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Transcript
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