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The UPS
Team 5
Team 5: Staff
► Michael
Myers
► Fernando Muñoz
► Jesus Lopez
► Adam Bitter
► Jake Koturbo
► BSEE
► BSEE
► BSEE
► BSEE
► BSEE
2
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
3
Team 5: Contact Info
►
Michael Myers
►
►
Fernando Muñoz
►
►
Jesus Lopez
►
►
Adam Bitter
►
►
Jake Kotrba
►
Phone 1: 414-688-8367
414-229-3216
Email: [email protected]
Phone 1: 414-793-7832
414-761-1244
Email: [email protected]
Phone 1: 414-248-1364
414-383-8548
Email: [email protected]
Phone 1: 262-388-1132
262-338-6532
Email: [email protected]
Phone 1: 414-229-3049
414-229-3216
Email: [email protected]
4
Team 5: Weekly Availability
Worksheet
►
Michael Myers
►
Fernando Muñoz
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
►
►
Jesus Lopez
►
Adam Bitter
►
Jake Kotrba
5
Team 5: Weekly Project Meeting
Plan
►
►
►
Weekly Meeting 1:
- EMS 202, Monday 8-10 AM
Weekly Meeting 2:
- EMS 202, Monday 8-10 AM, Wednesday 8-10 AM
Weekly Meeting 3:
Owner: Jesus Lopez
Expected Attendees: all members
Purpose: Project integration, review and set weekly goals
Owner: Mike Myers
Expected Attendees: all members
Purpose: Project procedures adjustments
- EMS 202, Monday 8-10 AM, Friday 5-until PM
Owner: Adam Bitter
Expected Attendees: all members
Purpose: Weekly goals wrap up
Note: Meeting Owners Send Weekly Email Notices, Record Business-IssuesActions, Keep Weekly Attendance Records
6
Team 5: Total Resources
► 560
Man-hours
► Cost - $500.00
7
Team #: Decision Making
► Decisions
will be taken based on a majority vote
8
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.
9
AC
Vac
Sensor
Jake
+
Main
Switch
Jesus
Switch
Jesus
Quick
Charger
Fernando
Trickle
Charger
Fernando
+
Battery
Fernando
Vdc
Sensor
Jake
+ Inverter
Mike
Load
CPU
Adam
+
+
Idc
Sensor
Jake
User
Interface
Jesus
+
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.
11
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.
►
12
Performance Requirements
►
►
►
►
►
►
►
►
►
►
►
►
►
►
Input AC Voltage: 105-132 V
Input AC Current: max 15 A
Input AC Frequency: 60Hz +/- 3Hz
Output AC Voltage: 105-132 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
13
Standard Requirements
►
►
►
►
►
►
►
►
►
Operating Range: -15 -- 50ºC
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: 5200 Watt hours per year
Max Volume: 40000 cm3
Max Weight: 14 kg
14
Safety Requirements
Primary Safety Standards
► IEEE C62.41-1991 Surge Protective Devices
Standards UL 1449 Transient Voltage Surge
Suppressors
► IEC 60095-1 Lead-Acid Starter Batteries
Primary EMC Standards
► EN 50065-1:2001 Signaling on low-voltage
electrical installations in the frequency range 3 kHz
to 148,5 kHz
► ICES-003 Interference Causing Equipment
15
Business Case
►
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►
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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: 0.25 years
16
AC
Vac
Sensor
Jake
+
Main
Switch
Jesus
Switch
Jesus
Quick
Charger
Fernando
Trickle
Charger
Fernando
+
Battery
Fernando
Vdc
Sensor
Jake
+ Inverter
Mike
Load
CPU
Adam
+
+
Idc
Sensor
Jake
User
Interface
Jesus
+
Block Level Description
18
Name: Michael Myers
Major: Electrical engineering
Team 5: UPS
Assignment: block 1
Block 1: Inverter
Inverter
Once the power fluctuates outside the
boundaries a control switch will allow
the inverter power to transfer to the
circuit.
20
AC
Vac
Sensor
Jake
+
Charging
Switch
Jesus
Quick
Charger
Fernando
Power Source
Switch
Jesus
Trickle
Charger
Fernando
+ Inverter
Mike
Load
CPU
Adam
+
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake
User
Interface
Jesus
+
Power Inverter
 The
job of this inverter is to transfer 12Vdc
to 120Vac.
 This
device will always be on
 Control
flow
switch will allow inverter power to
22
Inverter Performance Requirements
Input: Analog (nominal)
► 12Vdc
► 30Adc
Output: Analog (nominal)
► 120Vac
► 60Hz
► 15Amps(maximum)
23
Inverter Standard Requirements
Operating Voltage:
► Max 5.25Vdc
► Min 4.75Vdc
Operating Temperature:
► Max 50 C
► Min -15 C
Humidity:
► Max 95% r.h.
24
Inverter Signal Table
Power Signals
Type
Direction
Voltage
Nominal
Voltage Range
Min
Max
Freq
Freq Range
Nominal
Min
Max
% V-Reg
V-Ripple
Current
Max
Max
Max
Power1 VCC +12
DCPower
Input
12.0V
10.2
13.2V
DC
0
N/A
5.00%
0.1V
18A
Power2 VCC -15V
ACPower
Output
120.0V
102V
132.0V
AC
57
63
5.00%
0.25V
15.00A
 Analog
and digital interfacing – N/A
25
Prototyping Plan
Block
Name
Block Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Inverter
700
700
Fiber Glass
Solder
Yes
Flat Pins
26
Block Diagram
Inverter Block
Battery
(12Vdc)
DC-AC
To 12Vac
Transformer
To 120Vac
Switch
(120Vac)
27
Resource Estimate
► 14.9%
of the Material Estimate
► Estimated 149 hrs.
28
Name: Fernando Muñoz
Major: Electrical engineering
Team 5: UPS
Assignment: Power Block
Block 2a: Charger (Rectifier)
Block 2b: Battery
Vac
Sensor
Jake
+
Charging
Switch
Quick
Charger
Fernando
Power Source
Switch
Trickle
Charger
Fernando
+ Inverter
Mike
Load
CPU
Adam
+
Battery
Fernando
Vdc
Sensor
Jake
User
Interface
Jesus
+
Idc
Sensor
Jake
30
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
31
Power Electrical Interface Signals
Power Signals
Type
Direction
Voltage
Nominal
Voltage Range
Min
Max
Freq
Freq Range
Nominal
Min
Max
% V-Reg
V-Ripple
Current
Max
Max
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
0
N/A
1.00%
0.01V
35A
Power-3 VCC
+14.3V
DC Power
Output
14.3V
12.15V
15.73V
DC
0
N/A
1.00%
0.01V
2A
32
Block diagram of Power Supply
System
120 VAC
Main Input
Transformer
Rectification
15.7 VAC
Smoothing
14.3 VDC
Regulation
14.3 / 5 VDC
Regulated
output
14.3 VDC
With
Ripple
33
5 VDC Power Regulated System
34
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.
35
 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.
36
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.
37
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.
38
Prototyping Plan
Block
Name
Power
Block Area
(cm2)
700
Total PCB
Area (cm2)
700
PCB
Substrate
Type
Copper
Comp
Attachment
Type
Solder
Socketed
Components
Types of
Connectors
No
B type plug
Flat Pins
39
Resource Estimate
► 24.8%
of the Material Estimate
► Estimated 73 hrs.
40
Name: Jesus Lopez
Major: Electrical engineering
Team 5: UPS
Assignment: blocks 3 and 6
Block 3: Switching Gear
Block 6: Display
Standard Requirements
Temperature range:
► 150 C Max
► -15 C Min
Operation humidity Range:
► 95 % Max Rh
Intended aplication:
► home
► office
42
Performance Requirements
Signal Interfaces (digital)
► +5 Vdc logic control
► LED display
Signal Interfaces (analog)
► +10%/-15% 120 Vac
► 60 Hz +/- 3 Hz
43
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.
44
AC
Vac
Sensor
Jake
+
Charging
Switch
Jesus
Quick
Charger
Fernando
Power Source
Switch
Jesus
Trickle
Charger
Fernando
+ Inverter
Mike
Load
CPU
Adam
+
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake
User
Interface
Jesus
+
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.
46
Main Switch Nominal Ratings
Control Input : 5 Vdc
Input:
120 Vac
Output:
20 A
47
Main Switch Signal Table
Voltage Range
Power Signals
Type
Direction
Freq Range
Voltage
Nominal
Min
Max
Freq
Nominal
Min
Max
% V-Reg
Max
V-Ripple
Max
Current
Max
Power1 VCC
+5
DC Power
Input
5.0V
4.75V
5.25V
0
0
0
5.00%
0.1V
1.2A
Power1 AC
AC Power
Input
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
Power2 AC
AC Power
Output
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
Power3 AC
AC Power
Input
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
48
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.
49
Charging Switch Nominal Ratings
Control Input : 5 Vdc
Input:
120 Vac
Output:
40 A
50
Charging Switch Signal Table
Voltage Range
Power Signals
Type
Direction
Freq Range
Voltage
Nominal
Min
Max
Freq
Nominal
Min
Max
% V-Reg
Max
V-Ripple
Max
Current
Max
Power1 VCC +5
DC Power
Input
5.0V
4.75V
5.25V
0
0
0
5.00%
0.1V
1.2A
Power2 AC
AC Power
Input
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
Power3 AC
AC Power
Input
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
1.0A
51
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.
52
AC
Vac
Sensor
Jake
+
Charging
Switch
Quick
Charger
Fernando
Power Source
Switch
Trickle
Charger
Fernando
+ Inverter
Mike
Load
Display
Jesus
CPU
Adam
+
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake
+
Display Nominal Ratings
Input:
Output:
8-bit digital signal
LED on/off state
54
Display Signal Table
Voltage Range
Power Signals
Type
Direction
Freq Range
Voltage
Nominal
Min
Max
Freq
Nominal
Min
Max
% V-Reg
Max
V-Ripple
Max
Current
Max
Power1 VCC +5
(switch)
DC Power
Input
5.0V
4.75V
5.25V
DC
0
N/A
5.00%
0.1V
1.2A
8-bit channel
Digital
Input
5.0V
4.75V
5.25V
DC
0
N/A
5.00%
0.1V
1.2A
55
Display is meant to be basic,
but complete.
An LED display chip will
represent the battery life.
56
Block 3 & 4 Prototyping Plan Template
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Component
s
Types of
Connector
s
35
700
N/A
Spade
connector
N/A
Spade
connector
35
700
N/A
Spade
connector
Block
Name
Block Area
(cm2)
Main
Switch
Charging
Switch
Display
100
700
Fiber glass
Solder
N/A
8-wire
ribbon
Spade
connector
Easy
disconnect
connector
57
Switch Resource Estimate
► 10.8
►
% of the material estimate
Estimated 80 hrs.
Display Resource Estimate
► 10.8
►
% of the material estimate
Estimated 30 hrs.
58
End of UPS blocks 3 and 4
!!!
59
Name: Adam Bitter
Major: Electrical engineering
Team 5: UPS
Assignment: CPU
AC
Vac
Sensor
Jake
+
Charging
Switch
Quick
Charger
Fernando
Power Source
Switch
Trickle
Charger
Fernando
+ Inverter
Mike
Load
CPU
Adam
+
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake
User
Interface
Jesus
+
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
62
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
63
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

64
CPU Performance Requirements
Input:
AC voltage:
DC voltage:
DC current:
8 bits, 5V DC
8 bits, 5V DC
8 bits, 5V DC
Output:
Display:
8 bits, 5V DC
Charging Switch: 1 bit, 5V DC
Power Switch:
1 bit, 5V DC
65
CPU Standard Requirements
Operating Voltage:
► Max 5.25Vdc
► Min 4.75Vdc
Operating Temperature:
► Max 50 C
► Min -15 C
Humidity:
► Max 95% r.h.
66
CPU Power Interface
Type
DC
Power
Direction
Input
Voltage
Nominal
5.0V
Voltage Range
Min
Max
4.75V
5.25V
Frequency
Nominal
0
Frequency Range
Min
Max
0
0
% VReg.
VRipple
Current
5%
0.2V
1.5A
67
CPU Digital Interface
Digital
Signals
Type
Direction
Input
Structure
Technology
Logic
Voltage
Characteristics
Vh Min
Ih Max
Vl Max
Il Min
Vac
Sensor 8bits
Digital
Input
Standard
TTL
5V
3.00V
1.0mA
2.2V
10uA
Vdc
Sensor 8bits
Digital
Input
Standard
TTL
5V
3.00V
1.0mA
2.2V
10uA
Idc Sensor
8-bits
Digital
Input
Standard
TTL
5V
3.00V
1.0mA
2.2V
10uA
Switch 1bit
Digital
Output
Standard
TTL
5V
3.25V
0.5mA
1.8V
0.1mA
Battery 8bits
Digital
Output
Standard
TTL
5V
3.25V
0.5mA
1.8V
0.1mA
Power 2bits
Digital
Output
Standard
TTL
5V
3.25V
0.5mA
1.8V
0.1mA
68
Block 5 Prototyping Plan Template
Block
Name
Block Area
(cm2)
Total PCB
PCB
Area (cm2) Substrate
Type
Comp
Attachment
Type
Socketed
Types of
Component Connector
s
s
CPU
100
12
solder
Yes
Copper
Ribbon
Cable
69
Resource Estimate
► 12.9%
of the Material Estimate
► Estimated 47.4 hrs.
70
Name: Jake Koturbo
Major: Electrical engineering
Team 5: UPS
Assignment: block 6
Block 6: Sensors :
Vac
Vdc
Idc
AC
Vac
Sensor
Jake
+
Charging
Switch
Quick
Charger
Fernando
Power Source
Switch
Trickle
Charger
Fernando
+ Inverter
Mike
Load
CPU
Adam
+
Battery
Fernando
Vdc
Sensor
Jake
Idc
Sensor
Jake
User
Interface
Jesus
+
Purpose:
It’s how the CPU interfaces with the input and
output power.
73
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
74
Sensor Performance Requirements
Input: Analog (nominal)
► 120Vac
► 5Vdc
► 15Adc
Output: Digital (nominal)
► 8-bits (5V logic)
75
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.
76
Sensor Standard Requirements
Operating Voltage:
► Max 5.25Vdc
► Min 4.75Vdc
Operating Temperature:
► Max 50 C
► Min -15 C
Humidity:
► Max 95% r.h.
77
Sensor Power Interface
Type
DC
Power
Direction
Input
Voltage
Nominal
5.0V
Voltage Range
Min
Max
4.75V
5.25V
Frequency
Nominal
0
Frequency Range
Min
Max
0
0
% VReg.
VRipple
Current
5%
0.2V
0.5A
78
Sensor Analog Interface
Analog
Signal
Type
Direction
Coupling
Voltage
Amplitude
Maximium
Impedence
Frequency Range
Min
Max
Min
Max
Leakage
Max
Vac
Analog
Input
Xfmr
132V
5k
20k
0
63Hz
500uA
Vdc
Analog
Input
Xfmr
14.3V
5k
20k
0
1Hz
500uA
Idc
Analog
Input
Xfmr
5.25V
5k
20k
0
1Hz
500uA
79
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
Digital
Output
Standard
TTL
5V
3.25V
0.5mA
1.8V
0.1mA
Idc 8-bits
Digital
Output
Standard
TTL
5V
3.25V
0.5mA
1.8V
0.1mA
80
Simplified Sensor
Analog
Signal
Convert to
a
proportion
al 0-5Vdc
analog
signal
CPU
ADC
Vcc~5V
81
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.
82
Placement of the Vac Sensor
AC power
Vac Sensor
AC power
CPU
83
84
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.
85
Placement of the Vdc Sensor
Quick
Charger
Trickle
Charger
Inverter
Vdc and Idc
Sensors
Battery
86
87
Idc Sensor
► Measure
the input and output battery
► Produce
an eight bit output directed to the
current.
CPU.
► Used
to engage or disengage the Quick
charger.
► Used
in conjunction with the Vdc sensor to
estimate battery expectancy.
88
Placement of the Idc Sensor
Quick
Charger
Trickle
Charger
Inverter
Vdc and Idc
Sensors
Battery
89
90
Block Prototyping Plan Template
Block
Name
Block Area
(cm2)
Total PCB
Area
(cm2)
PCB
Comp
Substrate Attachment
Type
Type
Socketed
Components
Types of
Connectors
Sensors
120
700
Fiber Glass
N/A
Spade
connector,
Cupper bus,
easy
disconnect
Wire Wrap
91
Resource Estimate
► 22%
of the Material Estimate
► Estimated 50 hrs.
92
End Block Level
Description
Begin Product Level Description
Prototype UPS Shelf
All Blocks will be packaged into a
shelf like orientation
Block Level Plan
Man Hours
Materials $
Inverter
Block 1
149
81
Power
Block 2
73
135
Switches
Block 3
80
59
Display
Block 4
30
59
CPU
Block 5
47.4
70
Sensors
Block 6
49.7
120
95
Estimated vs Available
► Total
Manpower hours: estimated- 560
available- 528
► Total
material cost:
estimated- $560
actual- $571
96
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
97
GANTT Chart Time Line
98
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.