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Electroluminescent Logo Cap Project

Electroluminescent Logo Cap Project. Team # 10 Milestone # 3 –System-Level Design Review. Team Members: Monica Pereira Monique Peregrina Liang Liufu Ifedayo Ogundana. Faculty Advisor/Reviewers: Dr. Michael Frank Dr. Bing Kwan Dr. Rajendra Arora. Sponsored by: Albert Daci.

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Electroluminescent Logo Cap Project

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  1. Electroluminescent Logo Cap Project Team # 10 Milestone # 3 –System-Level Design Review Team Members:Monica Pereira Monique Peregrina Liang Liufu IfedayoOgundana Faculty Advisor/Reviewers: Dr. Michael Frank Dr. Bing Kwan Dr. RajendraArora Sponsored by: Albert Daci

  2. Introduction/Overview of the Project • The purpose of this project is to design an original cap that implements electroluminescent technology. This cap will consist of a panel with flashing capabilities and with a hidden internal circuit. • Each cap will implement a switch with three states (turn on, flash, turn off) and be provided with an internal circuit with water resistant capabilities. In addition, the cap will come with a micro-USB charger hidden underneath the bill of the cap. Monica Pereira

  3. Additional Concept generation & Selection

  4. Prototype Concept Internal View Front View Monica Pereira

  5. Overall Design Components • Fitted baseball cap • LiPo rechargeable battery • Battery charger • 10cm x 10cm EL panel • 3V DC battery inverter • IC chip • Liquid Encapsulating epoxy resin Monica Pereira

  6. Component selection The following components have remained the same: PRT-00339 Lithium Polymer Battery Monica Pereira

  7. PRT-00339 Lithium Polymer micro-USB Battery Charger The LiPo Charger Basic uses a Microchip MCP73831T-2ACI/OT charge management controller to charge 3.7V Li-Po batteries at a rate of 500mA per hour. The board incorporates a charging circuit, status LED, connector for your battery (JST type), and USB connector. A small mounting hole allows this charger to be embedded into a project easily.  Monica Pereira

  8. IntersilLM555 timer IC • Specifications • Type: 555 type, Timer/Oscillator (Single) • Supply Voltage: 2 V ~ 18 V • Current: 60µA • Operating Temperature: 0ºC to 70ºC • Max Frequency: 1 MHz Monica Pereira

  9. Waterproofing/Insulating component Selection Liquid Encapsulating Epoxy Resin Reasons it was selected: • Excellent electrical insulation properties • Good storage stability • Supports high temperatures Monica Pereira

  10. Altered Selections

  11. EL Panels EL Panels from Surelight.com (Previous vendor was Adafruit) Monica Pereira

  12. Battery Inverter Previous Option In progress Approach: 3V ELI-IMC Battery Inverter Design our own inverter instead Monica Pereira

  13. SYSTEM DESIGN

  14. Top Level Block Diagram Liang Liufu

  15. Overall System Design Liang Liufu

  16. Inverter Design Requirements: • Input uses 3.7VDC • Output 110VAC • Output Current: >14mA • Output Frequency: 400Hz Liang Liufu

  17. Inverter Sub-circuit: Oscillator Wien-Bridge Oscillator Requirements • 3.7V input • 400Hz output • 20mA output Liang Liufu

  18. Oscillator Simulation • Output: • 4.7Vp-p • 27.6mAp-p • 395Hz Liang Liufu

  19. Inverter Sub-circuit: Resonant Circuit Requirements: • Amplify oscillator signal to achieve 110VAC • Maintain 400Hz • Output current of 14mAp-p Liang Liufu

  20. Resonant Circuit Simulation 113VACp-p output 12.1mAp-p output 400Hz output Liang Liufu

  21. Overall Inverter Circuit Liang Liufu

  22. Overall Circuit Simulation 110VACp-p Output 14.1mAp-p Output 395Hz Liang Liufu

  23. Timing IC Subsystem • In charge of controlling the blink pattern • Will allow the logo to flash every second • Uses a 555 Timing IC • Specifications: • Power consumption: 15 mW • Input voltage: 3.7V • Output Voltage: 3.7V • Frequency: 1 Hz MoniquePeregrina

  24. 555 Timing IC in Astable Mode MoniquePeregrina

  25. Transient Analysis on the Timing IC MoniquePeregrina

  26. FULl Circuit Simulation on blink state MoniquePeregrina

  27. RISK ANALYSIS MoniquePeregrina

  28. Technical Risks • Disconnected WiresProbability: Moderate Consequence: DevastatingStrategy • Moisture near Electronics Probability: Very HighConsequence: CatastrophicStrategy • OverheatingProbability: Moderate Consequence: Moderate Strategy • Battery Life DecreasedProbability: ModerateConsequence: ModerateStrategy • El Panel Not Bright EnoughProbability: LowConsequence: Severe Strategy • Timing IC Does Not Supply Enough Power Probability: LowConsequence: Moderate Strategy MoniquePeregrina

  29. Schedule Risks • Tasks Assignment • Probability- high; Consequences- moderate • Strategy – Proper communication amongst members. • Design dependencies • Probability- low; Consequences- moderate; Strategy- to be set aside for help from advisor • Personal complications • Probability- very low; Consequences – severe; Strategy – re-planning of task division • Individual productivity • Probability- high; Consequences – severe; Strategy- constant evaluation of individual progress IfedayoOgundana

  30. Budget Risks • More components may be needed Probability – moderateConsequence – minorStrategy – some funds are reserved • Damaging the timer IC and/or the inverter Probability – lowConsequence – severeStrategy – funds are reserved for purchase of extra major components • Unaccounted-for-costs Probability- lowConsequence- moderate, Strategy – low price components are purchased and expenses are cut down • Budget limitations Probability– low Consequence – moderate Strategy– component parts are ordered to together to reduce cost of shipping. Ifedayo Ogundana

  31. Updated Budget Current Expenses (Custom inverter) Expenses Subtotal = $413.89 → $650.00 - $413.89 = $236.11 (Under budget) Ifedayo Ogundana

  32. Current Expenses (Off-the-shelf inverter) For off-the-shelf inverter: Expenses Subtotal = $446.34 → $650.00 - $446.34 = $203.66 (Under budget) Ifedayo Ogundana

  33. EL Cap Budget Updated Per-Unit Budget Ifedayo Ogundana

  34. Current EL Cap Replication Budget (Custom inverter) Ifedayo Ogundana

  35. Updated Schedule Monica Pereira

  36. Thank You! Questions ? Monica Pereira

  37. Extra Slides for reference

  38. Li-Po Battery Performance • Safety Test • Test conditions: The following tests must be measured at flowing air and safety protection conditions. All batteries must standard charge and lay 24h.

  39. Cautions of charge & discharge • Charge • Charging current should be lower than values that recommend below. Higher current and voltage charging may cause damage to cell electrical, mechanical, safety performance and could lead heat generation or leakage. • Batteries charger should charging with constant current and constant voltage mode • Charging current should be lower than (or equal to ) 1A • Charging voltage must be lower than 4.25V • Discharge • Discharging current must be lower than (or equal to )2A • Discharging voltage must not be lower than 2.75V. • Over-discharge • It should be noted that the cell would be at an over-discharge state by its self-discharge. In order to prevent over-discharge, the cell shall be charged periodically to keeping voltage between 3.6-3.9V.

  40. EL Panel Specs Supply Current - Current in mA/cm2 versus supply voltage: As the supply current is increased for the EL panel, the supply voltage also increases. Figure 17 Supply Voltage vs Brightness

  41. The following factors have an impact on lifetime: • Higher Voltage • Higher Frequency • DC Supply • High Ambient Humidity • High Ambient Temperature Brightness can be increased by using a higher voltage or higher frequency. Higher voltage slightly decreases life time, but is preferred if higher supply current can be accepted. Brightness VsTimewith time. Unlike most other lighting which can critically fail, EL Panel brightness decreases with time.

  42. EL Panels emit light from 50VAC and increase in brightness with higher voltage up to 200VAC. The frequency should be over 50Hz. Brightness increases with higher frequency up to 1000Hz. However, it is recommended that frequencies in the range of 400-600Hz and voltages of no greater than 160VAC are used, otherwise the panel life will rapidly deteriorate.

  43. Timing IC and MOSFET Integration

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