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Atomic Clock Receiver - Enhancing Timekeeping Precision

Team of experts developing a device to automatically reset water softener clocks, improving efficiency and accuracy. Precise time signal synced with atomic clock for seamless operation. Stay on schedule with this innovative product.

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Atomic Clock Receiver - Enhancing Timekeeping Precision

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  1. Atomic Clock Receiver

  2. 318-595 Spring 2005, Team #4 318-595 Spring 2005, Team #4 Atomic Clock Receiver Atomic Clock Receiver Team Staff Jonathan West - BSEE Expertise: Microwave, VLSI, 6σ, Assembly Experience: 3 Co-ops @ GE Healthcare Michelle Hecyk - BSEE Expertise: PLD, Project Mgmt, Technical Writing Experience: 1 Co-op @ GE Cons & Industrial 2 Co-ops + 1.5 years @ GE Supply Ned Storer - BSEE Expertise: Communication, PCB layout Experience: 1.5 years intern @ Wells Mfg 2 Co-ops @ Pentair Water Harrison Chiu - BSEE Expertise: Software Simulation/Testing Experience: Software QA @ JCI for 8mo

  3. Team Affiliations • Designed for Pentair Water Treatment • Purpose: reset internal clock of water softener when power is lost. • Company Contact: Mike Lindfors

  4. 318-595 Spring 2005, Team #4 318-595 Spring 2005, Team #4 Atomic Clock Receiver Atomic Clock Receiver Team Dynamics • Chose project because it will give us industry experience developing a product for a company given desired product specifications and target cost. • Decisions made by consensus • Established team website to ease file sharing/storage and communication • Regular meetings Monday evenings and Sunday afternoons • Responsibilities assigned as follows: Jonathan West: Assembly & Proto Mgr, Archive Web Mgr Ned Storer: Project Integrator Harrison Chiu: PCB Layout Mgr Michelle Hecyk: Report & Presentation Mgr

  5. Team Resources • Estimated Hours: 500 hours • Actual Hours: 840 hours • Estimated development cost: $100.00 • Actual development cost: $276.17

  6. 318-595 Spring 2005, Team #4 318-595 Spring 2005, Team #4 Atomic Clock Receiver Atomic Clock Receiver Product Purpose • The purpose of this device is to provide an accurate time signal to an external device upon request. • Current applications require manual intervention to re-program correct time after loss of power. This project aims to automate this process, eliminating the need for manual intervention.

  7. 318-595 Spring 2005, Team #4 318-595 Spring 2005, Team #4 Atomic Clock Receiver Atomic Clock Receiver Product Functions • Accurate time will be maintained internally by periodically syncing the on-board clock with an atomic clock by means of the NIST radio station: WWVB. • A time request from the host system will be fulfilled instantaneously providing date and time (accurate to the second) in military format. • Device will be AC powered with battery back-up and run independently of any host system it is connected to. • Time output in RS232 format

  8. Competition ClockWatch Radio SyncBroadcast-based timeserver • Radio Sync acquires precise time from WWVB radio broadcast • Ideal for highly secure or remote installations • Can run off of either RS232 or and external source • Sold as a bundle with interface software for $199.95

  9. 318-595 Spring 2005, Team #4 318-595 Spring 2005, Team #4 Atomic Clock Receiver Atomic Clock Receiver Product Features • Manual Sync Option allows user to update system time on request • Optional external serial interface allowing PC hookup • System monitor

  10. 318-595 Spring 2005, Team #4 Atomic Clock Receiver Requirements Harrison Chiu

  11. Product Standard Requirements Market Geographics • Continental USA only • Europe and Hawaii possible with slight design modifications Market Demographics • Residential, Commercial, and Industrial Applications

  12. Market Size: $10M Annual Volume: 10,000 List Price: $60.00 Material Cost: $30.00 Mfg Cost: $10.00 Development Costs Engineering: $75,000 Materials: $1,000 Annual Sales: $0.6M Per Unit CM: $20 CM%: 33% Annual CM$: $1M ROI : 0.4 years Product Standard Requirements Business Case

  13. Product Standard Requirements User Warnings • Intended for use only within the Continental United States • Atomic Receiver may not be able to receive a signal in certain locations or during certain times of the day due to weak signal strength. • Electrical Shock Hazard! Keep away from liquids and do not try to disassemble this product

  14. User Inputs Master Reset Switch Resets product Manual Synch Button Decode WWVB Signal Update Internal Clock User Indicators ACR Receiver Indicators Visually displays incoming WWVB signal (Green) Indicates any errors that occur (Yellow) Power Indicator Red LED Signals circuit is powered Performance Requirements User Interface

  15. Performance Requirements Operational Modes • Power Modes: On • Functional Modes • Decode WWVB • Output Time (upon host unit request) • Standby (normal operation mode)

  16. Standard Requirements Power

  17. Performance Requirements Signal Characteristics

  18. Performance Requirements Electrical Transfer Performance

  19. Additional Standard Requirements Manufacturing and Lifecycle

  20. Additional Standard Requirements Mechanical

  21. Additional Standard Requirements Environmental

  22. 318-595 Spring 2005, Team #4 Atomic Clock Receiver Product Level Standard Requirements Health & Safety • Compliant with the following standards: • IEC 60950-1: IT equipment - Safety - Part 1: General Req. • UL 1270: Radio Receivers, Audio Systems, and Accessories • ISO9001:2000 Quality Management Systems-Requirements • Components • Minimum lead component usage in product • Power • Current limiting protected power source • Case • Plastic case insolated plastic • Weather resistance seal on casing • Max User surface potential = 0V EMC Standards • EN 61000 - General EMC Standard • EN 61204-3:2001 - Low Voltage Power Supplies DC Output. (Part 3: Electromagnetic compatibility)

  23. 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block Diagram

  24. 318-595 Spring 2005, Team #4 Atomic Clock Receiver Block 4 - Power Michelle Hecyk

  25. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power LOCATION ON BLOCK DIAGRAM

  26. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power DESCRIPTION • Provides DC voltage to all necessary components • Converts 120VAC to 3.3VDC • Plugs into any standard wall outlet • Provides battery back-up in case of power failure • Output voltage regulated to ensure maximum performance

  27. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power PERFORMANCE REQUIREMENTS Operational Modes User Interfaces

  28. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power PERFORMANCE REQUIREMENTS Electrical Interfaces & Power

  29. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power PERFORMANCE REQUIREMENTS Safety Ratings • Safety & EMC Standards • Primary Safety Standards: • IEC60950: IT equipment - Safety - Part 1: General • Primary EMC Standards: • EN61204-3: Low Voltage Power Supplies DC Output (Part 3: Electromagnetic compatibility)

  30. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power STANDARD REQUIREMENTS Mechanical and Manufacturing

  31. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power STANDARD REQUIREMENTS Environmental

  32. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power BLOCK DIAGRAM OF BLOCK

  33. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Block Schematic

  34. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block • Step-down incoming AC voltage to manageable level • Minimize power loss • Rectify AC voltage using full wave bridge rectifier • Provide low noise output signal

  35. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block • Transformer Calculations (Minimum): • Incoming AC voltage: 102-132V • Minimum output required to Main Feeder Block regulator is 4.3VDC • Bridge rectifier must be able to supply at least 4.4VDC with 102VAC input • Vsec=4.4VDC + 1.4VDC = 4.1VAC • 1.414 • Accounting for the 1.4V drop across rectifier and the RMS to peak relationship (1.414) we find 5VAC will be sufficient secondary rating. • Vo,min=Vi,min = 102VAC = 4.25 * 1.414 = 6VDC • N 24 • Transformer Calculations (Nominal): • Vo,nom=Vi,nom = 120VAC = 5VAC * 1.414 = 7.07VDC • N 24

  36. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block • Transformer Calculations (Maximum): • Incoming AC voltage: 102-132V • Maximum input voltage to Main Feeder Block regulator is 20VDC • Bridge rectifier must not supply more than 20VDC with 132VAC input • Using N=24 we find the following: Vo,max=Vi,max = 132VAC = 5.5VAC * 1.414 = 7.77VDC N 24 • Over-Current Protection Calculations: • F1 = 2*I = 2*.500 = 42mA • N 24 • To keep standard component values we will use a 1A fuse

  37. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power AC/DC Converter Block • Rectifier Calculations: Diode Specs - PIV (Peak Inverse Voltage) rating of 2.828 x Vsec is desirable 14V is not a standard value so we will use minimum of 35V @ 1A • Output Filter Capacitor Calculations: • Maximum ripple: 2.5% • Vripple=7.77V x 0.025 =.194Vrms • Vripple=2.828 x .194V = .549V • Time interval for charge pulse: t=1/(2*f)=1/(2*60)=8.3mS • To keep standard component values we will use a 6800uF capacitor

  38. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Main Feeder Block • Regulation: • Provides 3.3VDC Vdd signal to all blocks • Input Voltage Min: 4.3V • Output Voltage Range: 3.22 – 3.38VDC • Typical Output Voltage Noise: 20uVrms* *when Cout=10uF and Cbyp=.01uF • Min Ripple Rejection: 50dB • Max ripple rejection accomplished with .01uF bypass capacitor • Output capacitor provides improved transient response

  39. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Main Feeder Block • Battery Back-up Switch: • When Vin < 3.0V AND Vin < Vbatt: • Vcc switches to battery signal • Vout(min)= Vbatt-.2 • Iout(max) = 40mA • When Vcc returns above 3.0V: • Vcc switches to Vin signal • Vbatt returns to standby (I =.02uA) • BATT ON • Logic high when battery on • Useful for future applications where battery status information is required

  40. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Battery Supply Block • House and regulate back-up battery voltage (4AA Alkaline Batteries) • Provides 3.3VDC signal to Main Feeder Block • Input Voltage Min: 4.3V • Output Voltage Range: 3.22 – 3.38VDC • Typical Output Voltage Noise: 20uVrms* *when Cout=10uF and Cbyp=.01uF • Min Ripple Rejection: 50dB • Regulator design provides reverse battery protection

  41. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Battery Supply Block Battery Life Calculations: Using a standard 2500mAh battery we obtain the following results for battery life: CURRENT DRAW PER BLOCK

  42. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Power Block Passive Discrete Specifications

  43. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Bill of Materials

  44. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Manual Manufacturing Processes • Manual Solder: • Voltage Regulator 1 • Voltage Regulator 2 • Battery Holder • Transformer with heat sink • Manual Placement: • 4AA Batteries in Battery Holder • Insert Fuse in Power cable inlet • Connect power cable

  45. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Manufacturing Test Process Test 1 Primary Power Verification: Action 1: Apply 102VAC Verify: Output voltage 3.1 - 3.5 VDC Action 2: Apply 132VAC Verify: Output voltage 3.1 – 3.5 VDC Test 2 Battery Power Verification: Action 1: Step 1-Apply 120VAC for 10 seconds Step 2-Remove AC Power Verify: Output voltage 3.1 – 3.5 VDC Action 2: Apply 120VAC Verify: Output voltage 3.1 – 3.5 VDC

  46. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Block Reliability Analysis • Dominant parts for unreliability are: Power Transformer and Electrolytic Capacitors • Plan for reliability improvement: • Switch to higher rated temperature on transformer • Switch to ceramic or tantalum capacitors where possible

  47. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Sustainability Aspects: Obsolescence • Voltage Regulators have smallest Obsolescence Window. • Modern technology being used so corrective actions are not required.

  48. 318-595 Spring 2005, Team #4 Atomic Clock Receiver BLOCK 4 – Power Block Requirement Verification

  49. Amplifier Block Ned Storer

  50. 318-595 Spring 2005, Team #4 Description This block is responsible for receiving and amplifying the WWVB signal. It is the first block in the overall block diagram. Atomic Clock Receiver BLOCK 1 – Amplifier

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