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TEAM 2

TEAM 2. PROJECT TEAM ROLES. LPI : Dan Drews LSD: Wayne Stollenwerk LPM: Anthony Camomilli LRM: Anthony Camomilli LMM: Bhavi Mistry. Contact Info. Dan Drews Wayne Stollenwerk Bhavi Mistry Anthony Camomilli. Phone: 414-248-9551 Email: djdrews@uwm.edu

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TEAM 2

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  1. TEAM 2

  2. PROJECT TEAM ROLES • LPI : Dan Drews • LSD: Wayne Stollenwerk • LPM: Anthony Camomilli • LRM: Anthony Camomilli • LMM: Bhavi Mistry

  3. Contact Info • Dan Drews • Wayne Stollenwerk • Bhavi Mistry • Anthony Camomilli • Phone: 414-248-9551 • Email: djdrews@uwm.edu • Phone: 414-479-0283 • Email: wes@uwm.edu • Phone: 414-386-1152 • Email: bjmistry@uwm.edu • Phone: 262-385-6724 • Email: camomil2@uwm.edu

  4. Dan Drews Wayne Stollenwerk Bhavi Mistry Anthony Camomilli Expertise & Experience • Expertise: Microprocessors, Power Electronics Experience: None • Expertise: Electronics, Power Supply Experience: Co-op, Test Engineering, Documentation • Expertise: Signals & Systems, Analog Circuits Experience: None • Expertise: Solid-state Electronics, Short Circuit Protection, Documentation/Schematics, Component Selection/Cost Analysis Experience: Engineering Intern, Electrical Designer

  5. Total Resources 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.

  6. Decision Making • Project decisions shall be made in consensus • Majority vote with due compromise will be used to decide disagreements.

  7. 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

  8. 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

  9. 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.

  10. 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

  11. Block Diagram User Input/Display 3 PWM(Dan) 5 Temp Sensor w/ display (Anthony) 2 4 Battery Sensor (Bhavi) H-Bridge (Wayne) Motor

  12. Block Diagram Descriptions

  13. 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

  14. 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

  15. 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

  16. SAFETY HAZARDS AND MITIGATIONS

  17. 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)

  18. 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

  19. 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

  20. 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

  21. 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

  22. Abusive Or Unknowing Users • Mitigation Design/Devices/Materials/Packaging • Warning Labels • Affected Blocks • Battery Charger, Battery, Motor • Tests Required to Verify Protection • Precautionary Test

  23. EMC HAZARDS AND MITIGATION

  24. 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

  25. 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

  26. 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

  27. 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

  28. 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

  29. PRODUCT LEVEL DESIGN

  30. Block Prototyping Plan

  31. Gantt Chart Planning Prod. Design Proc. Design Validation Feedback SEPT OCT NOV DEC 4 11 18 25 2 9 16 23 30 6 13 20 27 4 11 13

  32. Individual Block Detail

  33. Block 2

  34. 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

  35. 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.

  36. 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)

  37. Block 2 Diagram Breakdown 4 Op-amps (LM 324) Switch Battery Series of Resistors Buzzer Battery Charger LED Display Zener Diode

  38. Block 2 Schematic

  39. Block 2 Bill Of Materials • --- Bill of Materials --- • Ref. Mfg. Part No. Description • D1 -- D diode • D2 -- D diode • D3 -- D diode • D4 -- D diode • D5 -- D diode • R1 -- -- resistor, 18K • R2 -- -- resistor, 3.9K • R3 -- -- resistor, 2.7K • R4 -- -- resistor, 680 • R5 -- -- resistor, 680 • R6 -- -- resistor, 15K • R7 -- -- resistor, 470 • R8 -- -- resistor, 470 • R9 -- -- resistor, 470 • R10 -- -- resistor, 100 • U1 Linear Technology LT1011 integrated circuit • U2 Linear Technology LT1011 integrated circuit • U3 Linear Technology LT1011 integrated circuit • U4 Linear Technology LT1011 integrated circuit

  40. 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

  41. 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

  42. Block 3

  43. 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.

  44. Block 3 Performance Requirements • PWM signal is designed for 24kHz so no noise is generated during switching.

  45. 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)

  46. Block 3 Diagram Breakdown User Input 12V Supply Potentiometer Voltage Divider PWM Signal Comparator Square Wave Oscillator Integrator

  47. Block 3 Preliminary schematic

  48. Block 3 Preliminary Bill of Materials • 1 LM324 OP-Amp $0.45 (block of 4) • 1 Potentiometer $4.50 per unit • 9 Resistors $0.15 per unit • 4 Capacitors $0.20 per unit (avg) • 1 Texas Instrument DRV103U $3.60 per unit • 1 Potentiometer $4.50 per unit • 1 Capacitor $0.13 per unit • Totals: $9.98 Discrete Design $8.32 IC Design

  49. Block 4

  50. 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.

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