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

2. 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

3. 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

4. Contact Info
Gerry Callison
Maria Schlicht
Ethan Spafford
Matt Risic
Vanessa White
Phone: (414)
Phone: (414)
Phone: (262)
Phone: (262)
Phone: (608)

5. Weekly Availability Worksheet
Gerry Callison
Maria Schlicht
Ethan Spafford
Matt Risic
Vanessa White
Time 1: Monday nights Time 2: Friday any
Time 3: Saturday any
Time 1: Monday after 5p Time 2: Tue after 4p
Time 3: Fridays after 4p
Time 3: Fridays any Time 4: Sat any
Time 1: Monday after Time 2: Tues any
Time 3: Thursday 1-6
Time 1: Monday after 5:30 Time 2: Fri after 5
Time 3: Saturday any Time 4: Sunday any

6. Weekly Project Meeting Plan
Weekly Meeting 1: 3rd Floor Lab, Monday 5-7 PM
Owner: Gerry Callison
Weekly Meeting 2: 3rd Floor Lab, Tues 12-2 PM
Owner: Matt Risic
Weekly Meeting 3: 3rd Floor Lab, Friday 12-2 PM
Owner: Ethan Spafford
Weekly Meeting 4: 3rd Floor Lab, Sat 12-2 PM
Owner: Maria Schlicht

7. Total Resources Estimate
400 Manhours, approximately 80 per member
$300 or key part availability for material and prototyping

8. Information Media Roles
Website URL and Web master: Matt Risic
Project Archiver: Vanesssa White
Presentation Mgr: Gerry Callison
Report Mgrs: Maria Schlicht/Ethan Spafford

9. 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

10. Timeline February March April May Define Initial Design Component
Selection
Build Prototype
Verification
Refine
Design
Documentation

11. Time Line Summary Man Completion Hours Date Basic Product Definition
Compilation/Definition of /4
Team Logistics/Operation
Team Resources Allocation 1 2/15
Product Level Requirements /4
Standard/Performance
Proto-Type Block Diagram
Block Diagram with /5
Assignments and Interfaces
Block Review Team T/A 1 2/18
Productization
Develop Product Level /10
Verification and Requirement Plan
Compilation/Development of MFG /30
Processes, Block Diagrams
Design Plans for Testing Disposal 4 4/19
and Service

12. 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 2 4/30
Plan
Compilation of Resource Expenditure 1 5/5
and Budget Chart
Documentation
Compilation of Individual /5
MSWord Reports
Compilation of Final MSWord Report 1 5/10
and PowerPoint Slide Show

13. 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

14. Refined Block Diagram
Gerry
Matt
Maria
Ethan
Vanessa

15. 3 MODES OF OPERATION
AC to DC.
DC to DC.
DC to AC.

16. 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.

17. 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.

18. 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.

19. TOP-LEVEL FUNCTIONALITY REQUIREMENTS
The user can input 0-50Vdc or 0-120VAC 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.

20. Block Requirements

21. Power Control
Matt Risic

22. Power Control
Gerry
Matt
Maria
Ethan
Vanessa

23. 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.
This will vary from mode of operation.

24. ATMega88 Microprocessor
Uses RISC Architecture
131 Instruction Set
C and Assembly Coding
32 x 8 General Purpose Registers
8KB Programmable Flash
512 Bytes EEPROM
1KB SRAM
28 Pin Chip

25. ATMega88 Operating Conditions
Operating voltage between V
Operating temperature between -40 to +85 degrees Celsius
V, V
At 1MHz consumes 1.8V, 240uA
At 32 kHz consumes 1.8V, 15uA
Power-down Mode is 0.1uA at 1.8V

26. 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.

27. AVR Studio 4 Integrated Coding, Compiling and Debugging Software
Configurable Memory
Support for C, Pascal, BASIC and Assembly
Simulator Port Activity Logging and Pin Input

28. Standard Requirements Power Control
Humidity Range 0%RH to 70%RH
Block Cost <$20
Parts Count <30
Block Size <48cm2
Block Mass <95.5 grams
Max Power Consumption <20W
Operating Temperature Range 5C to 35C
Storage Temperature Range 0C to 50C
Operating Humidity %
Reliability (MTBF) 3 Years

29. Performance Requirements Power Control
Input Voltage V (+/- 3%)
Full Scale Output Voltage +5V (+/- 3%)
Interfaces with User Interface, Control Power, Switch Driver, AC Sensor and Internal Sensor

30. Inverter-Rectifier
Gerry Callison

31. Inverter-Rectifier
Gerry
Matt
Maria
Ethan
Vanessa

32. 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, 400V, 10A, Vgth=2-4V
Inverter- 2 phase pulse width modulated.
Rectifier- full wave, uncontrolled (meaning voltage level is not adjusted in this converter).

33. Inverter/Rectifier Interfaces
From Power Control: 0/3.3Vdc binary wave to drive PWM function.
MOSFET can be driven directly from Power Control (no driver needed).
To/from internal sensor: varying level of DC, depends upon user command.
To/from filter: varying power, depending on functionality.

34. 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%

35. Performance Requirements Inverter-Rectifier
Input Voltage Vdc, 0-120VAC
Full Scale Output Voltage 0-50Vdc, 0-120VAC
Inverter/Rectifier Life 5 Years
% Error <10%

36. DC to DC Converter
Gerry Callison

37. DC to DC Converter
Gerry
Matt
Maria
Ethan
Vanessa

38. DC to DC functionality
Unique Challenge: Because of multidirectional flow of power, both ends needed to function as inputs or outputs.
Solution: Dual Buck-Boost converters, which share some parts.
A buck-boost converter can raise or lower DC voltage.
Requires 2 IRF740A MOSFETS.
This converter is where the voltage is adjusted to user-commanded level.

39. DC to DC interfaces
From Power Control: Vdc binary signal drives MOSFETs, manipulating output based upon duty cycle of signal.
MOSFETs driven directly from power control.
To/from DC sensor: Varying power, depending upon functionality.
To/from internal sensor: Varying level of DC, depending upon user command.

40. 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%

41. Performance Requirements DC/DC Converter
Input Voltage Vdc, 0-120VAC
Full Scale Output Voltage 0-50Vdc, 0-120VAC
Inverter/Rectifier Life 5 Years
% Error <10%

42. User Interface
Maria Schlicht

43. User Interface
Gerry
Matt
Maria
Ethan
Vanessa

44. User Interface

45. User Interface Overview
The User can select three modes of operation (AC–DC,DC-AC & DC-DC)
User can defined level/Type of power
The User can access to review or modify terminal settings by using the up and down arrows keys, navigate through the configuration screen.
Electrical Safety for User

46. User Interface Importance
Changing settings take affect immediately (without powering off the terminal)
User can reset the user interface without having to remove and then re-apply power or battery.
User friendly

47. Standard Requirements User Interface
Humidity Range 0%RH to 70%RH
Block Cost $10.00
Parts Count 4
Block Size (H) x 111(W)x 48(D) mm
Block Mass grams
Max Power Consumption W max. (0.105
Operating Temperature Range 0˚ C to 55˚C
Storage Temperature Range -20˚C to 85˚C
Operating Humidity 5 to 95% at 0˚ to 55˚C
Heat Dissipation W (8.5 BTU/Hour)
Reliability (MTBF) 5 Years
Allocations
Cost 25 %
Parts 5 %
Unique Parts 5 %
Power Cons. 5 %
Mass 5 %
Area PCB 5 %

48. Performance Requirements User Interface
Input Voltage +24V (+/-5%)
Full Scale Output Voltage +24V (+/-12%)
User Interface Life 5 Years
% Error 10%
Display (type) Liquid Crystal Display (LCD) with LED Backlighting
Display (size) 73mm (w) x 42mm (h)
Certifications UL
CE marked for all applicable
CSA (c-UL Class I Div 2 Hazardous)

49. AC Filter
Ethan Spafford

50. AC Filter
Gerry
Matt
Maria
Ethan
Vanessa

51. Standard Requirements AC Filter
Humidity Range 0%RH to 70%RH
Block Cost <$20
Parts Count <20
Block Size <40cm2
Max Power Consumption <2W
Operating Temperature Range 0C to 50C
Storage Temperature Range 0C to 50C
Reliability (MTBF) 2 Years
Allocations
Cost 5%
Parts 10%
Unique Parts 12%
Power Cons. 1%
Mass 2%
Area PCB 5%

52. Performance Requirements AC Filter
Input Voltage Vdc or 0-120VAC
Full Scale Output Voltage Vdc or 0-120VAC
Filter Life 2 Years
Forces non-linear load to draw sinusoid current
Couple with passive filters to remove noise from APF and harmonics from INV/RECT
Acts in both directions:
-AC input – creates cleaner voltage for Rectifier
-AC output – forces non–linear load to draw sinusoid
Disadvantages:
-May drastically increase cost as well as complexity of controller programming
-Passive filter designs made in parallel in event APF becomes overly complex.

53. Control Power
Ethan Spafford

54. Control Power
Gerry
Matt
Maria
Ethan
Vanessa

55. Standard Requirements Control Power
Humidity Range 0%RH to 70%RH
Block Cost <$20
Parts Count <20
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
Allocations
Cost 10%
Parts 10%
Unique Parts 12%
Power Cons. N/A
Mass 10%
Area PCB 5%

56. Performance Requirements Control Power
Input Voltage voltage input by user
Full Scale Output Voltage Vdc (+/- 2%)
Additonal voltage levels may be needed as sensors are determined.
Control Power Life 2Years
Dual Power Suppies
Supply connects made to both DC I/O and AC I/O
Switching circuit routes the user input voltage and disables output voltage connection
AC Input path: transformer-rectifier-voltage/Regulator-Sensors/MicroController/PowerFilter/etc
DC input path: amplifier-voltage/regulator-sensors/microcontroller/powerfilter/etc
If battery becomes necessary
Immediately after startup the AC or DC input will act as power supply to the rest of the unit as well as the battery charger.

57. Temperature Control
Ethan Spafford

58. Temperature Control
Gerry
Matt
Maria
Ethan
Vanessa

59. Standard Requirements Temperature Control
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
Allocations
Cost 1%
Parts 2%
Unique Parts 2%
Power Cons. 1%
Mass 1%
Area PCB 1%

60. Performance Requirements Temperature Control
Input Voltage +5V (+/- 5%)
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

61. Sensors
Vanessa White

62. Input Sensors Overview
Provide electrical isolation from input power to electronic components
Measure voltage level of input – output a reduced level signal to processor

63. DC Sensor
Gerry
Matt
Maria
Ethan
Vanessa

64. DC Sensor Considerations
Polarity reversal of input voltage
Maximum tolerable signal to processor
Large input range makes determination of nominal voltage for calculating input resistance difficult – may introduce large error

65. DC Sensor Block Interfaces
To/from Input/Output: Receives or passes input/output power (0-50VDC)
From Control Power: Receives +12VDC power supply
To Power Control: Passes voltage level signal (0-5VDC)
To/from DC/DC Converter: Passes input power (0-50VDC) after processor determines it is within acceptable limits; passes output power to output

66. Standard Requirements DC Sensor
Humidity Range 0%RH to 70%RH
Block Cost <$2
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
Allocations
Cost 5%
Parts 12%
Unique Parts 12%
Power Cons. 10%
Mass 7%
Area PCB 10%

67. Performance Requirements DC Sensor
Input Voltage VDC
Full Scale Output Signal Voltage (to processor) V (+/-10%)
Full Scale Output Voltage (to DC/DC converter) V
Supply Voltage V
Current Consumption < 20mA
DC Sensor Life 2 Years

68. AC Sensor
Gerry
Matt
Maria
Ethan
Vanessa

69. AC Sensor Considerations
Out of range input voltage (European or other supply voltage outside nominal 120VAC not permitted to pass)
Input power surges or dips (response time)
Takes advantage of on-board ADC in processor

70. AC Sensor Block Interfaces
To/From Input/Output:Receives or passes input/output power (nominally 120VAC)
From Control Power: Receives +12VDC power supply
To Power Control :Passes voltage level signal (0-5VAC)
To/From AC Filter : Passes input power (nominally 120VAC) after processor determines it is within acceptable limits; passes output power to output

71. Standard Requirements AC Sensor
Humidity Range 0%RH to 70%RH
Block Cost <$3
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
Allocations
Cost 7%
Parts 12%
Unique Parts 13%
Power Cons. 10%
Mass 7%
Area PCB 10%

72. Performance Requirements AC Sensor
Input Voltage VAC (+/- 10%)
Full Scale Output Signal Voltage (to processor) VAC,+5VDC (+/- 5%)
Full Scale Output Voltage (to Inverter-Rectifier) VAC
Supply Voltage VDC
AC Sensor Life 2 Years

73. Internal Sensor
Gerry
Matt
Maria
Ethan
Vanessa

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

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

76. Internal Sensor Block Interfaces
From Control Power: Receives +12VDC power supply
To Power Control: Passes voltage level signal (0-5VAC or 0-5VDC)
To/From DC/DC Converter: Receives or sends internal DC power (0-50VDC)
To/From Inverter-Rectifier: Receives or sends internal AC power (nominally 120VAC)

77. Standard Requirements Internal Sensor
Humidity Range 0%RH to 70%RH
Block Cost <$3
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
Allocations
Cost 7%
Parts 12%
Unique Parts 13%
Power Cons. 10%
Mass 7%
Area PCB 10%

78. Performance Requirements Internal Sensor
Input Voltage VDC , VAC (+/-10%)
Full Scale Output Signal Voltage (to Processor) VAC, +5VDC (+/-5%)
Full Scale Output Voltage (to Inverter-Rectifier or DC/DC Converter) VDC , 0-120VAC
Supply Voltage VDC
Internal Sensor Life 2 Years

79. Power Consumption by Block
Control Power <20W
Inverter-Rectifier <3W
User Interface 2.5W
AC Filter <1W
DC/DC Converter <3W
DC Sensor <3W
Internal Sensor <3W
AC Sensor <3W
Cooling <1W
Control Power <10W
Total Power: <49.5W