Download Electrical Engineering Test Plan

P09003 Test Plan
1
P09003 Interactive Game For Child
Test Plans & Results
By: Alana Malina, Ketan Surender, Jesse Muszynski
Table of Contents
MSD I: WKS 8-10 TEST PLAN
1.1
1.2
1.3
1.4
Introduction
Sub-System/Critical Components Being Tested
Approval Guide, Sponsor
Test Strategy
MSD II WKS 2-4: FINAL TEST PLAN
2.1
2.2
2.3
2.4
2.5
Data Collection Plan
Measurement Capability
Test Conditions and Setup
Sponsor/Customer Requests/Considerations
Test Procedure
MSD II WKS 3-10 DESIGN TEST VERIFICATION
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Component
Subsystem
Reliability
Logistics and Documentation
Definition of Success
Contingency and Mitigation
Design Summary & Conclusion
Function/Performance Reviews
2
2
2
3
3
6
6
6
6
6
6
9
9
10
11
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P09003 Test Plan
1. MSD I: WKS 8-10 TEST PLAN
1.1. Introduction
The goal of this project is to create a handheld game for Luke, a 9 year old child with
severe visual limitations. The Electrical Engineering team is tasked with developing a
hardware platform to accommodate game play and future development. This platform
will include microprocessor (Parallax Propeller), 4” LCD screen, two stereo speakers, a
headphone jack, vibration modules for tactile feedback, SD card integration for and
buttons for user interface.
1.2. Sub-Systems/Critical Components Being Tested
1.2.1. User Input
1.2.1.1.
Mechanical/Electrical Interface for Buttons
1.2.2. Audio
1.2.2.1.
Volume Control
1.2.2.2.
Headphone Jack
1.2.2.3.
Stereo Speakers
1.2.2.4.
Amplifier
1.2.3. Display
1.2.3.1.
Power Connection
1.2.3.2.
NTSC Connection
1.2.4. Tactile Feedback (Vibration)
1.2.4.1.
Activation of Motors
1.2.4.1.1. Individually
1.2.4.1.2. Together
1.2.4.2.
Sensitivity Variation
1.2.4.3.
Motor Current
1.2.5. External SD Cartridge
1.2.5.1.
Read Data/Gameplay
1.2.5.2.
Audio Playback
1.2.6. Power
1.2.6.1.
LCD
1.2.6.2.
Microprocessor
1.2.6.3.
Audio Subsystem
1.2.6.4.
Vibration Modules
2
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Figure 1: Electrical System Block Diagram
1.3. Approval; Guide, Sponsor
Approved by:
Team Members – Alana Malina, Ketan Surrender, Jesse Muszynski, Chris Yang
Guide – Professor George Slack
Sponsor – NSF, Dr. Debartolo
1.4. Test Strategy
1.4.1. Product Specifications
Electrical Specifications
Metric
Pass/Fail Criteria
Audio
Frequency
300 – 8k Hz
Headphone Interface (Jack)
Size
1/8 Inches
Battery Life
Play Time
2 Hours
Power
Battery Output
7.4 Volts
Save Battery
Idle time
5 Minutes
Table 1: Electrical Specifications
Need
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1.4.2. Hardware Tests
Subsystem
Test #
User Interface
UI1
A1
Audio
A2
A3
Tactile
Feedback
(Vibration)
V1
External SD
Cartridge
SD1
P1
P2
P3
Power
P4
P5
P6
P7
Test
Description
Ensure electrical
interface of Buttons is
consistent, individual
Buttons
and simultaneous
button presses can be
logged
Electrical Measurement
of DAC Filter and
Audio Frequency
Amplifier Frequency
Response
Response w/o
Transducer Load
Verify that audio
Headphone/Speaker transducer switches
Switching
promptly when changing
in and out headphones
Verify speaker volume
Audio Volume
adjusts accordingly
Motors can be turned on
independently as well
Motors and
as together. Also have
Sensitivity
varying levels of
intensity.
Verify gameplay and
Interface
audio playback from SD
Card
Charged Batt.
Test battery voltage off
Voltage
the charger.
Run resource heavy
Battery Life
game (utilizing all
subsystems)
Measure current
delivered from battery
Nominal On Current
during normal game
play.
Measure maximum
current delivered from
Max On Current
battery during play,
verify PTC does not trip.
Verify that PTC
PTC Trip Current
(resettable fuse) trips at
rated trip current.
Nominal Sleep
Verify that sleep current
Current
is less than 500µA
Verify 3.3V supply is
within regulator output
+3.3V Supply
range over full load
range
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P8
+12V Supply
P9
+12V Enable
Verify +12V supply is
within regulator output
range
Verify +12V enable
provides proper current
and voltage through
MOSFET.
1.4.3. Integration Testing
1.4.3.1.
Electrical Systems Integration
1.4.3.1.1. Power + Audio
1.4.3.1.2. Power + Tactile Feedback
1.4.3.1.3. Power + Display
1.4.3.1.4. Power + Audio + Display +Tactile Feedback
1.4.3.1.5. Gameplay and Audio from SD Card
1.4.3.1.6. Hard Boot
1.4.3.1.7. Hard Shutdown
1.4.3.2.
PCB Integration
1.4.3.2.1. Integrate appropriate systems onto one or more PCBs
1.4.3.3.
IT Integration
1.4.3.3.1. Software Shutdown
1.4.3.3.2. Software Boot
1.4.3.4.
ME/ID Integration
1.4.3.4.1. Ensure components fit
1.4.3.4.2. Verify Electrical/Mechanical Button Interface
1.4.3.4.3. Verify wire harness connections
1.4.3.4.4. SD Card Interface
1.4.4. Test Equipment Available
1.4.4.1.
Triple Output DC Power Supply
1.4.4.2.
Oscilloscope
1.4.4.3.
Digital Multi-Meter
1.4.4.4.
Function Generator
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2. MSD II WKS 2-4: FINAL TEST PLAN
2.1. Data Collection Plan
2.1.1. Phases of Testing
2.1.1.1.
Component
2.1.1.1.1. Vibration Motor Current Consumption
2.1.1.1.2. Speaker clarity/choice verification
2.1.1.1.3. PTC (Resettable Fuse) trip current verification
2.1.1.1.4. SD Card Interface – Data
2.1.1.1.5. SD Card Interface – Sound
2.1.1.2.
Subsystem
2.1.1.2.1. Audio Amplifier Power (No Audio)
2.1.1.2.2. Audio Amplifier Power (With Audio)
2.1.1.2.3. 3.3V DC/DC Converter
2.1.1.2.4. 12V DC/DC Converter
2.1.1.2.5. LCD + 12V DC/DC Converter
2.1.1.3.
Integration
2.1.1.3.1. PCB verification through test points
2.1.1.4.
Reliability
2.1.1.4.1. Battery performs as expected under normal use
2.2. Measurement Capability, Equipment
No Additional Needs
2.3. Test Conditions, Setup Instructions
Tests will be performed at room temperature. Pre-Integration and initial
integration testing will be done with a current limited lab power supply set to
6VDC
2.4. Sponsor/Customer Requests/Considerations
None
2.5. Test Procedure
2.5.1. Pre-Integration
2.5.1.1.
Components
2.5.1.1.1. Speaker Clarity/Choice
2.5.1.1.1.1.
Speaker “A” Projects Unlimited Rectangular
Speaker
2.5.1.1.1.2.
Speaker “B” Kobitone Circular Speaker
2.5.1.1.1.3.
Mounted both speakers in foam to simulate
enclosure conditions
2.5.1.1.1.4.
Wired speakers to headphone jack
2.5.1.1.1.5.
Plugged headphone jack to laptop and tested
spoken word along with different genres of music
2.5.1.1.1.6.
Test executed in room with “average” acoustics to
simulate environment it will be used in
2.5.1.1.1.7.
Jesse, Ketan, and Alana subjectively performed the
test
2.5.1.1.2. PTC (Resettable Fuse) Current Verification
2.5.1.1.2.1.
Measure and record the resistance of the part with
a 4 wire ohm-meter
2.5.1.1.2.2.
Connect a Bourns MF-NSMF110-2 in series with a
6V lab supply and set the current to 1.1amps, the
specified hold current for the part. Allow the part to
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sustain this current for 30minutes and record both
the current and voltage drop across the part.
2.5.1.1.2.3.
Measure and record the resistance of the part with
a 4 wire ohm meter immediately after removing
1.1amp test current.
2.5.1.1.2.4.
Measure and record the nominal trip current of the
part by slowly ramping up the current limit on the
power supply until the part goes in to its high
resistance state.
2.5.1.1.2.5.
Record the voltage and current supplied to the part
in its high resistance state.
2.5.1.1.3. SD Card Interface – Data
2.5.1.1.3.1.
Utilize PropDOS data transfer software
(FSRW/Femto Basic code)
2.5.1.1.3.2.
Utilize PropDOS .wav player (from Rays Logic)
2.5.1.2.
Subsystems
2.5.1.2.1. Audio Amplifier (No Power)
2.5.1.2.1.1.
Lab Power Supply providing 3.3 V, with ammeter
monitoring current to breadboard
2.5.1.2.1.2.
LM4836, C10, and C3 were placed on TSSOP
Proto-Board
2.5.1.2.1.3.
All other components were prototyped using
breadboard and interfaced to TSSOP Proto-Board
2.5.1.2.1.4.
Apply 3.3 VDD to Audio Hardware
2.5.1.2.1.5.
Ground Audio Inputs
2.5.1.2.1.6.
Set Volume Pot to Maximum Setting
2.5.1.2.1.7.
Ground Shutdown Pin of LM4836
2.5.1.2.1.8.
Monitor Running No Audio Current
2.5.1.2.1.9.
Connect Shutdown Pin of LM4836 to VDD
2.5.1.2.1.10.
Monitor Shutdown Current
2.5.1.2.2. Audio Amplifier (With Audio)
2.5.1.2.2.1.
Lab Power Supply providing 3.3 V, with ammeter
monitoring current to breadboard
2.5.1.2.2.2.
LM4836, C10, and C3 were placed on TSSOP
Proto-Board
2.5.1.2.2.3.
All other components were prototyped using
breadboard and interfaced to TSSOP Proto-Board
2.5.1.2.2.4.
Apply 3.3 VDD to Audio Hardware
2.5.1.2.2.5.
Set Volume Pot to Maximum Setting
2.5.1.2.2.6.
Ground Shutdown Pin of LM4836
2.5.1.2.2.7.
Apply Signal Generator (Hi-Z) to Audio Inputs
2.5.1.2.2.8.
Apply Sinusoidal Input Signal
2.5.1.2.2.8.1. Vary Vpp
2.5.1.2.2.8.2. Vary Frequency
2.5.1.2.2.9.
Monitor Power Supply Current for variations
2.5.1.2.3. 3.3V DC/DC Converter
2.5.1.2.3.1.
Use Maxim Pre-designed DC/DC Converter
2.5.1.2.3.2.
Use pre-made development board and adopt layout
for our overall PCB layout.
2.5.1.2.3.3.
Verify functionality.
2.5.1.2.4. 12V DC/DC Converter
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2.5.1.2.4.1.
2.5.1.2.4.2.
Use Maxim Pre-designed DC/DC Converter
Use pre-made development board and adopt layout
for our overall PCB layout.
2.5.1.2.4.3.
Verify functionality.
2.5.1.2.5. LCD Power Test
2.5.1.2.5.1.
Measure and record current supplied to the
MAX618 step-up DC/DC converter in its enabled
state with No Load. The MAX618 should be
supplied 6VDC from a lab power supply.
2.5.1.2.5.2.
Measure and record current supplied to the
MAX618 step-up DC/DC converter in its shutdown
mode while the LCD is connected. The MAX618
should be supplied 6VDC from a lab power supply.
2.5.1.2.5.3.
Measure and record current supplied to the
MAX618 step-up DC/DC converter in its enabled
state while the LCD is connected. The MAX618
should be supplied 6VDC from a lab power supply.
2.5.1.2.5.4.
Measure and record the current supplied to the
MAX618 while it is in shutdown mode and the LCD
is connected. The MAX618 should be supplied
6VDC from a lab power supply.
2.5.1.2.5.5.
Perform the same test as in 1.4 while the MAX618
is supplied 8VDC from a lab power supply.
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3. TEST RESULTS
3.1. Component
3.1.1. Vibration Motor Power Consumption
Motor Big Test Data
V
I (mA)
1.5
60
2
90
2.5
115
3
190
3.3
210
3.4
218
Stall 3.3
310
Motor Small Test Data
V
I (mA)
1.5
45
2
58
2.5
80
3
102
3.3
118
3.4
167
Stall 3.3
420
3.1.2. Speaker Choice
Jesse, Ketan, and Alana subjectively all agreed on Speaker Choice B
(Korbitone, Circular shape) by listening to different varieties of music and
a spoken word track.
3.1.3. PTC Trip Current Verification
Test
1.1
1.2
1.2
1.3
1.4
1.5
1.5
Measurement
Resistance
Voltage Drop
Current
Resistance
Trip Current
Current
Voltage
Value
0.174
0.89
1.1008
0.176
1.4
0.1163
7.2
Ω
V
A
Ω
A
A
V
Calculations
Resistance of part at
1.1A
R=V/I
0.8085 Ω
Power dissipated in tripped
state
P=V*I
0.6978 W
3.1.4. SD Card Interface (Data and Audio)
Data transfer and Audio playback were verified via gameplay
3.1.5. LCD Power Testing
Test
1.1
1.2
1.3
Voltage Current
/SHDN
6
460 µA
H
6
10.1 µA
L
7.2
388 mA
H
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1.4
1.5
6
8
137 µA
206 µA
L
L
Results of this test show that the LCD draws additional current through the inductor
on the MAX618 which is always connected to the input supply voltage. Because of
this a P-channel MOSFET is recommended to clamp off the supply to the MAX618
when disabling the LCD is desired.
*Test did not need to be re-run with new power source voltage of 7.2V. The purpose
of he test was to verify the need for a PMOS switch in front of the LCD power circuitry
to put the LCD into a low power state.
3.2. Subsystem
3.2.1. Audio Amplifier Power Measurements – No Audio
Hardware Setup
I (mA)
P(mW)
Running No Audio 15.71
51.843
Shutdown
0.03696
0.0112
I - RMS Power Supply Current
P - Power Consumed by Audio Hardware
3.2.2. Audio Amplifier Power Measurements – With Audio
Vpp (V)
Freq (Hz)
I (mA) P(mW)
0.5
440
49.24 162.492
0.5
1000
49.94 164.802
0.5
4000
50.98 168.234
0.5
8000
49.94 164.802
1.5
440 121.58 401.214
1.5
1000 123.27 406.791
1.5
4000 127.06 419.298
1.5
8000 123.94 409.002
3.3
440 245.56 810.348
3.3
1000 247.33 816.189
3.3
4000 254.68 840.444
3.3
8000 248.06 818.598
Vpp - Input Signal Peak to Peak Voltage
Freq - Input Signal Frequency
I - RMS Power Supply Current
P - Power Consumed by Audio Hardware
3.2.3. 3.3V DC/DC Converter
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Verified 7.2V step down to 3.3V
3.2.4. 12V DC/DC Converter
Verified 7.2V step up to 12V
3.3. Reliability*
LCD
Motors
Processor
Audio
Min V
11
Nom V
12
Max V
14
mA
175
0
2.7
2.7
3.3
3.3
3.3
?
3.6
5.5
32.8
80
333
mAh at 6V
350
Battery Size for 4 hour life
Battery Size for 3 hour life
Battery Size for 2 hour life
*Done for 6V, 1600mAh Battery
Comments
Asume 10% duty cycle for motors at
18.04 3.3V
44
183.15 Max Output Power
2380.76
1785.57
1190.38
Actual test results show that 7.2V 700mAh battery will run approximately 1.7 hours.
3.4. Logistics and Documentation
Complete test documentation and results can be found in the project notebooks of Ketan
Surrender and Jesse Muszynski. Relevant test results have been reproduced from
these notebooks here and on Google Docs which will be published to EDGE.
3.5. Definition of a Successful Test
A successful test is measured by how well the results match what we expected.
3.6. Contingencies/Mitigation
No electrical hardware problems were encountered or are expected to be encountered.
The selected battery pack physical dimensions did not match with the designed case
space and a different battery pack was selected (6V to 7.4V). No changes to the
circuitry had to be made because of the chosen regulator circuitries.
3.7. Design Summary & Conclusion
The Electrical Engineering team successfully designed and developed a first
generation playable platform. This version of the device meets all of the system
specifications. Game play is achieved via data transfer from a SD card
cartridge. The vibration modules, speakers, and headphone jack provide nonvisual cues and feedback to the user during game play. A playing time of 1.5
hours goes beyond the requested expectation. While only a prototype, this
device has laid the groundwork for future work in Senior Design teams to
continue developing this assistive device.
3.8. Function/Performance Reviews
3.8.1. Debriefing Faculty Guide
3.8.2. Lab Demo with Guide/Customer
3.8.3. Meeting with Sponsor