Millennium Infrared Sound System

Millennium Infrared Sound System

Capstone Design Team #2 Team Members Eenas Omari Ayodeji Opadeyi
Kevin Erickson Brian Felsmann Rick Ryer BSEE BSEE, BSCS

Project Description: A wireless audio system using infrared technology Primarily designed for Home Theater Systems to eliminate speaker wires Accepts any analog audio input and transmits the signal to the wireless amplifiers. Uses owner’s already existing speakers. Not proprietary to any audio manufactures equipment

Benefits of Product: A plug-n-play system compatible with existing audio receiver and speakers Eliminates speaker wires around the living room Does not use RF technology which could have inference from other popular home electronic devices (telephones, Wi-Fi, Radio) Fast easy installation

Targeted Market of Product: Consumer Electronics market Marketed in the United States and Canada Targeted Demographic 18 – 30 year olds with Home Theater Systems MSRP $ $125

Project Selection: Reasonable low cost project Unique product Similar, more expensive, products using RF technology An interest from team members

Capstone Design Team #2 Expertise and Experience
Eenas Omari Expertise: Electronics (Filters), Circuit design, RF Control systems, Digital Design, Communications. Ayodeji Opadeyi Expertise: EMC, Programming (C++, Java, Assembly), Powers, Circuit design, RF Experience: 1 year Co-op at Harley Davidson Kevin Erickson Expertise: Analog/Digital Design, Fiber Optics, Programming, AC Generators Experience: 2 years Co-op at Harley Davidson Brian Felsmann Expertise: Communication systems, Fiber Optics, Programming, Digital design. Experience: 1 year internship at Johnson Controls Rick Ryer Expertise: Embedded Systems, Microprocessors, Digital Circuits, Assembly Programming. Experience: 4 summer internships at GE medical.

Capstone Design Team #2 Available Resources: Actual Resources:
1200 –1600 Man-hours 15-20 hours/week per team member Includes lab time, periodic meetings, and personal time $500-$750 for material and prototyping $100-$125 per team member Actual Resources: 1000 Man-hours $250 for materials and prototyping

MIRSS Performance Requirements
Power Inputs AC Power (U.S. and Canada) 102 – Hz Short circuit protection for transmitter and receiver ESD Protection Electrical Interfaces Analog input from audio receiver 60 watt analog output to speakers Analog input is digitalized and sent via infrared emitter and photodiode and converted back to an analog signal

MIRSS Performance Requirements
ADC & DAC: 16 bit resolution conversion 44.1 kHz Sampling frequency (minimum) Total propagation delay from input to output < 30 μs Amplifier Requirements: 60 Watts peak power 97 dB SNR 0.0015% THD+N (Total Harmonic Distortion + Noise) 100 dB CMRR

MIRSS Standard Requirements
Temperature Ranges Operating Temperatures: 10°C – 40°C Storage Temperatures: -10°C –70°C Humidity Ranges Operating humidity: 20% – 85% Storage humidity: 10% – 95% Product Life 5 years 30 day warranty

MIRSS Standard Requirements
Product Dimensions Transmitter, 6” W x 2” H x 6” L 2 PCB Boards for Transmitter Total Area: 195 cm2 Receiver, 9” W x 3” H x 9” L 2 PCB Boards for Receiver Total Area: 466 cm2 (per receiver) Safety Requirements Primary Safety Standards UL 6500, IEC 61603, IEC 61558 EMC Safety Standards INC61204, IEC 55103, IEC61000

MIRSS Safety Requirements Overview
Primary Safety Standards UL 6500: Audio/Video and Musical Instrument Apparatus for Household, Commercial, and Similar General Use IEC 61603: Transmission of audio and related signals using infra-red radiation IEC 61558: Electrical, Thermal, and Mechanical safety of portable transformers EMC Safety Standards IEC 61204: Safety and EM requirements of switching power supplies up to 600 V IEC 61000: Specifies compliance with interference from EM sources and limits EM interference that can be emitted

MIRSS Transmitter Block Diagram
Analog Channels from Receiver (Left & Right Rear) Transmitter Power Supply ADC IR Transmitter Analog Digital Transmitter Infrared

MIRSS Receiver Block Diagram
Infrared Receiver × 2 Receiver Power Supply Amplifier DAC IR Receiver Analog Digital Analog Channel to Speaker

MIRSS Complete Product Block Diagram
Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker

MIRSS Block Allocations

MIRSS Transmitter Block Diagram
Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Eenas Omari

Transmitter Power Supply
Block Description An electrical device that transforms the standard wall outlet electricity (AC) into lower voltages (DC) Will supply voltage to both the Analog to Digital converter (ADC) and the Infrared transmitter (IR Transmitter). Block Owner: Eenas Omari

Transmitter Power Supply Standard Requirements
Temperature: - Operating Temperature: 10 – 60 oC. - Storage Temperature: 10 – 40 oC. Humidity: - Operating Humidity: 20– 85 %Rh. - Storage Humidity: 10 – 95 %Rh Block Owner: Eenas Omari

Transmitter Power Supply Standard Requirements
Mechanical: - Max PCB Area: cm2 - Max Volume: cm3. - Max Mass: kg - # PCB: 1. - # Connectors : 1 Power: Voltage Range (AC): 102 V < Vin < 132 V Life Cycle: - Life : 5 years - Reliability : 5 years. - Disposal : Recycle. Standard Requirements Continued… Block Owner: Eenas Omari

Transmitter Power Supply Performance Requirements
User indicator: - Input Indicator: Bright light, Full Darkness. - Indicator: Power on Red LED. Operational Modes: - On/Off Electrical Interfaces: - Input Voltage Range (AC) : 102 V < Vin < 132 V - Output Voltage Ranges: ± 4.75 V < Vout < ± 5.25 V ± <Vout < ± V - Frequency Range: < f < 63 Hz Block Owner: Eenas Omari

MIRSS-2K5 Block Diagram Power Distribution
Analog Channels from Receiver (Left & Right Rear) +5 volts Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital +/-5,15 volts Infrared Receiver × 2 +5 volts Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Eenas Omari

Transmitter Power Supply Block Diagram
Outputs Voltage Regulator (DC/DC) Input +5 Volts AC/DC Conversion Voltage Regulator (DC/DC) 120 volts AC +15 Volts Voltage Regulator (DC/DC) Isolation Rectifier +5 Volts Voltage Regulator (DC/DC) -5 Volts AC/DC Conversion Positive voltage regulator. Voltage Regulator (DC/DC) Negative voltage regulator -15 Volts Block Owner: Eenas Omari

Circuit Design Block Owner: Eenas Omari

Transmitter Power Supply Transformer Selection
Block Owner: Eenas Omari

Transmitter Power Supply Transformer Analysis
** DC Voltage (After Filtering) ** Filter Capacitor Calculation: Block Owner: Eenas Omari

Transmitter Power Supply Voltage Regulators
Finding the resistance values for the voltage regulators use the following equations: For the negative voltage. The adjustable current could be neglected because it’s small (micro Amps). Block Owner: Eenas Omari

Transmitter Power Supply Positive Voltage Regulators
Resistance ratios: +5 volts DC: R2/R1 = 3 R1 = 180 Ω R2 = 560 Ω Power Dissipation: 200 +15 volts DC: R4/R3 = 11 R3 = 220Ω R4 = 2.4kΩ Block Owner: Eenas Omari

Transmitter Power Supply Negative Voltage Regulators
**R6, , R8 is selected to be 120Ω: -5 volts DC: R5 = 3 X 120Ω = 360Ω -15 volts DC: R7 = 11 X 120Ω = 1.3 kΩ Block Owner: Eenas Omari

Summary of Worst Case Analysis:

Transmitter Power Supply Component Selection
Symbol Value Resistors R1,R3 R2,R4 R5 R6 R7 R8,R10 R9 180Ω 560Ω 220Ω 2.4kΩ 360Ω 120Ω 1.3kΩ Capacitors C,C C1,C3,C5,C7,C9 C2,C4,C6,C8,C10 4700uF (Electrolytic) 1.0 uF (tantalum) 10 uF (alum electrolytic) Block Owner: Eenas Omari

Detailed design Block Owner: Eenas Omari

Transmitter Power Supply Transformer Simulation

Transmitter Power Supply Simulation
+24 volts -24 volts Block Owner: Eenas Omari

Transmitter Power Supply 5V Regulator Simulation
Output Voltage Input Voltage Block Owner: Eenas Omari

Transmitter Power Supply 15V Regulator Simulation
Output Voltage Input Voltage Block Owner: Eenas Omari

Transmitter Power Supply Verification
Primary AC Input Voltage Secondary AC Input Voltage Block Owner: Eenas Omari

DC Voltage After Bridge Diodes. 0.143 V Ripple 78.0 Volts Block Owner: Eenas Omari

Positive DC Voltage After Rectification -39.0 Volts 0.109 V Ripple 0.143 V Ripple Negative DC Voltage After Rectification 39.0 Volts 0.099 V Ripple Block Owner: Eenas Omari

5V Regulator Output Voltage .293 V ripple -5 V Regulator Output Voltage 0.109 V ripple Block Owner: Eenas Omari

15V Regulator Output Voltage 0.126V ripple -15 V Regulator Output Voltage 0.113 V ripple Block Owner: Eenas Omari

Transmitter Power Supply Reliability
Block MTBF: Years Block FIT: per billion hours Dominant Parts for the unreliability are: - Electrolytic Capacitors - LED. Block Owner: Eenas Omari

Transmitter Power Supply Obsolescence Analysis
Yageo (CFR-25JB-120R) Primary Attributes: Carbon Resistor (Panasonic – ECG)EEA-FC1E100 Primary Attributes: Tantalum, Electrolytic Capacitors Erlich Ind (EID-164J48) Primary Attributes: Transformer Fairchild,National Semiconductor(LM337T,LM317MDT) Primary Attributes: Voltage Regulator Secondary Attributes: Technology (Bipolar) Package (SOT) Obsolescence Window (0.75,12.25) Present Year (P) = Block Owner: Eenas Omari

Obsolescence analysis continued…
µ + 2.5σ - P µ + 3.5σ - P Diodes Inc(1N5404-T) Primary Attributes: Diodes, LED Secondary Attributes: Technology (CMOS) Package (MCM) Voltage (5v+) Obsolescence Window (0.25,5.55) Present Year (P) = Obsolescence analysis continued… Block Owner: Eenas Omari

Transmitter Power Supply Sustainability
Top three worst case parts are: - Carbon Resistors - Diodes and LEDs. - Voltage Regulators Carbon resistors are the worst (negative sustainability). Possible actions would be using any other type of resistors; such as metal film, voltage regulators that uses CMOS technology would have a better life parameters. Block Owner: Eenas Omari

ADC Performance Requirements
Power Inputs DC Power ±4.75V – ±5.25 V DC Power ±14.25V – ±15.75 V Electrical Interfaces Analog Input Digital Output Input-Output SNR 90dB Maximum Throughput Rate 100 kHz Total Harmonic Distortion 0.1% Block Owner: Ayodeji Opadeyi

Transmitter Layout Allocated Power Supply Area is 4” × 4” × 2”

MIRSS-2K5 Block Diagram Transmitter Receiver × 2 Transmitter
Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Ayodeji Opadeyi

ADC Standard Requirements
Temperature Ranges Operating Temperatures -40°C – 85°C Storage Temperatures -65°C –150°C Max Volume cm3 Max Mass 0.1kg Block Owner: Ayodeji Opadeyi

ADC Block Diagram 5 VDC Input -5 VDC Input Serial Output to
IR Transmitter Differential Input Block Owner: Ayodeji Opadeyi

ADC Schematic Block Owner: Ayodeji Opadeyi

ADC Key Components Product Eight 5% tolerance resistors, ½ W
Part of the signal conditioning to reduce the analog input to the ADC Two op-amps High speed, low noise to condition the input signal by attenuating the analog input 2 Max195 chips (Surface mount) 85 kSps max 16 bit resolution, serial output 1.7 MHz max clock frequency Block Owner: Ayodeji Opadeyi

ADC Resistor Selection
Noise was considered when choosing the resistors vn2 = 4kTRB From the above equation we can see that when the resistor is increased, the square of the noise voltage also increases. The current entering the ADC also has to be minimized, therefore I chose resistors appropriately. With the above considerations in mind, I chose my resistor values in order to have the ADC input current at a minimum, and the noise voltage at a minimum. R1 = 10 kΩ R2 = 3.9 kΩ R5 = R1 || R2 = 3k Ω R7 = 100 Ω Block Owner: Ayodeji Opadeyi

Gain Error due to Resistor Tolerances
ADC Worst Case Analysis Gain Error due to Resistor Tolerances Block Owner: Ayodeji Opadeyi

ADC Testing and Verification
Analog Input to op-amp Reduced Analog input to ADC Block Owner: Ayodeji Opadeyi

ADC Testing and Verification
End of Conversion Signal ADC Digital Output with 0 V input 0 V = binary Block Owner: Ayodeji Opadeyi

ADC Reliability Analysis
Block FITs: 745.1 failure Units per billion hours MTBF: 153.1 years Most unreliable ADC, and Capacitors Possible solutions to improve the reliability Use more reliable capacitors ADC cannot be changed Block Owner: Ayodeji Opadeyi

ADC Life Parameters Component Type μ σ 2.5σ 3.5σ μ+2.5σ-p μ+3.5σ-p
MAXIM IC MAX427 Primary Attribute: Device Type (Amplifier) Secondary Attribute: Technology (Bipolar) Package (DIP) Voltage (15V) Obsolescence window: (0.25, 5.55) 2004.5 1975 1987 1992.5 8.3 12.5 7.8 5.3 20.75 31.25 19.5 13.25 29.05 43.75 27.3 18.55 19.75 0.75 1 0.25 28.05 8.8 5.55 MAXIM IC MAX195 Primary Attribute: Device Type (A/D Converter) Secondary Attribute: Technology (CMOS) Voltage(5V) 2001.5 2010 15.5 35.75 23.3 48.25 Present Date (p) = Block Owner: Ayodeji Opadeyi

ADC Life Parameters Component Type μ σ 2.5σ 3.5σ μ+2.5σ-p μ+3.5σ-p
YAGEO RESISTOR Primary Attribute: Device Type (Carbon Film) Obsolescence window: (-4.25, 4.25) 1980 8.5 21.25 29.75 -4.25 4.25 NICHICON/ BC COMPONENTS CAPACITOR Primary Attribute: Device Type (Electrolytic) Obsolescence window: (4.5, 14.5) 1985 10 25 35 4.5 14.5 Present Date (p) = Block Owner: Ayodeji Opadeyi

ADC Obsolescence Analysis
Resistor Use Metal Film Resistors. A/D Converter Use converter with lower voltage amplitude requirements. Use latest surface mount technology. Amplifier Use better process technology (preferably CMOS). Use lower powered amplifiers with less voltage requirements. Block Owner: Ayodeji Opadeyi

Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Kevin Erickson

IR Transmitter Block Description
Transmit 2 channels of digital audio to their respective IR receiver/amplifier. Be able to transmit the signals 25 feet to IR receiver. Block Owner: Kevin Erickson

IR Transmitter Performance Requirements
Power Inputs 4.75 – 5.25 Volts DC Electrical Interfaces Serial Digital Input from ADC block Digital Infrared output to IR Receiver block Infrared wavelength λ = 950 nm Block Owner: Kevin Erickson

IR Transmitter Standard Requirements
PCB Circuit Area 35 cm2 Unique Parts Infrared Emitter Temperature Ranges Operating Temperatures: -40°C – 100°C Humidity Ranges Operating humidity: 20% – 85% Safety IEC 61603 Transmission of audio and related signals using infrared radiation Block Owner: Kevin Erickson

IR Transmitter Block Diagram
Infrared Emitter Driver 16 bit serial data sent via Infrared Emitter (950 nm) Digital Audio sampled at 44.1 kHz 16 bit serial data IR Receiver ADC The input is a series of 0’s and 1’s from the ADC block. The output is infrared pulses of the 0’s and 1’s sent to a photodiode in the IR Receiver Block Owner: Kevin Erickson

IR Transmitter Schematic
5 Volt supply from transmitter power supply block Digital audio data input from ADC block D1 is an infrared emitting diode R1 is a current limiting resistor 2 circuits needed (left and right channel) Block Owner: Kevin Erickson

IR Transmitter Key Components
Infrared Emitter Transmit 25 feet to IR receiver (continuous forward current >50 mA) Fast switching time (<100 ns) Transistor Maximum continuous drain current of >200 mA Current Limiting Resistor Power rating and heat dissipation Block Owner: Kevin Erickson

IR Transmitter Key Component Selection
Osram Opto Semiconductors SFH-4301 Continuous Forward Current: 100 mA Switching Time: 10 ns Wavelength emission: 950 nm Fairchild Semiconductor BS-170 Continuous drain current: 500 mA Switching Time: 10 ns Block Owner: Kevin Erickson

IR Transmitter Key Component Selection
Current Limiting Resistor 10Ω carbon film resistor ½ Watt Block Owner: Kevin Erickson

IR Transmitter Verification and Prototyping Plan
Simulate IR Transmitter circuit with SPICE program Particular attention to Infrared Emitter current Prototype IR Transmitter circuit on proto board Verify current through Infrared Emitter in lab environment Design IR Receiver to test and verify distance of system Block Owner: Kevin Erickson

IR Transmitter Verification
SPICE Simulation shows 175 mA through the infrared emitter 1.8 Volt drop across Current limiting resistor. IEmitter = 180 mA for both Left and Right Channel from Lab evaluation Block Owner: Kevin Erickson

IR Transmitter Obsolescence Analysis
Component Type μ σ μ+2.5σ-p μ+3.5σ-p OSRAM Infrared Emitter Primary Attribute: Infrared Emitter Secondary Attribute: CMOS Technology Other Package 5V process Obsolescence window: (0.25, 5.55) 2004.5 2010 1999 1992.5 8.3 12.5 5.6 5.3 19.75 35.75 7.5 0.25 28.05 48.25 13.1 5.55 KEMET Capacitors Primary Attribute: Ceramic Obsolescence window: (9.5,14.55) 1980 14 9.5 14.5 Primary Attribute: Tantalum & Electrolytic Obsolescence window: (4.5,14.5) 1985 10 4.5 YAGEO Resistors Primary Attribute: Carbon Film Obsolescence window: (-4.25,4.25) 8.5 -4.25 4.25 Present Date (p) = Block Owner: Kevin Erickson

IR Transmitter Reliability and Sustainability
MTBFTransmitter =131.3 years FITTransmitter = 869 per billion hours 3 Worst Parts Carbon Film Resistors Infrared Emitters Capacitors (not including ceramic) Possible Corrective Actions Switch to Metal Film Resistors No Direct Corrective Action for Infrared Emitter Possible switch to all ceramic capacitors Block Owner: Kevin Erickson

Receiver Power Supply Transmitter Receiver × 2 IR Transmitter ADC
(Kevin) ADC (Ayo) IR Receiver DAC Amplifier (Brian) Transmitter Receiver × 2 Analog Channels from Receiver (Left & Right Rear) Analog Digital Power Supply (Eenas) Infrared Analog Channel to Speaker Receiver (Rick) Block Owner: Rick Ryer

Receiver Power Supply Block Description
Supplies IR Receiver, DAC, and audio amplifier in the receiver unit. Plugs into 120 V line voltage and provides: +/- 5 V 0.25 A for DAC +/- 15 V 0.25 A for IR Receiver +/- 35 V 2 A for audio amplifier Block Owner: Rick Ryer

Receiver Power Supply Standard Requirements
Temperature Range Storage: -10 oC to 70 oC Operating: 10 oC to 40 oC Humidity Range Storage: 2% to 98% RH Operating: 2% to 98% RH Maximum PCB area 1277 cm2 Block Owner: Rick Ryer

Receiver Power Supply Performance Requirements
Power Input: 102 to 132 V 57 to 63 Hz Power Output: DC output – 5 A total 0.25 A at +/- 5 V, ± 0.25 V 0.25 A at +/- 15 V, ± 0.75 V 2 A at +/- 35 V, ± 1.0 V Block Owner: Rick Ryer

Receiver Power Supply Signal Definitions
Block Owner: Rick Ryer

Receiver Power Supply Block Diagram
Signal Isolation and Conditioning (Rectifier) Feedback & Isolation Switching Control Voltage Transformer with Regulator +/- 35 V +/- 15 V +/- 5 V AC input Block Owner: Rick Ryer

Receiver Power Supply Detailed Schematic

Receiver Power Supply Schematic Notes
Voltage Regulators +/- 5 V DC regulator uses LM2585 +/- 15 V DC regulator uses LM2588 +/- 35 V DC regulator uses LM2587 Implementation Mostly Thru-Hole technology for prototype Nearly all surface mount for product. Block Owner: Rick Ryer

Receiver Power Supply Block Attributes
Block Location This block will reside in a metal enclosure at the rear of the receiver package. It will reside on its own circuit board within this enclosure. Connection to other PCB will be made via heavy gauge wire and a connector Testing This block requires no special testing other than verify the performance requirements. Safety standard testing will rely on the success of the metal enclosure as shielding Block Owner: Rick Ryer

Receiver Power Supply Layout

Receiver Power Supply Key Component Selection
Transformer Must provide at least 70 VA power for audio amplifier (35 V at 2 A) Must support 5 A on secondary windings 35 V regulator Must switch fast enough to sustain 70 W on output Must provide +/- 35 V at output Must accept +/- 18 V DC input (based on transformer specifications) Block Owner: Rick Ryer

Receiver Power Supply Lab Results
Transformers Block Owner: Rick Ryer

Receiver Power Supply Lab results
Regulators Block Owner: Rick Ryer

Receiver Power Supply Reliability
Greatest λ contribution is from Capacitors, Transformer, and Connector! Block Owner: Rick Ryer

Reliability after 1 month (warranty period): R(0.08) = 99.86% Reliability after 1 year: R(1) = 98.27% Block Metrics FITs: Failures per billion hours MBTF: 187 years Block Owner: Rick Ryer

Worst failure contributors Capacitors Connectors Transformer Corrective Actions Use capacitors with higher voltage rating Use stronger polymer for connector Use multiple, smaller transformers for the different supplies. Block Owner: Rick Ryer

Receiver Power Supply Obsolescence
Ohmite (MOX J) Primary Attributes: Metal Film Resistor 14.5 26.5 Panasonic – ECG (ECJ-3YB1E564K) Primary Attributes: Ceramic Capacitor 9.5 23.5 Belfuse (A ) Primary Attributes: Transformer 15.5 21.5 National Semiconductor (LM2585,LM2588) Primary Attributes: Voltage Regulator Secondary Attributes: Technology (Bipolar) Package (SOP) 15 0.75 5.75 21.25 13.25 12.25 Present Year (P) = Block Owner: Rick Ryer

Receiver Power Supply Obsolescence Analysis
Worst Part is voltage regulator Bipolar technology main limitation Replace with CMOS part if possible All other parts provide comfortable margin for obsolescence Block Owner: Rick Ryer

Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Kevin Erickson

IR Receiver Block Description
Receives the infrared signal from the IR Transmitter block Converts the infrared light to a voltage Conditions the signal to a logic level voltage for the DAC block Block Owner: Kevin Erickson

IR Receiver Performance Requirements
Power Inputs ±14.25 – ±15.75 Volts DC Electrical Interfaces Infrared Input from IR Transmitter block Infrared wavelength λ = 950 nm Serial Digital Output to DAC block Block Owner: Kevin Erickson

IR Receiver Standard Requirements
PCB Circuit Area 45 cm2 Unique Parts Photo Diode High Speed, Low Distortion, Voltage Feedback Amplifier Temperature Ranges Operating Temperatures: -40°C – 85°C Humidity Ranges Operating humidity: 2% – 98% Block Owner: Kevin Erickson

IR Receiver Block Diagram
16 bit serial data sent via Infrared Emitter (950 nm) 16 bit serial data to DAC block Photodiode Transimpedance Amplifier Comparator DAC Block Owner: Kevin Erickson

IR Receiver Schematic Transimpedance Amplifier Comparator Photodiode
2 circuits needed (left and right channel) Transimpedance Amplifier Comparator Photodiode D1 is a photodiode (λPeak=900nm) U1 creates the transimpedance amplifier U2 is a 5V comparator for 5V logic Block Owner: Kevin Erickson

IR Receiver Key Components
Photodiode Fast switching time Daylight Filter Op-Amp High slew rate Large gain bandwidth product Low input biasing current Low input voltage noise Block Owner: Kevin Erickson

IR Receiver Key Component Selection
Osram Opto Semiconductors SFH-229FA Optical Rise and Fall time: 10ns Max Photo Current: 20 μA Peak Wavelength: 900 nm Sensitivity Range: 730 – 1100 nm Daylight Filtering Case National Semiconductor LM6171 Slew Rate: 3600 Volts/ μsec Gain Bandwidth Product: 100 MHz Max Input Biasing Current: nA Voltage Noise: 12 nV/√Hz Block Owner: Kevin Erickson

IR Receiver Transimpedance Amplifier
A Typical IPhoto = 5μA from photodiode IPhoto Block Owner: Kevin Erickson

IR Receiver Prototyping and Verification Plan
Prototype IR Receiver circuit(s) on proto board Set up IR Transmitter to transmit 1 kHz 0-5 Volt square wave Observe that the IR Receiver works under short distances Lengthen the distance between the IR Transmitter and IR Receiver and observe the output of the amplifier Speed up IR Transmitter to 1 MHz Explore other Photodiode circuits to meet distance and/or speed requirements Block Owner: Kevin Erickson

IR Receiver Verification
Suggested screen captures Output of op-amp Digital Photo showing distance of transmission Block Owner: Kevin Erickson

IR Receiver Life Parameters
Component Type μ σ μ+2.5σ-p μ+3.5σ-p OSRAM Photodiode SFH-229FA Primary Attribute: Photodiode Secondary Attribute: CMOS Technology Other Package 5V process Obsolescence window: (0.25, 5.55) 2004.5 2010 1999 1992.5 8.3 12.5 5.6 5.3 19.75 35.75 7.5 0.25 28.05 48.25 13.1 5.55 National Semiconductors LM6171 Primary Attribute: Op-amp Secondary Attributes: CMOS Technology DIP Package Obsolescence window: (0.25,5.55) 1987 7.8 1.0 8.8 KEMET Capacitors Primary Attribute: Ceramic Obsolescence window: (9.5,23.5) 1980 10 9.5 23.5 YAGEO Resistors Primary Attribute: Carbon Film Obsolescence window: (-4.25,4.25) 8.5 -4.25 4.25 Present Date (p) = Block Owner: Kevin Erickson

IR Receiver Reliability and Sustainability
MTBFTransmitter =125.6 years FITTransmitter = 908 per billion hours 3 Worst Parts Carbon Film Resistors Photodiode Op-Amp Possible Corrective Actions Switch to Metal Film Resistors No Corrective Action for Photodiode Switch to a newer package design on op-amp (SOP) Block Owner: Kevin Erickson

Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Ayodeji Opadeyi

DAC Performance Requirements
Power Inputs DC Power 4.75 – 5.25 V, DC Power ±14.25 – ±15.75V Electrical Interfaces Analog Output, Digital Input Input-Output SNR 90dB Maximum Throughput Rate 100 kHz Total Harmonic Distortion 0.1% Block Owner: Ayodeji Opadeyi

DAC Standard Requirements
Temperature Ranges Operating Temperatures -40°C – 85°C Storage Temperatures -65°C –150°C Max Volume cm3 Max Mass 0.1kg Block Owner: Ayodeji Opadeyi

Outputs to Power Amplifier
DAC Block Diagram Outputs to Power Amplifier 5 VDC Input DAC Serial Input from IR Receiver Differential Output Block Owner: Ayodeji Opadeyi

DAC Key Components Eight 5% resistors ½ W two op-amps
For restoring the signal to its original form two op-amps Amplifying the signal to its original amplitude Low noise, high speed amplifiers 2 Max542 chips (Surface mount) Converts the digital signal back to analog 16 Bit serial input Block Owner: Ayodeji Opadeyi

DAC Schematic Block Owner: Ayodeji Opadeyi

DAC Resistor Selection
The resistors were chosen to reverse the attenuation caused by the ADC signal reduction, but it had to be amplified by 2 because the reference voltage of the ADC is 5V, and that of the DAC is 2.5V. R1 = 20 kΩ R2 = 3.9 kΩ R5 = R1 || R2 ≈ 3.3k Ω Block Owner: Ayodeji Opadeyi

Gain Error due to Resistor Tolerances
DAC Worst Case Analysis Gain Error due to Resistor Tolerances Block Owner: Ayodeji Opadeyi

DAC Block Reliability Most unreliable parts Block FITs:
571.3 failure Units per billion hours MTBF: 199.7 years Most unreliable parts DAC, and Capacitors Solution to improve the reliability Use more reliable capacitors DAC cannot be changed. Block Owner: Ayodeji Opadeyi

DAC Life Parameters Component Type μ σ 2.5σ 3.5σ μ+2.5σ-p μ+3.5σ-p
MAXIM IC MAX427/MAX400 Primary Attribute: Device Type (Amplifier) Secondary Attribute: Technology (Bipolar) Package (DIP) Voltage (5V) Obsolescence window: (0.25, 5.5) 2004.5 1975 1987 1992.5 8.3 12.5 7.8 5.3 20.75 31.25 19.5 13.25 29.05 43.75 27.3 18.55 19.75 0.75 1 0.25 28.05 8.8 5.55 MAXIM IC MAX542 Primary Attribute: Device Type (D/A Converter) Secondary Attribute: Technology (CMOS) Voltage(5V) Obsolescence window: (0.25, 5.55) 2001.5 2010 15.5 35.75 23.3 48.25 Present Date (p) = Block Owner: Ayodeji Opadeyi

DAC Life Parameters Component Type μ σ 2.5σ 3.5σ μ+2.5σ-p μ+3.5σ-p
YAGEO RESISTOR Primary Attribute: Device Type (Carbon Film) Obsolescence window: (-4.25, 4.25) 1980 8.5 21.25 29.75 -4.25 4.25 NICHICON/ BC COMPONENTS CAPACITOR Primary Attribute: Device Type (Electrolytic) Obsolescence window: (4.5, 14.5) 1985 10 25 35 4.5 14.5 Present Date (p) = Block Owner: Ayodeji Opadeyi

DAC Worst Case Parts Resistor D/A Converter Amplifier
Use Metal Film Resistors. D/A Converter Use converter with lower voltage amplitude requirements. Use latest surface mount technology. Amplifier Use better process technology (preferably CMOS). Use lower powered amplifiers with less voltage requirements. Block Owner: Ayodeji Opadeyi

Analog Channels from Receiver (Left & Right Rear) Transmitter Transmitter Power Supply (Eenas) ADC (Ayo) IR Transmitter (Kevin) Analog Digital Infrared Receiver × 2 Receiver Power Supply (Rick) Amplifier (Brian) DAC (Ayo) IR Receiver (Kevin) Analog Digital Analog Channel to Speaker Block Owner: Brian Felsmenn

Audio Power Amplifier Block Description
Receives analog signal from DAC Block Goes through 3 stages of filtering and amplification to drive loudspeaker 2 Power Op-Amps From D/A Converter To Loudspeaker Output Stage Input Stage Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design
Standard Requirements Operating Temperature Range: 0-40°C Relative Humidity (max): 90%RH (max) Performance Requirements Voltage Gain: dB (min) Output Power: W Signal-to-Noise Ratio (SNR): 98 dB (min) Common Mode Rejection Ratio (CMRR): 100 dB (min) Frequency Response: kHz Total Harmonic Distortion (THD + Noise): % (max) Block Owner: Brian Felsmenn

Audio Power Amplifier Block Description
DC Power Supply Negative Feedback Output Audio Signal Input Audio Signal 2 Power Op-Amps Output Stage Input Stage From D/A Converter To Loudspeaker Negative Feedback DC Power Supply Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Issues
Additional Design Issues: Thermal Protection Maximum Power Dissipation Heat Sink Determination Voltage Gain & Feedback Over Voltage and Under Voltage Protection Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Overall Design Configuration
Parallel Amplifier Configuration – use two op-amps connected in parallel to drive load Design both amplifiers to have close to identical gain Connect audio input to both op-amps Connect op-amp outputs in parallel to drive single load Ideally each amplifier shares output current equally Divides Power Dissipation between two LM3876 ICs to reduce heat stress on each IC Block Owner: Brian Felsmenn

Power Requirements Calculation Output Power = 60 W Load Impedance = 8Ω Peak Output Voltage = √(2*RL*Po) = V Peak Output Current = √(2*Po/RL) = 3.87 A Need Power Supply Voltage = 30.98V + 5V = 35.98V ≈ 35 V Block Owner: Brian Felsmenn

Op-Amp and Feedback Design & Calculations Non-inverting op-amp configuration with negative feedback R4 and R6 set the gain of op-amp Gain (nominal) = R6/R4 + 1 = 20kΩ/1kΩ +1 =21 Gain (nominal) = 20log(21) = 26 dB Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Schematic Op Amp and Feedback
Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Error Calculations
Offset Error Contribution: Error Voltage due to Vio (Input Offset Voltage): Verror = Vio(1+Rf/Rp) Verror = 10mV(1+20k/1k) = 210 mV Conclusion: offset error due to op-amps has insignificant effect on design Block Owner: Brian Felsmenn

Gain Error: (5% tolerance resistors) Gain (nominal) = 1 + Rf/Rp = k/1k = 21 Resistor Tolerances: Assume Rf = Rf + 5% and Rp = Rp – 5%, then If Rf = 21k and Rp = 0.95k, then Av = k/0.95k = 23.1 Gain Error = Av(nom) – Av = 21 – 23.1 = 2.1 Conclusion: 5% tolerance too large to match gain accurately for parallel configuration Choose resistors with 1% tolerances to set gain Block Owner: Brian Felsmenn

Gain Error (1% tolerance resistors) Gain (nominal) = 1 + Rf/Rp = k/1k = 21 Resistor Tolerances: Assume Rf = Rf + 1% and Rp = Rp – 1% then Rf = 20.2k and Rp = 0.99k Then Av = 1 + Rf/Rp = k/0.99k = 21.4 Gain Error = Av(nom) – Av = 21 – 21.4 = 0.4 Conclusion: 1% resistors offer much better gain error and matching for parallel amplifier configuration Block Owner: Brian Felsmenn

Input Stage Design Calculations: Need high-pass filter to prevent oscillations: R1 and C1 create a high-pass filter: Choose R1 = 47kΩ and C1= 1μF So F = 1/(2π*R1*C1) = 3.38 Hz (cut-off freq) C1 is also a coupling capacitor Need high-pass filter on feedback loop for unity gain at DC: R4 and C2 create a high-pass filter: Choose R4 = 1kΩ and C2 = 47μF So F = 1/(2π*R4*C2) = 3.38 Hz (cut-off freq) R4 is also a gain determining resistor Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Schematic – Input Stage

Power Supply Input Circuit Design Power Supply and Filtering Capacitors Capacitors C4, C5 and C6 provide power supply filtering and bypassing Need filtering and bypassing capacitors to smooth out any power supply ripple voltages and DC voltage to op-amps will remain constant Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Schematic DC Power Supply

Output Stage Design & Calculations: Need to stabilize output stage with a pole that reduces high frequency instabilities R9 and C7 create a high frequency pole: Choose R9 = 2.7Ω and C7 = 0.1μF F = 1/(2π*R9*C7) = 5.89 MHz R10 balances current to loudspeaker caused by gain or DC offset differences between op-amps Choose R10 = 0.1Ω (3W power rating) Block Owner: Brian Felsmenn

Audio Power Amplifier Detailed Design Schematic- Output Stage

Audio Power Amplifier Detailed Design – Parallel Configuration

Audio Power Amplifier Detailed Design - Schematic

Maximum Power Dissipation Power dissipation is the power that is converted to heat within the amplifier Important parameter used to determine heat sinking requirements and output power Pi + Ps = Po + Pd (Conservation of Energy) Input Signal Power (Pi) Output Signal Power (Po) Audio Power Amplifier Power from DC Power Supply (Ps) Power Dissipated (Pd) Block Owner: Brian Felsmenn

Maximum Power Dissipation Calculation Parallel Amplifier Configuration Load Equivalent Resistance: RL(parallel) = RL(total) * Number of ICs driving load RL(parallel) = 8 Ω * 2 ICs driving load = 16 Ω Maximum Power Dissipation: PDmax = (Vcc2)/(2π2*RL(parallel)) PDmax = (70V2)/(2π2*16 Ω) = W Total PDmax = 2 ICs * PDmax = 2 * W = W Block Owner: Brian Felsmenn

Heat Sink Determination Sink to Ambient Thermal Resistance Calculation θJC = thermal resistance (junction to case) = 0.8ºC/W θCS = thermal resistance (case to sink) = 0.2ºC/W θSA = thermal resistance (sink to air) θSA = [(TJmax - TAmb) - PDmax(θJC + θCS)] / PDmax θSA = [(150°C - 50°C) ( )] /31.03 = 2.22°C/W θSA = 2.22°C/W for worst case (ambient temp of 50ºC) Conclusion: choose heat sink with θSA ≤ 2.22°C/W Block Owner: Brian Felsmenn

Thermal Protection Circuits
Audio Power Amplifier Detailed Design Features of LM3876 Audio Amplifier Thermal Protection Circuits Protection to prevent long-term thermal stress When die temperature exceeds 150°C, the LM3876 shuts down until temperature falls below 145°C, then amp restarts Improves reliability Still need an adequate heat sink to prevent IC from approaching 150°C Block Owner: Brian Felsmenn

Audio Power Amplifier Features of LM3876 Audio Amplifier Device Protection
Under-Voltage Protection of LM3876 built in protection allows power supplies and voltage across capacitors to reach full values before amp turned on to prevent DC output spikes Over-Voltage Protection of LM3876 built in protection limits the output current while providing voltage clamping Block Owner: Brian Felsmenn

Audio Power Amplifier LM3876 Audio Amplifier Important Electrical Characteristics
Typical Value Conditions THD+N (Total Harmonic Distortion + Noise) 0.01% – 0.016% f = 20Hz – 20kHz Supply = ± 35V Output Power = 60W Load = 8Ω CMRR (Common Mode Rejection Ratio) 120 dB SNR (Signal-to-Noise Ratio) 114 dB f = 1kHz Output Power = 40W Block Owner: Brian Felsmenn

Audio Power Amplifier Prototyping Plan
Block Area: cm2 Total PCB Area: cm2 PCB Substrate Type: outsourced Comp Attachment Type: solder Types of Connectors speaker terminals Block Owner: Brian Felsmenn

Audio Power Amplifier Obsolescence Analysis Table

Audio Power Amplifier Reliability and Obsolescence Analysis
Conclusions: MTBF = 373.2 FIT = 7.74 Worst Case Parts: Carbon Film Resistors (phase-out region) Electrolytic Capacitors Possible Solutions to correct worst parts Substitute metal film resistors for carbon film Substitute other capacitor types Block Owner: Brian Felsmenn

Audio Power Amplifier Block Requirement Verification
Verification Plan Evidence Operating Temperature Lab Testing Measurement Frequency Response Scope Traces/ Simulation Voltage Gain Common CMRR Scope Traces Signal-to-Noise Ratio (SNR) Output Power Block Owner: Brian Felsmenn

Mass Production Strategy
# of boards: 6 (2 for the transmitter and 2 for each of the receivers) Technology: Multilayer PCB Packaging: CC (Lead-less chip carrier)

Mass Production Parts List
Primarily Surface Mount parts A few through hole components (Power Supply parts) Pb-Free devices Automated circuit board production

Mass Production Assembly
Transmitter Surface Mount Design 2 PCB’s Power Supply ADC and Infrared Emitter AC Power Plug-in Speaker Terminals (left and right channel input) Small Power Connector between PCB’s Total Number of Components: 62 Total Area of Components: mm2 Receiver DAC, Infrared Receiver, and Audio Amplifier Speaker Terminal (output) Total Number of Components: 115 Total Area of Components: mm2

Production Assembly Procure Parts & Part Setup Substrate Fabrication Surface Mount Assembly, testing and Packaging Process of Printed Circuit Boards Fab, Comp Prep Bake, Clean Mechanical Hand Operations Circuit Testing and Stressing Screen Solder Paste Circuit Board Placement Auto Component Placement Power Connectors to Each Circuit Board Reflow Solder Finished Product Testing Packaging

Transmitter Circuit Board Placement
Product Assembly Transmitter Circuit Board Placement

Receiver Circuit Board Placement
Product Assembly Receiver Circuit Board Placement

Circuit Testing Power Supplies With-in nominal range of specified output voltages Audio Amplifier (8Ω Load) Frequency Response Gain SNR & THD

Finished Product Testing Meets Transmit and Receive Distances SNR & THD ESD Stressing Thermal Cycling Mechanical Shock and Vibration EMC

Capstone Design Team #2 Acknowledgements
Special Thanks to Harley-Davidson Motor Company Jim Cummins Rajendra Naik Jeff Kautzer

Prototype Demonstration

Millennium Infrared Sound System

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Millennium Infrared Sound System

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