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318-595 Capstone Project
Dynamic Aquatic Environmental Controller
Team #4
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PICTURE OF
DAEC
1
318-595 Capstone Project
Team 4: Dynamic Aquatic Environmental Control
• Controls Temperature, pH, conductivity, and oxygen level
• Monitors vital environmental conditions of fish tanks
• Provide information on current environmental conditions
in the fish tank.
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318-595 Capstone Project
Team 4: Expertise & Experience
• Shawn Bentley
• Chris Mueller
• Erick Janke
• Expertise: Industrial Electric Motors,
Nanotechnology,
Expertise: 2 internships
• Expertise: DSP, Materials Engineering
Experience: 1 internship
• Expertise: Industrial Controls
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318-595 Capstone Project
Team 4: Expertise & Experience
• Nic Langlois
• Jack Huynh
• Expertise: Microwave Engineering, EMF
Experience: Physics research
• Expertise: Power System Testing
Experience: Industrial Power System Testing
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318-595 Capstone Project
Team 4: Summary
– Estimation Summary
• Estimated total man-hours – 480 hours
– system design tasks ~ 50 hours
– detailed design tasks ~ 70 hours
– verification tasks ~ 120 hours
– documentation tasks ~ 240 hours
Note: This is only an estimation the manpower may
reduce throughout the semester
• Estimated cost - $400
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318-595 Capstone Project
Team 4: Performance Requirements
Sensors
• Temperature sensitivity of +/- 1 degree C
• pH Sensitivity of +/- .5
• Salinity sensitivity of +/- 5% mS
• O2 sensitivity of +/- 5% ppm Dissolved O2
Controller
• Analogue input output channels x 4
• Digital input output channels 8 bit x 3
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318-595 Capstone Project
Team 4: Performance Requirements
Display
• Alphanumeric LCD display minimum 4 line.
• No back light
Keypad
• Simple Alphanumeric keypad 12 key layout
Operational modes
• On
• Off
General
• Salt water tank operation
• Tank size from 50 gal up to 400 gal
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318-595 Capstone Project
Team 4: Standard Requirements
Environmental
• Operating Temperature Range: 50 – 90 OC
• Operating Humidity Range: 0 – 100 %
R.H. non-condensing
• Storage Temperature Range: -10 – 70 OC
• Storage Humidity Range: 0 – 100 %
R.H. non-condensing
• Storage Duration: 1 year
Mechanical
• DC driven Solenoids 12 – 24 V
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318-595 Capstone Project
Team 4: Standard Requirements
Power
• Nominal voltage 120 Vac  102 – 132 Vac
• Nominal frequency 60 Hz  57 – 63 Hz
• Maximum Power Consumption: 250 W
• Plug type B
Life Cycle
• Product Life Time: 10 years
• Full Warranty Period: 60 days
• Service Strategy: Factory Repair
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318-595 Capstone Project
Team 4: Key Risk Areas
• Compensating for non-linearity transducers
• Temperature dependant transducers
• Unknown time in programming
• Unknown costs concerned with out prototyping
• Interfacing unknown devices
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318-595 Capstone Project
Team 4: Safety Standards

UL1018: Electric Aquarium Equipment
 These requirements cover commercial and household electric equipment for use on or in
aquariums in indoor locations at 300 volts or less, in accordance with the National
Electrical Code, NFPA 70, such as heaters, pumps, filters, aerators, reflectors, hoods,
electrically wired stands, and similar equipment

UL 60730-1A: Automatic Electrical Controls for Household and Similar Use
 This Standard applies to the inherent safety; to the operating values, operating times, and
operating sequence where such are associated with equipment safety; and to the testing
of automatic electrical control devices used in, or in association with, household or
similar equipment.

UL 1244: Electrical and Electronic Measuring and Testing Equipment
 This standard applies to electrical, electronic, or electromechanical measuring
or testing equipment designed to measure, or observe, and indicate quantities of
electrical or electronic phenomena, or to supply electrical or electronic
quantities for measuring purposes.
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318-595 Capstone Project
Team 4: Safety Requirements
• Electrical components will be adequately protected from the
humid environment to prevent shorting and other dangerous
failures due to corrosion.
• Unit has a GFCI enabled power source.
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318-595 Capstone Project
Team 4: EMC Standard Summary
• 61000-3-3 EMC Part 4: Limitation of voltage fluctuations and
flicker in low-voltage supplies < 16 A
– Application: Power Supply
– Why: Product power supply could fail and cause lighting to
flicker
• 61000-4-2 EMC Part 4: ESD immunity tests
– Application: Entire Product
– Why: Product may give off static discharge if contacted by
humans
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318-595 Capstone Project
Team 4: EMC Standard Summary
• 61000-4-5 EMC Part 4: Surge immunity tests
– Application: Entire Product
– Why: Product must be susceptible to electrical disturbances
such lightning
• 61000-4-11EMC Part 4: Voltage dips, short interruptions and
variations
– Application: Entire product
– Why: Want to know if the product will work while
experiencing a dip in voltage or after a voltage dropout
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318-595 Capstone Project
Team 4: Block Diagram
Power Supply
Sensor Block 1
Keypad & Display
Microcontroller
Device Block 1
Device Block 2
Sensor Block 2
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318-595 Capstone Project
Team 4: Block Diagram Description
Block #
Owner
Block
Name
Brief description of
Block Function
Power
Interfaces
Digital
Interfaces
Analog
Interface
1
Shawn
Power
Supply
Converts AC to DC
In: AC
Out:0-30VDC
None
None
2
Chris
Sensors & Signal
Cond.
Acquires aquatic
data/ Amplifies
signal of sensors
In: +/-12VDC
Yes
Yes
3
Jack
Output
Cond. & Devices
Prepares output
signal / Corrects
aquatic environment
In: 5 VDC /
None
Yes
None
4
Erick
Controller
Interpret input from
sensor, control
operation of Devices
5 VDC
Yes
Yes
5
Nic
Keyboard &
Display
Displays readable
data for user
In: 5VDC
Out: 0/5 VDC
Yes
None
Shawn
Feeder
Delivers food to
creatures in tank
IN: 3VDC
Yes
None
*6
16
* Optional Block
318-595 Capstone Project
Team 4: Block Diagram Assignment
Power Supply
Sensor Block 1
Keypad & Display
Microcontroller
Key
Shawn Chris
Erick
Nic
Jack
Device Block 1
Device Block 2
Sensor Block 2
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318-595 Capstone Project
Team 4: Block #5 Signal Summary
Block Name:
Block Number:
Power Signals
Power1 VCC -12V (Temp Signal Cond)
Power2 VCC +12V (Temp Signal Cond)
Power1 VCC +5 (MicroController)
Power1 VCC +5 (Heater Out Interface)
Power2 AC Input (Heater Out Interface)
Digital Signals
Type
DC Power
DC Power
DC Power
DC Power
AC Power
Type
Direction
Input
Input
Input
Input
Input
Dir
Digital1 (keyboard) (6 bits) (MicroController)
Digital
Digital2 (display) (6 bits) (MicroController)
Digital
Digital3 (outputs to control devices) (4 bits) (MicroController)
Digital
Digital (1 bit) (Heater Output Interface)
Bidir
Output
Output
Analog Signals
Direction
Temperature Signal Conditioner
MicroController
Type
Analog
Analog
Analog
Analog
Analog
Output
Input
Input
Input
Input
Voltage
Nominal
12.0V
12.0V
5.0V
5.0V
120V
Output
Structure
Tristate
Tristate
Tristate
Voltage Range
Min
Max
11.4V
11.4V
4.75V
4.75V
102V
12.6V
12.6V
5.25V
5.25V
132V
Input
Structure
Tech
Standard TTL
Standard TTL
Standard TTL
Freq
Nominal
DC
DC
DC
DC
60Hz
Freq
Nominal
2.0Mhz
2.0Mhz
10hz
Freq Range
Min
Max
57Hz
Logic
Voltage
5V
5V
5V
Coupling Voltage Max
Impedance
Amplitude
Min
Max
Direct
Direct
Direct
Direct
Direct
5.0V
5.0V
5.0V
5.0V
5.0V
1k
1k
1k
1k
1k
ohm
ohm
ohm
ohm
ohm
2Kohm
2Kohm
2Kohm
2Kohm
2Kohm
N/A
N/A
N/A
N/A
63Hz
Vih Min
2.0V
N/A
2.0V
Freq Range
Min
Max
dc
dc
dc
dc
dc
1hz
1hz
1hz
1hz
1hz
% V-Reg
Max
0.05
0.05
0.1
0.05
0.15
Iih Max
120uA
N/A
N/A
V-Ripple
Max
0.25V
0.25V
0.1V
0.1V
N/A
Current
Max
0.1A
0.1A
0.5A
.01A
2A
Input Characteristics
ViL Max IiL Max Vth Min
0.8V
N/A
N/A
-2.6mA
N/A
N/A
N/A
N/A
N/A
Leakage
Max
10uA
10uA
10uA
10uA
10uA
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318-595 Capstone Project
Block 1 – Sensor Block
Owner: Chris Mueller
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318-595 Capstone Project
Team 4: Description, Block 1
Block Description and Purpose
• Capture Salinity, pH and O2 levels from the tank
• Convert the Salinity, pH and O2 level information into an
analogue signal
• Send an analogue signal to the microprocessor.
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318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Block Diagram
Power
Supply
9 VDC
pH Sensor
Conductivity
Sensor
O2 Sensor
Signal
Conditioning
Signal
Conditioning
Analogue Signal
to the
Microprocessor
0–5V
Signal
Conditioning
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318-595 Capstone Project
Team 4: Block #1 Signal Summary
Power Signals
Power1 VCC +12V
Power2 VCC -12V
Power3 AC Input
Power4 VCC +12V
Power5 VCC -12V
Power6 VCC 5V
Power7 VCC 5V
Type
(chris)
(chris)
(eric)
(eric)
(eric)
(eric)
Digital Signals
DC Power
DC Power
AC Power
DC Power
DC Power
DC Power
Type
Direction
Input
Input
Input
Output
Output
Dir
Voltage
Nominal
5.0V
12.0V
120V
12.0V
12.0V
5.0V
Output
Structure
Voltage Range
Min
Max
11.4V
11.4V
102V
10.8V
11.4V
4.5V
Input
Structure
12.6V
12.6V
132V
13.2V
12.6V
5.5V
Tech
Freq
Nominal
DC
DC
60Hz
DC
DC
DC
Freq
Nominal
Freq Range
Min
Max
57Hz
Logic
Voltage
Digital1 Data15-Data0
Digital2 Bit3-Bit0
Digital3 D7-D0
Analog Signals
Digital
Digital
Digital
Type
Input
N/A
Standard TTL
2.0Mhz
Input
N/A
Schmitt
CMOS
0.5Mhz
Bidir
Tristate
Standard TTL
5.0Mhz
Direction
Coupling Voltage Max
Impedance
Amplitude
Min
Max
5V
5V
5V
Analog1 RF Amp Output
Analog2 Audio Output
Analog
Analog
Output
Output
450Khz
20
Direct
Capacitive
5.0V
1.0V
800 ohm
6.8ohms
1.2Kohm
9.2ohms
N/A
N/A
63Hz
N/A
N/A
N/A
Vih Min
2.0V
N/A
2.0V
Freq Range
Min
Max
460Khz
20Khz
% V-Reg
Max
0.1
0.05
0.15
0.05
0.05
0.1
Iih Max
V-Ripple
Max
0.075V
0.075V
N/A
0.25V
0.25V
0.1V
Current
Max
1.5A
1.5A
1.0A
1.5A
1.5A
1.5A
Input Characteristics
Output Cha
ViL Max IiL Max Vth Min Vth Max Voh Min
400uA
0.8V
10uA
N/A
400uA
0.8V
Leakage
Max
-1.2mA
-10uA
-1.2mA
N/A
1.5V
N/A
N/A
2.6V
N/A
N/A
N/A
2.4V
10uA
N/A
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318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Standard Requirements
• Max operating temperature = 32˚C
• Operating Humidity Range: 0 – 100 % R.H. non-condensing
• Storage Temperature Range: -10 – 70 OC
• Storage Humidity Range: 0 – 100 % R.H. non-condensing
• Maximum Storage Ambient Temperature = 70 C
23
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Standard Requirements continued
• Maximum Total Parts: 40
• Maximum Parts and Material Cost: $150
• Maximum Assembly and Test Cost: $50
• Total PCB Area ~100 cm2
• Maximum Total Weight: .5 Kg
24
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Performance Requirements
• Ph/ORP Electrodes:
– Maximum output voltage: +3 V
– Maximum output impedance: 2 Mohms
• Conductivity Electrode:
– Maximum output impedance: 2 Mohms
• Op Amps:
– Max voltage input: 9 V
– Unity Gain
– Low Noise
25
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Safety & EMC Requirements
• Primary Safety Standards
– UL 1018: Electric Aquarium Equipment
– UL 1244: Electrical and Electronic Measuring and
Testing Equipment
• EMC Requirements
– 61000-4-2: ESD immunity tests
– 61000-4-5: Surge immunity tests
– 61000-4-11: Voltage dips, short interruptions and
variations
26
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Reliability Estimates
• Total Fits (λ): 536.2
• MTBF: 212.8 years
• Warranty Period: ¼ year
• Failures at ¼ year: .001 unit
• 1% Failures: 2.138 years
27
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Prototyping
Block Name
Block
Area
(cm2)
Total PCB
Area
(cm2)
PCB Substrate
Type
Comp Attachmet
Type
Socketed
Components
Types of
Connectors
100
20
Etching
Solder
OP Amps
Copper
Sensors and Signal
Conditioning
28
318-595 Capstone Project
Block 2 – Power Source
Owner: Shawn Bentley
29
318-595 Capstone Project
Team 4: Block 2, Individual Block Description / Block
Diagram
• Delivers current and voltage as needed by other
blocks
• Protects other blocks by preventing surges
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318-595 Capstone Project
Team 4: Individual Block Description, Block 2
Block Diagram
AC Outlet
120V
Rectifier
Rectifier
Current
Protection
Rectifier
Transformer
Regulator
Regulator
Regulator
LOAD
(12)V
1A
LOAD
(-12)V
1A
LOAD
(5)V
1A
Capacitor
31
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Performance Requirements/Signal Input/Output
Voltage (V):
• Input 120V (AC)
• Output voltages of 5V, 12 V, -12V.
• Output 2 AC voltages of 120V (AC)
Current (I):
• Provides current of 1A to all outputs
32
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Standard Requirements
• Max operating temperature = 32˚C
• Operating Humidity Range: 0 – 100 %
R.H. non-condensing
• Storage Temperature Range: -10 – 70 OC
• Storage Humidity Range: 0 – 100 %
R.H. non-condensing
33
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Safety & EMC Requirements
• Primary Safety Standards
– UL 1018 - Electric Aquarium Equipment
– UL 1244 - Electrical and Electronic Measuring and Testing
Equipment
• EMC Requirements
– 61000-3-3 - of voltage changes, voltage fluctuations and
flicker in public low-voltage supply systems
– 61000-4-2 - Electrostatic discharge immunity test
– 61000-4-5 - Surge immunity tests
– 61000-4-11 - Voltage dips, short interruptions and
34
variations
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Prototyping
Block 2
Block
Area
(cm2)
Total PCB
Area
(cm2)
Power
Supply
200
40
PCB
Substrate
Component
Attatchment
Type
Etching Solder
Types of
Connectors
Copper
35
318-595 Capstone Project
Team 4: Individual Block Description, Block 1,
Resources
• EMS LAB used for testing.
• Man hours approx. 40
• Materials include transformers, PCB board,
diodes, regulators, etc.
36
318-595 Capstone Project
Team 4: Individual Block Description, Block 1
Reliability Processing
•
•
•
•
Total λ = 766.424
MTBF (years) = 15.1007
Warranty of five years
Device most likely to fail is a capacitor. The capacitor
can be replaced with a filter package.
37
318-595 Capstone Project
Block 3 – Device block
Owner: Jack Huynh
38
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Block purpose and description
•Interface with Microcontroller output signals to energize
the relays.
•Use the relays to switch 120 VAC to solenoid valves of
chemical dispensers and air pumps
39
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Block Diagram 1
+12 VDC
120 VAC
From Power Supply
Micro Controller
(TTL) 5 V
Output conditioner
Ph Control
50W Max
Output conditioner
Conductivity Control
Output Conditioner
Aerator
40
318-595 Capstone Project
Block 3 : Signal summary
Block Number:
Nominal
Power1,2(PH,Cond Out Interface)VCC +12V
Power3(Aerator Out Interface) VCC +12V
Power4 AC Input(Ph Out Interface)
Power5 AC input(Conductivity Out Interface)
Power6 AC input (Aerator Out Interface)
Digital Signals
Digital1(Ph out Interface)
Digital2(Cdct Out Int)
Digital3 (Aerator Out Int)
DC Power
DC Power
AC Power
AC Power
AC Power
Type
Digital
Digital
Digital
Input
Input
Input
Input
Input
Dir
Input
Input
Input
12V
12V
120V
120V
120V
Output
Structure
N/A
N/A
N/A
Min
11.4V
11.4V
102V
102V
102V
Input
Structure
Standard
Schmitt
Standard
Max
12.6
12.6
132V
132V
132V
Tech
TTL
TTL
TTL
Nominal
DC
DC
60Hz
60Hz
60Hz
Freq
Nominal
10 hz
10 hz
10 hz
Min
57Hz
57Hz
57Hz
Logic
Voltage
5V
5V
5V
Max
N/A
N/A
63Hz
63Hz
63Hz
Vih Min
2.0V
2.0V
2.0V
Max
0.05
0.05
0.15
0.15
0.15
Iih Max
20uA
20uA
20ua
Max
0.25
0.25
N/A
N/A
N/A
Max
20 mA
20 mA
1.0A
1.0A
1.0A
Input Characteristics
ViL Max
IiL Max Vth Min
0.8V
0.8V
0.8V
-.4uA
-.4uA
-.4mA
N/A
N/A
N/A
41
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Safety and EMC Standards
Safety Standards
 UL1018: Electric Aquarium Equipment
 UL 60730-1A: Automatic Electrical Controls for Household
and Similar Use
EMC Standards
 61000-4-2 EMC Part 4: ESD immunity tests
• 61000-4-5 EMC Part 4: Surge immunity tests
• 61000-4-11EMC Part 4: Voltage dips, short interruptions and
variations
42
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Standard Requirement
•
•
•
•
•
•
•
•
Operating Temperature Range : 32-900 C
Operating Humidity Range : 0-100%
Storage Temperature range: -10 – 700 C
Storage Humidity Range : 0 – 100%
Storage duration : 1 year
Input Voltage Range: 102-132 VAC
Input Current Range :20uA – 2A
Maximum Power Consumption: 50 W
43
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Performance Requirements
•
•
•
•
Diode circuit protection over voltage surge
Input voltage : AC & DC
1-bit digital signal (TTL) input
Indoor operation
44
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Signal Input and Output Summary
• Power signals:
Input: 120 Vac (nominal) min:102 max:132
12 Vac (nominal) min:11.4 max 12.6
• Digital signal(1bit):
Input : 0-5 Vdc
45
318-595 Capstone Project
Team 4: Individual Block Description, Block 3
Prototyping plan
Block
Name
Block
#3
Block
Area
(cm2)
Total
PCP
(cm2)
200
20
PCP
Comp
Sub straight Attachment
Type
Type
Etching
Solder
Socketed
Components
No
Types
of
Connectors
DIP/
Ribbon
46
318-595 Capstone Project
Block 4 – Keypad and Display
Owner: Nic Langlois
47
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Block purpose and description
• Give the user an interface with the product allowing for the
user to set up the operational parameters for the DAEC
• Allow the user to see what the present settings are for the
DAEC
• This block primarily consists of a display unit and a keypad
interface with the supporting electronics.
48
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Performance requirements
Performance requirements
• Mechanical lifetime for keypad ~1million per key
• 5 Vdc power @ 1.2 mA nominal
• Standard 12 button alphanumeric keypad
• 8 bit digital input to display
• 4 bit input/out to/from keypad
Operational Modes
• Setup – when setting up the device it will prompt for each of
the four parameters in turn
• Standby – when not taking input from the keypad, stored
setting values will be displayed
49
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Standard requirements
Standard requirements
• LCD and Keypad mounted to the housing for the unit
• Backlit LCD display
• Large LCD display (minimum 16x4 character display)
• 5 Vdc logic
50
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Safety and EMC Standards
Safety Standards
 UL1018: Electric Aquarium Equipment
 UL 60730-1A: Automatic Electrical Controls for Household
and Similar Use
EMC Standards
 61000-4-2 EMC Part 4: ESD immunity tests
• 61000-4-5 EMC Part 4: Surge immunity tests
• 61000-4-11EMC Part 4: Voltage dips, short interruptions and
variations
51
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Block Diagram
5 Vdc from Power source
Display
Keypad
Signal processing
Signal processing
8-Bit Signal to Microprocessor
4-Bit Signals to/from Microprocessor
52
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Signal Summary
Block Name:
Block Number:
Power Signals
Power1 VCC +5
Digital Signals
Digital in from M.C.
Digital out to M.C.
Type
DC Power
Type
Digital
Digital
Direction
Input
Dir
Input
Output
Voltage
Nominal
5.0V
Output
Structure
N/A
Tristate
Voltage Range
Min
Max
4.75V
Input
Structure
5.25V
Tech
Standard TTL
TTL
Freq
Nominal
Freq Range
Min
Max
DC
Freq
Nominal
20 MHz
20 MHz
N/A
Logic
Voltage
5v
5v
Vih Min
2.0V
N/A
% V-Reg
Max
0.05
Iih Max
400uA
N/A
V-Ripple
Max
0.1V
Current
Max
1.2A
Input Characteristics
ViL Max IiL Max Vth Min
0.8V
N/A
-1.2mA
N/A
N/A
N/A
53
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Prototyping Plan
Block
Area
Block Name (cm2)
Keyboard and
Display
100
PCB
Total PCB Substrat
Area
e
(cm2)
Type
4
N/A
Comp
Attachment
Type
Socketed
Components
Solder
Yes
Types of
Connectors
Dip/Ribbon
54
318-595 Capstone Project
Team 4: Individual Block Description, Block 4
Reliability
Max FITS = l total = 152,121
MTBF = 1/ l total = .7499
Part With Higher l = LCD Display
How To improve
A LED display would give a much lower l. A second option is to
select a specific LCD display with a known low l. In either
case the ltotal would be significantly reduced.
55
318-595 Capstone Project
Team 4: Individual Block Description, Block 5
Block Description and Purpose
• Input Analog input from Device Blocks 1&2
• Produce Digital outputs for Control Blocks 1&2
• Interface with Keyboard
• Interface with Display
• Owner: Erik Janke
56
318-595 Capstone Project
Team 4: Individual Block Description, Block 5
Signal Summary
Power Signals
Power1 VCC +5
Digital Signals
Digital1 (keyboard) (8 bits)
Digital2 (display) (8 bits)
Digital3 (Device block 1) (1 bit)
Digital3 (Device block 2) (3 bits)
Analog Signals
Sensor Block
Sensor Block
Sensor Block
Sensor Block
1 (Temp.)
2 (PH)
2 (Cond.)
2 (O2)
Type
DC Power
Type
Digital
Digital
Digital
Digital
Type
Analog
Analog
Analog
Analog
Direction
Input
Dir
Bidir
Output
Output
Output
Direction
Input
Input
Input
Input
Voltage
Nominal
5.0V
Output
Structure
Tristate
Tristate
Tristate
Tristate
Coupling
Direct
Direct
Direct
Direct
Voltage Range
Min
Max
4.75V
5.25V
Input
Structure
Standard
Standard
Standard
Standard
Voltage Max
Amplitude
5.0V
5.0V
5.0V
5.0V
Tech
TTL
TTL
TTL
TTL
1k
1k
1k
1k
Freq
Freq Range
Nominal
Min
Max
DC
0
N/A
Freq
Nominal
2.0Mhz
2.0Mhz
10hz
10hz
Impedance
Min
Max
ohm
10K ohm
ohm
10K ohm
ohm
10K ohm
ohm
10K ohm
Logic
Voltage
5V
5V
5V
5V
dc
dc
dc
dc
Vih Min
2.0V
N/A
2.0V
2.0V
Freq Range
Min
Max
1hz
1hz
1hz
1hz
% V-Reg V-Ripple
Max
Max
10.00%
0.1V
Iih Max
120uA
N/A
20uA
20uA
Current
Max
0.5A
Input Characteristics
ViL Max IiL Max Vth Min Vth Max
0.8V
N/A
0.8V
0.8V
-2.6mA
N/A
-.4mA
-.4mA
N/A
N/A
N/A
N/A
Leakage
Max
10uA
10uA
10uA
10uA
57
N/A
N/A
N/A
N/A
318-595 Capstone Project
Team 4: Individual Block Description, Block 5
Block Diagram
+5VDC
From
Power Supply
Microcontroller
Key board
(TTL)
0.0 – 5.0 VDC
10kW Max Imp
From Sensor Block 1
0.0 – 5.0 VDC (qty 3)
10kW Max Imp
From Sensor Block 2
To Display
(TTL)
Temperature
To Device Block 1
(TTL)
PH
Conductivity
To Device Block 2
(TTL) (qty3)
O2
58
318-595 Capstone Project
Team 4: Individual Block Description, Block 5
Safety and EMC Standards
Safety Standards
 UL1018: Electric Aquarium Equipment
 UL 60730-1A: Automatic Electrical Controls for Household
and Similar Use
EMC Standards
 61000-4-2 EMC Part 4: ESD immunity tests
• 61000-4-5 EMC Part 4: Surge immunity tests
• 61000-4-11EMC Part 4: Voltage dips, short interruptions and
variations
59
318-595 Capstone Project
Team 4: Individual Block Description, Block 5
Standard Requirements/Reliability Estimates
•
•
•
•
•
Max operating temperature = 32˚C
Total λ = 8770
MTBF (years) = 13.0
No Warranty needed for this portion
Operating Humidity Range: 0 – 100 %
R.H. non-condensing
• Storage Temperature Range: -10 – 70 OC
• Storage Humidity Range: 0 – 100 %
R.H. non-condensing
60
318-595 Capstone Project
Team 4: Individual Block Description, Block 5
Prototyping Plan
Block Name
Microcontroller
Block
Area
(cm2)
100
Total PCB
Area (cm2)
PCB
Substrate
Type
100
Etching
Comp
Attachment
Type
Solder
Socketed
Components
Yes
Types of
Connectors
DIP/Ribbon
61
318-595 Capstone Project
Team 4: Individual Block Description, Block 6
Block Description and Purpose
•
Convert temperature to analog signal
•
Interface with Microcontroller
• Owner: Erik Janke
62
318-595 Capstone Project
Team 4: Individual Block Description, Block 6 Signal
Summary
Power Signals
Power1 VCC -12V
Power2 VCC +12V
Digital Signals
Type
DC Power
DC Power
Type
Direction
Input
Input
Dir
Voltage
Nominal
12.0V
12.0V
Output
Structure
Voltage Range
Min
Max
11.4V
12.6V
11.4V
12.6V
Input
Structure
Tech
Freq
Freq Range
Nominal
Min
Max
DC
0
N/A
DC
0
N/A
Freq
Nominal
Logic
Voltage
Vih Min
% V-Reg V-Ripple
Max
Max
5.00%
0.25V
5.00%
0.25V
Iih Max
Current
Max
0.1A
0.1A
Input Characteristics
ViL Max IiL Max Vth Min
None
Analog Signals
Analog Signal 1
Type
Analog
Direction
Output
Coupling Voltage Max
Impedance
Amplitude
Min
Max
Direct
5.0V
1k ohm
10k ohm
Freq Range
Min
Max
dc
1hz
Leakage
Max
10uA
63
318-595 Capstone Project
Team 4: Individual Block Description, Block 6
Block Diagram
+5VDC
+/-12VDC
From
Power Supply
Temperature
Sensor
Signal
Conditioner
To analog input of Micro Controller
64
318-595 Capstone Project
Team 4: Individual Block Description, Block 6
Safety and EMC Standards
Safety Standards
 UL1018: Electric Aquarium Equipment
 UL 60730-1A: Automatic Electrical Controls for Household
and Similar Use
EMC Standards
 61000-4-2 EMC Part 4: ESD immunity tests
• 61000-4-5 EMC Part 4: Surge immunity tests
• 61000-4-11EMC Part 4: Voltage dips, short interruptions and
variations
65
318-595 Capstone Project
Team 4: Individual Block Description, Block 6
Standard Requirements/Reliability Estimates
•
•
•
•
•
Max operating temperature = 32˚C
Total λ = 72.8
MTBF (years) = 1566
No Warranty needed for this portion
Operating Humidity Range: 0 – 100 %
R.H. non-condensing
• Storage Temperature Range: -10 – 70 OC
• Storage Humidity Range: 0 – 100 %
R.H. non-condensing
66
318-595 Capstone Project
Team 4: Individual Block Description, Block 6
Prototyping Plan
Block Name
Sensor Block 1
Block
Area
(cm2)
25
Total PCB
Area (cm2)
PCB
Substrate
Type
5
Etching
Comp
Attachment
Type
Solder
Socketed
Components
No
Types of
Connectors
DIP/Ribbon
67
318-595 Capstone Project
Team 4: Individual Block Description, Block 7
Block Description and Purpose
• Read TTL input from Microcontroller
• Switch 120VAC (250W max) signal to heater
Owner: Erik Janke
68
318-595 Capstone Project
Team 4: Individual Block Description, Block 7 Signal
Summary
Power Signals
Power 1
Digital Signals
Digital (1 bit)
Analog Signals
Type
AC Power
Type
Digital
Type
Direction
Input
Dir
Input
Direction
Voltage
Nominal
120V
Output
Structure
Tristate
Coupling
Voltage Range
Min
Max
102V
132V
Input
Structure
Standard
Voltage Max
Amplitude
Tech
TTL
Freq
Freq Range
Nominal
Min
Max
60Hz
57Hz
63Hz
Freq
Nominal
10hz
Impedance
Min
Max
Logic
Voltage
5V
Vih Min
2.0V
Freq Range
Min
Max
% V-Reg V-Ripple
Max
Max
0.15
N/A
Iih Max
20uA
Current
Max
2A
Input Characteristics
ViL Max IiL Max Vth Min Vth Max
0.8V
-.4mA
N/A
Leakage
Max
None
69
N/A
318-595 Capstone Project
Team 4: Individual Block Description, Block 7
Block Diagram
+5VDC
120VAC
From Power Supply
From Micro Controller
(TTL)
Output
Conditioner
Heater
250W Max
70
318-595 Capstone Project
Team 4: Individual Block Description, Block 7
Safety and EMC Standards
Safety Standards
 UL1018: Electric Aquarium Equipment
 UL 60730-1A: Automatic Electrical Controls for Household
and Similar Use
EMC Standards
 61000-4-2 EMC Part 4: ESD immunity tests
• 61000-4-5 EMC Part 4: Surge immunity tests
• 61000-4-11EMC Part 4: Voltage dips, short interruptions and
variations
71
318-595 Capstone Project
Team 4: Individual Block Description, Block 7
Standard Requirements/Reliability Estimates
•
•
•
•
•
Max operating temperature = 32˚C
Total λ = 15987
MTBF (years) = 7.14
No Warranty needed for this portion
Operating Humidity Range: 0 – 100 %
R.H. non-condensing
• Storage Temperature Range: -10 – 70 OC
• Storage Humidity Range: 0 – 100 %
R.H. non-condensing
72
318-595 Capstone Project
Team 4: Individual Block Description, Block 7
Prototyping Plan
Block
Area
Block Name (cm2)
Device Block 1
50
Total PCB
Area (cm2)
PCB
Substrate
Type
5
Etching
Comp
Attachment
Type
Solder
Socketed
Components
No
Types of
Connectors
DIP/Ribbon
73
318-595 Capstone Project
Team 4: Block Prototyping Plan
Block Name
Block
Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Power Supply
100
0
N/A
Solder
No
Wire
Sensors and Signal
Conditioning
100
20
Etching
Solder
Yes
DIP/Ribbon
Output Conditioning
and Devices
200
20
Etching
Solder
No
DIP/Ribbon
Microcontroller
100
100
Etching
Solder
Yes
DIP/Ribbon
Keyboard and
Display
100
0
N/A
Solder
No
Dip/Ribbon
74
318-595 Capstone Project
Team 4: Summary of Above
• Total Block Area = 600 cm2
• Signal Conditioning and Microcontroller will be printed on a
etched circuit board
• Socketed Components will primarily be chips
75
318-595 Capstone Project
Team 4: Reliability Report
Max FITS = l total = 172,212
MTBF = 1/ l total = .662 Years
Part With Higher l = EM relays in output Interface
How To improve
Suggested Change LCD to LED display, which will reduce the base l
from 1165 to 165.6. This will significantly reduce the overall l.
76
318-595 Capstone Project
Team 4: Reliability Summary
Block Number
Block Name
Block l Totals in
FITs
Block 1
Sensors and Signal Conditioning
536.188
Block 2
Power Supply
766.424
Block 3
Output Devices and Conditioning
Block 4
Keypad and Display
Block 5
Microcontroller
Block 6
Input Temperature
Block 7
Output Temperature
Total FITs
6053.253
152121.318
8699.562
1.562
4034.103
l Total
172212.411
MTBF (Yrs)
0.662
MTBF (Hrs)
5806.782
w
Warranty (w) Period in Years =
0.01
F(w)
Failures at 1 Warranty Period =
0.015
Failures at 1 Year =
0.779
F (10 Yr)
Failures at 10 Years =
1.000
F(t) = 1%
Time in Years for 1% failures =
0.007
F(t) = 1%
Time in Days for 1% failures =
2.432
F (1 Yr)
77
318-595 Capstone Project
Reliability Test Plan
Stress
24 Hour
Model
10 Year
Model
Max Input
Voltage
140 Vac
150 Vac
Number of
Power
Cycles
1
50
50F-90F
50F-90F
Number of
Thermal
Cycle
1
100
Max Shock
Grms
2
100
Number of
Shock
Cycles
2
1000
Thermal
Range
Accelerated
Stress
Model
Accelerated
1 Cycle
Time
Acceleratio
n Factor
N/A
N/A
N/A
N/A
N/A
N/A
78