1. Electrical Engineering 595 Capstone Design Team #4 Universal Power Box

2. Project Abstract
With the immense selection of electrical devices used in everyday lives, there can be much need to convert between one type of power source into another. The Universal Power Box (UPB) will combine many types of conversions into one product.
Cost, reliability, accuracy and safety are key aspects in the scope of this project.

3. Product Description
The user will attach a power source to the UPB, then enter a desired output power type and level.
The UPB will sense the type of power the user is inputting.
The UPB utilizes a Flyback DC to DC converter and an H-bridge inverter which doubles as a full-wave rectifier for power conversion.
The power converters are run by a microprocessor, which takes input from a variety of feedback sensors. All converters are pulse-width modulated.
An internal power supply, which draws from the power input by the user, powers the UPB.

4. Product Feature Set Desired Features of the UPB:
The UPB will be able to convert AC to DC, DC to AC, and DC to DC.
The user will interact with the UPB through an LCD and numeric keypad.
The UPB will draw its internal power supply from the input power.
The UPB will have a Total Harmonic Distortion sufficiently low for consumer electronics applications.
The UPB will have a weight, size, and durability that allows it to be portable.

5. Target Market
This product is being developed for use with consumer electronics in the North American environment.
Common applications will include:
Creating 120 VAC from a car outlet (for both 14Vdc and 42Vdc systems).
Replacing consumer electronic AC to DC adapters.

6. Staff Gerry Callison, BSEE Maria Schlicht, BSEE Ethan Spafford, BSEE
Expertise: Power Systems, Digital Design, Presentation
Experience: 3 years experience at Johnsons Controls
Maria Schlicht, BSEE
Expertise: Micro controllers, PLCs, Project Management, Technical Writing, Language Skills
Experience: 8 years experience at Rockwell Automation
Ethan Spafford, BSEE
Expertise: RF, Circuit Design, Optical Communication, PSpice Software

7. Staff Matt Risic, BSEE/BSCS Vanessa White, BSEE
Expertise: High Level Programming, Assembly, Computer Networks, Computer Organization
Experience: Two summers interning at Philips Advance Transformer
Vanessa White, BSEE
Expertise: Digital Design, Micro controllers, PLC Logic
Experience: One year experience at Harley Davidson

8. Team Logistics
Meetings: Held on a need basis, usually in the evenings of weeknights. Tasks were primarily delegated to individuals, to maximize productivity. On average, each team member spent about 10 hours per week on the project.
Decision making: Conesus/Majority vote.
Project duties:
Webmaster: Matt Risic
Archiver: Vanessa White
Presentation Manager: Gerry Callison
Report Manager: Ethan Spafford
Graphics Manager: Maria Schlicht

9. Product Performance Requirements
Input voltage ranges:
14-50Vdc
VAC
Maximum input current: 7 amps
Output power: 75 watts
Output voltage ranges:
Maximum output current: 5 amps
Total Harmonic Distortion < 5%

10. Product Standard Requirements
Operating Requirements
0-50 degrees Celsius
0-70% RH
Maximum product size 2000 cm^3
Maximum product mass 2kg
Maximum parts count 200
3 Years Component Life

11. Productization Aspects & Requirements
Legal/Ethical Aspects & Requirements
Includes UL labels
Includes safety labels (liability protection)
All labels and user manual in English and Spanish
Safety/Health Aspects & Requirements
Includes proper shielding
Safety directions in product manual

12. Productization Aspects & Requirements
Sustaining Aspects & Requirements
This product does not require field service
Design team will monitor field defects for future versions
Reliability Aspects & Requirements
1 year warranty standard
Products which fail under warranty should be returned for analysis.

13. Productization Aspects & Requirements
Environmental Aspects & Requirements
Proper disposal: Recycled, NOT thrown in general refuse
The following power and EMF tests should be used:
IEC
IEC
IEC
IEC EN

14. Block Diagram
Gerry
Matt
Maria
Ethan
Vanessa

15. Functional Block Description Agenda
Microprocessor - Matt
User Interface - Maria
Power Conversion - Gerry
Internal power & Cooling - Ethan
Sensor & I/O - Vanessa

16. Product Definition: User Requirements
Product: Universal Power Box
Industry Family: Consumer Electronics
Useful to eliminate the multitude of power adapters needed for many electronic devices so that they may be powered by any battery or standard wall plug regardless of the type of power required by the device
Intended for use in home electronics devices
The UPB will deliver power with simplicity!
Many different power adapters available, but none known that combine AC-DC, DC-AC, and DC-DC in one product

17. Project Selection
Best fit for scope of project and component availability
Fullest use of skills and experience of team
Major risks
Electrical Safety
Electronic Overload
Physical Durability
Other projects rejected for lack of variety in tasks and their limited scope
Decision unanimously supported by team
Selection Process
Majority vote after input from faculty advisors

18. 3 MODES OF OPERATION
AC to DC.
DC to DC.
DC to AC.

19. AC to DC operation overview
AC voltage applied to I/O AC.
Uncontrolled Inverter/Rectifier converts AC to DC.
Buck-Boost converter adjusts output DC voltage to user-defined level.

20. DC to DC operation overview
User inputs DC to I/O DC.
Buck-boost converter adjusts DC to user defined level of DC.
Inverter/Rectifier switches configure to pass through output DC without altering it.

21. DC to AC operation overview
User inputs DC through I/O DC.
Buck-boost converter adjusts level of DC necessary for proper AC output.
Inverter/Rectifier runs PWM switching to output AC.

22. TOP-LEVEL FUNCTIONALITY REQUIREMENTS
The user can input 14-50Vdc or VAC to get out 0-50Vdc or 0-120VAC.
Separate adapter cables will allow for various power supplies to be connected to the UPB
The UPB will sense the level/type of input power, then output a user-defined level/type of power.
The UPB will be able to output 150 Watts of power.
The UPB will be able to output 5 Amps of current.

23. Block Requirements

24. Power Control
Matt Risic

25. Power Control
Gerry
Matt
Maria
Ethan
Vanessa

26. Block Purpose
The Power Control is the center of the Universal Power Box
The programming is responsible for converting input waves into necessary output voltage waves
Microprocessor will control the LCD display based on user input from the keypad
Different scenarios will be performed based on the power conversion being performed

27. Standard Requirements Control
Humidity Range 0%RH to 70%RH
Block Cost <$15
Parts Count <20
Block Size <48cm2
Block Mass <95.5 grams
Max Power Consumption <20W
Operating Temperature Range 0C to 75C
Storage Temperature Range 0C to 75C
Operating Humidity %
Reliability (MTBF) 3 Years

28. Performance Requirements Control
Input Voltage V (+/- 3%)
Full Scale Output Voltage +3.3V (+/- 3%)
Minimum speed 1Mhz
Desired Memory 1K SRAM
Programming Language Assembly
Number of Registers 32

29. Input/Output Voltages
Sensor
AC Sensor
Switch Driver
0-3.3V
3.3V
Power Control
0-3.3 V 6V
Control Power
0.15 V
Cooling V
0.15V
LCD Display
Keypad

30. Microprocessor Selection
Atmel ATMega169v Microprocessor
Advanced RISC Architecture
130 Instruction Set
C and Assembly Coding
32 x 8 General Purpose Registers
16KB Programmable Flash
512 Bytes EEPROM
1KB SRAM
64 Pin Chip

31. Chip Size

33. CPU/ALU Timing Diagrams

34. SRAM Timing Diagram

35. Programming Examples

36. Memory Hierarchy

37. ATMega169v Operating Conditions
Operating voltage between V
Operating temperature between -40 to +85 degrees Celsius
Up to 1 MHz Clock Speed
Power Consumption
At 1MHz consumes 1.8V, 400uA
At 32 kHz consumes 1.8V, 20uA
Power-down Mode is 0.5uA at 1.8V

38. Microprocessor Selection
Selected over other considerations because of best benefits per cost ratio.
Available locally or over Internet
Dependable and respectable manufacturer.
Manuals, examples and tutorials readily available.

39. Programming Software AVR Studio 4.08
Integrated Coding, Compiling and Debugging Software
Configurable Memory
Support for C, Pascal, BASIC and Assembly
Simulate Port Activity Logging and Pin Input

40. Programming Software AVR Studio 4 Service Pack
Adds support for the ATMega family
Builds upon the AVR Studio 4 software
Improved documentation and help features

41. Programming Software AVR LCD Visualizer
Create and modify LCDs with editor
Debug and visualize with AVR plug-in
Real run-time updates

42. LCD Flowchart

43. Block Component Cost ATMega169v microprocessor - $10.81
STK500 Board - $79.00
STK502 Expansion Board - $99.00
AVR Studio 4.08 – FREE
AVR Studio 4 Service Pack – FREE
AVR LCD Visualizer - FREE

44. User Interface
Maria Schlicht

45. User Interface
Gerry
Matt
Maria
Ethan
Vanessa

46. User Interface

47. USER INTERFACE OVERVIEW
The user interface will contain a 12-key numeric keypad to enter the voltage desired by the user. It will also contain a 16 x 2 LCD display.
Display Capacity of 25 segment and 4 Common Terminals
The inputs include:
The User can select three modes of operation (AC–DC,DC-AC & DC-DC)
User can defined level/Type of power
The User will have access to review or modify terminal settings by NUMERIC keys, navigate through the configuration screen.
Electrical Safety for User

48. USER INTERFACE IMPORTANCE
Changing settings take affect immediately (without powering off the terminal)
User can reset the interface without having to remove and then re-apply power or battery.
User friendly

49. USER INTERFACE STANDARDS REQUIREMENTS
Proto Cost $ % Allocation 35.1%
Production cost $ % Allocation 5%
Proto Parts Count Unique Parts 0
Production Parts Count Unique Parts 0
Max. Product Size (L x W in cm) (7 x 2) LCD (5 x 6.8) Keypad
Max. Product Weight (kg) 0.50
Max. Power Consumption (W)
Max. Operating Temp Range (degrees °C) 0°C to 50°C
Min. Operating Humanity Rage (rh%) <95%, non-condensing
Reliability and Life (MTBF in yrs, %R 1 yr, %R 5yrs) 5 yrs, 1 yr at 2%, 5 yrs at 10%
Disposal/Recycle/Maintenance (# of recycles parts, Hazards) European Standard, prEN
Safety and Regulatory Standards UL508C/CSA 22.2

50. USER INTERFACE PERFORMANCE REQUIREMENTS
LCD Operating Values:
Logic Supply Voltage Range: V
LCD Supply Voltage Range: V
Input High Voltage VIH: V
Input Low Voltage VIL: 0.65V
Output High Voltage VOH: 2.3V
Output Low Voltage VOL: 0.5V
Max. Input Current IDD: 1.2mA
Temp. (Operating) TOPR: 0°C - 50°C
Temp. (Storage) TSTG: -10°C - 60°C
Viewable from 1 ft.
Keypad Operating Values:
Insulation Resistance:
> 1.01k at 500V
Max. Output Current IOUT: mA for .5 sec
Temp. (Operating) TOPR: °C - 70 °C
Temp. (Storage) TSTG: 150°C
Contact Bounce: < 10mS
Frequency: dB

51. USER INTERFACE BLOCK DIAGRAMS

52. USER INTERFACE PRODUCTIZATION REQUIREMENTS
User Interface Controls:
12-button keypad: Digits 0-9, Pound sign, and Start key.
Safety Features:
Illuminated display indicates voltage present
Temperature range as specified by overall product
Components to be chosen to comply with temperature requirements
Hand Assembly:
Keypad and LCD display manually assembled, all other components can be automatically installed.
Societal/legal/Monetary Aspects:
Pushbuttons (ergonomic & friendly)
Material Degradation
Rust and corrosion
Suitable for electrical conditions
Disposability/Recycle ability:
Parts recyclable as PCB assembly
Reliability:
Prototype: Length of project
Production: yr @ 2% %

53. KEYPAD SCHEMATICS

54. Inverter-Rectifier
Gerry Callison

55. Inverter-Rectifier
Gerry
Matt
Maria
Ethan
Vanessa

56. Inverter/Rectifier functionality
H-bridge topology- allows for one circuit to function as inverter or rectifier.
H-bridge topology features four power-electronic switches.
IRF740A MOSFET
Inverter- 2 phase pulse width modulated.
Rectifier- full wave, uncontrolled (meaning voltage level is not adjusted in this converter).

57. Inverter/Rectifier Interfaces
From Power Control: 0/3.3Vdc binary wave to drive PWM function.
Goes through IR2181 high/low driver.
To/from internal sensor: varying level of DC, depends upon user command.
To/from filter: varying power, depending on functionality.

58. Standard Requirements Inverter-Rectifier
Humidity Range 0 to 70 %RH
Block Cost <$6.00
Parts Count <30
Block Size <20cm2
Block Mass <100grams
Max Power Consumption <3W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %RH
Reliability (MTBF) 5 Years
Allocations
Cost 15%
Parts 15%
Unique Parts 14%
Power Cons. 20%
Mass 5%
Area PCB 12%

59. Performance Requirements Inverter-Rectifier
Input Voltage Vdc, VAC
Full Scale Output Voltage Vdc, VAC
Maximum Input current 5 amps
Maximum Output Current 5 amps
Maximum Power Passed 75 watts
Inverter/Rectifier Life 5 years
Amplitude Modulation Ratio .8
% Error <10%

60. SO WHERE DID THESE NUMBERS COME FROM !?!?!?!

61. Input Voltage: 14-170 Vdc, 108-132 VAC
108 VAC: 120 VAC – 10% = 108 VAC
132 VAC: 120 VAC + 10% = 132 VAC
14 Vdc: Voltage of current automotive systems
170 Vdc:
To achieve 132VAC out with Ma = .8
Vdc max = V1 ÷ Ma = 132 ÷ .8 = 165 ~ 170 Vdc

62. Output Voltage: 14-85 Vdc, 108-132 VAC
108 VAC: 120 VAC – 10% = 108 VAC
132 VAC: 120 VAC + 10% = 132 VAC
14 Vdc: Voltage of current automotive systems
119 Vdc:

63. Maximum Input Current = 5 amps Maximum Output Current = 5 amps Maximum Power Passed = 150 watts Amplitude Modulation Index = .8
5 amps: Agreed upon by group
75 watts: Agreed upon by group
.8 Amplitude Modulation Index:
Forces to harmonics to higher frequencies, where they are easily filtered
Causes Vin = 170 Vdc (V1 = Ma*Vdc), which components can easily handle.

64. TOPOLOGY

65. A standard H-bridge topology was used.

66. OPERATIONAL DIAGRAM

67. COMPONENT SELECTION

68. POWER SWITCHES (MOSEFETS)
REQUIREMENTS (with error margins):
Vdss of at least 350 Volts
Current of at least 8 amps
Gate threshold voltage of 3.3 Volts
Switching Frequency of at least 100kHz
CHOSE: International Rectifier IRF740A MOSFET, which exceeds all minimum requirements.
IRF740A features built in diode to always allow for current to flow from source to drain

69. MOSFET DRIVERS REQUIREMENTS:
3.3 Volt logic level
Maximum high-side voltage of at least 350 Volts
Switching frequency of at least 100kHz
CHOSE: International Rectifier IR2181 high and low side driver, which exceeds all minimum requirements.

70. DC to DC Converter
Gerry Callison

71. DC to DC Converter
Gerry
Matt
Maria
Ethan
Vanessa

72. DC to DC functionality
Unique Challenge: Because of multidirectional flow of power, both ends needed to function as inputs or outputs.
Solution: Dual ended flyback converter, which share some parts.
A flyback converter can raise or lower DC voltage to a sufficient gain.
Requires 2 IRFP350 MOSFETS.
This converter is where the voltage is adjusted to user-commanded level.

73. DC to DC interfaces
From Power Control: Vdc binary signal drives MOSFETs, manipulating output based upon duty cycle of signal.
MOSFETs driven from power control through IR2181 high and low side driver chip.
To/from DC sensor: Varying power, depending upon functionality.
To/from internal sensor: Varying level of DC, depending upon user command.

74. Standard Requirements DC to DC Converter
Humidity Range 0 to 70 %RH
Block Cost <$4.00
Parts Count <20
Block Size <20cm2
Block Mass <60grams
Max Power Consumption <3W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %RH
Reliability (MTBF) 5 Years
Allocations
Cost 10%
Parts 10%
Unique Parts 5%
Power Cons. 20%
Mass 3%
Area PCB 7%

75. Performance Requirements DC/DC Converter
Input Voltage Vdc
Maximum Input Current 5 amps
Full Scale Output Voltage Vdc
Maximum Output Current 7 amps
Maximum Power Passed 75 watts
Inverter/Rectifier Life 5 Years
% Error <10%

76. SO WHERE DID THESE NUMBERS COME FROM !?!?!?!

77. Input Voltage: 14-170 Vdc Output Voltage: 14-170 Vdc
14 Vdc: Voltage of current automotive systems
119 Vdc: Maximum output of Inverter/Rectifier
Output Voltage: Vdc
14 Vdc: Voltage of current automotive systems
170 Vdc: Required by Inverter/Rectifier to achieve 132 VAC

78. Maximum Input Current = 7 amps Maximum Output Current = 5 amps Maximum Power Passed = 75 watts
To achieve 14V to 170V conversion, maximum voltage amplification = 12.2
75 watts ÷ 132 VAC = .57 amps at max voltage
.57 amps * 12.2 = 7 amps
5 amps: Agreed upon by group
75 watts: Agreed upon by group

79. TOPOLOGY

80. Initially, a buck-boost topology was planned, but it was ruled out due to nonideal effects

81. A dual ended flyback topology was used

82. OPERATIONAL DIAGRAM

83. COMPONENT SELECTION

84. PULSE TRANSFORMER(S) REQUIREMENTS:
Turns Ratio of at least 8:1
ET constant of at least 350 V*uS
ET constant = pulse width*pulse magnitude
CHOSE: C&D Technologies 1003 (must cascade 3 to achieve 8:1 turns ratio).
Turns Ratio = 2:1:1 (when cascaded = 8:1:1)
ET = 400 V*uS

85. POWER SWITCHES (MOSEFETS)
REQUIREMENTS (with error margins):
Vdss of at least 350 Volts
Current of at least 9 amps
Gate threshold voltage of 3.3 Volts
Switching Frequency of at least 100kHz
CHOSE: International Rectifier IRF740A MOSFET, which exceeds all minimum requirements.
IRF740A features built in diode to always allow for current to flow from source to drain

86. MOSFET DRIVERS REQUIREMENTS:
3.3 Volt logic level
Maximum high-side voltage of at least 400 Volts
Switching frequency of at least 100kHz
CHOSE: International Rectifier IR2181 high and low side driver, which exceeds all minimum requirements.

87. Power
Ethan Spafford

88. Power
Gerry
Matt
Maria
Ethan
Vanessa

89. Standard Requirements Power
Humidity Range 0%RH to 70%RH
Block Cost <$20
Parts Count <28
Block Size <12cm2
Block Weight <500grams
Max Power Consumption N/A
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Reliability (MTBF) 1Year

90. Performance Requirements Power
Input Voltage voltage input by user
Full Scale Output Voltage Vdc (+/- 2%)
Control Power Life 2Years
Dual Power Supplies
Supply connects made to both DC I/O, AC I/O and 12V Battery
Switching circuit routes the user input voltage and disables output voltage connection
AC Input path: Solid State Relay-Transformer-Rectifier-Solid State Relay -voltage Regulator-Sensors/Micro-Controller/Cooling/etc
DC input path: Solid State Relay-Flyback Converter-Solid State Relay-Voltage Regulator-sensors/microcontroller/Cooling/etc
Immediately after startup the AC or DC input will act as power supply to the rest of the unit

91. Control Power Circuit

92. Input Power Select Input Selected from Key Pad – Signal sent from PC
Inverting Schmitt Trigger sends signals to solid state relays and to inverter to solid state relays
PC Low Signal opens DC
PC High Signal opens AC

93. DC Input Flyback Converter
Converts Input DC Voltage from 14-50V to 12.6V
Average Input current between 75mA-270mA

94. AC Input Step Down Transformer Rectifier
Converts 120AC to 12.6Vdc
Transformer steps down voltage from 170Vpk to 15Vpk
Rectifier
Vo,max = 13.6V
ΔV = 1.3
Vo,avg = 12.3V

95. Component Costs Component amount Total
Solid State Relays(low Voltage) 3 ≈$18.50
Solid State Relay(high Voltage) 1 ≈$21.00
AC Transformer 1 ≈$6.00
Fly-Back Transformer 1 ≈$6.00
Diodes/Resistors/Caps 18 ≈$5.00
Op amps 2 ≈$1.50
MOSFET 1 ≈$1.50

96. Temperature Control AC Filter
Ethan Spafford

97. Temperature Control AC Filter
Gerry
Matt
Maria
Ethan
Vanessa

98. Standard Requirements Temperature Control & AC Filter
Humidity Range 0%RH to 70%RH
Block Cost <$15
Parts Count <7
Block Size <40cm2
Block Weight <100grams
Max Power Consumption <2W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Reliability (MTBF) 2 Years

99. Performance Requirements Temperature Control & AC Filter
Input Voltage +12V (+/- 2%)
Temp Cont Life 2Years
Fan and Heat sinks
PCB designed for ideal heat dissipation
Temperature warning and shut down
When Tmax reached warning light notifies user to turn off unit
Unit shuts itself off when Tmax is reached
AC Filter
Input Voltage Vdc or 120VAC
Full Scale Output Voltage Vdc or 120VAC
Filter Life 2 Years

100. AC Filter Circuit Diagrams
Single Low-Pass RLC Filter
Use potentiometer
R obtained experimental
If necessary ladder network or composite filter can be easily added
ωc slightly higher so that operating frequency is below the “knee” of attenuation (100Hz)

101. Component Costs Component amount Total
Inductors/Resistors/Caps 18 ≈$2.50
Fan/HeatSinks/TmaxIC 6 ≈$15

102. Sensors
Vanessa White

103. Sensors Overview
Sensors provide electrical isolation from input power to controller components
Measure voltage level of input – output a reduced level signal to processor
Take advantage of on-board ADC in processor

104. DC Sensor
Gerry
Matt
Maria
Ethan
Vanessa

105. DC Sensor Considerations
Maximum tolerable signal to processor
Nominal current expected for measurement
Large input range makes determination of nominal voltage for sensor input difficult – may introduce large error

106. Standard Requirements DC Sensor
Humidity Range 0%RH to 70%RH
Block Cost (Production) <$10
Parts Count <24
Block Size <40 cm2
Block Mass <140 grams
Max Power Consumption <3 W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %
Reliability (MTBF) 2 Years

107. Performance Requirements DC Sensor
Input Voltage: 14-50VDC
Full Scale Output Signal Voltage (measured V to processor): +3.3V (+/-10%)
Supply Voltage: +12V
Current Input: 10mA (nominal)
Current Consumption: < 50mA
Response Time : < 2ms
25C: < +/- 5%
Linearity: < 0.5%

108. DC Sensor Block Interfaces
From Input/Output: Receives input power (14-50VDC)
From Internal Power: Receives +12VDC power supply
To Controller: Passes voltage level signal (V measured, 0-3.3VDC)
Internal Power +12V
0-3.3V
14-50 VDC
DC Sensor
Controller

109. Detail Design DC Sensor
LEM Transducer – LV 20-P
R1 – Calculated based on expected voltage to be measured and nominal current of 10mA

110. AC Sensor
Gerry
Matt
Maria
Ethan
Vanessa

111. AC Sensor Considerations
AC input only
Nominal current expected for measurement
Maximum tolerable signal to processor

112. Standard Requirements AC Sensor
Humidity Range 0%RH to 70%RH
Block Cost (Production) <$10
Parts Count <24
Block Size <40 cm2
Block Mass <140 grams
Max Power Consumption <3 W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %
Reliability (MTBF) 2 Years

113. Performance Requirements AC Sensor
Input Voltage: 120VAC (+/- 10%)
Output Signal Voltage (to processor): 3.3VDC
Supply Voltage: +12VDC
Current Input: 10mA (nom)
Current Consumption: < 50mA
Response Time : < 2ms
25C: < +/- 5%
Linearity: <0.5%

114. AC Sensor Block Interfaces
To/From Input/Output: Receives input power (nominally 120VAC)
From Internal Power: Receives +12VDC power supply
To Control: Passes voltage level signal (V measured, 0-3.3VDC)
Internal Power +12V
0-3.3V
120 VAC
AC Sensor
Controller

115. Detail Design AC Sensor
LEM Transducer – LV 20-P
R1 – Calculated based on expected voltage to be measured and nominal current of 10mA

116. Internal Sensor
Gerry
Matt
Maria
Ethan
Vanessa

117. Internal Sensor Overview
Monitors internal voltage between DC/DC Converter and Inverter-Rectifier
Passes measured voltage level to processor for verification of level within tolerances and any corrections to be made

118. Internal Sensor Considerations
Bi-directional system – measures both DC and AC levels
Response time for corrections

119. Standard Requirements Internal Sensor
Humidity Range 0%RH to 70%RH
Block Cost (production) <$20
Parts Count <24
Block Size <40 cm2
Block Mass <140 grams
Max Power Consumption <3 W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %
Reliability (MTBF) 2 Years

120. Performance Requirements Internal Sensor
Input Voltage : 14-50VDC , 120VAC (+/-10%)
Full Scale Output Signal Voltage (to Processor): +3.3VDC
Supply Voltage: +12VDC
Current Input: 10mA (nom)
Current Consumption: < 50mA
Response Time : < 2ms
25C: < +/- 5%
Linearity: <0.5%

121. Internal Sensor Block Interfaces
From Internal Power: Receives +12VDC power supply
To Power Control: Passes measured voltage level signal (0-3.3VDC)
To/From DC/DC Converter: Receives or sends internal DC power (14-50VDC)
To/From Inverter-Rectifier: Receives or sends internal AC power (nominally 120VAC)
Internal Power +12V
0-3.3V
Controller
Inverter-Rectifier
120 VAC
Internal Sensor
DC-DC Converter
14-50 VDC

122. Detail Design Internal Sensor
LEM Transducer – LV 20-P
R1 and R2– Calculated based on expected voltage to be measured and nominal current of 10mA

123. I/O Vanessa White

124. I/O Overview
Provides circuit protection for sensors and electronic components of power conversion blocks
Switching circuit prevents power flow into electronic components until measured voltage is determined acceptable

125. DC I/O Considerations Polarity reversal of input voltage
Electrostatic discharge
Inrush current
Driving switch from controller current/voltage

126. Standard Requirements DC I/O
Humidity Range 0%RH to 70%RH
Block Cost (Production) <$10
Parts Count <24
Block Size <40 cm2
Block Mass <140 grams
Max Power Consumption <3 W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %
Reliability (MTBF) 2 Years

127. Performance Requirements DC I/O
External Input Voltage: VDC
Full Scale Output Voltage: +50VDC
Control Voltage: 3.3VDC
Input/Load Current: < 10A
Switching Speed (Pickup/Dropout Time): < 3ms
Pickup Voltage: 4VDC (max)
Dropout Voltage: 1VDC (min)

128. DC I/O Block Interfaces
To/from Input/Output: Receives DC input power (14-50VDC) or passes output power (14-50VDC)
From Controller: Receives digital signal based on measured voltage (Vok)
To/from DC/DC Converter: Passes input power (14-50VDC); passes output power to output
DC-DC Converter
14-50 VDC
14-50 VDC
0/3.3V
DC I/O
Controller

129. Detail Design DC I/O
Solid State Relay – current limiting and switching for input power flow
BJT driver - drive current to relay
Capacitance – ESD
Thermistor – current limiting for sensors

130. AC I/O Considerations
AC input only, but can be DC or AC out, depending on mode (DC-DC or DC-AC)
Out of range input voltage (European or other supply voltage outside nominal 120VAC not permitted to pass)
Electrostatic discharge
Inrush current

131. Standard Requirements AC I/O
Humidity Range 0%RH to 70%RH
Block Cost (Production) <$10
Parts Count <24
Block Size <40 cm2
Block Mass <140 grams
Max Power Consumption <3 W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Operating Humidity %
Reliability (MTBF) 2 Years

132. Performance Requirements AC I/O
External Input Voltage: 120VAC (+/- 10%)
Full Scale Output Voltage: 132VAC,+50VDC
Control Voltage: 3.3VDC
Input/Load Current :< 8A
Switching Speed (Pickup/Dropout Time): < 3ms
Pickup Voltage: 4VDC (max)
Dropout Voltage: 1VDC (min)

133. AC I/O Block Interfaces
To/From Input/Output: Receives input power (nominally 120VAC) or passes output power (nom. 120VAC or VDC)
From Control: Receives digital signal based on measured voltage (Vok)
To/From AC Filter : Passes input power (nominally 120VAC); passes output power to output
AC Filter
120 VAC
14-50 VDC / 120VAC
0/3.3V
AC I/O
Controller

134. Detail Design AC I/O
Solid State Relay – current limiting and switching for input power flow
BJT driver - drive current to relay
Capacitance – ESD
Thermistor – current limiting for sensors

135. Timeline

136. Time Line Summary Man Completion Hours Date Basic Product Definition
Compilation/Definition of /4
Team Logistics/Operation
Team Resources Allocation /15
Product Level Requirements /4
Standard/Performance
Proto-Type Block Diagram
Block Diagram with /5
Assignments and Interfaces
Block Review Team T/A /18
Productization
Develop Product Level /10
Verification and Requirement Plan
Compilation/Development of MFG 19 4/30
Processes, Block Diagrams
Design Plans for Testing Disposal /19
and Service

137. Time Line Summary Documentation Est.Man Completion Hours Date
Proto-Typing
Integrate BL Proto-Type into /24
Product Level Proto-type
Testing of Fully Integrated /24
Proto-type
Execution of PL Verification/Validation 14 4/30
Plan
Compilation of Resource Expenditure /5
and Budget Chart
Documentation
Compilation of Individual /5
MSWord Reports
Compilation of Final MSWord Report /10
and PowerPoint Slide Show