Download EE595_Team2_P2_Fall07

TEAM 2
PROJECT TEAM ROLES
•
•
•
•
•
LPI :
LSD:
LPM:
LRM:
LMM:
Dan Drews
Wayne Stollenwerk
Anthony Camomilli
Anthony Camomilli
Bhavi Mistry
Contact Info
• Dan Drews
•
Phone: 414-248-9551
Email: [email protected]
• Wayne Stollenwerk
•
Phone: 414-479-0283
Email: [email protected]
• Bhavi Mistry
•
Phone: 414-386-1152
Email: [email protected]
• Anthony Camomilli
•
Phone: 262-385-6724
Email: [email protected]
Expertise & Experience
•
Dan Drews
•
Expertise: Microprocessors, Power Electronics
Experience: None
•
Wayne Stollenwerk
•
Expertise: Electronics, Power Supply
Experience: Co-op, Test Engineering,
Documentation
•
Bhavi Mistry
•
Expertise: Signals & Systems, Analog Circuits
Experience: None
•
Anthony Camomilli
•
Expertise: Solid-state Electronics, Short Circuit
Protection, Documentation/Schematics,
Component Selection/Cost Analysis
Experience: Engineering Intern, Electrical
Designer
Total Resources
17.5 hrs/week
Lab meetings
17.5 hrs/week
Team meetings
30.0 hrs/week
Individual contribution
Total number of hours contributed by the team is 65hrs/week
• Estimated cost for the proposed Project is $ 300
• However the design cost may vary towards the completion of the project.
Decision Making
• Project decisions shall be made in
consensus
• Majority vote with due compromise will
be used to decide disagreements.
Proposed Product Summary
•
DC Servo Motor Controller
–
–
–
–
–
–
–
–
2hp variable speed brushless servo
motor
with 12VDC supply
Safe design, with intuitive user
inputs
Applied as a trolling motor
Economical
Secondary motor for use in shallow
areas or where quite operation is
preferred
Environmentally friendly
Similar to other products on the
market
Designed for the Consumer Market
Project Selection
• Overall Selection Process
– This project is supported best by the abilities of all
team members
– Risks include low margins, competitive market
– Other projects fell outside the scope of this class
as well as requirements for special parts requiring
long lead time
– Unanimously supported by all team members
SYSTEM LEVEL REQUIREMENTS
• Performance Requirements:
•
•
•
•
High efficiency (>80%)
Low noise
(<75 dB)
Extended lifetime (5+ years)
Power Modes will be ON/OFF,
Forward/Reverse
• Basic Mechanical capabilities will be
speed control.
SYSTEM LEVEL REQUIREMENTS
Standard Requirements
•
•
•
•
•
•
Energy source will be 12V Battery Operating
Temperature range: 5 – 45 °C
Storage Temperature range: -55 – 125 °C
Minimum operating voltage range: 10 – 14.7V
U.S. Market (Low Budget Consumer)
Max Power Consumption: 480 Watts
Block Diagram
User Input/Display
PWM 3
(Dan)
Battery Sensor
(Bhavi)
2
H-Bridge
(Wayne)
Motor
4
Temp Sensor
w/ display
(Anthony)
5
Block Diagram Descriptions
Block
#
Block Name
Owner
2
Battery sensor
Bhavi
3
PWM
4
5
Brief Description
Of Block Function
Power
Interfac
es
Digital
Interfaces
Analog
Interface
s
Control, charge and
sense the battery.
Other details not yet
decided.
In:
12VDC
None
Out: LED
Array
Dan
Supplies H-Bridge with
adjustable duty cycle
square wave
In:
12VDC
None
In: Pot.
Out:
square
wave
H-Bridge
Wayne
H-Bridge will boost
power of PWM signal
and deliver to the
motor, includes shootthrough protection
In:
12VDC
None
In: PWM
signal
Out:
Motor
Driver
Water Temp.
Sensor w/
display
Anthony
Measures and displays
accurate temp
In:
12VDC
Out: LCD
Display for
Temp
In:
Sensor
Ethics Considerations
–
Quality and Safety
• We will use UL listed components
–
Adequate Verification and Validation
• We will have our data independently verified by another team member
–
Ensuring legal compliance
• We will research prior patents and compliance with current safety standards
–
Conflict of interest
• Not applicable
–
Bribery and kickbacks
• We are not worth bribing
–
Treatment of confidential or proprietary information
• Not applicable
–
Environmental Damage
• We will use ROHS compliant devices
–
Outside employment/business activities
• We will complete all work internally
Ethics & Intellectual Property
•
United States Patent 6,276,975
– Trolling motor battery gauge
– August 21, 2001
•
United States Patent 5,254,932
– Charging voltage control circuit for battery chargers
– October 19, 1993
•
United States Patent 6,377,012
– Servo system controller
– April 23, 2002
•
Mitigation Strategy
– Design around with more modern components
Ethics Considerations
– Quality and Safety
• We will design our trolling motor out of RoHS
compliant materials and provide documentation
as to safe operation of the device
– Ensuring legal compliance
• We will conform to national safety standards
that govern the electrical safety for aquatic
machinery
SAFETY HAZARDS AND
MITIGATIONS
SAFETY TEST STANDARDS USED
IN DC MOTOR CONTROLLER
• UL 1004
(Safety Standard Electric Motors)
• EN 60204-1
(Safety of machinery –Electrical equipment of
machines)
• EN 60529
(Degree of protection provided by enclosures
(IP-Code)
Unsafe Single Point/Device
Failures
• Mitigation Design/Devices/Materials/Packaging
– Logic control
– Fusing the devices
• Affected Blocks
– H-Bridge
• Tests Required to Verify Protection
– Logic Testing
– Torture Test
Burns from Hot, Touchable
Surfaces
• Mitigation
Design/Devices/Materials/Packaging
– Insulated electrical enclosure
• Affected Blocks
– None
• Tests Required to Verify Protection
– Simple Heat Measurements during lab
Electric Shock
• Mitigation
Design/Devices/Materials/Packaging
– Insulated water-proof materials, fusing
• Affected Blocks
– Battery charger, Motor
• Tests Required to Verify Protection
– Ground Fault Test
Fire, Explosion or Shattering
• Mitigation
Design/Devices/Materials/Packaging
- Reverse voltage protection and fusing
• Affected Blocks
– All the blocks
• Tests Required to Verify Protection
– Short circuit Test
Abusive Or Unknowing Users
• Mitigation
Design/Devices/Materials/Packaging
– Warning Labels
• Affected Blocks
– Battery Charger, Battery, Motor
• Tests Required to Verify Protection
– Precautionary Test
EMC HAZARDS AND MITIGATION
EMC STANDARD TESTS USED IN
DC MOTOR CONTROLLER
• IEC:6100-4-2 ESD Immunity
• IEC:6100-4-3 Radiated Radio Frequency Immunity
• IEC:6100-4-4 Electrical Fast Transient/Burst
immunity
• IEC:6100-4-6 Conducted Radio Frequency Immunity
• IEC:6100-4-9 Pulsed Magnetic Field Immunity
Electro-Static Discharge
• Mitigation
Design/Devices/Materials/Packaging
– Shielding. Insulation and Passive Line Protection
• Affected Blocks
– All
• Tests Required to Verify Protection
– ESD testing at touch points
Magnetic Field Energy
• Mitigation
Design/Devices/Materials/Packaging
– Shielded Wire
• Affected Blocks
– H-Bridge, Servomotor
• Tests Required to Verify Protection
– Test for Radio-active and conductive Noise
RF Electric Field Energy
• Mitigation
Design/Devices/Materials/Packaging
– Component selection
• Affected Blocks
– The temperature displayer
• Tests Required to Verify Protection
– Verifying component certification like UL listings
Interference with Other
Electronic Systems
• Mitigation
Design/Devices/Materials/Packaging
– Minimize circuit paths to prevent loops
• Affected Blocks
– H-Bridge, PWM and Battery charger circuit
• Tests Required to Verify Protection
– Secured lab testing
PRODUCT LEVEL DESIGN
Block Prototyping Plan
Block
Name
Block
Area
(cm2)
Located
on Board
#
(1, 2, ..
etc)
Board
Substrate
Type
Comp
Attachment
Type
Board
Types of
Dimensio Connect
ns
ors
(cm x cm)
Battery
Indicator
3.5 cm2
1
Bread
Board
Spring
Tension
5 cm2
Molex
PWM
6.3 cm2
2
PC Board
Through
Hole
7.8 x 7.0
88.98
cm2
Soldered
Wires
H-Bridge
29.3 cm2
2
PC Board
Through
Hole
7.8 x 7.0
88.98
cm2
Soldered
Wires
Temp
Sensor
55 cm2
3
Bread
Board
Spring
Tension
7.62x5.08 Molex
38.7 cm2
Gantt Chart
SEPT
OCT
NOV
DEC
4 11 18 25 2 9 16 23 30 6 13 20 27 4 11 13
Planning
Prod. Design
Proc. Design
Validation
Feedback
Individual Block Detail
Block 2
Block 2 Description and Purpose
•
Block 2 is a Battery Sensor circuit which consists of a Voltage Detector circuit
and Temperature sensor
•
It is connected to Battery charger circuit and Battery
•
It is an important block because it senses when the battery should begin
charging at different voltage levels.
•
The block also has a temperature sensor which senses the overheating of the
battery while its operation.
•
The block uses 4 Opamps and the combination of resistors and Led’s circuitry
for efficient operation
Block 2 Performance Requirements
•
•
•
•
•
Battery chemistry: Lead acid
Battery capacity: 12V, 50A
Switch Type: Push, On/Off
Sensory: Temperature sensor
Modified circuit uses Zener diode to fix the voltage at
reference level voltage.
Block 2 Standard Requirements
• Energy source: 12V Battery
• Minimum Operating temperature Range: -30 to +150
degree Celsius
• Minimum Operating Voltage Range- 5V to 15V
• Manufacturing Cost- $ 5.00/unit
• US Market (Low Budget Customer)
Block 2 Diagram Breakdown
Switch
Battery
Battery
Charger
Series of
Resistors
Zener Diode
4 Op-amps
(LM 324)
Buzzer
LED Display
Block 2 Schematic
Block 2 Bill Of Materials
•
--- Bill of Materials ---
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Ref.
D1
D2
D3
D4
D5
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
U1
U2
U3
U4
Mfg.
Part No.
-D
-D
-D
-D
-D
--------------------Linear Technology
Linear Technology
Linear Technology
Linear Technology
Description
diode
diode
diode
diode
diode
resistor, 18K
resistor, 3.9K
resistor, 2.7K
resistor, 680
resistor, 680
resistor, 15K
resistor, 470
resistor, 470
resistor, 470
resistor, 100
LT1011
integrated circuit
LT1011
integrated circuit
LT1011
integrated circuit
LT1011
integrated circuit
Block 2 Bill of Materials
•
•
•
•
IC 324 - $0.33/unit
Led’s- $1.00/4 units for 3mm
Zener diode-$ 0.19/unit
Total cost $ 5.00
Block 2 Theory Of Operation
• Battery sensor circuit consists of Voltage detector circuit which
uses 4 Op-amps combined in a package of IC 324
• The non-inverting terminals are connected to the potential
divider chain consisting of resistors
• A reference voltage is set at 5V using Zener diode
• When the circuit is connected to the battery, the battery voltage
will be sampled by the detector circuit and depending on the
voltage levels at the output Led’s will be on
Block 3
Block 3 Description and Purpose
• Block 3 contains the PWM (pulse width modulation) control for the
motor. Using op-amps a triangle wave generator and a
comparator can be designed to a specific frequency, in this case
24kHz, and a 12V pulse width modulated signal can be produced.
The requirements for this output as set by Block 4. Block 4
requires an absolute minimum current of 10 A and the low
voltage needs to be below 0.8V.
• Texas Instruments produces a PWM solenoid driver that will
accomplish the task of this block while meeting the standard and
performance requirements.
Block 3 Performance
Requirements
• PWM signal is designed for 24kHz so no noise is generated during
switching.
Block 3 Standards Requirements
Standard Requirements
•
•
•
•
•
Energy source will be 12V Battery Operating
Operating Temperature range: 5 – 45 °C
Storage Temperature range: -55 – 125 °C
Minimum operating voltage range: 10 – 14.7V
U.S. Market (Low Budget Consumer)
Block 3 Diagram Breakdown
User
Input
12V Supply
Potentiometer
Voltage Divider
Comparator
Square Wave
Oscillator
Integrator
PWM Signal
Block 3 Preliminary schematic
Block 3 Preliminary Bill of
Materials
•
•
•
•
1
1
9
4
• 1
• 1
• 1
LM324 OP-Amp
Potentiometer
Resistors
Capacitors
$0.45 (block of 4)
$4.50 per unit
$0.15 per unit
$0.20 per unit (avg)
Texas Instrument DRV103U
Potentiometer
Capacitor
$3.60 per unit
$4.50 per unit
$0.13 per unit
• Totals:
$9.98 Discrete Design
$8.32 IC Design
Block 4
Block 4 Description and Purpose
• Power supply for the DC servo motor (trolling motor)
• Capability to to spin the motor in forward or reverse
direction
• Utilize PWM on the power return
• Two n-channel mosfets are used to control the PWM
• One mosfet for forward one for reverse
• PWM signal supplied by block 3
• Three way switch turns on the fet drivers and power
relays.
Block 4 Performance
Requirements
• Original design requirement to supply 0 - 40 amps to the
to the trolling motor by PWM at 20KHZ
• Modified design After testing for locked rotor current 0 –
52 amps.
• Original configuration was h-bridge with 2 p-channel
mosfets and 2 n-channel mosfets
• Modified design replaces p-channel mosfets with power
relays and shunt diodes to reduce power loss and
generate less heat
• Design required to accept input at 5V logic or battery
level logic for PWM input signal
Block 4 Standards Requirements
Standard Requirements
•
•
•
•
•
Energy source will be 12V Battery Operating
Operating Temperature range: 5 – 45 °C
Storage Temperature range: -55 – 125 °C
Minimum operating voltage range: 10 – 14.7V
U.S. Market (Low Budget Consumer)
Presentation P2
Block 4 Diagram Breakdown
Forward position
Three way switch
Forward power relay
Reverse position
Reverse power relay
Mosfet driver on
Mosfet driver on
PWM input from block 3
Forward mosfet driver
Forward n-channel mosfet
Reverse mosfet driver
Reverse n-channel mosfet
Block 4 Preliminary schematic
Block 4 Preliminary current
simulation PWM at 1% duty cycle
Block 4 Preliminary current simulation
PWM at 50% duty cycle
Block 4 Preliminary current simulation
PWM at 99% duty cycle
Block 4 PWM Simulation
waveforms
Block 4 PWM Simulation
waveforms
Block 4 PWM Simulation
waveforms
Block 4 Preliminary Bill of
Materials
•
•
•
•
•
•
•
•
•
•
1
3-way 15VDC 1Amp switch $1 per unit
2
shunt diodes 200V 10Amp
(t0-220) $0.78 per unit
2
Power relays 12V 70Amp
$5.34 per unit
2
n-channel mosfets 55V 80Amp
(T0-220) $1.52 per unit
2
Fet drivers (6A low side)
(SOIC) $1.24 per unit
2
1UF ceramic monolithic capacitors for fet drivers $0.10 per unit
2
.1UF ceramic monolithic capacitors for fet drivers $0.10 per unit
1
pcb $5.00 per unit
1
heat sink for fets
$1 per unit
Total cost $25.50
Block 4 Additional Detail
Detailed Design Calculations & Component Selections
• Device Package Type Rationale
• Package for n-mosfet (T0-220) was determined by cost, ease of prototype,
heat sinkability, and availability
• Package for power relays was determined by size, cost, and availability
• Package for fet drivers was determined by cost and availability
• Package for Diodes was determined by cost and availability
• Nominal Resistance, Capacitance, Inductance Values & % Tolerance Calculations
• All values determined by component data
• Resistor Compositions, Capacitor Dielectric, Inductor Winding; Selection Rationale
• Capacitors choosen by low esr category
Block 4 Additional Detail
(cont)
• Resistor, Capacitor, Inductor, Diode, Transistor & IC Max Voltage Calculations
• Max voltages based on component data and assigned max battery voltage of
14.7V
• Resistor, Inductor, Transistor, Diode, Xfmr, & IC Max Power Calculations
• Max power based on measured current and Max Battery voltage
(53A*14.7V)=880W
• Max power of n-channel fets based on rdson .0065*53*53 = 18.25W
• Power Electronics Heat Sink qj Calculations and Max Die Temp Rise Above Ambient
• Calculations based on data sheet
•
Wire Gauges, Interconnect Contact, & Trace Width Ratings
• 8AWG based on 53Arms for operated
Block 5
Block 5 Description and Purpose
• Block 5 consists of a temperature sensing
circuit and a user display.
• It is intended that this should allow the user to
choose a more ideal location for fishing.
Block 5 Performance
Requirements
• Low power consumption (<1.75w)
• Limited power available
• Heat dissipation
• Temperature sensing accuracy (+/- 3°)
• 12VDC Input
• Small Footprint
Block 5 Standards Requirements
Standard Requirements
•
•
•
•
•
Energy source will be 12V Battery Operating
Operating Temperature range: 5 – 45 °C
Storage Temperature range: -55 – 125 °C
Minimum operating voltage range: 10 – 14.7V
U.S. Market (Low Budget Consumer)
Block 5 Diagram Breakdown
12VDC Input
Sensor
LCD Driver
LCD
Block 5 Preliminary Schematic
Block 5 Theory of Operation
• The 7106 is a direct drive LCD driver with integrated
differential inputs
– No current limiting required for LCD to function
– Allows for direct sensor input
– Reduced part count and wide operating range
• The temperature sensing is accomplished by
measuring the voltage change of a diode due to
temperature fluctuation
– Easily Measured phenomenon
– Low component count, robust package
– Precision calibrated
Block 5 Additional Detail
• 7106 was chosen because it has a compact package
• Low resistor tolerances where chosen to reduce error (1%)
• 25 turn potentiometers where chosen for greater precision
• Low power components reduce the need for greater heat
dissipation
• Diode chosen for greater sensor sensitivity
• Total component count limited to allow nesting under LCD
Block 5 Preliminary Bill of
Materials
BOM ITEM
QTY
PART #
ITEM DESCRIPTION
COST
TOTAL
1
1
67-1790-ND
LCD 3.5 DIGIT .50" REFLECTIVE TN
$3.78
$3.78
2
1
1N4148FS-ND
DIODE SGL JUNC 100V 4.0NS DO-35
$0.04
$0.04
3
1
TC7106ACPL-ND
IC ADC 3 1/2DGT LCD DVR 40-DIP
$4.50
$4.50
4
2
P300KCACT-ND
RES METAL FILM 300K OHM 1/4W 1%
$0.17
$0.34
5
2
490-2889-ND
TRIMPOT CERM 50K OHM 25TRN TOP
$0.85
$1.70
6
1
P160KCACT-ND
RES METAL FILM 160K OHM 1/4W 1%
$0.17
$0.17
7
1
399-4209-ND
CAP .1UF 50V 20% CER RADIAL
$0.16
$0.16
SUM
$10.69
Thank You