data Feedback AC disengaged when lid is open AC voltage accessibility Pass/fail indication Reason for failure UUT on indication Test Bench on indication Number of test steps under 5 Cooling Internal Temperature < 50 ˚C Processing Length of test < 5 minutes Successfully calibrate UUT AC disengaged when lid is open Tx and Rx data to/from UUT AC voltage accessibility Establish communication with UUT Safety Internal Temperature < 50 ˚C AC disengaged when lid is open Transparent safety enclosure Able to withstand UUT failure AC voltage accessibility

Constant Voltage Load

Constant Current Load

Stress Analysis for Enclosure Metal

Thermal Analysis

UML Diagrams

UML Diagram Cont’d

RS-232 Proof of Concept

Autotransformer Mathematical Proof of Concept

AC Inputs  Two autotransformers were needed to satisfy AC input specifications  The outputs of the transformer will be controlled by a relay  The relay will be controlled by the Arduino Microcontroller  The Hammond Manufacturing Hard Wired 170 Series autotransformer will step down 115 V to 85 V  E100E SOLA HD autotransformer will step from 120 V to 264 V with the added 24 V winding

Feasibility Analysis of Design

Enclosure Material Selection

Enclosure and Safety Shield

Circuitry and Resistor Layout

Airflow Analysis

Airflow Analysis Cont’d

Preliminary Bill of Materials Line ItemPartVendorManufacturerQuantityPrice 16 ", 200 W Tubular ResistorFarnellVishay4~40 2Arduino MegaSparkFunArduino/ATMEL1~$ x 4 (characters) LCDSparkFunN/A1$18 4E075E - Autotransformer (High Line)NewarkSola-HD1$ C - Autotransformer (Low Line)MouserHammond1$ Ohm Tubular ResistorNewarkMulticomp2$5.66

Test Plan  Are the physical measurements ≤ the required dimension?  Measure the physical dimensions of the enclosure  Is the length of the test ≤ 5 min?  Time the entire test starting from power supply board set up finishing with the verification of entire unit test.  Is the Internal Temperature ≤ 50 Celsius?  Use a thermometer to measure  Are there indications of passing/failure of the test fixture?  Verify that the GUI lists pass/fail after a test in complete  Does the AC disengage when lid is open?  Verify power turns off when Safety Shield is opened  Is the AC voltage accessible?  Verify that the AC voltage is not accessible and is within the enclosure.  Is the safety enclosure transparent?  Verify that the Safety Shield is transparent and that the UUT is visible  Is the enclosure able to withstand a failure of the UUT?  Run stress tests and force tests on the base and the safety shield to see how much heat and force each can withstand  Has communication with the UUT been established?  Verify GUI indicates communication has been made  Has data been transmitted and received to/from the UUT?  Verify from GUI that data is being shared and received through the proper completion of the test  Has the UUT been successfully calibrated?  Verify there is an LED indicator that the UUT  Is there reason for failure feedback?  Verify that the GUI states a failure and where in the test it fails  Is there an indication that the UUT is on?  Verify that there is an LED indicator that the UUT is powered on, and a label saying ‘UUT Power On’  Is there an indication that the Test Bench is on?  Verify there is an LED indicator and a label saying ‘Test Bench Power On,’ and verify that the LED is on

Test Plan Cont’d  Are the number of test steps less than 5?  Complete set up and verify that the number of steps is less than five per each test (PS Board test, Controller Board Test, and Entire Unit Test)  Is there a quick (dis)connect?  Verify the connect and disconnect time is less than 5 seconds for each.  Is the time to set up less than 1 minute?  Time the setup of the enclosure  Is the set up difficult?  Based on time to set up and the number of steps, verify that those requirements are met, which will indicate ease of setup.  Is the test data being stored?  Connect SD card and USB to computer to see if test data is being stored  Is the budget under $1500?  Yes/No

Next 7 Weeks… Detailed Design Activities Updated Test Plan Finalize detailed CAD Active Loads PCB Layout Final schematics Bill of Materials Code Algorithms Prototyping Activities Active Load – Constant Current Active Load – Constant Voltage RS232 Communications CNC of Enclosure Materials Risk Assessment

Questions/Concerns?