1. Electrical Engineering 595 Capstone Design Team #4 Universal Power Box
An Evolution in Function
Monday, May 10, 2004

2. Staff (1) Gerry Callison, BSEE Maria Schlicht, BSEE
Expertise: Power Systems, Digital Design, Presentation
Experience: 3 years experience at Johnson 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 (2) 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. 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) combines many types of conversions into one product.
Cost, reliability, accuracy and safety were key aspects in the scope of this project.

5. Product Description
The user attaches a power source to the UPB, then enters a desired output power type and level.
The UPB senses the type of power the user inputs.
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.

6. Product Feature Set
The UPB can convert AC to DC, DC to AC, and DC to DC.
The user interacts with the UPB through an LCD and numeric keypad.
The UPB draws its internal power supply from the input power.
The UPB has a Total Harmonic Distortion sufficiently low for consumer electronics applications.
The UPB has a weight, size, and durability that allows it to be portable.
Many different power adapters available, but none known that combine AC-DC, DC-AC, and DC-DC in one product

7. Target Market
This product is being developed for use with consumer electronics in the North American environment.
Product NOT approved for Medical Applications
This product will be distributed through electronics and hardware retailers.
Common applications include:
Creating 120 VAC from a car outlet (for both 14Vdc and 42Vdc systems).
Replacing consumer electronic AC to DC adapters.

8. Product Performance Requirements
Input voltage ranges:
14-50Vdc
60Hz
Maximum input current: 7 amps
Output power: 75 watts
Output voltage ranges:
Maximum output current: 5 amps
Total Harmonic Distortion < 5%

9. Product Standard Requirements
0-50 degrees Celsius
0-70% RH
Maximum product size 2000 cm3
Maximum product mass 2kg
Maximum parts count 200
Greater than 95% reliability for 6 months

10. Block Diagram

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

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

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

14. Block Requirements

15. Power Control
Matt Risic

16. Power Control

17. Block Purpose
The Power Control is the center of the Universal Power Box
The programming is responsible for converting input data from the DC Sensor and relaying the PWM waveform to the Inverter Rectifier
Microprocessor will control the LCD display based on user input from the keypad
Input will be taken from the IC driver connected to the keypad

18. 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

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

20. Input/Output Voltages
Internal Sensors
Gate Signals
DC-DC Converter
AC Sensor
Vmeas AC
0 / 3.3V
0-3.3V
Vmeas I1
Vmeas I2
DC Sensor
Inverter Rectifier
Gate Signals
0-3.3V
0-3.3V
0 / 3.3V
Vmeas DC
Power Control
0-3.3V
Power Source
3.3V
AC I/O
Control Power
0 / 3.3V
2 Bits
Vpower
Relay / Duty Cycle
DC I/O
Output
Input
IC Osc
0 / 3.3V
4 Bits
4 Bits
2 Bits
Vpower
LCD Display
Keypad

21. Microprocessor Selection
Atmel ATMega169v Microprocessor
1 MHz Clock Speed
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

22. 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

24. MPU Pin Configuration
Port A (PA7-PA0) Bi-directional I/O port with pull-up resistors
COM0:3 and SEG0:3 for LCD Controller
Port B (PB7-PB0) Bi-directional I/O port with pull-up resistors
Port C (PC7-PC0) Bi-directional I/O port with pull-up resistors
Port D (PD7-PD0) Bi-directional I/O port with pull-up resistors
Port E (PE7-PE0) Bi-directional I/O port with pull-up resistors
Port F (PF7-PF0) Analog inputs to A/D Converter
Port G (PG7-PG0) 5 bit bi-directional I/O port with pull-up resistors
LCDCAP (Pin 1) External Capacitor Reservoir for LCD Display
RESET (Pin 20) Reset Pin
VCC (Pins 21,52) +3.3V Power Pin
AVCC (Pin 64) Supply Voltage for Port F and A/D Converter
GND (Pins 22,53,63) Ground Pin

25. 0/3.3V Sensor
0/3.3V to AC I/O
0/3.3V to DC I/O
0/3.3V sensor
0/3.3V AC
0/3.3V DC
Ground
+3.3V
LCD Pin 4
LCD Pin 5
LCD Pin 6
Ground
+3.3V
470nF Cap
Bit 0 Control Power
Bit 1 Control Power
LCD Pin 7
LCD Pin 8
LCD Pin 9
LCD Pin 10
LCD Pin 11
LCD Pin 12
LCD Pin 13
LCD Pin 14
0 / 3.3V Inverter Rectifier
0 / 3.3 V Inverter Rectifier
0 / 3.3V DC-DC Converter
0 / 3.3 V DC-DC Converter
Reset
+3.3V V
Ground
Driver Pin 16
Driver Pin 17
Keypad Pin 1
Keypad Pin 2
Keypad Pin 3
Keypad Pin 4

26. CPU/ALU Timing Diagrams

27. 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

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

29. Output Program Flowchart
WELCOME TO UPB!
1.DC-DC 2.AC-DC
3.DC-AC NO
(1-3?)
YES NO NO
(2?)
(3?)
(1?)
YES
YES
YES
DC-DC
ENTER DC OUTPUT
AC-DC
ENTER DC OUTPUT
DC-AC
120V AC NO NO
(14-50?)
(14-50?)
YES
YES
DC-DC
XXV DC
AC-DC
XXV DC

30. Input Program Flowchart
Regular Program Execution NO
Key press?
YES
Interrupt Cycle
Import Keystroke
Decode Input in MPU
Output to LCD
Send to PWM
End Interrupt Cycle

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

32. Reliability Prediction
Part
Quantity
Joints ΛB
π t
π v
π e
π q Λ
AtMega169v MPU 1 64
150
6.989
2.718
1.5
Total:
3 year reliability: %

33. User Interface
Maria Schlicht

34. User Interface

35. 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.
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 the terminal settings using NUMERIC keys to navigate through the configuration screens.
Electrical Safety for User

36. User Interface Standard Requirements
Max. Product Size
( L x W ) in cm
(7 x 2) LCD
(5 x 6.8) Keypad
Max. Product Weight
0.50 kg
Max. Operating Temp Range
0°C to 50°C
Min. Operating Humanity Rage
<95%, non-condensing
Reliability and Life (MTBF)
5 yrs, 1 yr at 2%, 5
Disposal/Recycle/Maintenance
CSA Standard, EN
Safety and Regulatory Standards
UL508C/CSA 22.2

37. User Interface Performance Requirements
LCD Operating Values:
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
Operating Temperature TOPR: 0°C - 50°C
Storage Temperature TSTG: 0°C - 60°C
Viewable feet.

38. User Interface Performance Requirements
EDE 1144 Keypad Encoder IC:
Supply Voltage: V
Max. Current sunk by an output pin: mA
Max. Current source by an output pin: 5.0 mA
Max. Current source by an output pin: 5.0 mA
Max. Current sunk by all 3 column inputs: mA
Max. Current source by all 4 row outputs: 5.0 mA
Keypad Operating values:
Max. output current: mA
Min. Operating Humanity Rage
<95%, non-condensing

39. User Interface Block Diagram
Input
(Keypad)
ATmega169
(Process)
Output
Display
(LCD)
DISPLAY MENU
DC-DC 2. AC-DC
DC-AC

40. 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: 1 yr @ 2% %

41. Schematic (Keypad and EDE1144)

42. Detailed Schematic (Keypad and EDE1144)

43. LCD CONNECTOR FUNCTION 2051 PIN NUMBER & NAME
Data Line 6
18, P1.6 2
Data Line 1
13, P1.1 3
Power – 5VDC 4
Not Connected 5
Display Adjust 6
Data Line 7
19, P1.7 7
Data Line 2
14, P1.2 8
Ground 9 10
Data Line 3
15, P1.3 11
LCD Enable
8, P3.4 12
Data Line 4
16, P1.4 13
Data Line 0
12, P1.0 14
LCD Read/Write
6, P3.2 15
Data Line 5
17, P1.5 16
LCD RS
7, P3.3

44. 64-QFP socket (ATmega169)
QFP bread boarding adapter with Aprilog CL production socket.
The socket permits insertion and removal of the package without soldering, thus making the devices, as well as the adapter re-useable.
The 64-QFP package can be plugged into a standard production 64-pin DIP socket or directly into solder less breadboard.

46. User Interface Failure Analysis
PART
QTY
JOINTS
l B πT πV πE πQ l
KEYPAD 1 16 25
11.782
0.400
1.5
289.74
LCD 7 20
SOCKETS 8 14 5
1.548
0.138
12.15
64-QFP 64 30
3.773
0.943
501.57
FLAT CABLE 2 15
0.136
18.35
CAPACITORS 17
0.140
168.66
RESISTORS
18.2
0.137
389.95
CONNECTORS 9
0.050
166.31
SWITCH
0.223
3.63
(FAILURE RATE) TOTAL
MTBF
1 YR RELIABILITY
96.9%
πT = Temperature Stress Factor
πV = Electrical Stress Factor
πE = Environmental Factor
πQ = Quality Factor

47. Block Component Cost QTY. ITEM PRICE TOTAL TOTAL COST $112.95 1
LCD Module
$29.00
Keypad
$10.39
64-QFP
$57.00
EDE 1144
$7.50 17
Capacitor ea.
$0.10
$1.70 8
Resistors
$0.08
$0.64 2
Socket
$ 0.48
$1.16 9
Connector
$0.50
$4.50
TOTAL COST
$112.95

48. Prototype

49. Inverter-Rectifier
Gerry Callison

50. Inverter-Rectifier

51. 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- Single phase pulse width modulated.
Rectifier- full wave, uncontrolled (meaning voltage level is not adjusted in this converter).

52. Inverter/Rectifier Interfaces
14 to 170Vdc
Power IO
14-170Vdc or
VAC
Power IO
H-bridge/fullwave rectifier
Internal Sensor
AC Sensor
IR2181 based
Switch Driver
0 to 3.3Vdc binary
(with respect to MOSFET sources)
0 to 3.3Vdc binary
(with respect to
ground)
3.3Vdc
Power Control
Control Power

53. 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%

54. 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%

55. PERFORMANCE REQUIREMENTS DERIVATIONS (1) 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

56. PERFORMANCE REQUIREMENTS DERIVATIONS (2) Output Voltage: 14-119 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:

57. 5 amps: Agreed upon by group 75 watts: Agreed upon by group
PERFORMANCE REQUIREMENTS DERIVATIONS (3) Maximum Input Current = 5 amps Maximum Output Current = 5 amps Maximum Power Passed = 75 watts Amplitude Modulation Index = .8
5 amps: Agreed upon by group
75 watts: Agreed upon by group
.8 Amplitude Modulation Index:
Causes Vin = 170 Vdc (V1 = Ma*Vdc), which components can easily handle.

58. A standard H-bridge topology was used.

59. OPERATIONAL DIAGRAM

60. Prototype
MOSFETs
Drivers

61. 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.

62. 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.

63. RELIABILITY PREDICTION
Part
Quantity
Joints ΛB
π t
π v
π e
π q Λ
Mosfet 4 3 5
1.548
0.307
1.5 1
22.79
Driver 8
27.3
0.208
68.1
.1uF cap 2
0.183
6.815
4148 diode
2.4
0.996
0.142
1.868
470 resistor
18.2
11.78
0.137
97.49
Total:
197.1
2 year reliability: %

64. $ Cost $
Costs assume volume of 1,000,000 units produced in given production run:
$1.65 X 2 IR2181 MOSFET drivers
$0.73 X 2 IRF740A MOSFET’s
$0.17 X 4 Filter Capacitors
$0.008 X 2 1n4007 Diodes
$0.005 X 2 5Ω Resistors
TOTAL BLOCK COST = $5.466

65. DC to DC Converter
Gerry Callison

66. DC to DC Converter

67. DC to DC functionality
Unique Challenge: Because of multidirectional flow of power, both ends needed to function as inputs and 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 IRF740A MOSFETS.
This converter is where the voltage is adjusted to user-commanded level.

68. (with respect to MOSFET sources)
DC to DC interfaces
14 to 50Vdc
Power IO
DC to DC Flyback
Converter
14-170Vdc
Power IO
DC Sensor
Internal
Sensor
IR2181 based
Switch Driver
0 to 3.3Vdc binary
(with respect to MOSFET sources)
0 to 3.3Vdc binary
(with respect to
ground)
3.3Vdc
Power Control
Control Power

69. 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%

70. 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%

71. PERFORMANCE REQUIREMENTS
DERIVATIONS (1)
Input Voltage: 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

72. PERFORMANCE REQUIREMENTS
DERIVATIONS (2)
Maximum Input Current = 7 amps Maximum Output Current = 5 amps Maximum Power Passed = 75 watts
7 amps:
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

73. Initially, a buck-boost topology was planned, but it was ruled out due to nonideal effects (esp. in inductor)

74. A dual ended flyback topology was used

75. OPERATIONAL DIAGRAM

76. Prototype
Smoothing Capacitors
Transformer Array
MOSFETs
Drivers

77. 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

78. POWER SWITCHES (MOSFETS)
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.

79. 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.

80. RELIABILITY PREDICTION
Part
Quantity
Joints ΛB
π t
π v
π e
π q Λ
Mosfet 2 3 5
1.548
0.307
1.5 1
11.39
Driver 8
27.3
0.208
34.05
4.7u cap
210
0.264
259.5
.1uF cap 4
0.183
6.815
4148 diode
2.4
0.996
0.142
1.868
470 resistor
18.2
11.78
0.137
97.49
10M resistor
Transformer 33
79.04
Total:
587.6
2 year reliability: %

81. $ Cost $
Costs assume volume of 1,000,000 units produced in given production run:
$3.49 X 3 Pulse Transformers
$1.65 X 2 IR2181 MOSFET drivers
$0.819 X 2 Smoothing Capacitors
$0.73 X 2 IRF740A MOSFET’s
$0.17 X 4 Filter Capacitors
$0.008 X 2 1n4007 Diodes
$0.005 X 2 5Ω Resistors
$0.005 X 2 10MΩ Resistors
TOTAL BLOCK COST = $17.584

82. Power
Ethan Spafford

83. Power

84. Control Power Interfaces
Power Control
Internal Sensor
-12,12V
AC Input
0 / 3.3V Switch Control
3.3V
0-3.3V Duty Cycle
AC Sensor
120VAC
-12,12V
12V
Cooling
Control Power
-12,12V
DC Sensor 5V 5V
3.3V
14-50V
Inverter/Rectifier
DC Input
LCD Display

85. Power Overview Sealed lead acid batteries power device at Start-up
Processor signals to Power the user’s input selection – Power adjusts switches to use input supply
Power Converts external input voltages to supply device

86. 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) 2Year

87. Performance Requirements Power
Input Voltage Vdc, Vac
Output Voltage /-12, 5.2, 3.3Vdc (+/- 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

88. Control Power Circuit

89. 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

90. DC Input Path Flyback Converter
Converts Input DC Voltage from 14-50V to 12.9V
Average Input current between 75mA-270mA

91. AC Supply Path Center Tapped Transformer with Bipolar Supply
Half wave rectifier steps down Converts 120AC to
36VAC
Transformer steps down voltage from 170Vpk to 30Vpk
Rectifier
Vo,max = +/- 13.8V (Vd =0.6V)
Vo,avg = +/- 13.7V

92. Block Costs
Costs assume volume of 1,000,000 units produced in given production run
Component
Quantity
Cost per Unit
Total
Photo Triac 4
$2.12
$8.48
AC Transformer 1
$9.53
Fly-Back Transformer
$6.12
Diodes 10
$0.11
$1.10
Capacitors 5
$0.10
$0.50
Resistors 11
$0.009
Voltage Regulator
12V
$0.16
-12
$0.32
Zener Diode 6.8V
$0.099
Zener Diode 8.7V
$0.056
Quad Op Amp
$0.23
Batteries Sealed Pb 2
$9.31
$18.62
$44.98

93. RELIABILITY PREDICTION
Part
Quantity
Joints ΛB
π t
π v
π e
π q Λ
Capacitors electrolytic 5 2 22
1.5
1.25
Voltage Regulator 3
4.589
Op Amp 1 20
57.60
MOSFET
3.2
2.741
resistors 9
0.7
14.242
diodes 7
1.6
Photo Triac 4
120
Transformer 6
3.767
Zener Diode
4.5614
Batteries Pb
15.079
Totals
2 Year Reliability: 98.12%

94. Temperature Control AC Filter
Ethan Spafford

95. Cooling AC Filter

96. Cooling and AC Filter Interfaces
VAC, VDC
AC Filter
Inverter
Rectifier
Photo
Triac
Photo
Triac
AC I/O
Blocked For DC input
Photo
Triac
VAC, VDC
-5/+5V Switch Signal
12V
Power
Power
Cooling 5V

97. Cooling and AC Filter Overview
Control Device Temperature
Control Fan Speed to minimize power loss at low temperatures
Alert user of over heat conditions
AC Filter
Remove Harmonics from AC signal

98. Standard Requirements Cooling & 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 Cooling & AC Filter
Temperature Control
Input Voltage 12VDC and 5VDC
Temp Cont Life 2Years
Fan Temperature warning
When Tmax reached warning light and buzzer notifies user to turn off unit
AC Filter
Input Voltage VAC and 5VDC, 14-50VDC
Output Voltage VAC, 14-50VDC
Filter Life 2 Years
7amp 200V component ratings

100. Cooling Circuit
Temperature IC Controls Fan Speed By Varying PWM Duty Cycle with Temperature
Minimizes Power Consumption at lower temperatures – Auto Shut down below 25°C
Alerts User of Overheat Conditions and Fan Malfunctions
Temperature
PWM Duty Cycle
T<25C
Off
25C<T<29C
50%
29C<T<33C
60%
33C<T<37C
70%
37C<T<41C
80%
41C<T<45C
90%
45C<T<55C
100%
55C<T
100% with Over Temp Alert

101. AC Filter Circuit Diagrams
Single Low-Pass RLC Filter
Use potentiometer
R obtained experimental
Break frequency 1kHz
60Hz < fb/10
Filter gain at 60Hz = 0 dB

102. Component Costs Cooling
Costs assume volume of 1,000,000 units produced in given production run
Component
Quantity
Cost per Unit
Total
BJT 2N222 1
$0.24
DC Fan
$6.51
Fan Controller and Temperature IC
$1.37
LED 2
$0.80
Capacitors
$0.10
Resistors 4
$0.009
$0.036
IC triple inverter
$0.11
$9.17

103. Component Costs AC Filter
Costs assume volume of 1,000,000 units produced in given production run
Component
Quantity
Cost per Unit
Total
Photo Triac 3
$2.12
$6.36
Capacitor 1
$2.98
Inductor
$0.74
$10.08

104. RELIABILITY PREDICTION AC Filter
Part
Quantity
Joints ΛB
π t
π v
π e
π q Λ
Photo Triac 3 4 12
1.5
1.25
Capacitors
electrolytic 1 2 22
42.243
Inductor 33
Total
381.51
2 Year Reliability: 99.33%

105. Reliability Prediction Cooling
Part
Quantity
Joints ΛB
π t
π v
π e
π q Λ
Brushless DC fan 1 2 10
1.5
1.25
10.336
IC (temp control, inverter) 22
140
resistors 4
0.7
4.7473
Capacitors Ceramic
0.5
2.9599
LED 9
16.829
BJT 3 5
4.3086
Total
298.49
2 Year Reliability: %

106. Sensors
Vanessa White

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

108. DC Sensor

109. DC Sensor Considerations
DC input only
Maximum signal to processor (Vcc in ADC)
Nominal current expected for measurement
Large input range makes determination of nominal voltage for sensor input difficult – may introduce large error

110. Standard Requirements DC Sensor
Humidity Range 0%RH to 70%RH
Block Cost <$10
Parts Count <10
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

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

112. 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
14-50VDC
0-3.3V
I/O
DC Sensor
Controller

113. Detail Design DC Sensor
LEM Transducer – LV 20-P
R1 – Calculated based on expected voltage to be measured and nominal current of 10mA
Rm – Calculated from current conversion ratio in transducer and Vmeas constraint

114. Detail Design Component Selection DC Sensor
LEM LV 20-P voltage transducer
Closed loop Hall effect
Performance
Input Voltage: V
Ipn: 10mA
Current ratio K: 1000:2500
Supply Voltage: +/-12V or +/- 15V
Response Time : 40us
Ipn, 25C: +/- 1.1%
Linearity: < 0.2%

115. Detail Design Component Selection DC Sensor
Constraints:

116. Detail Design Component Selection DC Sensor
Choosing nominal values/accounting for tolerances:
R1=7.15kOhm, 0.6W
Rm=187Ohm, 0.125W
Check IPN:
Power Ratings:

117. Component Costs DC Sensor
Qty
Cost
Transducer 1
$16.70
R1, 7.15kOhm
$0.05
Rm, 187Ohm
$0.079
Total
$16.829

118. DC Sensor Reliability
2 Year Reliability: 99.93%

119. Prototype DC Sensor

120. AC Sensor

121. AC Sensor Considerations
AC input only
Maximum signal to processor (Vcc in ADC)
Nominal current expected for measurement

122. Standard Requirements AC Sensor
Humidity Range 0%RH to 70%RH
Block Cost <$10
Parts Count <10
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

123. Performance Requirements AC Sensor
Input Voltage: 120VAC (+/- 10%)
Full Scale Output Signal Voltage (measured V to processor): +3.3V
Supply Voltage: +/-12VDC
Response Time : < 2ms
25C: < +/- 5%
Linearity: <0.5%

124. 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)
+/- 12V
Internal Power
0-3.3V
I/O
AC Sensor
Controller

125. Detail Design AC Sensor
LEM Transducer – LV 20-P
R1 – Calculated based on expected voltage to be measured and nominal current of 10mA
Rm – Calculated from current conversion ratio in transducer and Vmeas constraint

126. Detail Design Component Selection AC Sensor
Choosing nominal values/accounting for tolerances:
R1=15kOhm, 2W
Rm=150Ohm, 0.25W
Closest nominal value =150
Check IPN:
Power Ratings:

127. Component Costs AC Sensor
Qty
Cost
Transducer 1
$16.7
R1, 15kOhm
$0.91
Rm, 150Ohm
$0.02
Total
$17.63

128. AC Sensor Reliability
2 Year Reliability: 99.9%

129. Prototype AC Sensor

130. Internal Sensor

131. 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

132. Internal Sensor Considerations
Bi-directional system
Response time for corrections
Large measuring range

133. Standard Requirements Internal Sensor
Block Cost <$20
Parts Count <20
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
Humidity Range 0%RH to 70%RH
Reliability (MTBF) 2 Years

134. Performance Requirements Internal Sensor
Input Voltage: VDC
Full Scale Output Signal Voltage (to Processor): +3.3VDC
Supply Voltage: +/- 12VDC
Response Time : < 2ms
25C: < +/- 5%
Linearity: <0.5%

135. 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 passes internal DC power (14-170VDC)
To/From Inverter-Rectifier: Receives internal DC power ( ) or passes internal DC power (14-170VDC)
+/-12V
Internal Power
0-3.3V
Controller
VDC
Inverter-Rectifier
Internal Sensor
DC-DC Converter
VDC

136. 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
Rm1 and Rm2 – Calculated from current conversion ratio in transducer and Vmeas constraint

137. Detail Design Component Selection Internal Sensor
From DC-DC Converter:
Choosing nominal values/accounting for tolerances:
R1=10 kOhm, 3W
Rm1=75 Ohm, 0.5W
Power Ratings:

138. Detail Design Component Selection Internal Sensor
From Inverter / Rectifier:
Choosing nominal values/accounting for tolerances:
R2=15 kOhm, 2W
Rm=150 Ohm, 0.25W
Closest nominal value =150
Check IPN:
Power Ratings:

139. Component Costs Internal Sensor
Qty
Cost
Transducer 2
$33.4
R1, 10kOhm 1
$0.54
R2, 15kOhm
$0.91
Rm1, 75Ohm
$0.019
Rm2, 150 Ohm
$0.02
Total
$34.89

140. Internal Sensor Reliability
2 Year Reliability: 99.78%

141. Prototype Internal Sensor

142. I/O Vanessa White

143. I/O Overview
Provide 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

144. DC I/O

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

146. Standard Requirements DC I/O
Humidity Range 0%RH to 70%RH
Block Cost (Production) <$10
Parts Count <15
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

147. Performance Requirements DC I/O
Input Voltage: VDC
Full Scale Output Voltage: +50VDC
Control Voltage: 3.3VDC
Load Current: 7A
Switching Speed (Pickup/Dropout Time): < 10ms

148. 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
To DC Sensor: Passes input power (14-50 VDC)
DC-DC Converter
14-50 VDC
14-50 VDC
0/3.3V
I/O
DC I/O
Controller
14-50 VDC
DC Sensor

149. Detail Design DC I/O EM Relay – switching for input power flow
FET driver circuit - drive relay from digital signal
Capacitor – ESD protection
Fuse – Over current protection

150. Detail Design Component Selection DC I/O
Omron G6C-114P-US
12V coil rating
10A, 380VAC, 125VDC contact rating
200mW power consumption
10ms max set/reset time (mean set 5ms, mean reset 2ms)
2N7000 FET
Vth = 0.8V – processor Vol, max = 0.5V, Voh, min=2.3V
1000pF capacitor
10A fuse
DC metal shell socket

151. Component Costs DC I/O Component Qty Cost EM Relay 1 $5.32 FET $0.047
capacitor
$0.025
10A fuse
$0.30
DC socket
$1.49
Diode
$0.039
Total
$7.221

152. DC I/O Reliability
2 Year Reliability: 97.9%

153. Prototype DC I/O

154. AC I/O

155. 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
Driving switch from controller current/voltage

156. Standard Requirements AC I/O
Humidity Range 0%RH to 70%RH
Block Cost (Production) <$10
Parts Count <15
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

157. Performance Requirements AC I/O
Input Voltage: VDC, 120VAC (+/- 10%)
Full Scale Output Voltage: 132VAC,+50VDC
Control Voltage: 3.3VDC
Load Current: 5A
Switching Speed (Pickup/Dropout Time): < 10ms

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

159. Detail Design AC I/O EM Relay –switching for input power flow
FET driver circuit – drive relay from 3.3V digital signal
Capacitor – ESD protection
Fuse – Over current protection

160. Detail Design Component Selection AC I/O
Omron G6C-114P-US
12V coil rating
10A, 380VAC, 125VDC contact rating
200mW power consumption
10ms max set/reset time (mean set 5ms, mean reset 2ms)
2N7000 FET
Vth = 0.8V – processor Vol, max = 0.5V, Voh, min=2.3V
8A fuse
NEMA 5-15R AC receptacle
2 pole, 3 wire grounded, 15A, 125V

161. Component Costs AC I/O Component Qty Cost EM Relay 1 $5.32 FET $0.047
capacitor
$0.025
8A fuse
$0.30
AC receptacle
$1.29
Diode
$0.039
Total
$7.021

162. AC I/O Reliability
2 Year Reliability: 98%

163. Prototype AC I/O

164. Productization

165. Productization Aspects & Requirements
Legal/Ethical Aspects & Requirements
Basic operator’s manual including usage and troubleshooting instructions will be included
Includes UL labels and safety labels. All labels and user manual in English
Six month warranty
No known liabilities regarding malfunctions
Safety/Health Aspects & Requirements
Proper fusing and over-voltage protection are incorporated
Components derated for worst-case operation limits
Packaging is user-friendly and free of sharp edges
All components are enclosed and non-accessible by the user. User manual contains required warnings and comprehensive installation instructions

166. Productization Aspects & Requirements
Environmental Aspects & Requirements
Upon disposal, all required state and local recycling requirements will be adhered to.
The product will adhere to the following power and EMF tests:
IEC
IEC
IEC
IEC EN
Sustaining Aspects & Requirements
Field service not supported for this product.
Design team will monitor field defects for future versions.
Reliability Aspects & Requirements
6 month warranty standard
Products which fail under warranty should be returned for analysis and repair.

167. Product Reliability 1 Year Reliability: 91.0%
6 month reliability: 95.4%
Justifies a 6 month warranty

168. $ Final Cost $ User Interface: $112.95 Control Power: $44.97
Internal Sensor: $34.89
AC Sensor: $17.63
DC to DC converter: $17.584
DC sensor: $16.829
Microprocessor: $10.81
AC Filter: $10.68
Cooling: $9.15
DC I/O $7.221
AC I/O $7.021
Inverter/Rectifier $5.466
TOTAL: $

169. PCB Layout

170. Production Plan

171. Appendix
Prototype Functionality
Product BOM
Project Timeline

172. Inverter/Rectifier, DC to DC Converter MOSFET Drivers
Unsuccessful waveform
encountered in testing:

173. Product BOM

174. Timeline

175. 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

176. 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

177. Questions???