team 2 final presentation 12-7 download

1. Project IntroductionDenis Sterjo

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TEAM 2

Denis Sterjo David

Messer

Power Line Induction Clamp Light

Evan Reichelt

Cassandra Appleton

Colin Hermann

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EXPERTISE & EXPERIENCE

Denis Sterjo• Degree sought: BSEE Fall '15, MSEE Fall '17• Expertise: Low Power Analog Circuit Design, Op Amps, Comparators,

Voltage Regulators, Sensors, Bluetooth, Fault Circuit Indicators• Experience: Eaton (4 years)David Messer• Degree sought: BSEE/Econ Spring '16• Expertise: Drives, Hardware Layouts• Experience: Rockwell Automation (3 years)Cassandra Appleton• Degree sought: BSEE Fall '15• Expertise: Chemical, Six Sigma Quality Control, R&D• Experience: PPG (5 years)

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EXPERTISE & EXPERIENCE

Evan Reichelt • Degree sought: BSEE Fall '15• Expertise: Lean Manufacturing, Electrical Power Distribution/Protection and

Analysis, Material Handling, Product Management,• Experience: Harley Davidson (8 Months), Kohler Co. (6 Months), Flatley Corp.

(4 Years), Costco Wholesale (8 Years)• Colin Hermann• Degree sought: Physics Spring '14, BSEE Fall '15• Expertise: RF, Electronics• Experience: N/A

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2. PRODUCT DESCRIPTIONDenis Sterjo

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PRODUCT DESCRIPTION

• Sustainable streetlight.• Clamps to existing distribution lines. Target operating voltage range: <69kV.• Reduces power consumption on the grid. Powered by induced magnetic field.• Target market: USA• Intelligent control system and Bluetooth to provide a user interface.

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Replace with updated slide - Denis-Evan Reichelt

Cassandra Appleton

3. Project Plan & Resource

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Project Plan & Resource Balance

Detailed Task Plan SpreadsheetTeam Project Definition & System Design Phases with Dates, Owners, and Manhours

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Detailed Task Plan SpreadsheetTeam Detailed Design Phase by Block

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Detailed Task Plan Spreadsheet

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Detailed Task Plan Spreadsheet

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Project Plan & Resource Balance12


Total Estimated Resources•Eng Labor Hours: 931•Prototype Funds: $171•Other Funds: $0

Total Estimated Project

•Eng Labor Hours: 950•Total Prototype Costs: $100

• Components:$91.73

• Fabs & Proto Boards: $10.67• Hardware & Enclosures:$TBD

•Other Project Costs: $• Report Binding

$TBD• Copies, Office Supplies $TBDActions Taken

1. Reduced Scope: Chose cheaper options for components across all blocks

2. Agreed to increase labor hours available to complete project.

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Detailed Task Plan Spreadsheet Total Estimates

Block Number Estimated Actual Notes

Material $ Manpower Material

$ Manpower

1 $55 325 $12.49 328.8 2 $52 142 $22.38 145.6

3 $10 156.5 $ 160.1 4 $49 136.30 $32.49 139.9

5 $5 172 $19.06 175.6

Total $171 931.8 $91.73 950 Total Available 950

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Project Basic Business Case

• Estimated Average Product Selling Price (ASP$):$70• Estimated Annual Product Sales Volume in Units: We estimate a volume of 100,000 units a year.• Estimated Per Unit Cost of all Parts & Materials @ above volume: Estimate to be $35 per unit• Estimated Per Unit Cost of all Assembly, Test & Mfg @ above volume: Estimate to be $7.50 per unit.• Estimated Total Development Cost in $ incl Labor & Material: Development cost before going to production will be around $30,000 including engineering time, test fixture etc.

• Calculate the Annual Sales Revenue $ = 7,000,000• Calculate the Annual Var Costs $ = (Unit Material $ + Mfg $) * Annual Volume:$ 4,250,000• Calculate the Per Unit CM$ = ASP$ – (Unit Material $ + Mfg $): 70-42.50=$27.50• Calculate the CM% = Per Unit CM$/ASP$: 27.50/70=39%• Calculate the Annual CM$ = Unit CM $ * Volume = Annual Sales $ - Annual Var Costs $: 2.5M• Calculate the ROI (Return on Investment) Time in Years = Est Dev Cost $/Annual CM$: 1.5 years

Inputs

Outputs

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Evan Reichelt

4. Logistics & Operating Mechanics

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LOGISTICS & OPERATING MECHANISMS

Team Member Roles

Name Role

Denis Sterjo

System Designer

David Messer

Prototype Director

Cassandra Appleton

Presentation Manager

Colin Hermann

Report/Test Manager

Evan Reichelt

Project Integrator

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LOGISTICS & OPERATING MECHANISMS

Meetings:• Meeting we held every Saturday from 9AM-8PM and every Monday after the Lab.• Each team member would work individually during the week to prepare for Saturday.Data Archives and file compilations:• Used Office365 Outlook to store all the data.• Lead Presentation Manager to handle compiling and formatting of Power Point.Decision Making Process:• Consulted with the group on all major issues and took majority vote.• Received feedback from the instructor and lab TA regarding project design.

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David Messer

5. Product Requirements

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• Utilize Magnetic Energy from Power Line.• CT output to provide sufficient energy to charge the battery: 11.1

VDC and >~10mA at 10A of line current.• More efficient LED based design. Estimate 400 lumens of output

light.• Light efficiency: Achieve minimum required illumination with Low

Power LEDs, less than 10W.• Resistance to extreme weather conditions such as Ice, Snow,

Extensive rain, extreme heat and sub-zero temperatures• Bluetooth interface for monitoring and control.

PRODUCT REQUIREMENTS 20

SAFETY, EM, REQULATORY – PRODUCT LEVEL

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Denis Sterjo

6. Block Implementation

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BLOCK DIAGRAM

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BLOCK OWNERS

• Sterjo- Block 1• Messer- Block 2• Hermann- Block 3• Appleton- Block 4• Reichelt- Block 5

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Cassandra Appleton

7. Intellectual Property Search

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INTELLECTUAL PROPERTY – CASE 1

Patent and Patent NumberSolar Powered Street Lighting SystemUS 4841416 A Issued March 2, 1988

Patent summaryA street light that is independent of any external power supply. Solar panels charge a maintenance-free wet- cell battery with sufficient capacity to power street lights. An optional cord for attachment to an automotive cigarette light is available to charge an automotive battery.

MitigationAlthough our streetlight will not require an external power supply, we will not be utilizing solar energy to power our light. We propose using a CT to harvest the energy of the powerline’s magnetic field to power the light, as well as charging the lithium ion battery in our circuit.

Patent Expiration DateMarch 2, 2005

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INTELLECTUAL PROPERTY – CASE 2

Patent and Patent NumberStreet Light with Wind Power Generator• US 20090080182 A1• September 25th, 2007

Patent SummaryA street light that has a wind power generator attached to the post. The wind power generator includes the shaft connected to the generator and multiples blades connected to the shaft. A circuit board that contains an MCU is used to communicate between the light and the chargeable battery, which is connected to the generator.

MitigationOur streetlight will not use harvested wind energy to power the light. We propose using a CT to harvest the energy of the powerline’s magnetic field to power the light, as well as charging the lithium ion battery in our circuit. Although our MCU will be tied to the battery charging circuit similar to the referenced design, it will also be tied into the CT to continuously monitor the current drawn.

Patent Expiration DateSeptember 25, 2024

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David Messer

8. Safety & Ethics Considerations

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SAFETY CONCERNS -Shock

Block Affected• The Ct clamping

ConcernThe installation of the device could possibly shock someone due to the high voltage of the power line

Mitigation• A certified installer should only be

used. • A “Hot Stick” should be used in order

to minimize risk of bodily injury

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SAFETY CONCERNS - BURNS

Block AffectedBlock 1: Current Transformer (CT), AC-DC Converter

ConcernThe power on the output of AC-DC converter might be high enough to cause the LDO to get hot.

Mitigation• this will not be a touchable surface as

the board will be sealed with potting material.

• the potting material will also act as a heat sink to dissipate a majority of the heat.

Safety Standards• IEC 60695-8-1• IEC 60695-1-1 & TC 89

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SAFETY CONCERNS – SINGLE POINT COMPONENT FAILURE

Blocks AffectedAll Blocks

ConcernUnsafe conditions from single point component failure

Mitigation• add redundancy circuit for battery

protection• add safety circuit to protect

microcontroller from any input power failure

• add battery reverse plug in protection circuit

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ETHICAL CONCERN 1

Block effected Block 5: Bluetooth Interface

ConcernThe Concern is that without proper security someone may be able to hack into the streetlight whenever they please.

Mitigation• Bluetooth has it’s own security protocol that we will rely on for the prototype

• The Mass produced device will need to have a proper expert with more experience in security than ourselves will need to encrypt the device

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ETHICAL CONCERN 2

Block AffectedBlock 2: The Battery

ConcernProper disposal of the battery and possible consequences to human health

Mitigation• Federal regulations do not exist

specifically for lithium-ion battery disposal

• Plan on using all resources available to contract with lithium-ion battery recycling facilities

• Proper safety labels

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ETHICAL CONCERN 3

Block AffectedBlock 1: Current Transformer (CT), AC-DC Converter

ConcernVoltage drop across the CT coil will induce a back EMF on the line

MitigationDesign the Current Transformer to have as little Back EMF as possible

StandardIEEE1433

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Colin Hermann

9. Electromagnetic Compatibility

Considerations

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ELECTROSTATIC DISCHARGE RISK AND MITIGATION

Blocks Affected• All BlocksMitigation• Backwards Battery Protection• Raise ground Voltage level to protect

against Arcing• Protection diodes to protect

connections traveling to Microcontroller

Applicable Standards• IEC61000-4-2 HBM• IEC61000-4-2 Air Discharge

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INTERFERENCE INVOLVING OTHER SOURCES

Blocks Affected• Microcontroller• BluetoothMitigation• Shield the Microcontroller • Operate antenna at acceptable

frequency

Applicable Standards• IEC61000-4-6• IEC61000-4-8• CISPR11/22

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POOR AC POWER QUALITY

Blocks Affected• CT Ac/Dc conversionMitigation• Check incoming power turn of

connection if needed• Add tolerance for AC impurities

Applicable Standards• IEC 61000-4-11

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10. Design Block 1

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CT, AC-DC Conversion, Battery ChargingBattery Heating and Current Detect

Block Owner: Denis Sterjo

BLOCK 1

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Description:• Design the Current Transformer as the source of energy for charging

the battery.• Design of AC-DC conversion circuit.• Design Battery Charging Circuit. • Design a Circuit to detect minimum line current threshold which

provides sufficient energy to charge the battery: Determined to be 10A.

• Design battery heating circuit to convert the energy from the CT into heat under extreme low ambient temperatures.

BLOCK 1: CT, AC-DC, BATTERY CHARGINGBATTERY HEATING AND CURRENT DETECT.

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Purpose of Current Transformers:• Source of Energy for battery charging and battery heating circuit. • Supplies AC power at the output.• Split Iron Core CT will be used. • Input: Power Line AC current. Output: AC power.Purpose of AC-DC Conversion:• Convert Output of CT AC power to DC power.• LDO regulator at the output.• Ripple reduced using a bulk capacitor at the output. • Input: AC power from output of CT. Output: DC power

BLOCK 1: PURPOSE 42

Purpose of Battery Charger:• Suitable for charging 11.1V Li-Ion. • Provides CC and CV charging .• Input: 13V-13.3V DC. Output: 11.1V DC, I_max=200mA.Purpose of Current Detect:• Detect power line current level when I_line is greater than

the required value to provide sufficient energy. 10A or >12V.

• Output toggles at 60Hz when condition met.• Input: AC power from output of CT. Output: DC powerPurpose of Battery Heating:• Heat the battery at extreme low temperatures. • Resistive heater using energy from the CT.• Input: 13.2V DC. Output: Energy as heat.

BLOCK 1: PURPOSE 43

BLOCK 1: INPUT/OUTPUTS.44

Sub-Block Signal Input Signal OutputCurrent Transformer

1A- 600A Up to 30 Vac

AC-DC Conversion

Up to 30Vp 1V-13.3V

Current Detect

1Vac-30Vac 3V square wave

Battery Charging

11.1Vdc-13.3Vdc

11Vdc-11.2Vdc

Battery Heating

1Vdc-13.3Vdc Heat

BLOCK1:INPUT/OUTPUTS SUMMARY

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AC-DC ConversionCT

Battery Charging

Battery Heating

Current Detect Circuit

Microcontroller Battery

BLOCK 1: LOCATION IN PRODUCT BLOCK DIAGRAM.

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Req # Description Requirement Notes

B1 Material Cost Allocation (Max Parts Cost)

CT: $12Battery Charger: $2.85Comparators: $ 1Dual N-Channel MOS Switch: $0.5Caps and resistors: $1.5LDO: $2

Total:$21

B2 Asm & Test Cost Allocation $5 $21+$5=$26

B3 Max Number of Parts Allocation

30-40 components.

BLOCK 1: REQUIREMENTS: COST47

Req # Description Unit Min Nom Max Notes

E1 Operating Temp Range oC -20°C 25 70°C

E2 Operating Humidity Range %rH 5 - 90 Non-Considering

E3 Operating Altitude Range Meters 0 500 3,000 500 meters above seal level

E7 Applicable EMC Standards IEC61000-4-2

E8 Applicable Safety Mitigations

Hot touchable Surfaces, IEC 60695-8-1

BLOCK1: REQUIREMENTS-ENVIRONMENTAL48


P1A Operating Input Voltage RangeOutput of CT, Input of AC-DC Conversion

V 1 13.2 30V AC-DC conversion

P1B Operating Input Current RangePower Line Current

A 1 30 600 Input Current considered Line Current

P1C Oper Input Voltage Freq Range Hz 57 60 63 Applicable for AC onlySingle or 3 phase

P1D Input Power Energy Source Input power source is Current Passing though the Power Line.

P1E Power Dissipation W 0 0.5 5

P1S1 Input Power 1 Safety Req 1 Components attached to the output of CT to meet Power Specs forMax power CT can provide.

P1-S2 Input Power 1 Safety Req 2 Reverse battery protection.

BLOCK 1: REQUIREMENTS - INPUT POWER49


M1 Mass AllocationCT

Kg 0.9 1 1.5 Mass of CT

M2 Volume Allocation CM3 .38 .38 .4 Volume of CT

M4 PC Board Area Allocation CM2 2 3 6

M5 Mechanical Shock Grms 1 1.5 2 Duration

M6 Mechanical Vibration Grms 1 1.7 2 Duration

M7 Enclosure Material(s) & EMC Shielding

Plastic material, potted with poly-urithane potting material. CT overmolded.

M8 Interface Connector Types Wires from the CT

BLOCK 1: REQUIREMENTS - MECHANICAL50

CT

Battery Charging

Battery Heating

Current Detect Circuit

BLOCK 1: PERFORMANCE REQUIREMENTS (OVERALL)

Block 1

Up to 600A, Saturates at 300A

30Vp(max), 0.6A max

3V, sqr.wave,60Hz

Resistive Heat11.1V, 200mA

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D1 Minimum Current for sufficient charging

A 8 10 12

D2 Temperature range of battery heater °C 10 25 70

D3 Frequency range (CT and Current Detect)

Hz 57 60 63

D4 CT saturation input current A 280 300 320

D5 Battery charge time Hours 8 11 16

D6 LDO efficiency %

D7 Battery charger efficiency %

BLOCK 1: PERFORMANCE REQUIREMENTS52

BLOCK 1: DETAILED FUNCTIONALITY SCHEMATIC53

BLOCK 1: DETAILED FUNCTIONALITY SCHEMATIC54

BLOCK 1: DETAILED FUNCTIONALITY SCHEMATIC. CURRENT TRANSFORMER AND

AC-DC

• CT: 500 turns, overmolded. M2-7Mil Grain Oriented Silicon Steel or GOES. L=1.2H-3H, L_nom=2H, R_wnd=9Ohm-15Ohm• C1 to create resonant circuit at 60Hz.• LT3012B: V_out=13.17V, I_out=250mA-500mA, V_dropout= 200mV• C2 is bulk cap to reduce ripple to <5%• TBU and MOV for over voltage protection and surge protection.

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LINEAR REGULATOR VS BUCK CONVERTER

Linear Regulator: Buck Converter:

Efficiency: High at light load low at worse load.Light Load: Vin= 12 V, Iin=20mA. Vout=11.8V, Iout=19.96mA

Efficiency= =99.9%max efficiency

Worse load: =41%, but Iout=500mA, Charger limitscurrent to 200mA so we have more than twice the current we need.

• Efficiency: High at worse load low for light load. In general efficiencyis high.• HF switching induces noise.• Complex design.• More expensive.

Which topology is best suited for our battery charging application?Need max output current at low line currents or “light” load.Should consider life of battery.

Conclusion: Linear Regulator Better Choice!

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BLOCK 1: DETAILED FUNCTIONALITY SCHEMATICCURRENT DETECT

• Output will toggle at 3V, 60Hz when I_line>10A or when Vct>12V.• Ultra LP comparator based design.• Features push-pull output stage.• R1 for hysteresis.• U2 for enhanced noise immunity.

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BLOCK 1: DETAILED FUNCTIONALITY SCHEMATICBATTERY CHARGER

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BLOCK 1: DETAILED PRODUCTION DESIGN (THEORY OF OPERATIONS)

1. TBU-DT is a Transient Blocking unit providing protection to my block from surges coming from the CT. Designed to meet requirements of an ideal protector.

• To simplify operation: Two main blocks inside the deice , current limiting functional block and voltage disconnect functional block. TBU responds to both overcurrent and overvoltage faults. by disconnecting the CT from the rest of circuitry.

• Provides protection if these conditions are met: Itrip=1A or Vclamp=100V and response time is 1uS.

• Device auto resets when Voltage drops below 40V. Series resistance of the device is 5.8 Ohms.

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2. Current Transformer has three components: Primary windings, Core and Secondary windings: Np=1, Ns=500.

• Nominal Inductance is 2H, Windings Resistance = 10Ohm.

• CT core is made of M2-7MIL Grain Oriented Silicon Steel with laminations spaced

at max of 0.0004 inches.• AC current in primary produces a Magnetic Field in the core which the induces an AC current in the secondary.

• Voltage output dependent on I_secondary and load,

• V_out= max 30Vp. Transformer saturates at 300A of line current.

• Iout_max= 300/500=600mA.

• Add 3.3uF capacitor (C1) to output of CT to resonate at 60Hz for max power delivered to the load.

• The AC output of transformer is converted to DC via a full bridge rectifier (BR1).

• Capacitor to the output of FBR added to reduce ripple <5%. C2=2500uF.

3. LT3012B is a linear regulator which regulates the output to 13.17V and limits current to 250mA-500mA. Low Quiescent current, low dropout voltage (40uA&200mV).

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4. The output of Linear Regulator Provides power to the battery (charging) or

battery heating circuit (warm).Use Dual-N-Channels MOSFETs to accomplish this.

“Charge” and “Warm” derived from the microcontroller. Either U5 or U6 is ON.

IRF7341: Dual N-Channel MOSFET, V_ds = 55V, Ids=3A, Vgs=+/-20V, Vth=1.5V(max)

Charge=HIGHCharge the battery. Warm=HIGHWarm the battery.

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5. Battery charger (starts operating when Charge=1 and EN=1 both controlled by MCU):i. Suitable for Li-Ion batteries. Vout set to 11.17V (by R3 and R4).ii. Limit charge current to 200mA ( R1)iii. Thermal regulation (R3), stops charging when battery falls below -10°C or above 45°C.iv. Full featured Contact Current and Constant Voltage charging.

v. Bypass ceramic capacitor of 1uF or higher at the input and output pins. 1uF input and 10uF at the output , C1=1uF and C2=10uF

vi. Charging Status Indication. Battery heating:i. Flexible resistive heater wrapped around the battery.ii. Warm battery when ambient temperature falls below -10°C.iii. We can duty cycle between heating and charging controlling the temperature of thebattery.

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6. Current Detect Circuit:

• The input of Current Detect is the output of CT.

• Designed with built in hysteresis and enhanced noise immunity to toggle when line

current >10A or when output of CT output voltage >12V (12-0.5=11.5V).

• R5 provides hysteresis and the bottom comparator (U2) is for enhanced noise immunity.

• When output of U1 is HIGH, output of U2 is LOW and vice versa. Basically R7 acts as a

pullup/pulldown resistor for the CT2 signal providing better stability and enhanced noise

immunity.

• Comparator used: LPV7215MF, features: Ultra Low Power Consumption (580nA),Low

Propagation delay, push-pull output stage, rail to rail input.

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BLOCK 1: DETAILED PRODUCTION DESIGN (BOM)

Total Cost:$23.01Total Parts QTY: 37Total PCB area: 3 cm^2CT and heater not included(external not in PCB).

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BLOCK 1: DETAILED PRODUCTION DESIGN CALCULATIONS

CT and AC-DC conversion calculations:C1 calculations: L=2H, Rwindings= 10 Ohm, Fr= 60Hz, C1=?. Circuit to resonate at ~60Hz:

Fr=

Solve for C1:

𝐶 1= 18∗𝜋2∗𝐹 𝑟 2 =

18∗𝜋 2∗602 3.3𝑢𝐹 . h𝑊𝑖𝑡 𝐶1=3.3𝑢𝐹 ,𝐹 𝑟 𝑎𝑐𝑡𝑢𝑎𝑙=61.9𝐻𝑧 .

Q factor calculations:

𝑄=𝜔∗ 𝐸𝑛𝑒𝑟𝑔𝑦𝑆𝑡𝑜𝑟𝑒𝑑𝑃𝑜𝑤𝑒𝑟 𝐿𝑜𝑠𝑠

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CT and AC-DC conversion calculations:

C2 calculation. C2 to reduce ripple voltage to <5%:

For full wave rectification we use this formula:

𝐶 2𝑚𝑖𝑛=𝐼𝑜𝑢𝑡

2∗ 𝑓𝑒∗𝑉𝑟 (𝑝−𝑝), 𝐼𝑜𝑢𝑡= 300 𝐴

500 𝑡𝑢𝑟𝑛𝑠=0.6 𝐴 ,𝑉𝑟 (𝑝−𝑝 )=0.05∗30𝑉𝑝=1.5𝑉

𝐶 2𝑚𝑖𝑛=0.6

2∗60∗1.5 =2.38𝑚𝐹𝑜𝑟 𝑔𝑟𝑒𝑎𝑡𝑒𝑟 . h𝐶 𝑜𝑠𝑒𝐶 2=2500𝑢𝐹

LT3012B calculations:

𝑉𝑜𝑢𝑡=1.24∗(1+ 𝑅2𝑅3 )+ 𝐼𝑎𝑑𝑗∗𝑅2 , 𝐼 𝑎𝑑𝑗=30𝑛𝐴@25 °𝐶

Solve for R2 and R3, R2=3.32 MΩ and R3= 348 kΩ:

𝑉𝑜𝑢𝑡=1.24∗(1+ 3.32∗106

348∗103 )+30∗10− 9∗3.32∗106=13.17𝑉

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Current Detect calculations:RC Calculations: R=2.7 MΩ and C=850nF

𝐹𝑐= 12∗𝜋∗𝑅∗𝐶=

12∗𝜋∗2.7∗106∗850∗10−9 =69.4𝐻𝑧

Hysteresis calculations (R5):

𝑉 h𝑦𝑠𝑡𝑒𝑟𝑒𝑠𝑖𝑠=2∗ 𝛽∗𝑉𝑐𝑐=6∗ 𝛽

𝛽= 𝑅11𝑅5+𝑅11

=2.7∗106

2.7∗106+698∗103 =0.8

𝑉 h𝑦𝑠𝑡𝑒𝑟𝑒𝑠𝑖𝑠=6∗0.8=4.8𝑉

When output of U1 is HIGH, output of U2 is LOW and vice versa. Basically R7 acts as a pullup/pulldown resistor for the CT2 signal providing better stability and enhanced noise immunity.

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Battery Charger:

𝑉 h𝐶 𝑎𝑟𝑔𝑒=1.170𝑉 ∗(1+𝑅17

(𝑅18+160 ) )h𝑉𝐶 𝑎𝑟𝑔𝑒=1.170𝑉 ∗(1+1.54∗106

180∗103+160)=11.17𝑉

𝑅𝑝𝑟𝑜𝑔𝑟𝑎𝑚=𝑅1= 297.5𝑉h𝐼𝑐 𝑎𝑟𝑔𝑒=

297.5𝑉200𝑚𝐴=1.5𝑘𝛺

Battery charge time:Battery: 2200mAh

Charge current should be 8%-10% of mAh rating (chose 9%)charge current= 0.09*2200=198mA

h𝐶 𝑎𝑟𝑔𝑒 𝑇𝑖𝑚𝑒=h𝑚𝐴 𝑟𝑎𝑡𝑖𝑛𝑔

h𝐶 𝑎𝑟𝑔𝑒𝐶𝑢𝑟𝑟𝑒𝑛𝑡=2200200 =11𝐻𝑜𝑢𝑟𝑠

Assuming 20% losses:

h𝐶 𝑎𝑟𝑔𝑒 𝑇𝑖𝑚𝑒=2200+(0.2∗2200)

200=13𝐻𝑜𝑢𝑟𝑠

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BLOCK 1: VERIFICATION PLAN

Key Requirement Verification Strategy Results

CT and AC-DC: Functionality. Max Voltage, ripple, regulation

Lab test and simulation Proved out in both lab test and simulation

Battery Charging:Charge current vs Line Current.BW of CT. Current Limit, Output voltage

Lab test and simulation Simulation proved out. Some lab test done.

Battery Heating:Temperature vs Line Current.

Lab test WIP

Current detect:Verify operation above and below threshold current.

Simulation Simulation proved out

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BLOCK 1: VERIFICATION

CT:

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CT output at 10A:

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CT output at 100A:

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LT3012B-Linear Regulator:

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LT3012B-Linear Regulator-Input Ripple:

Vr(p-p)=851mVpp

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LT3012B-Linear Regulator-Output Current and Output Voltage:

Simulation under worse case load condition. We see that regulator can maintain Vout=13.2V and Iout=440mA.

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BLOCK 1: VERIFICATIONCurrent Detect (CT output =11V, Output is low):

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BLOCK 1: VERIFICATION PLANCurrent Detect (CT output =12V, Output toggles):

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BLOCK 1: VERIFICATION PLAN

Current Detect (CT output =12V, Output to micro):

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Charger Output Voltage=11.1V

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Charger Output Current=200mA

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BLOCK 1: VERIFICATIONDetermine BW of CT

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Determine BW of CT

0 100 200 300 400 500 6000

2000

4000

6000

8000

10000

12000

14000

16000

Line Frequency vs Charge Current

Line Frequency vs Charge Current

Line Frequency- Hz

Char

ge C

urre

nt (u

A)

Peak (55Hz-70Hz),(13.6mA)

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RELIABILITY AND SUSTAINABILITY ANALYSIS

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11. Design Block 2

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Block 2: Battery, Buck Converter, Overcharge Protection

David Messer

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BLOCK 2: BATTERY, BUCK CONVERTER, OVERCHARGE PROTECTION

Purpose of Lithium-Ion Battery:

• To provide power to the LEDs, MCU, and bluetooth circuit• Continuous 11.1V to LEDs via a load switch• Utilize a Buck converter to step 11.1V down to 3V for the

processor and Bluetooth circuit

Purpose of Overcharge Protection:

• To prevent the battery from charging above 11.5V• Comparator circuit comparing V_out through a divider network

against a divided V_batt signal• Overcharge_int to the processor goes high when V_batt > V_out

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PERFORMANCE AND STANDARD REQUIREMENTS

• Battery must be able to handle overcharge voltage before the cutoff is engaged

• Meet battery protection requirements• Comparator must trigger Overcharge_Interrupt signal (3V) to

microprocessor

• Support the power requirements for the MCU, LEDs, and Bluetooth feature

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SIGNAL INPUT/OUTPUT

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OVERALL BLOCK DIAGRAM

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BLOCK 2: REQUIREMENTS: COST



$32.74

B2 Asm & Test Cost Allocation $10.00


33

90


E1 Operating Temp Range oC Charge: 0Discharge: -20

4040

Charge: 50Discharge:

60

E2 Operating Humidity Range % 0 95 Non Condensing

E3 Operating Altitude Range Meters - 50 3,000

E7 Applicable EMC Standards N/A


Reverse protection for battery, Overcharge interrupt from comparator to processor

BLOCK 2: REQUIREMENTS: ENVIRONMENTAL - BATTERY

91

Req #

Description Unit Min Nom Max Notes

P1A Operating Input Voltage Range

V 8.4 11.1 12.6 DC Voltage

P1B Operating Input Current Range

A 5mA 25mA 100mA

P1C Oper Input Voltage Freq Range

Hz -- -- -- DC Voltage

P1D Input Power Energy Source Rectified current is fed to the battery from a CT.

P1E Power Dissipation W ~1 Not charging, powering MCU and Bluetooth when needed

P2E Power Dissipation W ~5 Charging, powering MCU, Bluetooth, light

P1S1 Input Power 1 Safety Req 1 Battery voltage is fed to a comparator in the battery overcharge protection circuit. When the battery voltage reaches above a certain level, the comparator sends a signal to the MCU, which in turn opens a switch in the battery charging circuit.

P1-S2

Input Power 1 Safety Req 2 We are using battery reverse protection.

BLOCK 2: REQUIREMENTS: INPUT POWER - BATTERY

92

Req #

Description Unit Min Nom Max Notes

M1 Mass Allocation Kg 0.145

M2 Volume Allocation CM3 72.352 68mm(L) x 56mm(W) x 19mm(H)

M4 PC Board Area Allocation CM2 38.08 Will not be mounted on PCB

M5 Mechanical Shock Grms -- N/A Duration

M6 Mechanical Vibration Grms -- N/A Duration


Bulk composite material.

M8 Interface Connector Types Bare leads.

BLOCK 2: REQUIREMENTS: MECHANICAL - BATTERY

93


D1 Battery Output V 10.8 11.1 12.6 Buck and Overcharge (comparator) circuit is designed around 11.1V nominal.

D2 Charge Voltage V 8.4 11.1 12.9 Charge cutoff: 12.9VDischarge cutoff: 8.4V

D3 Operating Temperature: Charge °C 0 40 45

D4 Operating Temperature: Discharge °C -20 40 60

D5 Standard Charge: Constant Current (CC)

mA 1100

D6 Standard Discharge: Constant Current (CC)

mA 1100

BLOCK 2: PERFORMANCE REQUIREMENTS - BATTERY

94

BLOCK 2: DETAILED SCHEMATIC

95

THEORY OF OPERATIONS

•Lithium-Ion battery is charged from rectified DC current

•11.1V from the battery is supplied to the LED load switch where the MCU closes the switch to allow the LEDs to power up

•MCU receives “enable” signal from light sensor

•Buck converter is utilized to step 11.1V down to 3V

•3V powers MCU, and load switch to Bluetooth

•Comparator samples divided voltage from Buck Converter’s V_out and battery voltage level

•Sends 3V output to MCU for Overcharge Interrupt function to protect the battery

•Use (2) P channel Mosfets to provide battery reverse protection96

BUCK CONVERTER SIMULATION AND CALCULATIONS

97

BATTERY OVERCHARGE PROTECTION SIMULATION - LOW

Interrupt not enabled

• V(Over_Charge_Int) is low when divided V_batt < divided V_buck

• Allows battery to continue charging

98

BATTERY OVERCHARGE PROTECTION SIMULATION - HIGH

Interrupt enabled

• V(Over_Charge_Int) is high when divided V_batt > divided V_buck

• Comparator outputs a 3V signal to the microprocessor to disable charging of the battery

99

DETAILED PRODUCTION DESIGN BOM

100

RELIABILITY AND SUSTAINABILITY ANALYSIS

SUSPECTABILITY

RELIABILITY

101

VERIFICATION PLAN AND RESULTS

Key Requirement Verification Plan Results

Buck Converter steps 11.1V down to 3V for MCU and Bluetooth circuit

LTSpice simulations Passed simulation, 3V output verified

Comparator sends 3V Overcharge_Int signal to MCU when Battery charges

over 11.5V

Calculate resistor values in divider network, run LTSpice simulations

Passed Simulation, comparator output goes

high above 11.5V

102

12. Design Block 3

MicrocontrollerColin Hermann

103

MICROCONTROLLER

Description

• To control all the functions of the streetlight• On/off• Monitor power supply• Temperature monitoring (on/off heating element)

• To be able to send information to user interface and be overridden by such interface

• Analog to Digital conversion done in the Microcontroller

104

REQUIREMENTS: COST



$10

B2 Asm & Test Cost Allocation $ 4.00


However many needed

105


E1 Operating Temp Range oC -40 25 75 Considering ambient temperature of 10 oC

E2 Operating Humidity Range % 0 100 Non Condensing

E3 Operating Altitude Range Meters - 50 - Not specified

E7 Applicable EMC Standards

E8 Applicable Safety Mitigations 2000V ESD (human body model)RoHS compliant1000V ESD Charged Device Model

BLOCK 3: REQUIREMENTS: ENVIRONMENTAL

106


P1A Operating Input Voltage Range

V 2 3 5 DC

P1B Operating Input Current Range

MA 1 2 5 DC

P1D Input Power Energy Source Battery

P1E Power Dissipation mW 2 6 10

P1S1 Input Power 1 Safety Req 1 .1 uf capacitor from Vdd to ground

P1-S2 Input Power 1 Safety Req 2 NA

REQUIREMENTS: INPUT POWER107

INPUT / OUTPUT

Inputs

• Battery Charge

• Temperature sensor

• 3V power/GND

• Light sensor

• Bluetooth

Outputs

• Battery Charge on/off

• Heating Circuit

• Light Circuit

• Bluetooth

108

BLOCK DIAGRAM

109

ELECTRICAL SCHEMATIC

110

ELECTRICAL SCHEMATIC

111

ELECTRICAL SCHEMATIC MASTER RESET

112

MICROCONTROLLERTHEORY OF OPERATION

• The control of the streetlight will be managed with interrupt service routines.

• It will raise and lower output pins depending on the interrupt.

• It will switch between low energy and high energy depending on the modes.

113

BILL OF MATERIALS

PRODUCTION BILL of MATERIALS - BOM (*Select Symbol Font for Some Units)

*|

Annual Product Volume --> 100000

Item # Generic Part NameQTY per Product Function Nominal Value Unit* Tol% Main Attribute Other Attributes Package

Annual Part Volume

1 ARM EFM32GG280F512 1 Micro Controller na na low power QFP-100 100,0002 capacitors 11 Capacitor 0.1 uF 20% Fixed Ceramic TR 1,100,0003 resistors 4 Resistor 10 KW 5% Fixed Film CT 200,0004 10uF capacitor 1 Capacitor 10 uF 5% Fixed Ceramic 25V 0603 100,0005 capacitor 15 pF 2 Capacitor 15 pF 5% Fixed Ceramic 250V -55,125 TR 200,0006 zener diode 1 2 Volts 5% Voltage Control TR 100,0007 LT1018 comparator 1 Comparator Vin = 1.1 - 40 Volts LT Family S8 100,0008 watchdog timer 1 IC 80us, 5.5v, -40, 125 TDFN 100,0009 crystal 1 32.768kHZ -40, 80 SOJ 100,00010 resistor 27Kohm 1 Resistor 27 KW 5% -55, 155, 100V 402 100,00011 resistor 40k 3 Resistor 40 KW 1% -55, 155, 100V 603 300,00012 resistor 1 meg 3 Resistor 1Meg W 5% -55, 155, 603 100,00013 push button 1 push button -20, 85, 35V 100,00014 1uf capacitor 1 Capacitor 1 uF 10% Fixed Ceramic 1206 100,000

$Cost Each @ Annual Volume

$Cost TotalPer Product

PCB SolderAttachment # of Pins

Footprint Areain cm2 on PCB

PlacementMethod

Manual Assembly, Manual Soldering,

and Adjustment Costs Mfg 1 Mfg 1 Part #5.25$ $5.25 SMT - Reflow 100 2.37 Fully Automatic Robot $0.10 SL EFM32GG280F5120.01$ $0.05 SMT - Reflow 2 0.005 Fully Automatic Robot $1.20 murata GRM155R71H104ME14D0.00$ $0.00 SMT - Reflow 2 0.005 Fully Automatic Robot $0.20 Yageo RC0402J R- 0710KL

0.0300 0.0300 SMT 2 0.0128 Fully Automatic Robot $0.10 Murtara ElectronicsGRM21BR61E106KA73L0.06$ $0.13 SMT - Reflow 2 0.012 Fully Automatic Robot $0.20 johansen tech 251R14S150JV4T0.04$ $0.04 SMT - Reflow 2 0.038 Fully Automatic Robot $0.10 diodes incorporatedBZT52C2V0-7-F2.79$ $2.79 SMT - Reflow 8 0.31 Fully Automatic Robot $0.10 Linear Technology LT1018IS8#TRPBF1.68$ $1.68 SMT - Reflow 8 Fully Automatic Robot $0.10 Maxim Integrated MAX16058ATA22+T0.18$ $0.18 SMT - Reflow 2 0.304 Fully Automatic Robot $0.10 Abracon ABS25-32.768KHZ-T0.00$ $0.00 SMT - Reflow 2 0.005 Fully Automatic Robot $0.10 Yageo RC0402JR-0727KL0.04$ $0.12 SMT - Reflow 2 0.005 Fully Automatic Robot $0.10 Yageo 9C06031A4002FKHFT0.00$ $0.00 SMT - Reflow 2 0.0128 Fully Automatic Robot $0.10 Yageo RC0603JR-071ML0.31$ $0.31 TH - Wave 4 not placed on pcb Fully Automatic Robot $0.10 E-switch KS-01Q-01

0.0270 0.0270 SMT - Reflow 2 0.0512 Fully Automatic Robot 0.10$ TDK Corp C3216X7R1H105K160AB

Total Components $10.61 Total ComponentsArea in cm2 3.1308 Total Manual Costs 2.70$

Part Cost= 10.61Part Assembly = 2.70

114

PRODUCTION DESIGN COMPONENT SELECTION

Microcontroller Selection

• The Arm M3 Microcontroller was chosen because of popularity and the it’s low power

• It is a low power Microcontroller that will be beneficial to extend the time the battery will last

• It has 100 pins with about 86 of them being I/O and the primary thing that we needed was that the microcontroller has a Analog to Digital Convertor which runs at 1 million samples per second.

Capacitors

• We choose ceramic capacitors because they are cheap and they are just to protect the power supply, so we did not need the Capacitor to be high end

• Values were chosen for RC time in master power on reset and to buffer in brownout protection

115

PRODUCTION DESIGN COMPONENT SELECTION

Resistors• 40 k resistors were suggested •1 meg ohm was used to keep the current in the uA range•Needed a voltage supply so used 11.1V power and a voltage dividerZener diode•To help establish a voltage comparator wanted a 2V Zener diodeComparator• Chosen for it’s voltage range also it is used in other Blocks

116

SIMULATION OF BROWNOUT CIRCUIT

<-Zoomed out Version

About 20us delay

117

SIMULATION OF MASTER RESET CIRCUIT

118

DESIGN FOR MANUFACTURING

Microcontroller

• The Microcontroller can at maximum have a 3V signal on the 12 bit analog to digital convertor. This means the convertor has an error of .7mV. The ADC error is stated to be 3 bits which means the error will be 5.8 mV

• The SNR is calculated to be 73.9 db

• Delay times is not a concern since the microcontroller will be operating at a fraction of the clock speed that it is designed for

Capacitor

• The tolerance of the capacitors does not matter since these are solely responsible for protecting the Microcontroller from variations in the power supply

119

BLOCK 3: RELIABILITY AND SUSTAINABILITY

Reliability

Sustainability

Component Description QtyBase l FITs

Max Rated Temp Co (Tr)

Max Oper Temp Co (Ta)

Max Rated Voltage (Vr)

Max Oper Voltage (Va) pT pV pE pQ Total l

Capacitor 12 2 125 50 50 3 1.548 0.144 3.000 1.000 16.0754Microcontroller 1 55 150 50 4.1 3 1.249 2.069 3.000 1.000 426.383Resistor 11 0.7 155 50 100 5 1.210 0.140 3.000 1.000 3.91314Capacitor 15pF 2 2 125 50 250 5 1.548 0.138 3.000 1.000 2.56538crystal 1 15 85 50 20 3 3.773 0.161 3.000 1.000 27.4107watchdog timer 1 27.3 125 50 5.5 3 1.548 0.449 3.000 1.000 56.9567zener diode 1 3.2 150 50 30 2 1.249 0.145 3.000 1.000 1.74248comparator 1 5 85 50 40 3 3.773 0.147 3.000 1.000 8.30561

Total 30 543.4

120

PROTOTYPE

Similarities

• All of the code and the Microcontroller it self will be the same in both prototype and production

Differences

• We will use a board that will allow for us to program the Microcontroller

121

13. Design Block 4

Owner: Cassandra Appleton

122

Sensor Block123

LED light Block124

Lux (symbol: lx) is SI unit of luminous emittance, measuring luminous flux per unit area.

Measures of the total "amount" of visible light emitted by a source.

Luminous flux measurements reflect the varying sensitivity of the human eye to different wavelengths of light.

Lumens are related to Lux in that one lux is one lumen per square meter.

LUX & LUMENS 125

Lumen (symbol: lm): SI derived unit of luminous flux

Traditional Bulb low W high W

150 w 2600 lumens(lm) 25.00 28

100 w 1600 lumens(lm) 16.00 20

75 w 1100 lumens(lm) 9.00 13

60 w 800 lumens(lm) 6.00 8

40 w 450 lumens(lm) 4.00 5

LED W equivalentTypical for reference

LUMENS 126

LUX & LUMENS 127

LED LIGHT

•Via Sundance Solar

•Operating VDC (11-15)

•Lumens ~585•More than 40w (450)•Less than 60w (800)

•Requires Edison mount

128

Sensor Block 129

Block 4 Requirements: Cost



$22.38 Will vary if we pick a light off the shelf.

B2 Asm & Test Cost Allocation $1 We are doing these.


7

130


E1 Operating Temp Range oC -30 25 80 Would improve with more expensive CdS sensor.

E2 Operating Humidity Range % NA NA 100 Non Condensing

E3 Operating Altitude Range Meters NA NA NA Street level. Habitable areas.

CdS Photoresistor

Block 4 Requirements: Environmental131


E1 Operating Temp Range oC -30 NA 40 Would improve with more expensive CdS sensor.

E2 Operating Humidity Range % NA NA 100 Non Condensing

E3 Operating Altitude Range Meters NA NA NA Street level. Habitable areas.

LED light

Block 4 Requirements: Environmental

132


P1A Operating Input Voltage Range V 2.7 3 3.3 DC

P1B Operating Input Current Range of CdS photoresistor

A 4.3 NA 5.9 µA

P1C Vout A 0 NA 3.3 VDC. No “nominal’ either ON or OFF

P1D Oper Input Voltage Freq Range Hz NA NA NA

P1E Input Power Energy Source Inverter within overall design from Block 2 with ~3VDC.

P1F Power Dissipation mW 0 X 90 Varies with device and ambient temperature

P1S1 Input Power 1 Safety Req 1 DC straight


Block 4 Requirements: Input Power (CdS)

133


P1A Operating Input Voltage Range V 11 11 15 DC from Block 2 Battery

P1B Operating Input Current Range of CdS photoresistor

mA NA 750 NA Range not given

P1C Vout A 0 NA 3.3 VDC. No “nominal’ either ON or OFF

P1F Power Dissipation W NA 9 NA Range not given.

P1S1 Input Power 1 Safety Req 1 DC straight from Block 2 battery


Block 4 Requirements: Input Power (LED Streetlight)

134


M1 Mass Allocation Kg 0.005 0.01 0.05 Limits of acceptability

M2 Volume Allocation CM3 5 10 20

M4 PC Board Area Allocation CM2 NA NA NA Separate

M5 Mechanical Shock Grms NA NA NA

M6 Mechanical Vibration Grms NA NA NA


Plastic

M8 Interface Connector Types AWG wiring.

Block 4 Requirements: Mechanical (CdS) 135

Both CdS Photoresistor & LED streetlight


D1 Light Brightness for Sensor Lux 0 578 X Varies. Prototype indoors for now. Future, for the sun.

D2 Light Brightness for LED light. Lumens NA 585 NA Based on budget. A range is not given for the bulb chosen.

D3 Powering of Comparators Volts 1 2.9 3.3 Needs to be +/- 0.3 from VDD which is 3VDC.

D4 Output from Comparator Circuit Overall

Volts 2.97 3 3.3 To microprocessor.

Block 4: Performance Requirements 136

Primary Functions/Modes:• CdS Photoresistor sensor detects light when

presentMeasured Qty Range(s):

• Current function of resistance• From 5-20k to 200k

LED Street Light- Power• Low power. Cannot exceed 11 watts for needs

Measured Qty Accuracy(lux detection):• For prototype ~585

Power Qualities: • Sensor circuit maxed at ~3.3 volts• LED Street Light power~11 watts

Block 4: Performance Requirements137

Block 4 Description of Function(CdS photoresistor, Comparator)

• CdS Photoresistor • Light Exposure: 5-10

kΩ• Darkness: 200 kΩ

• CdS Photoresistor tied into Comparator

• The comparator powered• +/-3VDC

• Threshold Voltage ~ 3VDC• Vout connected to the

microprocessor • voltage as an

interrupt. • This interrupt allows the

microprocessor to turn on the LED light

138

Block 4: Purpose & Function

Block 4: CdS Photoresistor Range [0-3 VDC]

• Main purpose is to detect light. • The input light electrochemically interacts with photoresistor

• alters it’s resistance. • decreases with increasing incident light intensity

• exhibiting photoconductivity becoming more conductive

• composed of a high resistance semiconductor• In darkness ~200 kΩ• In the light, lower resistance of 5-10kΩ.

• The sensor becomes more conductive

139


Block 4: CdS Photoresistor cont’d

•can be applied in light-sensitive detector circuits

• for light- and dark-activated switching circuits.

•On light exposure light on a • photoresistor exceeds a certain

predesigned frequency• photons absorbed by semiconductor

giving bound electrons enough energy to jump into the conduction band.

• The resultant free electrons, along with their hole partners conduct electricity proportional to the lower resistance. certain wavelength bands.

140


Comparator circuit• CdS Photoresistor voltage passes through a comparator

• Comparator voltage threshold ~ 3 VDC• Includes 4 resistors, 2 cap to reduce noise• The comparators is a LPV7215 Comparator

integrated w/ CdS photoresistor (R2)• Source 3 VDC• If the output exceeds the predesigned threshold of 3 volts, then passes that voltage to the microprocessor so it can enable the streetlight.

• 4 resistors • 300 kΩ, 40 kΩ, 500 kΩ, and 1MΩ.

141


Comparator Circuit cont’d•2 fixed ceramic 0.1 µF capacitors•One parallel with R1 on the +3V line entering the Noninverting Pin of the invertor at pin 2.

•The other is attached to the +Vcc of the invertor at pin 8 and the +3 voltage source.

•These bypass capacitors help in reducing noise of power supply in the system.

142


Comparator Circuit cont’d

•Capacitors (1uF)• Ideally no AC signal 3VDC• Possible Noise [ 3 + n(t) ] V with AC n(t)

• Cap is Open DC• AC is short is case any is introduced from DC source

143

Block 4 Description oF Function(CdS photoresistor, Comparator)

Component Unit Input Output Notes

CdS Photoresistor VDC 3 Varies

Light VDC 3 3

Dark VDC 3 0

Comparator VDC 3 Varies

Light VDC 3 3

Dark VDC 3 0

Comparator Connected to Microprocessor

144

Block 4: Signals

Block Name: CdS Photoresistor & Comparator, Plus StreetlightBlock Number: 4

Power Signals To - From Type Direction Block-Block Voltage Freq % V-Reg V-Ripple CurrentBlock #'s Interconnect Nominal Min Max Nominal Min Max Max Max Max

Power1 VCC +3VDC 2,4 DC Power Input PCB Trace 3.0V 0.8 60 DC N/A N/A N/A N/APower2 VCC -3VDC 2,4 DC Power Input PCB Trace 3.0V 0.8 60 DC N/A N/A N/A N/APower 3+VCC +11VDC 2,4 DC Power Input Wire 120V 10.8 12.6 DC N/A N/A 0.15 N/A N/APower 4 -VCC -11VDC 2,4 DC Power Input Other 12.0V 10.8 12.6 DC N/A N/A 0.01 N/A N/A

Voltage Range Freq Range

Digital Signals To - From Type Dir Block-Block Output Input Tech Freq LogicBlock #'s Interconnect Structure Structure Nominal Voltage Vih Min Iih Max ViL Max IiL Max Vth Min Vth Max

Digital1 Data15-Data0 4 , 5 Analog Input Wire N/A Standard TTL N/A 3VDC 2.85 0.3 3.15 -1.2mA N/A N/A

Input Characteristics

Analog Signals To - From Type Direction Block-Block Coupling Voltage Max LeakageBlock #'s Interconnect Amplitude Min Max Min Max Max

Analog1 RF Amp Output 4 , 5 Analog Output PCB Trace Direct 3.15 VDC N/A N/A N/A N/A N/A

Impedance Freq Range

145

Block 4: Simulation Values For CdS Photoresistor Ranges

•Exposed to light R2 (Cds) ranges from 5-10kΩ

•In darkness the R2 (CdS) : 200kΩ•The behavior is tied into the comparator•The following slides have values for these ranges

146

Block 4: Simulation Values For CdS Photoresistor

147

Block 4: Simulation Values For CdS Photoresistor

•CdS Photoresistor

Calculation From Specs 1lux / 0.6 Ω

0.6 Ω / 1lux * 347 Ω = 758 lux

148

TOLERANCES

Worst Case -/+ 5% all components

•CdS still drops Vout to 0VDC at ~300 Ω

•Roughty 500 lux which is acceptable (brighter side Sunrise/Sunset)

149

BLOCK 4: BOM 150

Block 4: BOM 151

DFM for Block 4 152

Block 4: DFM Discussion

The transfer function or the sensor, current or voltage, will have a ratio range from 0 to 1.

• Dependent on the CdS exposure to light • will affect it's ability to conduct via resistance.

• This in turn will influence how much current will pass,• directly proportional to the amount of light.

• The gain will range from roughly 0.016, when the sensor is in darkness, to 1, when the sensor is exposed to light and allowing the full current to pass outputting 3 VDC on Vout.

• Pulse response and delay (TBD). • There will be no heat sinks on the sensor. Any overcurrent or surge voltage is done on the battery side, in Block 2.

153

Block 4: DFM Discussion

•The comparator cannot have a voltage offset more than 0.25V or total 2.75 volts.

•Microprocessor requires VDD +/- 0.3• roughly 2.7 volts.

•Comparator cannot to drop below 2.75 VDC.• Anything less with not allow the proper voltage to reach the microprocessor for processing

• Will not enable the LED Streelight's switch to ON. • It's Input Impedance ~ 1MΩ• The light is protected from overcurrent or surge voltage by the circuit protector on the battery side of the overall design located in Block 2.

154

Prototype SchematicLight Sensor and Comparator

Key Devices and Vital Operations for Block 4

(CdS photoresistor, Comparator)

155

General I/O for Block 4 (CdS photoresistor, Comparator)

Input of Light causes R2 CdS photoresistor to change voltage as a function of light exposure

Output of Voltage of roughly 3 VDC for Microprocessor

156

•Most important traits for Block 4 is performance. •Dependent on CdS photoresistor.

•Resistance must change directly as a function of light exposure

•With lower resistances in the presence of light from 5-10k

•3 volts output, and 0 V at 200k in the presence of darkness.

•This component drives the switching function of the streetlight

Key Devices and Vital Operations for Block 4 (CdS photoresistor, Comparator)

157

Reliability Analysis for Block 4 (CdS photoresistor, Comparator)

The components were analyzed for reliability by taking both temperature and voltage ranges into account.

Most of the resistors had a very wide range for operating temperature.

The limiting component for temperature is the photoresistor which is the most sensitive.

158

Block 4: Reliability and Sustainability 159

Block 5

Bluetooth Connectivity Owner: Evan Reichelt

160

Purpose

• Data Transmission• Wireless Connectivity• Transmit at Low Power Requirements• Transmit Large Distances• Minimize Frequency Interference• Secure Connectivity• Minimize Transmission Error Rate

161

Block 5: Description

• A magnet will activate a magnetic switch.

• The switch will send a signal to the microcontroller to activate the load switch.

• The load switch will then send +3V to the Bluetooth module.

• The Bluetooth module will then communicate back and forth with the microcontroller and linked user to relay required information.

• User interface will be through open source teraterm software

162

Location

•Block Inputs• UART TX• UART RTS• UART NRTS• UART NCTS• Reset

•Block Outputs• 2.4 Ghz

Bluetooth Connection

• Power– 3.0 V

VDD– GND

Block Name: BTBlock Number: 5

Power Signals To - From Type Direction Block-Block Voltage Freq % V-Reg V-Ripple CurrentBlock #'s Interconnect Nominal Min Max Nominal Min Max Max Max Max

Power VCC 2 DC Power Input PCB Trace 3V 2.7V 3.6V DC N/A 0.05 0.1V 70mA

Digital Signals To - From Type Dir Block-Block Output Input Tech Freq LogicBlock #'s Interconnect Structure Structure Nominal Voltage Vih Min Iih Max ViL Max IiL Max Vth Min Vth Max Voh Min Ioh Max VoL Max IoL Max

Uart TXD 3 Digital Output PCB Trace Tristate Standard CMOS 3V 2.1 0.0001 0.8 2.8 0.2Uart RXD 3 Digital Input PCB Trace Tristate Standard CMOS 3V 2.1 0.0001 0.8 2.8 0.2Uart_NRTS 3 Digital Output PCB Trace Tristate Standard CMOS 3V 2.1 0.0001 0.8 2.8 0.2Uart NCTS 3 Digital Input PCB Trace Tristate Standard CMOS 3V 2.1 0.0001 0.8 2.8 0.2PIO2-PIO7 3 Digital Bidir PCB Trace Tristate Standard CMOS 3V 2.1 0.0001 0.8 2.8 0.2Reset 3 Digital Input PCB Trace Tristate Standard CMOS 3V 2.1 0.0001 0.8 0.64 1.5 2.8 0.2

Analog Signals To - From Type Direction Block-Block Coupling Voltage Max LeakageBlock #'s Interconnect Amplitude Min Max Min Max Max

Internal Antenna 5 Analog Output PCB Trace 2 VSWR 50Ω 2400 2500

Output Characteristics

Impedance Freq Range

Voltage Range Freq Range

Input Characteristics

163

Block Level Diagram

Block 3: Colin HermannMicrocontroller

Sensors

Bluetooth activation switch – Normally Open Reed Switch

Block 2: Dave MesserPower

Supply ~3V

WT12-A-A14Bluetooth Chip w/ Internal Antenna

Block 5: Evan Reichelt

Analog

3V V

dd

Dig

ital

Dig

ital

Pulls High 3V

AnalogUser Interface

164

Bluetooth Chip Block

• BlueCore04: Houses the RF Receiver, Transceiver, and Synthesizer. The Microcontroller acts as an interrupt controller and event timer, runs the software stack and Controls the radio and host interfaces. It also houses a 16bit RISC MCU. A 48Kbytes of on chip Ram to support the RISC for the stack.

• Programmable I/0: Controlled by onboard firmware, 6 terminals.

• Int. Voltage Regulator 1.8V

• Flash Memory: Store protocol stack and Virtual Machine application.

• Balun/ Filter: changes the balanced I/O signal of the module to unbalanced signal of monopole antenna. The filter is bandpass (ISM)

• Chip Antenna & Matching: Matches the ACX AT3216 antenna to 50ohms

• UART: Interface with serial devices

• Crystal Oscillation - TCXO(8-40MHz) 26MHz

8 MbitFlash Memory

Balun & Filter

Bluetooth CoreHouses the Stack,, Interface, and Power

& Clock Management.

26 MHz Crystal

Matching

Internal Chip

antenna

+3.0V

PIO

Reset

USB

UART

SPI

PCM

165

Block 5 Requirements: Cost



$12.49 See Block Level BOM

B2 Asm & Test Cost Allocation $14.10 This accounts for module so it is not accurate.


8 See Block Level BOM

166


E1 Operating Temp Range

oC -40 25 85

E2 Operating Humidity Range

% - - 100 Non Condensing

E3 Operating Altitude Range

Meters - 50 - 3,000

E7 Applicable EMC Standards

EN 301 489-17:V2.1.1 ESD immunity, EN 61000-4-2:2009Radiated electric field immunity, EN 61000-4-3:2006 +A1:2008


EN 300 328 V1.7.1 Equivalent isotropic radiated power, Clause No 4.3.1 Frequency range, Clause No 4.3.3 Frequency hopping, Clause No 4.3.4 Medium access protocol, Clause No 4.3.5 Transmitter spurious emissions, Clause No 4.3.6 Receiver spurious emissions, Clause No 4.3.7

Block 5 Requirements: Environmental 167


P1A Operating Input Voltage Range V 2.7 3.0 3.6 DC

P1B Operating Input Current Range A 0.056 30 70 mA

P1C Oper Input Voltage Freq Range Hz - - - DC

P1D Input Power Energy Source Define Source: Power Supply Block 2 - Battery

P1E Power Dissipation W 0.01 1 Trans/Receive =70mA PeakStandby = 44.7 mAIdle = 3 mAIdle/deep Sleep = 0.056 mAData Trans 31.5/29.2 mA

P1S1 Input Power 1 Safety Req 1 Internal Power Regulator ( 1.8 V)

P1-S2 Input Power 1 Safety Req 2 Regulated Power from block 2

BLOCK 5 REQUIREMENT: INPUT POWER

168


M1 Mass Allocation Kg - - - Limits of acceptability

M2 Volume Allocation CM3 - - - Define min/max LxWxH – Just for the BT module

M4 PC Board Area Allocation CM2 - 7.944 - See BOM

M5 Mechanical Shock Grms -- - - Duration

M6 Mechanical Vibration Grms -- - - Duration


Protected by mu material, this material should not affect transmission or reception.

M8 Interface Connector Types UART, Internal Antena USB, Programmable I/O, Synchronous serial interface

BLOCK 5 REQUIREMENT: MECHANICAL 169

Block 5: Performance Requirements


D1 Operational temp C -40 85

D2 Range m 0 15 40 Nominal in standard primary electrical wire height above gound

D3 Throughput kbps 723.2433.9

2178.11306.9

Async, return sig. lessSync, return =same

D4 Transmission Power dBm -11 +3

D5 Resolution Range db -5 -25

D6 Receiving Signal Range dBm -82 -20 Tx>20

D7 Baud Rate Baud 1200 3.0M <=1%error max<=2%error min

170

Detailed Block 5 Diagram

C310pF

C610pF

C110pFWT12_A_14

Bluetooth Module

1234567891011121314 15

16171819202122232425262728

293031

Ferrite_Bead

RTS

RX_Blk3 Reset_Blk3

TX_Blk3

CTS

Block 5: Evan Reichelt

171

Production Design(Theory of Operation)

•The WT-12 Bluetooth module operates between 2.7V-3.6V and operates at a nominal voltage of 3.0V, but will require 3.3V if USB will be used

•The voltage regulated in block 2 is designed to supply block 5 with 3V, the module itself has an internal regulator as well (1.8V)

•A ferrite bead and capacitors are added to voltage inputs of the module to filter analog voltage

•Based on the module chosen, an external antenna is not required given the units 30m range

•UART interfacing is the preferred method for receiving and transmitting information with the microcontroller

172

Block 5: BOM

PRODUCTION BILL of MATERIALS - BOM (*Select Symbol Font for Some Units)

*|

Annual Product Volume --> 10000

Item # Generic Part NameQTY per Product Function Nominal Value Unit* Tol% Main Attribute Other Attributes Package

Annual Part Volume

$Cost Each @ Annual Volume

$Cost TotalPer Product

5 $0.006 WT12-A-AI4 1 Xmitter N/A User Defined IC BT Module User Defined 10,000 11.829$ $11.837 Reed Switch 1 Switch N/A User Defined SPST Reed Switch User Defined 10,000 0.540$ $0.548 10pF Capacitor 3 Capacitor 10 pF 1% Fixed Ceramic 0603 30,000 0.014$ $0.049 10k Resistor 1 Resistor 10 KW 1% Fixed Film 0.1W 0603 10,000 0.002$ $0.00

10 0.1uF Capacitor 1 Capacitor 0.1 uF 10% Fixed Ceramic X5R,25V 0603 10,000 0.006$ $0.0111 Ferrite Beads and Chips 1 Inductor 100 W 25% EMIFIL FERRITE CHIP 100 OHM 2A 0603 (GHz Noise) 0603 10,000 0.073$ $0.0712 $0.00

Total Components $12.49

PCB SolderAttachment # of Pins

Footprint Areain cm2 on PCB

PlacementMethod

Manual Assembly, Manual Soldering,

and Adjustment Costs Mfg 1 Mfg 1 Part # Distributor

SMT 32 3.58 A Fully Automatic $0.47 Silicon Labs WT12-A-AI4 DigikeySMT 2 0.0128 A Fully Automatic $0.02 Little Fuse Inc. 59170-1-S-00-D DigikeySMT 2 0.0128 A Fully Automatic $0.00 TDK Corporation C1608NP02A100D080AA DigikeySMT 2 0.0128 A Fully Automatic $0.00 Yageo RC0603FR-0710KL DigikeySMT 2 0.0128 A Fully Automatic $0.00 Taiyo Yuden TMK107BJ104KA-T DigikeySMT 2 0.0128 A Fully Automatic $0.00 Murata Electronics North America BLM18EG101TN1D Digikey

Total Components Area in cm2 7.944 Total Manual Costs 1.60$ 0

MANUFACTURER PART NUMBERSCOMPONENT-PCB ASSEMBLY DETAILS

173

Performance Requirement

•Function: On, Off, Receive Data, Send Data, Control

•Measured Range Measured Accuracy

•Measured Response•Measured Power Efficiency•Measured Error •Signal to Noise Ratio•User Input/Display(Tera Term Software)

•Operating Temperature Range (-40 to 85 degrees C)

•Operating Humidity Range (100% Max)

•Power Dissipation•Industry Compliant

174

Evan Connor Reichelt

Need to go back and review IEEE standards

Block 5: Performance Calculations

•Transmission Range•Near vs. Far Field Transition Point

The device use 2.4GHz ISM Band which is 83MHz wide. Uses frequency hopping to change between 79 1MHz wide channels.

•Signal Strength•Max Far field strength based on Antenna Radiated power

EField V/m = = 0.0048584 V/m Max O power(40m), 73.73dBuV/m0.003859 V/m Relative Tx Power (40m), 71.73dBuV/m

Transition Point (meters) = = ~=~ = 0.01987 = 0.02meters

175

BLOCK 5: WIRELESS PERFORMANCE

Performance •Bandwidth•Wireless Transmission Rate•Signal Strength (dB)•Range (m)•Bit Error Rate (BER)

Wireless Constraints•Throughput: 500 B/s•Latency: 100ms•Packet Loss: 5%•Range: Primary wire:12m (40ft), Secondary Electrical: 28 ft pole height, and NEC code mandates 18ft min line to ground distance above road.

•Bluetooth Standards are met

176

Block 5: Reliability

•Total FIT = 28.8•MTBF = 3,961.01 Years•The Blue tooth Module is the dominant aspect of unreliability, but the manufacturers reliability calculations show an MTBF of 284.13 Years.

•The WT12 could be improved by the use of higher quality components to increase the devices max rated temp., and lower max op. temp.

Component Description Qty Base l FITsMax Rated

Temp Co (Tr) Max Oper Temp

Co (Ta) Max Rated

Voltage (Vr) Max Oper

Voltage (Va) pT pV pE pQ Total l

WT12-A-AI4 1 19 125 50 15 5 1.548 0.223 3.000 1.000 19.6847Reed Switch 1 5 125 50 250 5 1.548 0.138 3.000 1.000 3.2067310pF ceramic capacitor 3 2 150 50 50 5 1.249 0.151 3.000 1.000 3.3994110k SMT resistor 1 0.7 125 50 100 5 1.548 0.143 3.000 1.000 0.463640.1uF ceramic capacitor 1 2 125 50 50 5 1.548 0.151 3.000 1.000 1.40447Ferrite Beads (inductor) 1 1 125 50 500 5 1.548 0.137 3.000 1.000 0.63477

Total 8 28.79

177

Block 5 Sustainability178

Block 5 Verification Test

Key Requirements• 1. Bandwidth• 2. Wireless Transmission Rate• 3. Signal Strength• 4. Range• 5. Bit Error Rate (BER)

Verification StrategyLab test & Simulation

179

Block 5 Test Results180

Denis Sterjo

11. Safety & Regulatory

Design

181

OVERALL SAFETY

• Battery protected implementing redundant reverse battery protection circuit.

• Battery Charging has thermal protection.

• Provide detailed installation guide following OSHA safety and regulation standards for overhead power line equipment (standard nr 1926.1410)

• Find potting material with high thermal conductivity.

• Attach board ground layer to Line potential to reduce effects of Corona.

182

Denis Sterjo

12. MANUFACTURABILITY

DESIGN

183

Manufacturability and Mass Production Strategy• At least 2 suppliers for each part, excluding battery and ICs. • All SMT parts placed automatically in production.• RoHS lead free solder to be used.• Test Strategy:

• Develop ICT test for the main PCB (>70% coverage )• Board level functional test (>95% coverage)• Pre-Pot functional test.( >70% coverage)• Post-Pot functional test.( >70% coverage)• Implement Gage R&R for all three functional tests• Keep at least 3 golden units in production

• Request weekly first pass yields via an online website.• Simple mechanical designMinimize the amount of assembly

stations minimizes production cost

184

13. SUSTAINABILITY DESIGN

Colin Hermann

185

PRODUCT SUSTAINABILITY186

PRODUCT SUSTAINABILITY PLAN

10 Years of Forward Production @ ~ 100k units/yr2026 Last Year of Service Support After Production StopTotal Production + Service Population = 10^6 unitsWorst Case (min 2) Components Obsolescence DatesPhoto Resistor: 2019 Consider replacing component.Bluetooth: 2023 Consider replacing the component

Product WEEE & RoHS Compliance StatementProduct is RoHS CompliantWEEE Materials List: Battery

Hazardous MaterialsBattery Follow Li-Ion disposal regulations.PCB: Proper labeling for recycling

Product End of Life Disposal StrategyComponents/Materials To Be Recycled: Plastic enclosureComponents/Materials To Be Landfilled: none

Total Energy Consumed By Product Over it’s LifeXX kW-Hrs (V*A*Hrs) = Energy Per Day X Usage Days in Life BB% of Total Energy Required Artificially (AC power, primary battery, etc.)

187

Counterfeit Component Mitigation PlanComponents will be Procured from either a licensed distributor or direct from the manufacturer.

All Component Sources will Be Qualified to AS5553 and AS608114 Components on Product BOM with Single Sources63 Components on Product BOM with Dual Sources Components most at risk• Resistors: All surface mount tech is at risk however since they are small they are at great risk. • Capacitors: they are small and surface mount. • Diodes: they are small and surface mount. Mitigation for the three components: Random testing and use only manufacturers and Licensed DistributorPlan for if Counterfeit is detected• Stop production and test components that may be counterfeit• Alert manufacturer or distributor of the discovered counterfeits• Report to GIDEP

188

14. RELIABILITY DESIGN

Denis Sterjo

189

PRODUCT LEVEL RELIABILITY

Initial Product Warranty Desired: 1 yearSuggested Warranty: 215 daysMost unreliable components: Battery, Microcontroller and Photo ResistorMost unreliable block: Block 4Most reliable block: Block 5MTBF= 58 yearsTotal FITs: 1950

190

Reliability Assessment

Dominant Unreliable Parts: Battery, Microcontroller and Photo Resistor

Adjustments to Warranty:• Reduce warranty to 6 months• Initiate a research project for finding a more reliable photo resistor and

battery (goal is to find new pin to pin compatible components so is easy to phase them in production and rev up the hardware).

• Replacing microcontroller requires extensive work in design.• Market provides limited options for a more reliable battery design.

191

Reliability Test Plan

Stress 24 Hour Model

10 Year Model

Accelerated Stress Model

Accelerated 1 Cycle

Time

Acceleration Factor

Max Input Voltage

30 30 Arrhenius N/A 36.6

Number of Power Cycles

3 10950 time 10 seconds

2880

Thermal Range -20 to 45 C -20 to 45 C

Coffin-Manson

N/A N/A

Number of Therm Cycles

1 3650 Coffin-Manson

6.4 days 384

192

15. Summary of Standards

193

STANDARDS WITH DESIGN

Standard Title CommentsIEC 60695-8-1 Fire Hazard Testing

IEC 60695-1-1 Heat Release

IEC 61140 Electrostatic Discharge From Device

IEC 61000-4-11 Electromagnetic Compatibility

IEC61000-4-6 EMC Immunity from external source

IEC61000-4-8 EMC Magnetic field Immunity

CISPR11/22 EMC Radiated and Conducted EM

IEC61000-4-2 EMC Electrostatic Discharge To Device

2011/65/EU RoHS Restriction of Hazardous Substances

194

16. LIFE LONG LEARNING

195

Areas to learn

Standards•Develop a better understanding of current standards and requirements.

• Market• Equipment

•Discuss specifics of product scopeRegulations

• Learn more about manufacturing regulations• Learn more about Patent Law

Design Tools•Programming tools•Circuit design software

Practicality & Application•General design for more universal applications•Possible design changes due to limiting components•Installation & Planned Maintenance Requirements•Public Opinion & Aesthetics

196

17. Prototype Description & Verification

197

SUMMARY OF BOM200

18. ACKNOWLEDGEMENT

S

201

ACKNOWLEDGEMENTS

DR. Mustafa Farrah• Provided help and wisdom whenever we needed it.DR. Jeffery Kautzer• Provided Clarification and help whenever we asked.UWM Faculty Especially Electrical Engineering Department• Taught us and helped us to get to the point that we are today.Family and Friends• For support and understanding over the last semester

202

QUESTIONS?

203

team 2 final presentation 12-7 download

Documents