1. Battery Charging System for Toy Truck
Capstone Design Project Spring 2007
AKA: Chain Saw

2. Kassie Shore Mark Noller Eric Fitch Josh Siehoff
Team #4: Staff
Kassie Shore
Mark Noller
Eric Fitch
Josh Siehoff
BSEE

3. Team #4: Expertise & Experience
Expertise: Soldering, PLC Programming, Project Manager
Experience: 4 Coop Semesters at B&S
Expertise: Soldering, EMC
Experience: 4 year at Harley
Expertise: Soldering, Microcontroller, Elec/Mech Tech
Experience: Military, Industrial Tech
Expertise: Flying Planes
Experience: Pilot
Kassie Shore
Mark Noller
Eric Fitch
Josh Siehoff

4. Team #4: Weekly Availability Worksheet
Kassie Shore
Mark Noller
Eric Fitch
Josh Siehoff
15-20 hrs/week
20 hrs/week
15 hrs/week

5. Team #4: Weekly Project Meeting Plan
Weekly Meeting 1: UWM, Wednesday 5:00-6:30 PM Kassie, All, Discuss Roles and Project Ideas
Weekly Meeting 2: UWM, Wednesday 5:00-6:30 PM Kassie, All, Needs for Project and Start Design
Weekly Meeting 3: UWM, Wednesday 5:00-6:30 PM Kassie, All, Continue Design and Split up the Project
Weekly Meeting 4: UWM, Wednesday 5:00-6:30 PM
Kassie, All, TBD
Weekly Meeting 5: UWM, Wednesday 5:00-6:30 PM
Weekly Meeting 6: UWM, Wednesday 5:00-6:30 PM

6. Team #4: Total Resources
60 hrs/week
$100-$1000+ pending sponsorship

7. Team #4: Decision Making
Our team will make decisions by consensus.
If we can not come to a consensus, we will seek our Lab Assistant.
The last option in our decision making process will be the Professor/Lecturer.

8. Emergency Vehicle Early Warning System
Control Unit
Heads-Up Display
Transmitter
Receiver
Power Source
Power Source
Product Description
Alerts traffic to oncoming emergency vehicles.
Control unit on emergency vehicles turns on when siren and lights are active.
Receiver and heads-up display are automatic.
Benefits
Increases time for motor vehicle get out of the way.
Decreases Emergency vehicles response time.
Major External Electrical and User Interfaces
Heads-up Display
Power switches
Mute/Activate button
External Power Inputs and Outputs
Uses 12 VDC vehicle power
RF signal output/transmitter

9. Game Whistle Clock Synchronizer
Whistle/Sensor
Clock Control
Transmitter
Receiver
Power Source
Power Source
Product Description
Synchronizes the referee whistle and the scorers clock
When the whistle is blown to stop play the clock will automatically stop
When the whistle is blown to start play the clock will automatically stop
Benefits
Eliminates the human time delay
Improves the integrity of the game.
Major External Electrical and User Interfaces
Whistle
On/Off switch
Clock control on scorer’s table
External Power Inputs and Outputs
Power source for whistle is 12VDC battery
Power source for scorers station is 120VAC with set down transformers.

10. Electronic Fuel Tank Switching Unit
Fuel Level Sensor
Digital Screen
Battery
Tank Switching Unit
Product Description
This unit would switch between fuel tanks in a small general aviation aircraft based on a timer input from the user. In the event that a tank gets too low for safe operation, the unit would automatically switch tanks.
Benefits
This unit would alleviate some workload in the cockpit.
The device would also eliminate errors in forgetting to switch tanks preventing fuel starvation.
Major external electric & user interfaces
The user interface would be a digital screen allowing the user to enter in the amount of time that they wanted to burn off of each tank. Thirty minutes would be entered if the user wanted to switch fuel tanks every half an hour.
The electronic unit would have a manual override.
External Power Inputs and Outputs
Power would be supplied by the 12-volt system that is standard to small aircraft

11. Battery Charging System for Toy Truck
Power Supply
Control
Inverter
Inductive Coils
Product Description
Toy truck battery charger
Slow trickle charge through induction connection
Benefits
Rechargeable battery more cost effective
Eliminates the need for additional connections to charge battery
Major External Electrical and User Interfaces
LEDs display the amount of time the battery has been on charge.
Inductive coils used for wireless charging.
External Power Inputs and Outputs
Power source on toy is the vehicle power
Induction loops pass the current to the toy vehicle for charging the batter

12. Project Selection
Project was selected because funding exists and completion is feasible. The scope of the project can be adjusted with minimal difficulty. The size of the project fits the team size and interests.
The major risks are in dealing with batteries and antennas.
The other projects were rejected due to lack of funding and inability to scope the project.
The project was unanimously supported by the team.

13. Proposed Product Summary Battery Charging System for Toy Truck
This battery charging system will allow the user to trickle charge without physical connections to the toy truck.
Primary benefit is to charge without having to physically connect to the charging system.
Other benefits:
Shows the length of time the battery has been on charge.
Quick, easy to use
Low maintenance
Intended application is to charge the battery on the truck for extended use.
The truck becomes fully automatic without having to connect up to the charging system.
The induction charging system is an unique idea.
Automotive/Entertainment/Promotional Industries

14. Vehicle Battery Charger
Power Supply
Inverter
Induction Loops
Vehicle Connection
Control w/LED Display

15. Block Diagram Description
Block Name
Owner
Brief Description
Of Block Function
Power
Interfaces
Digital
Analog 1
Power supply
Kassie
Converts residential 120VAC power to required voltage needed to power the charging circuit and its components.
In: 120V AC
Out: 12 VDC
In: None
Out: None 2
Inverter
Josh
Converts the input of 12VDC from the power supply to 12VAC at a given frequency in order to put the power through the coils.
In: 12VDC
Out: 12 VAC
In: 125Khz 5VDC
Out: Variable VAC control signal 3
Control
Eric
Regulates outgoing power to the toy vehicle depending on mode of operation and current battery state.
In: 12 VDC
Out: 5VDC, 125Khz 5VDC
In: Variable AC control signal 4
Induction loops
Mark
Transfer power from stationary unit to toy vehicle and rectify to DC voltage without having a physical wire connection.
In: 12 VAC

16. Requirements System – Standard Requirements
Market
Material Cost: $100
Manufacturing Cost: $50
Power
Energy Source: AC
Voltage Range: VAC – 132VAC
Power: W
Mechanical
Energy Source Connector: NEMA 5-15
Environmental
Min Oper Ambient Temp Range: 0 – 50C
Min Oper Ambient Humidity Range: 0 – 85%
Min Storage Ambient Temp Rang: -20 – 70C
Min Storage Ambient Humidity Range: 0 – 90%

17. Requirements System – Standard Requirements Cont.
Safety
Must comply with Part 15 of the FCC Rules regarding radio frequency devices
Manufacturing
Part count is undetermined
Life Cycle
Service Strategy
Repair at factory
Product disposal
Return to manufacturer

18. Requirements System – Performance Requirements
User Inputs
Input: Push Button
User Indicators & Displays
Indicator 1: Information
Indicator 1 type: Binary
Binary Indicator Technology: LEDs
Operation Modes
Power Modes: On, Off, Standby
Function Modes: Charging
Safety
Power Signal Ground Fault Max: 6 mAmps
Power Signal GF Max Trip Time: 16 msecs

19. Block 1 – Power Supply Owner - Kassie
Power Signals
Input: AC
Nominal Voltage: 120V , Range: 10.2V – 13.2V
Nominal Frequency: 60Hz, Range: 57Hz – 63Hz
Maximum Current: 10A
Output: DC
Nominal Voltage: 12V, Range: 11.60V – 12.60V
V ripple: 0.2V
Maximum Current: 20A
Digital Signals
N/A
Analog Signals

20. Block 2 – Inverter Owner - Josh
Power Signals
Input: DC
Nominal Voltage: 12V , Range: 10.2V – 13.2V
Maximum Current: 20A
Output: AC
Nominal Voltage: 24V, Range: 0V – 48V
Maximum Current: 10A
Nominal Frequency: 400 Hz, Range: Hz
Digital Signals
Input
Frequency Input
Nominal Frequency: 400Hz, Range: Hz
5V Logic Voltage
Analog Signals
Output
Frequency Control
Nominal Frequency: 60Hz, Range: Hz
Voltage Max Amplitude: 14.5V

21. Block 3 – Control Owner - Eric
Power Signals
Input: DC
Nominal Voltage: 12V , Range: 11.0V – 14.5V
Nominal Frequency: N/A
Maximum Current: 1A
Digital Signals
Output:
DC (frequency control)
Nominal Voltage: 5V, Range 2.4V- 5.5V
Nominal Frequency:400hz Pulse (control signal)
DC (LED Display)
Nominal Voltage:5V. Range 2.4V-5.5V
Maximum Current 100mA
Analog Signals
Nominal Voltage: 12V , Range 11.0V – 14.5V
Maximum current: 1.0A

22. Block 4 – Inductive Loops Owner - Mark
Power Signals
Input: AC
Nominal Voltage: 24V , Range: 0V – 48V
Nominal Frequency: 400Hz, Range: 100Hz – 500Hz
Maximum Current:10 A
Output: DC
Nominal Voltage: 13.8V, Range: 13.0V – 14.0V
V ripple: .2V
Maximum Current:30 A

23. Patents
US PN 6,972,543
Series resonant inductive charging circuit
December 6, 2005
US PN 5,694,023
Control and termination of a battery charging process
December 2, 1997
US PN 6,940,257
Battery charger
September 6, 2005

24. Ethical or Societal Issues
One issue that we have to address is to prevent too much current from entering the battery on the toy car during the charging process.
Another issue that we have to address is to make sure there is sufficient shielding around the coils.