Download Electroluminescence Cap Project

Team # 10
Milestone # 3 –System-Level Design Review
Faculty Advisor/Reviewers:
Dr. Michael Frank
Dr. Bing Kwan
Dr. Rajendra Arora
Sponsored by:
Albert Daci
Team Members:
Monica Pereira
Monique Peregrina
Liang Liufu
Ifedayo Ogundana
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• The purpose of this project is to design an original cap that
implements electroluminescent technology. This cap will
consist of a panel with flashing capabilities and with a
hidden internal circuit.
• Each cap will implement a switch with three states (turn on,
flash, turn off) and be provided with an internal circuit with
water resistant capabilities. In addition, the cap will come
with a micro-USB charger hidden underneath the bill of the
cap.
Monica Pereira
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4
Front View
Monica Pereira
Internal View
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•
•
•
•
•
•
•
Fitted baseball cap
LiPo rechargeable battery
Battery charger
10cm x 10cm EL panel
3V DC battery inverter
IC chip
Liquid Encapsulating
epoxy resin
Monica Pereira
Reference
No.
Description
REQN-001
The design must be able to light on, blink
and turn of.
Timing IC
REQF-002
Use slim batteries that maximize the
prototype efficiency
REQN-004
Components will be water resistant
REQN-006
Design will withstand common wear and
tear.
Li-Po rechargeable
battery & battery
charger
Epoxy resin
encapsulating material
Component fulfilling
this requirement
CAP-001
Panel must be able to turn on
continuously, blink and turn off.
Blinking will be fulfilled
through the timing IC
REQF-004
A miniature button switch should be
implemented in the bill to turn
on/flash/turn off the EL logo.
The three operating
modes will be
operated through the
single pole, triple-throw
switch
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The following components have remained the same:
Item
Nominal Capacity
1000 mAh
Nominal Voltage
3.7V
Standard Discharge
Current
0.2A
Max Discharge
Current
Cell Voltage
Weight
Monica Pereira
Specifications
2.0 A
3.7-3.9 V
Approx.: 20g
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The LiPo Charger Basic uses a Microchip MCP73831T2ACI/OT charge management controller to charge 3.7V
Li-Po batteries at a rate of 500mA per hour.
The board incorporates a charging circuit, status LED,
connector for your battery (JST type), and USB connector.
A small mounting hole allows this charger to be
embedded into a project easily.
Monica Pereira
Parameter
Value
Regulated output voltage
4.20 V
Temperature range
-40ºC to 85ºC
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• Specifications
• Type: 555 type, Timer/Oscillator (Single)
• Supply Voltage: 2 V ~ 18 V
• Current: 60µA
• Operating Temperature: 0ºC to 70ºC
• Max Frequency: 1 MHz
Monica Pereira
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Reasons it was selected:
• Excellent electrical insulation properties
• Good storage stability
• Supports high temperatures
Monica Pereira
Color
Black
Cure Cycle
24 h
Dielectric Strength
19.36 kV/mL
Pot Life
60 minutes
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EL Panels from Surelight.com (Previous vendor was Adafruit)
Specifications
Glow size
Panel lifetime
Operating voltage
Operating
frequency
Current Draw
Initial Brightness
Operating
Temperature
Panel Capacitance
Monica Pereira
EL panel
10cm X 10cm (3.95"
x 3.95")
Greater than 25000
hours
60-250V AC
50-5000 Hz
0.14mA/cm2 (max)
@ 110V / 400Hz
75 cd/m2
-50ᵒ C / 65ᵒ C
45nF
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3V ELI-IMC Battery Inverter
Weight
2.2g
Frequency
2500Hz
Power
Supply
Required
3V or 1.5V
DC
Monica Pereira
Design our own inverter instead
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Liang Liufu
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C5
0.1µF
555_Timing_IC
RA
1.0MΩ
VCC
RST
OUT
DIS
RB
220kΩ
THR
TRI
CON
Switch
GND
CT
1µF
Battery
3.7 V
C4
0.1µF
LM555CM
Key = Space
Oscillator_Circuit
R6
Resonant_Circuit
1kΩ
Switch_Circuit
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7
1
5
Wien_Bridge_Oscillator
3
150Ω
2
490Ω
L1
3.518H
V3
4
C1
1µF
R3
Liang Liufu
R1
6
R4
398Ω
Timing_IC_Circuit
C3
1µF
LM741CH
-3.7 V
R5
398Ω
PanelC
45nF
C2
1µF
PanelR
200Ω
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Requirements:
• Input uses 3.7VDC
• Output 110VAC
• Output Current: >14mA
• Output Frequency: 400Hz
Liang Liufu
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R4
Wien-Bridge Oscillator Requirements
• 3.7V input
• 400Hz output
1kΩ
R2
490Ω
V1
3.7 V
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• 20mA output
1
5
U1
3
Vout
6
2
V2
4
C1
1µF
R1
398Ω
Liang Liufu
C2
1µF
LM741CH
-3.7 V
R3
398Ω
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Output:
•4.7Vp-p
•27.6mAp-p
•395Hz
Liang Liufu
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Requirements:
• Amplify oscillator signal to achieve
110VAC
• Maintain 400Hz
• Output current of 14mAp-p
Liang Liufu
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113VACp-p output
12.1mAp-p output
400Hz output
Liang Liufu
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Liang Liufu
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110VACp-p Output
14.1mAp-p Output
395Hz
Liang Liufu
In charge of controlling the
blink pattern
• Will allow the logo to flash
every second
• Uses a 555 Timing IC
Specifications:
• Power consumption: 15 mW
• Input voltage: 3.7V
• Output Voltage: 3.7V
• Frequency: 1 Hz
•
Monique Peregrina
Monique Peregrina
Monique Peregrina
FULL CIRCUIT SIMULATION ON BLINK STATE
Monique Peregrina
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Monique Peregrina
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• Battery Life Decreased
• Disconnected Wires
• El Panel Not Bright Enough
• Moisture near Electronics
• Timing IC Does Not Supply Enough Power
• Overheating
Probability: Moderate
Consequence: Moderate
Strategy
Probability: Low
Consequence: Severe
Strategy
Probability: Low
Consequence: Moderate
Strategy
Monique Peregrina
Probability: Moderate
Consequence: Devastating
Strategy
Probability: Very High
Consequence: Catastrophic
Strategy
Probability: Moderate
Consequence: Moderate
Strategy
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• Tasks Assignment
• Probability- high; Consequences- moderate
• Strategy – Proper communication amongst members.
• Design dependencies
• Probability- low; Consequences- moderate; Strategy- to be set aside
for help from advisor
• Personal complications
• Probability- very low; Consequences – severe; Strategy – re-planning
of task division
• Individual productivity
• Probability- high; Consequences – severe; Strategy- constant
evaluation of individual progress
Ifedayo Ogundana
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• More components may be needed
Probability – moderate
Consequence – minor
Strategy – some funds are reserved
• Damaging the timer IC and/or the inverter
Probability – low
Consequence – severe
Strategy – funds are reserved for purchase of extra major components
• Unaccounted-for-costs
Probability- low
Consequence - moderate, Strategy – low price components are purchased and
expenses are cut down
• Budget limitations
Probability – low
Consequence – moderate
Strategy – component parts are ordered to together to reduce cost of shipping.
Ifedayo Ogundana
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CURRENT EXPENSES
(CUSTOM INVERTER)
Expenses Subtotal = $413.89 →
$650.00 - $413.89
= $236.11 (Under budget)
Ifedayo Ogundana
CURRENT EXPENSES (OFF-THE-SHELF INVERTER)
For off-the-shelf inverter:
Expenses Subtotal = $446.34 →
$650.00 - $446.34
= $203.66 (Under budget)
Ifedayo Ogundana
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EL Cap Budget
Updated Per-Unit Budget
Ifedayo Ogundana
CURRENT EL CAP REPLICATION BUDGET
(CUSTOM INVERTER)
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Ifedayo Ogundana
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Monica Pereira
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Monica Pereira
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EXTRA SLIDES FOR REFERENCE
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Safety Test
Test conditions: The following tests must be measured at flowing air and safety protection
conditions. All batteries must standard charge and lay 24h.
Item
Over charge
Over discharge
Short-circuit
Thermal shock
Test Methods
At 20±5°C charging batteries with constant current 3A to voltage
4.8V, then with constant voltage 4.8V till current decline to 0. Stop
test until batteries temperature is 10 degrees lower than max
temperature.
At 20±5°C discharge battery with 0.2A continuously 12.5h.
At 20±5°C connect batteries’ anode and cathode by wire which
impedance less than 50mΩ, keep 6h
Put the battery in the oven. The temperature of the oven is to be
raised at 5±10 degrees per minute to a temperature of 130degrees
and remain inside the oven 60 minutes.
Performance
No explosion or fire
No explosion or fire
No explosion or fire
No explosion or fire
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Cautions of charge & discharge
Charge
Charging current should be lower than values that recommend below. Higher current and voltage
charging may cause damage to cell electrical, mechanical, safety performance and could lead
heat generation or leakage.
Batteries charger should charging with constant current and constant voltage mode
Charging current should be lower than (or equal to ) 1A
Charging voltage must be lower than 4.25V
Discharge
Discharging current must be lower than (or equal to )2A
Discharging voltage must not be lower than 2.75V.
Over-discharge
It should be noted that the cell would be at an over-discharge state by its self-discharge. In order to
prevent over-discharge, the cell shall be charged periodically to keeping voltage between 3.6-3.9V.
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Supply Current - Current in mA/cm2 versus supply voltage:
As the supply current is increased for the EL panel, the supply voltage also increases.
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The following factors have an impact on
lifetime:
• Higher Voltage
• Higher Frequency
• DC Supply
• High Ambient Humidity
• High Ambient Temperature
Brightness can be increased by using a
higher voltage or higher frequency.
Higher voltage slightly decreases life time,
but is preferred if higher supply current
can be accepted.
Brightness Vs Time
with time.
Unlike most other lighting which
can critically fail, EL Panel
brightness decreases with time.
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EL Panels emit light from 50VAC and increase in
brightness with higher voltage up to 200VAC. The
frequency should be over 50Hz. Brightness increases
with higher frequency up to 1000Hz. However, it is
recommended that frequencies in the range of 400600Hz and voltages of no greater than 160VAC are
used, otherwise the panel life will rapidly deteriorate.
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