1. Background Customer Requirements Final Test Fixture Subsystems P16203: Smart Power Supply Test Bench CUSTOMER: Bear Power Supplies, Phelps, NY PROBLEM: The current testing procedure is long and tedious, taking about an hour to complete. With many units to be tested, there is a need for a more efficient procedure. MISSION: Reduce testing time, make the system should be semi- automatic, safe from high voltage, and easy to use. TEAM MEMBERS Andre Pelletreau (EE) Kerry Oliveira (EE) Jeremy Willman (ME) Radoslaw Maslanka (EE) Vincent Stowbunenko (EE) LCD Screen Fun Facts!!! 1,008,000 mg (at least) of Caffeine consumed Two team members are going to work at the same company post-grad 2 ounces of solder used throughout board construction For more information, visit our website using the QR code above ACKNOWLEDGMENTS Leo Farnand (MSD Guide) Danielle Sklepik Ali Putney Laura Joslyn RIT machine shop CONTROLLER BOARD Contains Arduino microcontroller Makes system semi-automatic Dictates the necessary voltage, current, and resistance Saves test data RELAY BOARD Responds to Arduino commands Automatically switches to necessary autotransformer, choosing AC voltage LOAD BOARD Responds to Arduino commands Constant current/constant voltage, adjusts load for test SOLIDWORKS DESIGN Butterfly locks and barrel bolts were chosen in order to make sure enclosure is fully locked and safe Assembled using L brackets for stability and support as well as being lightweight Slots were designed and cut for fans, LCD screen, AC connector and SD card attached HEAT TRANSFER ANALYSIS From this analysis, five 45 CFM fans were selected for intake and exhaust to stay under 50 degrees C. Individual 25 CFM fans as well as heat sinks were used to cool down the boards designed Concept Selection SAFETY A two part enclosure was designed, an Aluminum 6016 base with a Lexan scatter shield An emergency stop button quickly cuts power from the enclosure Reed switch to prevent opening of the enclosure while high voltage is supplied FUNCTIONALITY LCD screen for feedback on when/why a test failed LED indicators telling when system is ON/OFF SD card for data storage AC voltage monitor displaying current through system DURABILITY Aluminum base and Lexan scatter shield are durable and can withstand heat and if needed, a rarely occurring explosion CONVENIENCE Test procedures less than 5 steps total Test time less than 10 minutes Lexan scatter shield is transparent, Unit Under Test (UUT) is visible LCD SCREEN Provides feedback to operator on the current test Displays test status LEFT PICTURE Power MOSFETs on load board and load resistors generate a lot of heat Fans are attached to dissipate heat Autotransformers choose AC voltage Controller board makes system semi- automatic RIGHT PICTURE The right picture shows the metal base and Lexan scatter shield The scatter shield is transparent, and protects from any failure Emergency stop button will shut down the system Scatter Shield Emergency Stop Button Controller Board Load Board Load Resistors Metal Base Autotransformers Relay Board Fans LCD Screen AC Voltage Meter