EE595 Capstone Design Team 1 i1.

EE595 Capstone Design Team 1 i1

EE595 Capstone Design Team 1
Kahnec De La Torre – Lead Report Manager BSEE – Programming and Wireless Networking Mike Haynes – Lead Manufacturing Manager BSEE – VHDL Bounnong Khamphoumy – Lead Project Integrator BSEE – Electronics Jason Knedlhans – Lead System Designer BSEE – Audio Joseph Spitz – Lead Presentation Manager BSEE – Cacophonic Electronics

Selected Project A musical instrument
New variation on synthesizer Mounted like a keyboard or upright like a cello Enables user to produce varied sounds Digital Effects including echo, auto-wah, and distortion Analog overdrive effects Continuously variable frequency selector Requires both hands to play Much like stringed conventional instruments

The i1 Top View Volume Continuous Frequency Selector DSP Status Analog
And Digital Control Analog Effects & DSP Effects Toggles

The Instrument Analog Comparison System Frequency Selector
Attack / Decay Control Summing Amp Low Freq Oscillator Signal Routing Digital Controls Analog Audio Analog Controls Analog Control DSP State Serial 16 bit Digital Digital Control Analog Audio Output Analog Effects DSP Processor Power Supply Pre Amp Joe Mike Kahnec Filter DAC Jason Bounnong

Standard Requirements
Market Economic Total Market Size: $200,000 Estimated Annual Volume: 100 Minimum List Price: $2,000 Maximum Product Material Cost: $250 Maximum Production Cost: $200 Marketing Market Geography: U.S.A. Market Demography: Musicians – Age 13 and up Competitors: Roland, Yamaha, Tascam

Environmental Operating Temperature Range: 0 to 40 oC Humidity Range: 0 to 100 % R.H., N.C. Altitude Range: 0.5 to 1.5 ATM Storage Temperature Range: -10 to 70 oC Storage Duration of 1 year

Power Domestic Operating Voltage Range: 102 to 138 VAC Operating Frequency Range: 57 to 63 Hz Maximum Power Consumption: 150 W Connector Type: IEC 320 – C14 Non-Domestic Operating Voltage Range: 138 to 253 Vac Operating Frequency Range: 47 to 53 Hz

Standard Requirements Mechanical & Manufacturing
Maximum External Dimensions: 30.5 cm x 10.2 cm x 76.2 cm Maximum Product Mass: 5 kg Maximum Shock Force: 20 G’s Maximum Shock Repetitions: 20 Manufacturing Maximum Number of PCB’s: 2 Maximum PCB Area: 465 cm2 Maximum Part Count: 2000 Maximum Unique Parts: 200

Standard Requirements Mechanical & Manufacturing
Life Cycle Product Lifetime: 10 years Warranty Period: 90 days Service Strategy: Factory repair Product Disposal: Recycle or return to manufacture

Performance Requirements
User Inputs Frequency Selector Continuously variable selection Frequency range of 1.5 octave per selector Distance between chromatic notes between 2 and 5 cm Multiple Tap Selectors Selectable effects processing Patch synthesized audio through effect or bypass Analog Potentiometers To control output amplitude To set amplitude attack To set amplitude decay

Performance Requirements User Indicators and Displays
DSP effect state indicator Level of effect applied 3 digit minimum Maximum perception distance of 1 meter LED Indicators System on/off state Analog effect state Analog effect active Digital effect active

Performance Requirements Any Combination of Analog and Digital Effects
Modes of Operation Any Combination of Analog and Digital Effects Digital Effects On/off Effect Echo Distortion Auto-Wah Effect intensity Effect parameter Analog Effect On/off Adjustable overdrive intensity

Output Stage Output/Interface Connector: ¼” phono jack Output Resistance: 1 kW Output Voltage (peak to peak): 4 V Output DC offset: 0 VDC Overall SNR: 95 dB Overall THD: < 1 % Frequency Range: 20 Hz to 20 kHz

Performance Requirements Safety Requirements and Standards
Low potential on exposed surfaces, < 0.1 mV Maximum surface temperature of less than 40 oC Standards UL 469 Musical Instruments and Accessories UL 1310 Class 2 power units UL 1998 Software in Programmable Components UL 486 Wire Connectors

EMC Standards Standard Description Applies to Block # EN61001–3–3
Limitation of Voltage Fluctuation and Flicker in Low-Voltage Supplies < 16 A Block 5 IEC61000–4–4 Electrical Fast Transient & Burst IEC61000–4–5 Power Input Surge Immunity IEC61000–4–8 Power Frequency Magnetic Field Immunity IEC61000–4–11 Voltage Dip, Short Dropout & Variation Immunity EMC Part 4, Section 2 ESD immunity tests Blocks 1, 2, 3, 4 EMC Part 4, Section 7 General guide on harmonics measurement and instrumentation Blocks 2, 3, 4

Resources Time Resources Parts Monetary Resources 780 Resource Hours
12 hrs/week Initial Estimates 845 Resource Hours Mid-Semester Estimate 8.33% increase Parts 175 Total Parts 57 Unique Parts Possible bulk price decreases Monetary Resources $250 $50 per team member $250.22 0.09% increase

Reliability Product Level Block λFITS MTBF(yrs.) Block 1 142.60 800.00
1,169.11 97.57 Block 3 755.09 151.00 Block 4 2,678.55 43.3 Block 5 3,284.77 34.69 Totals: 15.52

Reliability Warranty Percentage of failed products within warranty period is 10% λ=(1/ total MTBF)= Using , the warranty period is 0.15 months or 54 days

Reliability Conclusions Total FITS: 7350.01 Total MTBF: 15.52 years
Components that dominate unreliability: Crystal Oscillator, Digital Signal Processor, and a 4-to-1 Multiplexer To improve reliability Cool parts Reduce operating voltages

Frequency Selector & Audio Signal Router Joseph Spitz

The i1 Analog Comparison System Frequency Selector
Attack / Decay Control Summing Amp Low Freq Oscillator Signal Routing Digital Controls Analog Audio Analog Controls Analog Control DSP State 16 bit Digital Audio 16 bit Digital Control Analog Audio Output Analog Effects Processor Including ADC & Memory Power Supply Pre Amp Joe Mike Kahnec Filter DAC Jason Bounnong

Frequency Selector & Audio Signal Router Functional Description
Allows user to play note Sums audio signals from the oscillator block into one signal Controls the attack of the notes played Sends signals to the effects blocks

Frequency Selector & Audio Signal Router Standard Requirements
Block Requirements Standard Requirements Min. Operating Temperature Range 0 to 60 ºC Min. Operating Humidity Range 0 to 100 % RH Non-Condensing Min. Storage Temperature Range (-10) to 70 ºC Min. Storage Humidity Range Min. Operating Voltage Range Source 1 -10.5 to -9.5 VDC Min. Operating Voltage Range Source 2 10.5 to 9.5 VDC Max. Power Consumption 5 W

Frequency Selector & Audio Signal Router
Block Requirements cont. Standard Requirements Min. Operating Temperature Range 0 to 60 ºC Min. Operating Humidity Range 0 to 100 % RH Non-Condensing Min. Storage Temperature Range (-10) to 70 ºC Min. Storage Humidity Range Min. Operating Voltage Range Source 1 -10.5 to -9.5 VDC Min. Operating Voltage Range Source 2 10.5 to 9.5 VDC Max. Power Consumption 5 W

Block Requirements Cont. Performance Requirements Frequency range per actuator 1.5 Octaves Control Voltage to LFO .5 to 2.5 VDC Distance Between Notes 2.5 cm to 5 cm Signal to Noise Ratio 95 dB THD < 0.2% Frequency Response 20 to 20k Hz Attack Range No delay to max gain to 2 sec delay to maximum gain

Block Diagram Actuation by User Voltage Scaling Position Sensor DC Signal DC Voltage 1 to 2.5V To LFO Effect Select/Bypass Input Attack Input Audio Signal 2 V Amplitude 100 to 10KHz Bus Of Audio Signals 2 V amplitude 100 to 10KHz Audio Signal Routing Summing Amplifier To Preamp To Analog Distortion To DSP Effects

Block Signal Tables

Block Diagram

Design Calculation Frequency vs. Chromatic Notes Transfer Function Graph

Design Calculation Potentiometer Resistance: Transfer Function for Vo: Frequency Select Schematic

Design Calculation Transfer Function for Vo: Frequency Select Schematic Graph of Transfer Function

Design Calculation Chromatic notes along Potentiometer: Graph of Notes Along Potentiometer

Design Calculation Using 20 inch (50.8 cm) Potentiometers: Graph of Notes Along Potentiometer

Design Calculation Multiply Signal to make it compatible with LFO Comparator: Frequency Select Schematic

Block Diagram

Low-Frequency Oscillator
Michael Haynes

Low Frequency Oscillator
Functional Description Receives a DC input and outputs an AC voltage By using a Voltage-controlled Oscillator (VCO), the DC input can control the output frequency An analog comparison system is used to ensure that no transients are heard after releasing pressure on the main interface

Low Frequency Oscillator -Standard Requirements-
Block Requirements -Standard Requirements- MANUFACTURING Max. number of parts 20 Max. parts and material cost $30 Max. assembly and test cost $20 Percentage of total product cost 10% LIFE CYLE Estimated maximum production lifetime 10 yrs. Full warranty period 3 mon. SAFETY STANDARDS EMC Part 4, Section 7-General guide on harmonics measurement and instrumentation EMC Part 4, Section 2- ESD immunity tests

Low Frequency Oscillator -Standard Requirements cont.-
Block Requirements -Standard Requirements cont.- MECHANICAL Max. number of printed circuit boards 1 Max. block weight 5 oz. Max. total PCB area 465 cm2 Percentage of final product PCB area 25% Max. shock force 20 G’s ENVIRONMENTAL Min. Operating Temperature Range 0 – 40 ºC Min. Storage Temperature Range -5 to 65 ºC Min. Operating Humidity Range 0 – 100 % N.C. Min. Storage Humidity Range Min. operating altitude range atm. Min. storage altitude range Max. storage duration 1 yr.

Low Frequency Oscillator -Standard Requirements cont.-
Block Requirements -Standard Requirements cont.- ELECTRICAL Analog Input Voltage Range 1.0 – 2.5 VDC Analog Output Voltage Range -1 to 1 VAC Input Current Range 2 .5 – 750 uA Output Current Range 0.1 – 500 mA Max. Current into pins +/- 50mA

Low Frequency Oscillator -Performance Requirements-
Block Requirements -Performance Requirements- POWER INPUTS Input Power Voltages +/- 5 VDC Power Input Tolerances +/- 0.1 V Max. Power Consumption 5 W ELECTRICAL INTERFACES Analog Input Frequency Range 0 – 10 Hz Analog Output Frequency Range 20 Hz – 20 kHz Output minimum SNR 50 dB Max. THD 5% Min. Input Impedance 100Ω Max. Output Impedance 10kΩ

Low Frequency Oscillator -Performance Requirements-
Block Requirements -Performance Requirements- APPLICABLE USER INTERFACES Types Switch, Knob Switch attributes DPDT MODES Types of waveforms Sinusoidal, Square, Triangle PROPAGATION DELAYS Comparator + Analog Switch < 500ns SAFETY Features Shock Isolation

Block Architecture Voltage-Controlled Oscillator VCO VDC SPDT Analog Switch -1 to 1 VAC 0.5 VDC Comparator Analog Comparison System

Signals Power Analog Digital

Complete Detailed Block Architecture
Low Frequency Oscillator Complete Detailed Block Architecture

Design CF Remember that the targeted output frequency range is 20 Hz to 20 kHz Four interface strips will be used; this means that four frequency ranges are needed The ranges are chosen to be: - Strip 1: 220 Hz to 292 Hz - Strip 2: 293 Hz to 390 Hz - Strip 3: 391 Hz to 520 Hz - Strip 4: 520 Hz to 645 Hz These ranges correspond to notes that can be played by an instrument and are all in the audible frequency range The output frequency is determined by: -Current into IIN pin -Size of capacitor CF -Input voltage Known values: -Input voltage has a range of volts for sound -CF is determined from the data sheet -Need to know the Rin value for each frequency range

Design cont. To get the oscillation frequency, Vin=1 to 2.5V, CF=0.1uF For Strip 1: Rin ~ 45.5kΩ For Strip 2: Rin ~ 34.1kΩ For Strip 3: Rin ~ 25.6kΩ For Strip 4: Rin ~ 19.2kΩ

Design cont. Producing different waveforms -Pins A0 and A1 are TTL/CMOS compatible and set the waveforms -Can switch waveforms at any time -Switching occurs within 0.3 μs Fine tuning: -Done with a 20kΩ potentiometer -Causes output frequency to vary +/- 70% its value A0 A1 WAVEFORM X 1 Sine wave Square wave Triangle wave

Comparator Design Used a comparator with TTL/CMOS-compatible outputs
Compares input voltage to a 0.5V reference voltage Designed to activate the switch when the input voltage falls below the reference voltage

Analog Switch Design Used a SPDT CMOS analog switch Operation
-In one position, no sound is at block output -In opposite position, oscillator output is sent through to block output

Voltage Divider Tolerances
Comparator Voltage Divider Tolerances Reference voltage needs to be 0.5 V Calculating resistor values for voltage divider: Input voltage range: 0-5 V Target Vout range from voltage divider: 0-1 V Need voltage divider to scale comparator input voltage to between 0.4 and 0.6 V -Choose Vout as 0.5V -Vin is 5V -Choose R1 to be 3kΩ So, R1 is 3kΩ and R2 is 333Ω Analysis at +/- 5% resistances: -R1=2850Ω, R2=346.5Ω, Vout= V -R1 =3150Ω , R2=313.5Ω, Vout= V Conclusion: 5% resistor tolerances are sufficient to use

Analog Design For Manufacturing (DFM) Plan
Low Frequency Oscillator Block Analog Design For Manufacturing (DFM) Plan

Low Frequency Oscillator Block
Passive Design

Total Product Bill of Materials
Low Frequency Oscillator Block Total Product Bill of Materials

Reliability Plan

Reliability Assessment
Low Frequency Oscillator Block Reliability Assessment For the entire block: -FITS: failures per 109 hours -MTBF: mean years before failure The comparator, switch, and the high-frequency waveform generator all have high λ and thus dominate the unreliability of the block -Because these components are IC’s, they encounter more stress than other less demanding parts such as resistors How to improve reliability: -Cool the parts with a heat sink -Use mil spec/range parts

Obsolescence Maxim MAX038 μ σ μ +2.5σ μ +3.5σ Primary attribute: Waveform Generator 2001.5 7.8 2021 2029 Secondary attribute: Package:(SOIC) 1995 6.5 2011 2018 Voltage:(5V) 1997.5 5.3 2016 Technology: (CMOS) 2010.0 12.5 2041 2054 Maxim MAX944 μ σ μ +2.5σ-p μ +3.5σ-p Primary attribute: Comparator 2003.0 11.1 2031 2042 Secondary attributes: Package:(SOIC) 1995 6.5 2011 2018 Voltage:(5V) 1997.5 5.3 2016 Technology: (CMOS) 2010.0 12.5 2041 2054

Obsolescence Maxim Max4855 μ σ μ +2.5σ μ +3.5σ Primary attribute: Analog Switch 2001.7 10.7 2028 2039 Secondary attribute: Package:(SOIC) 1995 6.5 2011 2018 Voltage:(5V) 1997.5 5.3 2016 Technology: (CMOS) 2010.0 12.5 2041 2054 Resistor μ σ μ +2.5σ μ +3.5σ Primary attribute: Carbon Film 1980 8.5 2001 2010 Secondary attribute: N/A

Obsolescence Potentiometer μ σ μ +2.5σ μ +3.5σ Primary attribute: Variable Resistor 1985 10.0 2010 2020 Secondary attribute: N/A Capacitor μ σ μ +2.5σ μ +3.5σ Primary attribute: Ceramic 1980 14 2015 2029 Secondary attributes: N/A Resistor μ σ μ +2.5σ μ +3.5σ Primary attribute: Metal Film 1990 12.0 2020 2032 Secondary attribute: N/A

Obsolescence Summary As can be seen, the analog switch and the comparator have long sustainability times This means they will not need to be replaced soon

Testing Tests performed on LFO Block -Verify that 0.5 reference voltage enters comparator -Verify input voltage range to VCO is volts -Verify output of the block is 2 Vpp -Verify output frequency is within range -Verify each waveform -Verify fine tuning adjustment -Make sure the switch does not click -Make sure that the output sound is cutoff when the interface is off

PCB Layout Using ExpressPCB
Low Frequency Oscillator Block PCB Layout Using ExpressPCB

Verification

Analog Effects & Preamp Kahnec De La Torre

Analog Effects & Preamp Functional Description
Provides additional sound effects through analog circuit Operates over 3 decade range (20 to 20kHz) User interface – Tone control Preamp Volume is controlled at the user interface User interface – Volume Control

Analog Effects & Preamp Standard Requirements
Block Requirements Standard Requirements Min. Operating Temperature Range 0 to 40 ºC Min. Operating Humidity Range 0 to 100 % RH Min. Storage Temperature Range (-10) to 70 ºC Min. Storage Humidity Range Min. Operating Voltage Range Source 1 Load Current Max 0.15A 5.67 to 6.93 VAC <0.1V Ripple Min. Operating Voltage Range Source 2 0.5mA 114 to 126 VDC <0.25V Ripple Min. Operating Voltage Range Source 3 0.5A 4.75 to 5.25 VDC <0.1V Ripple Max. Power Consumption 5 W

Analog Effects & Preamp Standard Requirements
Block Requirements Standard Requirements Manufacturing Life 10 Years Mechanical Life 5 Years Safety UL 469 Musical Instruments and Accessories UL 486 Wire Connectors EMC EMC Part 4, Section 2 EMC Part 4, Section 7

Analog Effects & Preamp Performance Requirements
Block Requirements Performance Requirements Analog Effects: Controlled by Voltage - 2V to +2V Signal to Noise Ratio 95 dB Output to Signal Routing Block - 2V to + 2v Analog Effect Multiple 2nd order harmonics Input Impedance 10 k Ohm Output Impedance 1 k Ohm

Analog Effects & Preamp Performance Requirements
Block Requirements Performance Requirements Preamp: Output Connector ¼ inch phono jack Output voltage – - 2V to +2V Total Harmonic Distortion < 0.2 % (20 to 20kHz) Signal to Noise Ratio 95 dB Output Frequency Range 20 Hz to 20 kHz Input Impedance 10 kΩ Output Impedance 1 kΩ Volume Control (Gain Range) Unity to -27 dB Including Mute

Analog Effects & Preamp
Block Diagram Audio Effect in From Signal Router Analog Control Vacuum Tube preamp Attenuator Analog Signal to Signal Router Preamp in from Signal Router Preamp Passive Noise Filter Volume Control

Signal Interfacing

Analog Effect Circuit

Attenuator Voltage divider gives ~2.6% of large signal from tube section.

Volume Control Tone Control ¼ inch Audio Jack

Preamp Analysis Low Pass Tone Control Gain High Pass

Analog Effects & Preamp Passive Component Specifications
Nominal Value or Max Value Adjustment Range, %/Turn Tolerance Around Nominal Derated Power Capacity Max Working Voltage Composition Dielectric or Form Pkg Resistor 2k, 10k, 47k, 100k Ohm 1% ¼ W Carbon Film Axial Potentiometer 2M Ohm, 1M Ohm 9% 5% Carbon Film Axial Fixed/Bypass Capacitor 0.1u, 5u 10u, 100u 10n 5V, 400V Electrolytic Axial

Bill Materials QTY Generic Name Package Place Area mm2 Attributes Tol% Cost Total Cost 2 lm833 opamp 8-DIP Auto 65.8 $0.48 $0.96 6 0.1 uF ceramic capacitors axial 16 16V $0.09 $0.54 1 0.1 uF capacitor Axial 600V 5 $1.28 1k ohm resistor 3.8 1 W 5% tol $0.42 100u 25V 10% tol 10 $0.22 12ax7 vacuum tube other Manual 387 $7.95 75k Ohm resistor 1/4W $0.44 47k Ohm resistor 1/4w $0.28 0.28 3 20k Ohm resistor 0.66 2k ohm resistor 1W 5% tol $0.16 $0.32 150k 4.4 1w .28 Potentiometer 6mm Squared 36 0.5W 1M ohm $0.88 $1.72 528.4 Totals $15.07

PCB Layout Pot Pot 12AX7 Vacuum Tube LM833 op amps 528 cm2

Analog Effects & Preamp Manufacturing & Testing Considerations
The 12AX7 Vacuum Tube Consider buying pre-tested tubes. Or must test tubes prior to assembly.

Even Order Harmonics

Digital Effects Jason Knedlhans

Attack / Decay Control Summing Amp Low Freq Oscillator Signal Routing Digital Controls Analog Audio Analog Controls Analog Control DSP State 16 bit Digital Audio 16 bit Digital Control Analog Audio Output Analog Effects DSP Processor Power Supply Pre Amp Joe Mike Kahnec Filter DAC Jason Bounnong

Functional Description
Digital Effects Functional Description Allows user to add digital audio effects to the original audio signals created by oscillators Converts analog audio signal to a digital signal Applies digital effects Distortion Echo Auto Wah Audio is then converted to an analog signal for final output stage.

Digital Effects Block Requirements Standard Requirements Min. Operating Temperature Range 0 – 40 ºC Min. Operating Humidity Range 0 – 100 % N.C. Min. Storage Temperature Range -10 – 70 ºC Min. Storage Humidity Range Min. Source 1 Voltage Range Min, Source 1 Current Draw 4.75 – 5.25 VDC 800 mA Min. Source 2 Voltage Range Min. Source 2 Current Draw -5.25 – VDC 200 mA Max. Power Consumption 500 mW

Digital Effects Block Requirements Standard Requirements Max. Parts and Material Costs $50 Max. Manufacturing Costs $20 Max. PCB Area 120 cm2 Max. Block Area Max. User Interface Voltage .01 μV Block Lifetime 10 years Service Strategy Factory Repair EMC Requirements EMC Part 4, Section 2 EMC Part 4, Section 7 Safety Requirements UL 469 Musical Instruments and Accessories

Digital Effects Block Requirements Performance Requirements Input & Output Audio Frequency Range 20 Hz to 20 kHz Input & Output Voltage Range +/- 4 V Minimum Throughput 50 ms Minimum Sampling Rate 44.1 kHz Max. Input Impedance 20 kW Max. Output Impedance 1 kW Minimum 1kHz 0.3 % Minimum SNR 95 dB

Performance Requirements Processor Requirements
Digital Effects Block Requirements Performance Requirements Processor Requirements Digital Word Length 16 bits Minimum Instructions Per Second 10 MIPS Direct bit Input Yes Multiply Function Preferred Serial Interfaces SPI, DCI, I2C, Standard 4 Wire Memory Size > 2 Kbytes

Digital Effects Block Diagram DSP Processor Analog Input Antialiasing
± 2V Antialiasing Filter DSP Processor ADC Serial Digital Controls 4 Analog Output Serial DSP State DAC Serial ± 2V Memory

Digital Effects Block Signal Table

Overall Block Schematic
Digital Effects Overall Block Schematic

Applicable Worst Case Analysis Plan (See DFM Analysis Guide)
Digital Effects Analog DFM Plan Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Input Signal Conditioning Audio ADC R, L & C Tol RLC Specs Gain vs Freq Gain Bandwidth Input Z Output Z DC Offset Voltage Volume Control Max Offset Voltage Over Current Protect Parameter Control Audio DAC Sample/Hold Required? Effect Select Noise Ripple Display Controller Output Current Available Over Current Protection

Input Stage Calculations
Digital Effects Input Stage Calculations Vi: -2 to 2 V Vo: 0 to 5 V Need for a 2.5 V dc offset Inverting Amplifier

Input Stage Worst Case Analysis
Digital Effects Input Stage Worst Case Analysis Low End Worst Case Analysis High End Worst Case Analysis

Digital Effects Input Stage Waveforms

Output Stage Calculations
Digital Effects Output Stage Calculations Input: 0 to 5 V Zero crossing created by coupling capacitor Vi: to 2.5 V Vo: -2 to 2 V Inverting Amplifier

Output Stage Worst Case Analysis
Digital Effects Output Stage Worst Case Analysis

Output Stage Waveforms
Digital Effects Output Stage Waveforms

Digital DFM – Timing Analysis
Digital Effects Digital DFM – Timing Analysis Timing Parameters Digital Signal Output Type Input Type Tsu Setup Th Hold Margin F max Tpulse Min Checked DSP Master (SPI) Serial 20 ns 10 ns 30 MHz 5 MHz 50 ns ADC Slave 15 ns 20 MHz 7 MHz DAC Slave 0 ns 100 ns (I2C) 0.9 ms 1 MHz -10 Hz +10 Hz Display Controller ns 400 kHz -5 Hz +5 Hz

Digital DFM – DC Drive Analysis DC Drive Device Parameters
Digital Effects Digital DFM – DC Drive Analysis DC Drive Device Parameters Digital Device Output Type Input Type Tech Type Vil max Vih min Iil (-) Iih Vol Voh Iol Ioh (-) Min Vhyst Checked DSP I2C Output Serial CMOS 0.2VDD 0.6VDD -1 mA 1 mA 0.6 VDD – 0.7 25 mA -25 mA 0.05VDD DSP SPI Digital Serial DAC (SPI) Analog 0.7VDD -2 mA 2 mA 0.01 V VDD ADC (SPI) 0.01V -25mA 25mA 1mA -1mA 0.07VDD Display Controller (I2C) BiMOS 0.8V 2.1V N/A 4.4 mA

Digital DFM – DC Drive Verification DC Drive Device Parameters
Digital Effects Digital DFM – DC Drive Verification DC Drive Device Parameters Interface Vilmax –Volmax Vohmin - Vihmin Iolmax - |Iilmin| |Iohmin| - Iihmax DSP – Display Controller (I2C) 0.8 V – 0.6 V = 0.2 V 5.3 V – 2.1 V = 3.2 V 25 mA – 1 mA = mA 25 mA – 1 mA = mA DSP – DAC (SPI) 5.3 V – 3.5 V = 1.8 V 25 mA – 2 mA = 23 mA ADC – DSP (SPI) 1 V – 1 V = 0 V 3.5 V – 3 V = 0.5 V 25 mA – 1 mA = 24 mA

Digital Effects I2C Concerns Pull Up Resistors
Current drawn by Rp must be greater than minimum sink current of 3 mA In a 400 kHz system, a rise time of 300 nsec must be maintained Improved ESD Susceptibility Rs must be low enough that at VOL the voltage at the input pin is not lower than VIL

SPI Prescaler Calculations
Digital Effects SPI Prescaler Calculations To insure reliable function FSCK is chosen to be 10 MHz

Digital Effects Firmware Flowchart

Digital Effects Bill of Materials Total Part Count: 36
Unique Part Count: 22

Digital Effects Reliability Analysis MTBF: 373336 hours or ~42.5 years
Crystal Oscillator creates greatest amount of FITS Use ceramic oscillator

Digital Effects Sustainability m s m+2.5s-p m+3.5s-p Device
Metal Film Resistors Primary Attributes: Device Type (Metal Film) Secondary Attributes: Technology Package Voltage 1990 N/A 12 14 26 Ceramic Capacitors Primary Attributes: Device Type (Ceramic Capacitor) 1980 9 23 Zener Diode Primary Attributes: Device Type (Specialty Consumer) 2001.5 1975 1987 1997 7.8 12.5 4.2 15 0.25 0.5 1.5 22.8 12.75 8.3 5.7 Potentiometer Primary Attributes: Device Type (Other R, L, C’s) 1985 10 4 ADC Primary Attributes: Device Type (A/D Converter) Secondary Attributes: Technology (CMOS) Package (SOP) Voltage (5V or above) 2010 1995 1992.5 6.5 5.3 35.25 5.25 -0.25 47.75 11.75 5.05 Display Digits Primary Attributes: Device Type (Display) 6 -1 -5 5

Digital Effects Sustainability m s m+2.5s-p m+3.5s-p Device DAC
Primary Attributes: Device Type (D/A Converter) Secondary Attributes: Technology (CMOS) Package (SOP) Voltage (5V or above) 2001.5 2010 1995 1992.5 7.8 12.5 6.5 5.3 15 35.25 5.25 -0.25 22.8 47.75 11.75 5.05 Dual Op Amp Primary Attributes: Device Type (Amplifier) Secondary Attributes: Technology (Bipolar) 2004.5 1975 N/A 8.3 19.25 0.25 27.55 12.75 Display Controller Primary Attributes: Device Type (Specialty, Consumer) Effects Select Switch Primary Attributes: Device Type (Other R, L, C’s) Secondary Attributes: Technology Package Voltage 1985 10 4 14 Microprocessor Primary Attributes: Device Type (16 bit Processor) 1994.5 1987 7 6 0.5 13 Crystal Oscillator

Digital Effects Sustainability Least Sustainable Aspects
Display Digits Decrease operating voltage Display Controller Microprocessor

Digital Effects PCB Layout 2 2 2 9 5 3 8 1 8 4 6 13 7
Digital Signal Processor 2 7 Segment Display 9 3 Display Controller 5 3 4 Digital-to-Analog Converter 8 5 Analog-to-Digital Converter 6 Dual Operational Amplifier 1 7 7 Oscillator 12 8 Potentiometer 9 SP4T Switch 8 10 Capacitor 4 11 Resistor 6 12 Zener Diode 13 13 Interface Connection

Manufacturing Considerations
Digital Effects Manufacturing Considerations Potentiometer must be manually placed SP4T switch must be manually placed Signal lines must be very clean

Digital Effects Test Considerations
Audio input stage voltage range correct ADC and DAC properly functioning All digital effects selectable and functioning Audio output stage voltage range correct

Digital Effects Waveforms

Power Supply Bounnong Khamphoumy

Power Supply Description Purpose Function
To provide each block with the voltage and current it needs. Function Interface between the product and the external power grid. Converts AC voltage into three separate, regulated DC voltages. Kept separate from the main PCB.

Power Supply Block Requirements

Sub-Circuit Block Diagram
Power Supply Sub-Circuit Block Diagram 120 VAC Fuse XFormer Bridge Rectifier Filter Voltage Regulator +5 VDC XFormer Bridge Rectifier Filter Voltage Regulator -5 VDC Fuse XFormer 6.3 VAC 230 VAC Fuse XFormer Bridge Rectifier Filter Voltage Regulator 100 VDC

Signal Definition Table
Power Supply Signal Definition Table

Power Supply Schematic

Power Supply 6.3 V Line – Transformer Worst-Case 1 Worst-Case 2
2.5 VA transformer; rated at 6.3 V, 400 mA. 24% voltage regulation. Turns Ratio – (Domestic), (Global) Worst-Case 1 A. Domestic (Vline = 132 V) No Load Vout = (132 / 18.25)*(1.24) = 8.97 V rms B. Global (Vline = 253 V) Vout = (253 / 19.17)*(1.24) = 8.59 V rms Worst-Case 2 A. Domestic (Vline = 102 V) Full Load Vout = 102 / 18.25 = 5.59 V rms B. Global (Vline = V) Vout = / 36.51 = 5.35 V rms

Power Supply 5 V Line – Transformer Worst Case 1 Worst Case 2
20 VA transformer; rated at 8 V, 2.5 A. 20% voltage regulation. Turns Ratio – (Domestic), (Global) Worst Case 1 A. Domestic (Vline = 132 V) No Load Vout = (132 / 14.38)*(1.20) = V rms B. Global (Vline = 253 V) Vout = (253 / 28.75)*(1.20) = V rms Worst Case 2 A. Domestic (Vline = 102 V) Full Load Vout = 102 / 14.38 = 7.09 V rms B. Global (Vline = V) Vout = / 28.75 = 6.8 V rms

5 V Line – Bridge Rectifiers
Power Supply 5 V Line – Bridge Rectifiers Average forward current rating, IF = 4 A. Non-repetitive peak forward surge current for <= 8.3 ms, IFSM = 125 A. Peak inverse voltage, PIV = 200 V. Max. Forward voltage drop, VF = 1.1 V per element. Worst Case 1 A. Vin = V rms Forward-Biased Vout = 11.02*sqrt(2) – 2*(.7) = VPeak Reverse-Biased Vin = *sqrt(2) = V (which is less than PIV) Worst Case 2 A. Vin = 6.8 V rms Output Voltage Vout = 6.8*sqrt(2) – 2*(1.1) = 7.42 VPeak (enough for output voltage and dropout voltage of regulator, ~ 6.5 V)

5 V Line – Capacitive Filter
Power Supply 5 V Line – Capacitive Filter 6800 μF electrolytic capacitor w/ a 20% tolerance. Working Voltage, VW = 35 V. Anticipated Load Current, IL = 1 A. Acceptable Voltage Ripple, VR = 1.5 V. Capacitance Analysis A. C = (IL*T) / (2*Vr) = (1*(1/60)) / (2*1.5) = 5.55 mF (will use a 6.8 mF cap. in actual design) Worst Case 1 A. Vin(from bridge) = V (which is less than cap's VW)

5 V Line – Capacitive Filter Cont.
Power Supply 5 V Line – Capacitive Filter Cont. Worst Case 2 Filter capacitor at -20%, +20%, and nominal. -20% +20%

5 V Line – Voltage Regulators
Power Supply 5 V Line – Voltage Regulators LT from Linear Technologies. Fixed 5 V output w/ 2% tolerance. Max. Load Regulation = 35 mV. Max. Ground Current, IG = 10 mA. Max. Dropout Voltage = 1.5 V. Worst Case Max. Power Dissipation PD = (Vi – Vo)*ILoad + Vi*IGround = (14.18 – 4.87)* *.01 = W Thermal Considerations A. Control Section TA = TJ – PD*(ΘHS + ΘCase-to-HS + ΘJC) = 125 – 18.76*( ) = ˚C B. Power Transistor = 150 – 18.76*( ) = ˚C Means, internal ambient temperature should be kept below 51 ºC Heatsinks are critical, but LDO also has a Built-in Thermal Shutdown (160 ºC).

Power Supply 100 V Line – Transformer Worst-Case 1 Worst-Case 2
6 VA transformer; rated at 115 V, 50 mA. 69% Voltage Regulation, according to actual benchtesting. Turns Ratio – 1 (Domestic), 2 (Global) Worst-Case 1 A. Domestic (Vline = 132 V) No Load Vout = (132 / 1)*(1.69) = V rms B. Global (Vline = 253 V) Vout = (253 / 2)*(1.69) = V rms Worst-Case 2 A. Domestic (Vline = 102 V) Full Load Vout = 102 / 1 = 102 V rms B. Global (Vline = V) Vout = V rms

100 V Line – Bridge Rectifier
Power Supply 100 V Line – Bridge Rectifier Average forward current rating, IF = 4 A. Non-repetitive peak forward surge current for <= 8.3 ms, IFSM = 125 A. Peak inverse voltage, PIV = 400 V. Max. Forward voltage drop, VF = 1.1 V per element. Worst-Case 1 A. Vin = V rms Forward-Biased Vout = *sqrt(2) – 2*(.7) = V Reverse-Biased Vin = *sqrt(2) = V (which is less than PIV) Worst-Case 2 A. Vin = V rms Output Voltage Vout = 97.75*sqrt(2) – 2*(1.1) = V

100 V Line – Filter & Regulator
Power Supply 100 V Line – Filter & Regulator 4.7 μF electrolytic capacitor w/ a 20% tolerance. Working Voltage, VW = 400 V. Anticipated Load Current, IL = .5 mA. Accepted Voltage Ripple, VR = 1 V. 100 V zener diode w/ 5% tol. Capacitance Analysis A. C = (IL*T) / (2*Vr) = ((.5E-3)*(1/60)) / (2*1) = 4.17 μF (will use a 4.7 μF cap. in actual design) Worst Case 1 A. Vout(from bridge) = V (which is less than cap's VW)

Power Supply PCB Layout

Passive Component Specs.
Power Supply Passive Component Specs.

Power Supply Connector and Harness Input Output
AC receptacle with IEC 320 compliance, will be used for AC input. Switch will be used to switch between domestic and non-domestic line voltages. Each transformer input equipped with current fuse. Outputs are +5VDC, -5VDC, 6.3VAC, +100VDC, and GND. Receptacle installed on Power Supply Board and Main Board, each. Utilizes 7 contacts, one for each voltage and three separate grounds. Contacts crimped to 18 AWG, stranded wire. Harness should be six feet in length; sufficient for Power Board to lay on floor. Receptacle Plug

Power Supply Bill of Materials

Reliability Assessment
Power Supply Reliability Assessment From the spreadsheet, we can see that the dominant parts for unreliability are the plastic shell connectors. It's failure rate is high for the method we chose, Method D. Reliability can be improved by having all the parts machine-placed, rather than by hand. Also if parts were purchased directly from the manufacturer, that would improve reliability. A last resort would be to design the power supply so that it is part of the main board. This would eliminate the need for the plastic shell connectors.

Prototype Information

Overall Prototype Plan
Construction 4 PCB’s Interface and LFO, Power, Digital Effects, Output Stage Power board separate from main unit Size of each 232 x 232 cm Total of 216,000 cm2 Total Volume: 9000 cm3 TTL and CMOS compatible Purfboard prototype board ¼” Phono output Functions Demonstrated Unique User Interface 3 input strips demonstrated vs. 6 in design Analog Overdrive

Appendices

High Level Gantt Chart

Block Task-Resources Estimate
Appendix-Low-Frequency Oscillator Block Task-Resources Estimate Project definition and system design phases: hours Verification, integration, and implementation phase: hours Testing and fabrication of final product: 40 hours Estimated total manhours: manhours Estimated total cost: $ (includes parts and fabrication)

Appendix-Low-Frequency Oscillator Fine Frequency Adjust
FADJ; [Max frequency deviation is +/- 70%] VFADJ = x (% deviation) VFADJ = x (+/-70) VFADJ = -2.4 and 2.4 RF = (VREF – VFADJ) / 250 μA RF = (2.5 – 2.4) / 250 μA = 400Ω RF = (2.5 – (-2.4) / 250 μA = 19.6 kΩ So, RF = 400Ω to 19.6kΩ for maximum frequency deviation (20kΩ pot) For 10kΩ potentiometer: 10kΩ = (2.5 – VFADJ) / 250 μA => VFADJ = 0 V=>0% deviation 100Ω = (2.5 – VFADJ) / 250 μA => VFADJ = 2.4 V=>-70% deviation

EE595 Capstone Design Team 1 i1.

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