1. The UPS Team 5

2. Team 5: Staff Michael Myers BSEE Fernando Muñoz Jesus Lopez
Adam Bitter
Jake Koturbo
BSEE

3. Team 5: Expertise & Experience
Michael Myers
Fernando Muñoz
Jesus Lopez
Adam Bitter
Jake Kotrba
Expertise: Power and Electromagnetics
Experience: Kimberly-Clark, General Motors
Expertise: Power, Motors
Experience: Airforce electrician
Expertise: Controls, Power
Experience: We energies, Gossen Corporation
Expertise: Controls
Experience: N/A
Expertise: Power, Motors
Experience: Chicago-Kenosha Building Developement

4. Team 5: Contact Info
Michael Myers
Fernando Muñoz
Jesus Lopez
Adam Bitter
Jake Kotrba
Phone 1:
Phone 1:
Phone 1:
Phone 1:
Phone 1:

5. Team 5: Weekly Availability Worksheet
Michael Myers
Fernando Muñoz
Jesus Lopez
Adam Bitter
Jake Kotrba
Time 1 (all members): Monday, 8:00 AM – 10:00 PM
Time 2 (all members): Wednesday, 8:00 AM – 10:00 PM
Time 3 (all members): Friday, evening, as needed

6. Team 5: Weekly Project Meeting Plan
Weekly Meeting 1: - EMS 202, Monday 8-10 AM
Owner: Jesus Lopez
Expected Attendees: all members
Purpose: Project integration, review and set weekly goals
Weekly Meeting 2: - EMS 202, Monday 8-10 AM, Wednesday 8-10 AM
Owner: Mike Myers
Purpose: Project procedures adjustments
Weekly Meeting 3: - EMS 202, Monday 8-10 AM, Friday 5-until PM
Owner: Adam Bitter
Purpose: Weekly goals wrap up
Note: Meeting Owners Send Weekly Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

7. Team 5: Total Resources
560 Man-hours
Cost - $500.00

8. Team #: Decision Making
Decisions will be taken based on a majority vote

9. Roles to Define & Assign
Project Integrator: Jake Kotrba, Owns weekly progress reports to TA. Logistics and communication of team meetings. Develops and Tracks overall project plan. Integrates Block design plans. Tracks expenditures. Owns project level verification and validation plan, capture and documentation of results.
Presentation Mgr: Jesus Lopez, Owns master MS Powerpoint slide set for team including formats, logos, fonts, colors, header/footer, backgrounds, rev control, submission of master floppy or CD for P1-P4 and Final Presentation.
Report Mgr: Adam Bitter, Owns master MS Word document for team including revision control, formats, logos, fonts, colors, header/footer, table of contents, submission of master floppy or CD for Final report.
Archive Web Mgr: Jake Kotrba, Owns weekly backup of all electronic material generated that week. Backup for Presentation Mgr and Report Mgr. Management of any team Web site resources.
Assembly & Proto Mgr: Michael Myers, Owns overall assembly level definitions, basic assembly drawings, master prototype & product parts lists, collection of block parts lists, procurement of proto components. Overall prototype mechanical and electrical assembly
PCB Layout Mgr: Fernando Muñoz, Owns overall PCB layout, Block to PCB mapping, PCB tools, PCB design drawings, PCB procurement, PCB assembly including special tools, soldering, wire-wrapping, drilling, and gluing.

10. + + + + + Vac Sensor Jake AC Switch Jesus Main Switch Jesus Load User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + + + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

11. Project Proposal
Uninterruptible Power Supply (UPS) and surge protector.
Supply uninterruptible power to computers, refrigerators, furnaces or other wanted appliances.
There is a competitive market for this product.
Targeted towards residential applications and small businesses.

12. Selection Process
This product was selected because the sufficient number of blocks it yields, even work distribution and team experience with power.
Risks include electrocution, sleep deprivation and damage to load device.
Other projects were rejected because of their complexity and marketing requirements.
This was a unanimously supported project.
We decided on this project based on input from the instructor and time restrictions.

13. Performance Requirements
Input AC Voltage: V
Input AC Current: max 15 A
Input AC Frequency: 60Hz +/- 3Hz
Output AC Voltage: V
Output AC Current: max 15 A
Output AC Frequency: 60Hz +/- 3Hz
Battery Size: 12V Automotive Battery
Battery Life: 1 Hour
Digital Functions: User display refreshed every 1/10 sec, monitoring and display input AC
User Interface: 7 segment LCD, push pad
Power Mode: Always on
Sensory: Current, Voltage and Frequency
Mounting: Feet
Plug: Type B

14. Standard Requirements
Operating Range: ºC
Max Operating Relative Humidity: 95%
Operating Pressure Range: 1 atm +/- 15%
Max Storage Duration: 10 years
Energy Sources: AC, automotive battery
Source connections: AC utility and DC battery
Power Consumption: Watt hours per year
Max Volume: cm3
Max Weight: 14 kg

15. Safety Requirements Primary Safety Standards
IEEE C Surge Protective Devices Standards UL 1449 Transient Voltage Surge Suppressors
IEC Lead-Acid Starter Batteries
Primary EMC Standards
EN :2001 Signaling on low-voltage electrical installations in the frequency range 3 kHz to 148,5 kHz
ICES-003 Interference Causing Equipment

16. Business Case Average Selling Price: $80
Product Annual Sales Volume: 15,000
Per Unit Cost of all Parts and Materials: $30
Per Unit Cost of all the Assembly, Test and Mfg: $30
Total Development Cost: $75,000
Annual Sales: $1,200,000
Per Unit CM: $20
CM%: 25%
Annual CM: $300,000
ROI Time: years

17. + + + + + Vac Sensor Jake AC Switch Jesus Main Switch Jesus Load User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + + + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

18. Block Level Description

19. Name: Michael Myers Major: Electrical engineering Team 5: UPS Assignment: block 1 Block 1: Inverter

20. Inverter
Once the power fluctuates outside the boundaries a control switch will allow the inverter power to transfer to the circuit.

21. + + + AC Vac Sensor Jake Charging Switch Jesus Power Source Switch
Load
User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

22. Power Inverter
The job of this inverter is to transfer 12Vdc to 120Vac.
This device will always be on
Control switch will allow inverter power to flow

23. Inverter Performance Requirements
Input: Analog (nominal)
12Vdc
30Adc
Output: Analog (nominal)
120Vac
60Hz
15Amps(maximum)

24. Inverter Standard Requirements
Operating Voltage:
Max 5.25Vdc
Min 4.75Vdc
Operating Temperature:
Max 50 C
Min -15 C
Humidity:
Max 95% r.h.

25. Analog and digital interfacing – N/A
Inverter Signal Table
Power Signals
Type
Direction
Voltage
Voltage Range
Freq
Freq Range
% V-Reg
V-Ripple
Current
Nominal
Min
Max
Power1 VCC +12
DC- Power
Input
12.0V
10.2
13.2V DC
N/A
5.00%
0.1V
18A
Power2 VCC -15V
AC- Power
Output
120.0V
102V
132.0V AC 57 63
0.25V
15.00A
Analog and digital interfacing – N/A

26. Prototyping Plan Inverter 700 Fiber Glass Solder Yes Flat Pins Block
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
Inverter
700
Fiber Glass
Solder
Yes
Flat Pins

27. Block Diagram Inverter Block Battery (12Vdc) DC-AC To 12Vac
Transformer
To 120Vac
Switch
(120Vac)

28. Resource Estimate
14.9% of the Material Estimate
Estimated 149 hrs.

29. Name: Fernando Muñoz Major: Electrical engineering
Team 5: UPS Assignment: Power Block Block 2a: Charger (Rectifier)
Block 2b: Battery
Jjkjk

30. + + + Vac Sensor Jake Charging Switch Power Source Switch Load User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

31. Power Inputs and Outputs
Transformer Input : 120 VAC / 20Amp
Transformer Output / Rectifier Input :
15.7 VAC (Step Down)
Rectifier Output #1 : 14.3 VDC
Rectifier Output #2 : 5 VDC

32. Power Electrical Interface Signals
Power Signals
Type
Direction
Voltage
Voltage Range
Freq
Freq Range
% V-Reg
V-Ripple
Current
Nominal
Min
Max
Power-1 AC Input
AC Power
Input
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
15A
Power-2 VCC +14.3V
DC Power
Output
14.3V
12.15V
15.73V DC
1.00%
0.01V
35A
Power-3 VCC +14.3V 2A

33. Block diagram of Power Supply System
120 VAC
Main Input
Transformer
Rectification
Smoothing
Regulation
14.3 / 5 VDC
Regulated
output
14.3 VDC
With
Ripple
15.7 VAC
14.3 VDC

34. 5 VDC Power Regulated System

35. Full-Wave Rectifier
Bridge Rectifier is used so four diodes are arranged so that both the positive and negative parts of the AC waveform are converted to DC.

36. Since output voltage out of the Rectifier still varies between 0V and -1.4V a smoothing capacitor is required so when the voltage increases in the first half of the voltage peaks, the capacitor charges up. Then while the voltage decreases to zero in the second half of the peaks the capacitor releases stored energy to keep output voltage as constant as possible.
After the smoothing process we regulate the rectifier output in order to get rid of Voltage Ripple, so we can get a more stable, accurate, known voltage for the circuit.

37. Charge Types
Trickle Charge : Constantly supplies the battery with 14.3 VDC at 2 Amps.
Quick Charge : When the battery is completely drained and commercial power is restored, the sensors will allow a much quicker charge of 14.3 VDC at 35 Amps charge the battery at a faster rate.

38. Main Purpose
Keep a constant charge in the battery so when commercial power is lost, the device to which the UPS is connected to stays on for about a half hour or until the battery drains completely.
Provide 5 VDC logic to the CPU which power s all essential controls and sensors.

39. Prototyping Plan Block Name Block Area (cm2) Total PCB Area (cm2) PCB
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
Power
700
Copper
Solder No
B type plug
Flat Pins

40. Resource Estimate
24.8% of the Material Estimate
Estimated 73 hrs.

41. Name: Jesus Lopez Major: Electrical engineering Team 5: UPS Assignment: blocks 3 and Block 3: Switching Gear Block 6: Display

42. Standard Requirements
Temperature range:
150 C Max
-15 C Min
Operation humidity Range:
95 % Max Rh
Intended aplication:
home
office

43. Performance Requirements
Signal Interfaces (digital)
+5 Vdc logic control
LED display
Signal Interfaces (analog)
+10%/-15% 120 Vac
60 Hz +/- 3 Hz

44. Switching Gear The mechanical switching for this
project will be effectuated by a double
pole double throw relay.
Power source switch.
Charging switch.
Note: other switches may be needed for different.
Blocks.

45. + + + AC Vac Sensor Jake Charging Switch Jesus Power Source Switch
Load
User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

46. Main Switch
The job of this switch is to select the power source to be used, AC or DC.
This switch selects AC power during normal operation.
The mechanism for this switch is controlled by a direct input from the micro-controller, which either closes or opens the switch.

47. Main Switch Nominal Ratings
Control Input : 5 Vdc
Input: 120 Vac
Output: 20 A

48. Main Switch Signal Table
Power Signals
Type
Direction
Voltage
Nominal
Voltage Range
Freq
Freq Range
% V-Reg
Max
V-Ripple
Current
Min
Power1 VCC +5
DC Power
Input
5.0V
4.75V
5.25V
5.00%
0.1V
1.2A
Power1 AC
AC Power
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
Power2 AC
Output
Power3 AC

49. Charging Switch
The job of this switch is to allow for a high battery charging mode.
This switch is regularly open and is closed only when the battery charge is very low.
The control for this switch is a direct input from the micro-controller, which either closes or opens the charging switch.

50. Charging Switch Nominal Ratings
Control Input : 5 Vdc
Input: 120 Vac
Output: 40 A

51. Charging Switch Signal Table
Power Signals
Type
Direction
Voltage
Nominal
Voltage Range
Freq
Freq Range
% V-Reg
Max
V-Ripple
Current
Min
Power1 VCC +5
DC Power
Input
5.0V
4.75V
5.25V
5.00%
0.1V
1.2A
Power2 AC
AC Power
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
Power3 AC

52. Display The display for the UPS will present the
following basic features:
On/Off manual power switch.
On/Off LED.
AC/DC LED.
Fast/Slow charging mode.
Remaining power indicator.
Note: other features will be considered if time yields an.
opportunity.

53. + + + AC Vac Sensor Jake Charging Switch Power Source Switch Load
Display
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

54. Display Nominal Ratings
Input: 8-bit digital signal
Output: LED on/off state

55. Display Signal Table Power Signals Type Direction Voltage Nominal
Type
Direction
Voltage
Nominal
Voltage Range
Freq
Freq Range
% V-Reg
Max
V-Ripple
Current
Min
Power1 VCC +5 (switch)
DC Power
Input
5.0V
4.75V
5.25V DC
N/A
5.00%
0.1V
1.2A
8-bit channel
Digital

56. Display is meant to be basic, but complete
Display is meant to be basic, but complete. An LED display chip will represent the battery life.

57. Block 3 & 4 Prototyping Plan Template
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
Main Switch 35
700
N/A
Spade connector
Charging Switch
Display
100
Fiber glass
Solder
8-wire ribbon
Easy disconnect connector

58. Switch Resource Estimate
10.8 % of the material estimate
Estimated 80 hrs.
Display Resource Estimate
Estimated 30 hrs.

59. End of UPS blocks 3 and 4 !!!

60. Name: Adam Bitter Major: Electrical engineering Team 5: UPS Assignment: CPU

61. + + + AC Vac Sensor Jake Charging Switch Power Source Switch Load User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

62. CPU The CPU will do the following things:
Read in a utility (AC) voltage signal
Read in a battery voltage signal
Read in a battery current signal
Control the switching of the power source switch
Control the switching of the charging switch
Output a battery life signal to the display

63. CPU
The CPU will switch to the battery when the voltage read in is below 105 V
When the battery is run dead the CPU will switch on the fast charger for a certain period of time

64. CPU
The CPU will send a signal to the display indicating the life of the battery based on the battery voltage level
If necessary it will also be able to send more outputs to the display

65. CPU Performance Requirements
Input:
AC voltage: bits, 5V DC
DC voltage: bits, 5V DC
DC current: bits, 5V DC
Output:
Display: bits, 5V DC
Charging Switch: 1 bit, 5V DC
Power Switch: bit, 5V DC

66. CPU Standard Requirements
Operating Voltage:
Max 5.25Vdc
Min 4.75Vdc
Operating Temperature:
Max 50 C
Min -15 C
Humidity:
Max 95% r.h.

67. CPU Power Interface Type Direction Voltage Nominal Voltage Range
Frequency Nominal
Frequency Range
% V-Reg.
V-Ripple
Current
Min
Max
DC Power
Input
5.0V
4.75V
5.25V 5%
0.2V
1.5A

68. CPU Digital Interface Digital Signals Type Direction Input Structure
Technology
Logic Voltage
Characteristics
Vh Min
Ih Max
Vl Max
Il Min
Vac Sensor 8-bits
Digital
Input
Standard
TTL 5V
3.00V
1.0mA
2.2V
10uA
Vdc Sensor 8-bits
Idc Sensor 8-bits
Switch 1-bit
Output
3.25V
0.5mA
1.8V
0.1mA
Battery 8-bits
Power 2-bits

69. Block 5 Prototyping Plan Template
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
CPU
100 12
Copper
solder
Yes
Ribbon Cable

70. Resource Estimate
12.9% of the Material Estimate
Estimated 47.4 hrs.

71. Name: Jake Koturbo Major: Electrical engineering Team 5: UPS Assignment: block Block 6: Sensors : Vac Vdc Idc

72. + + + AC Vac Sensor Jake Charging Switch Power Source Switch Load User
Interface
Jesus +
CPU
Adam
Quick
Charger
Fernando
Trickle
Charger
Fernando
Inverter
Mike + +
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake

73. Purpose:
It’s how the CPU interfaces with the input and output power.

74. Advantages of Using Sensors
Upper and lower limit can be adjusted with a small change in the CPU’s programming.
Example: Quick charger is turned on and off based on battery input current.
Qcharger on when I>1.9A
Qcharger off when I<1.5A

75. Sensor Performance Requirements
Input: Analog (nominal)
120Vac
5Vdc
15Adc
Output: Digital (nominal)
8-bits (5V logic)

76. Output continued… Directly interface with only the CPU
All sensor outputs will supply the eight bit signal to the CPU.
All sensors will use A/D converters and therefore use 5volt.

77. Sensor Standard Requirements
Operating Voltage:
Max 5.25Vdc
Min 4.75Vdc
Operating Temperature:
Max 50 C
Min -15 C
Humidity:
Max 95% r.h.

78. Sensor Power Interface
Type
Direction
Voltage Nominal
Voltage Range
Frequency Nominal
Frequency Range
% V-Reg.
V-Ripple
Current
Min
Max
DC Power
Input
5.0V
4.75V
5.25V 5%
0.2V
0.5A

79. Sensor Analog Interface
Analog Signal
Type
Direction
Coupling
Voltage Amplitude Maximium
Impedence
Frequency Range
Leakage Max
Min
Max
Vac
Analog
Input
Xfmr
132V 5k
20k
63Hz
500uA
Vdc
14.3V
1Hz
Idc
5.25V

80. Sensor Digital Interface
Digital Signals
Type
Direction
Input Structure
Technology
Logic Voltage
Output Characteristics
Voh Min
Ioh Max
Vol Max
Iol Min
Vac 8-bits
Digital
Output
Standard
TTL 5V
3.25V
0.5mA
1.8V
0.1mA
Vdc 8-bits
Idc 8-bits

81. Convert to a proportional 0-5Vdc analog signal
Simplified Sensor
Analog Signal
CPU
Convert to a proportional 0-5Vdc analog signal
ADC
Vcc~5V

82. Vac Sensor Measure the input voltage from the commercial supply.
Produce an eight bit output.
Signal is monitored by the CPU to initilize the use of the inverter.

83. Placement of the Vac Sensor
AC power
AC power
CPU

85. Vdc Sensor Measure the battery voltage.
Produce an eight bit output directed to the CPU.
Used to determine emergency CPU shutdown (when battery runs too low).
Used in conjunction with the Idc sensor to estimate battery expectancy.

86. Placement of the Vdc Sensor
Quick
Charger
Trickle
Charger
Inverter
Vdc and Idc
Sensors
Battery

88. Idc Sensor Measure the input and output battery current.
Produce an eight bit output directed to the CPU.
Used to engage or disengage the Quick charger.
Used in conjunction with the Vdc sensor to estimate battery expectancy.

89. Placement of the Idc Sensor
Quick
Charger
Trickle
Charger
Inverter
Vdc and Idc
Sensors
Battery

91. Block Prototyping Plan Template
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
Sensors
120
700
Fiber Glass
Wire Wrap
N/A
Spade connector, Cupper bus, easy disconnect

92. Resource Estimate
22% of the Material Estimate
Estimated 50 hrs.

93. End Block Level Description
Begin Product Level Description

94. All Blocks will be packaged into a shelf like orientation
Prototype UPS Shelf
All Blocks will be packaged into a shelf like orientation

95. Block Level Plan Man Hours Materials $ Inverter Block 1 149 81 Power73
135
Switches
Block 3 80 59
Display
Block 4 30
CPU
Block 5
47.4 70
Sensors
Block 6
49.7
120

96. Estimated vs Available
Total Manpower hours: estimated- 560
available- 528
Total material cost: estimated- $560
actual- $571

97. Plan Summary Man hours: previously 560 hrs. Now 528
Budget: previously 500 dollars. Now, estimated at 575 dollars. Increase the budget by 12 dollars per person.
Man hour distribution percentage:
25 System design task
25 Detailed design task
10 Verification
40 Documentation

98. GANTT Chart Time Line

99. Chronological Obstacles
Can’t begin to construct prototype until all parts have been obtained.
Can’t obtain all parts until part list has been compiled.
Can’t test the whole project as a hole until everyone gets their blocks put together and debugged.
Can’t test the whole project until all safety standards and regulations have been met.