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Capstone Design Project

Capstone Design Project. Self Heating Coffee Mug Team #2. General Description. A 14 ounce insulated beverage mug which has a built in warmer Simple 3 button control to set beverage temperature Easy to read 3 Digit display of beverage temperature

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Capstone Design Project

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  1. Capstone DesignProject Self Heating Coffee Mug Team #2 Capstone Design Project: Self Heating Coffee Mug

  2. General Description • A 14 ounce insulated beverage mug which has a built in warmer • Simple 3 button control to set beverage temperature • Easy to read 3 Digit display of beverage temperature • Runs off standard house current, 12V car cord or self contained rechargeable battery • Ergonomic and safe design for standard usage Capstone Design Project: Self Heating Coffee Mug

  3. Staff Gary Hueppchen BSEE Mohammad Alrasheed BSEE Muayyad M. Alameer BSEE Mones Omari BSEE Sultan Alanzi BSEE Pousay Sinv BSEE Capstone Design Project: Self Heating Coffee Mug

  4. Gary Hueppchen Mohammad Alrasheed Muayyad Alameer Mones Omari Sultan Alanzi Phousay Sinv Expertise: Power Systems, Computer Arch., Digital Experience: Itern. with ATC, EMS Dept Expertise: Computer Arch., Power Electronics Experience: None Expertise: Microprocessors, Digital Design, C++ Experience: None Expertise: Microprocessors, VLSI Design, Prog. Experience: None Expertise: Digital, Power Systems, Electronics Experience: None Expertise: Microprocessors, C++, Computer Arch. Experience: IT Dept, UPS, Project Mngmt at Kinko’s Expertise & Experience Capstone Design Project: Self Heating Coffee Mug

  5. Gary Hueppchen Mohammad Alrasheed Muayyad Alameer Mones Omari Sultan Alanzi Phousay Sinv Phone 1: 962-2666 Email: garymh@uwm.edu Phone 1: 628-8899 Email: mohammad@uwm.edu Phone 1: 628-5858 Email: malameer@uwm.edu Phone 1: 241-6440 Email: momari@uwm.edu Phone 1: 628-8844 Email: s_alanzi@hotmail.com Phone 1: 708-9695 Email: phousay@uwm.edu Contact Information Capstone Design Project: Self Heating Coffee Mug

  6. Gary Hueppchen Mohammad Alrasheed Muayyad Alameer Mones Omari Sultan Alanzi Phousay Sinv Time : Fri 3:00 PM Time : Fri 3:00 PM Time : Fri 3:00 PM Time : Fri 3:00 PM Time : Fri 3:00 PM Time : Fri 3:00 PM Weekly Availability Worksheet Capstone Design Project: Self Heating Coffee Mug

  7. Total Resources • 600 man-hours • $300 for material and prototyping • Estimated project required man-hours 550 • Estimated material cost $325 • Margin from our estimated resources: we were off by $25 and 50 man-hours Capstone Design Project: Self Heating Coffee Mug

  8. Decision Making • Our team will make decisions within all project guidelines by: Majority Vote • In the case we have a split decision, there will be a coin toss Capstone Design Project: Self Heating Coffee Mug

  9. IM Roles • Website URL and Web master: Muayyad Alameer - Owns submission of 355 Website data • Project Archiver: Mohammad Alrasheed - Owns weekly backup of all electronic material generated that week. • Presentation Mgr: Phousay Sinv - Owns master MS Powerpoint slide set for team incl revision control • Report Mgr: Sultan Alanzi/Mones Omari - Owns master MS Word document for team incl revision control Capstone Design Project: Self Heating Coffee Mug

  10. Project Selection • Out of the three proposals, the “Self Heating Coffee Mug” is the most favorable and unique idea. • Mechanical design and safety issues are the two major risks that we will face. • The other proposals were rejected due to their complexity over the given time period. • The “Self Heating Coffee Mug” proposal has been approved by all the members. Capstone Design Project: Self Heating Coffee Mug

  11. Operational Power modes are On / Off Touch Pad: 3 buttons (ON/OFF, Temp_up, Temp_down, Set) Dot Matrix output display: 3 digits indicating temperature and type (°F) 32 X 32 mm Display screen. Viewable distance is 0.5 meters Heating Coils wrapped around stainless steel inner cup Unique Components CPLD: Lattice M4-64/32 Temperature Sensor: Resistance Thermometer S17624 External Electrical Interfaces: 12 VDC Car adapter 120V AC 60Hz 3 prong Nema input Performance Requirements Capstone Design Project: Self Heating Coffee Mug

  12. AutoGadgets, Department Stores $10M/Region, Coffee Drinkers (67% of Adults) $30/unit as sold to customers North America 13 years & up General public $300/unit in proto production $20/unit in volume production 20000 of units/yr Competitors: Market Size: Min List Price: Market Geography: Market Demography: Intended Application: Max Proto Cost: Max Product Cost: Annual Volume: Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  13. Min Oper Temp Range: Min Oper Humidity Range: Min Oper Alt or Press Range: Min Storage Temp Range: Min Storage Humidity Range: Min Storage Alt/Press Range: Max Storage Duration: Energy Sources: Source Connection: Min Operating Voltage Range: Max Power Consumption: Battery Life -22 to 140 °F 0 to 100 Rh% Up to 15000 ft -40 to 175 °F 0 to 100 Rh% Up to 16000 ft 5 years AC, DC, Battery Permanent and Temporary 85-264V For AC, 6-12V for DC, 6-12V for Battery 30 Watts Total >20 minutes Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  14. Max Volume: Shipping Container Size: Max Mass: Power Connector(s): Max # of PC Bds: Max PCB Circuit Area: Max Shock: 23X15X10 cm 25x17x12 cm 1.5 Kilograms 12VDC car adapter, 120VAC (NEMA) plug 2 355 cm2 Total 30 G force (Grms), 10 Reps Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  15. Max Parts Count: Max Unique Parts Count: Parts/Mat $ Allocation: Asm/Test $ Allocation: Product Life, Reliability: Full Warranty Period: Product Disposition: Production Life Support: Service Strategy: 20 4 $15 $5 Time = 7 (yrs) 1 (yrs) Recycle (extract battery, circuit board, recycle plastic mug; stainless steel cup, rechargeable battery with disposal warning) 3 (yrs) Replace Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  16. Electromagnetic Compatibility Standards IEC 61000-4-2: Electrostatic Discharge (ESD) immunity. EN 50081-1: Electromagnetic Compatibility – Generic emission std. EN 50082-1: Electromagnetic Compatibility – Generic immunity std. EN 55014-1: Electromagnetic Compatibility – requirements for household appliances, electric tools and similar apparatus. EN 61204-3: Low voltage power supplies with DC output. Capstone Design Project: Self Heating Coffee Mug

  17. Safety Regulations • UL 174: Household Electric Storage Tank Water Heaters. • UL 197: Commercial Electric Cooking Appliances. • UL 231: Power Outlets. • UL 244A: Solid-State Controls for Appliances. • UL 745-3: Portable Battery-Operated Tools. • UL 834: Heating, Water Supply, and Power Boilers – Electric. • UL 1082:Household Electric Coffee Makers and Brewing-Type Appliances. • UL 2054: Household and Commercial Batteries. • UL 2089: Vehicle Battery Adapters. • UL 60335: Household and Similar Electrical Appliances. • UL 60730: Automatic Electrical Controls for Household and Similar Use. Capstone Design Project: Self Heating Coffee Mug

  18. Blocks Diagram Car cigarette / lighter Socket Gary Hueppchen Mohammad Alrasheed Muayyad Alameer Mones Omari Sultan Alanzi Phousay Sinv Commercial Plug (NEMA) 120 VAC 60Hz 120 VAC 60Hz 12 VDC 12VDC Block #1 Power Suppliers Block #2 Power Converters Block #3 CPLD Block #9 Mechanical Design 6VDC 1400mA 5VDC 12 VDC 1500 mA 6VDC 1400mA 12VDC 1500mA 2VDC 2VDC 5VDC Block #4 Touch Pad Block #5 Dot-Matrix LED Block #8 Heating Coils Block #6 Heat Sensor Block #7 Liquid Level Subroutine Capstone Design Project: Self Heating Coffee Mug

  19. Power Suppliers Capstone Design Project: Self Heating Coffee Mug

  20. Blocks Diagram Car cigarette / lighter Socket Commercial Plug (NEMA) 120 VAC 60Hz 120 VAC 60Hz 12 VDC 12VDC Block #1 Power Suppliers Block #2 Power Converters Block #3 CPLD Block #9 Mechanical Design 6VDC 1400mA 5VDC 12VDC 1500 mA 6VDC 1400mA 12VDC 1500mA 2VDC 2VDC 5VDC Block #4 Touch Pad Block #5 Dot-Matrix LED Block #8 Heating Coils Block #6 Heat Sensor Block #7 Liquid Level Subroutine Capstone Design Project: Self Heating Coffee Mug

  21. Rechargeable BatteryGeneral Description • Both charge and discharge characteristics are effected by the current, time, and temperature. • Batteries used under proper conditions of charging and discharging can be used 500 cycles or more. Capstone Design Project: Self Heating Coffee Mug

  22. 6.0 Volts (5 in series) 1.4 Amp.Hr 8.4 W 1.4 A * 1.5 hrs Voltage: Current: Max Power: Charge: Rechargeable Battery Performance Requirements Capstone Design Project: Self Heating Coffee Mug

  23. Dimensions: Parts Count: Product Weight: Battery Type: Block cost: Min operating voltage: Operating Temperature: Storage Temperature: Life Cycle 50.0 Height, 17.0 Diameter (mm) <20 0.32 Kg Ni-Cd $4*5 =$20 1.2V 0-45 C -20-35 C 2-3 yrs Rechargeable Battery Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  24. 1.4 * 0.74 * 0.5 (L.W.H inches) 0.8 m <15 0.4 lb $10 Dimensions: Wire Length: Parts Count: Product Weight: Block cost: Car Adaptor Performance Requirements • Voltage: Input: 12VDC • Output: 12 VDC ±5% • Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  25. Charging Circuit Car Adapt. 12 VDC 12VDC Charging Circuit 6vdc 12VDC Block#2 Low Battery 6vdc Full Battery 1400mA 6 VDC 1400mA Battery Capstone Design Project: Self Heating Coffee Mug

  26. Charging Circuit Schematic: Capstone Design Project: Self Heating Coffee Mug

  27. Charging Circuit • Calculations: Capstone Design Project: Self Heating Coffee Mug

  28. Safety Regulations • UL 745-3: Portable Battery-Operated Tools. • UL 2054: Household and Commercial Batteries. • UL 2089: Vehicle Battery Adapters. Capstone Design Project: Self Heating Coffee Mug

  29. Power Converters Capstone Design Project: Self Heating Coffee Mug

  30. Blocks Diagram Car cigarette / lighter Socket Commercial Plug (NEMA) 120 VAC 60Hz 120 VAC 60Hz 12 VDC 12VDC Block #1 Power Suppliers Block #2 Power Converters Block #3 CPLD Block #9 Mechanical Design 6VDC 1400mA 5VDC 12VDC 1500 mA 6VDC 1400mA 12VDC 1500mA 2VDC 2VDC 5VDC Block #4 Touch Pad Block #5 Dot-Matrix LED Block #8 Heating Coils Block #6 Heat Sensor Block #7 Liquid Level Subroutine Capstone Design Project: Self Heating Coffee Mug

  31. Part I: AC-DC Converter Technical Details • AC/DC converters are used to supply DC output voltage from a commercial Power supply (120VAC, 60 Hz NEMA plug) • Half-wave and Full-wave rectifiers can be used for Converting AC to DC. • Part used is 12-Volt 1500mA AC-to-DC Power Adapter. • Six-foot cord with polarized plug. • Thick, rugged plastic housing. Capstone Design Project: Self Heating Coffee Mug

  32. Parameters Input: Input Voltage: Line Frequency: Output: Output Voltage: Output Current: Output Power: Line Reg.: Load Reg.: Ripple and Noise: General: Efficiency: MTBF: Performance Requirements Minimum – Nominal – Maximum 85 VAC 120 VAC 264 VAC 47 Hz 50 Hz 400 Hz 12 VDC 1500 mA 3.0 W -1.0% +1.0% -1.0% +1.0% 1.0%Vout(mVpp) @ 20MHz bandwidth. 75% 250k-hours Capstone Design Project: Self Heating Coffee Mug

  33. Max Proto Cost: Proto Cost Allocated: Actual Cost: Max Parts: Actual Max Parts: Max Product Volume: Actual Vol.: Max Shipping container Vol.: Max Product mass: Min Oper. Temp Range: Min Oper. Humidity Range: Min Oper Alt or Press Range: Min Storage Temp Range: Min Storage Humidity Range: Min Storage Alt/Press Range: Max Storage Duration: $25 8.34% $21.99 80 20 (25%) 600 cm3 300 cm3 750 cm3 0.5 Kg -22 to 140 °F 0-100 Rh% Up to 16000 ft -40 to 175 °F 0-100Rh% Up to 16000 ft 5 years Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  34. Part II: Switching CircuitTechnical Details • The AC-DC converter and the Car adapter produce a nominal output voltage of 12 VDC. The Rechargeable Batteries (from Block#1) produce a nominal output voltage of 6VDC. The purpose of this Switching Circuit is to identify if the line carrying the nominal voltage of 12VDC is ON, and if so, to cut off the rechargeable batteries line. • This is done to restrict the batteries from working if either the AC-DC converter or the Car adapter is plugged in. • A simple circuit containing BJT ought to be used as a Switch. Capstone Design Project: Self Heating Coffee Mug

  35. Part III: Voltage RegulatorsTechnical Details • Nominal input voltages are 6VDC, 12VDC. However, most blocks require different sets of input voltages. This part is to provide these different values. • DC/DC converters are Power electronics circuits that convert DC voltage to a different voltage level. There are several DC-DC converters, such as; Linear Voltage Regulators, A Basic Switching Converter, The Buck Converter … Etc. • Part used is Adjustable Voltage Regulator LM317T. Capstone Design Project: Self Heating Coffee Mug

  36. Component: Charging Circuit CPLD Dot Matrix Touch Pad Heat Sensor Heating Coils Voltage (VDC) Min Voltage – Nom Voltage – Max Voltage - 12.0 - 4.75 5.0 5.25 1.8 2.0 2.8 1.8 2.0 2.8 5.0 5.0 5.1 5.5 / 11.0 6.0 / 12 7.0 / 13.0 Power Allocation Capstone Design Project: Self Heating Coffee Mug

  37. Parameters Input-Output Voltage Differential: Power Dissipation: Line Reg.: Load Reg. @ Vo <5.0 V: @ Vo >5.0 V: Adjustment Pin Current: Reference Voltage: Maximum Output Current @ Vi-Vo < 15 V: @ Vi-Vo = 40 V: RMS Noise: Performance Requirements Minimum – Nominal – Maximum 40 VDC 65 ºC/W (Internally Limited) 1.0 % 4.0 % 5.0 mV 25 mV 0.1% Vo 0.5 % Vo 100 uA 1.2 V 1.25 V 1.3 V 1.5 A 2.2 A 0.15 A 0.4 A 0.003 % Vo Capstone Design Project: Self Heating Coffee Mug

  38. Max Proto Cost: Proto Cost Allocated: Actual Cost: Max Product Volume: Max Shipping container Vol.: Max Product mass: Min Oper. Temp Range: Min Oper. Humidity Range: Min Oper Alt or Press Range: Min Storage Temp Range: Min Storage Humidity Range: Min Storage Alt/Press Range: Max Storage Duration: PCB area: $10 3.34% $1.99 x 2 + $0.2 x 9 = $5.78 600 cm3 750 cm3 0.1 Kg -22 to 140 °F 0-100 Rh% Up to 16000 ft -40 to 175 °F 0-100Rh% Up to 16000 ft 5 years 60 cm2 Standard Requirements Capstone Design Project: Self Heating Coffee Mug

  39. Schematics for Voltage Regulators Here, we desire a nominal output voltage of 2.0 V. The Regulated Output Voltage is given by: Vo = Vref ( 1 + R2/R1) + Iadj R2 knowing Iadj=100uA, we can determine the values of resistors by modifying the equation into: R2 = [ R1 (Vout – Vref) ] / [ Vref + (Iadj x R1) ] To produce Vo= 2.0 V, and by assuming R1 = 200 Ω, We find R2= 118.11 Ω. = 120 Ω. LM317T is a 3-terminal floating regulator. In operation, the LM317T develops and maintain a nominal 1.25V reference voltage (Vref). Capstone Design Project: Self Heating Coffee Mug

  40. Schematics for Voltage Regulators Similar to pervious slide, but here we desire a nominal output voltage of 5.0 V The Regulated Output Voltage is given by: Vo = Vref ( 1 + R2/R1) + Iadj R2 knowing Iadj=100uA, we can determine the values of resistors by modifying the equation into: R2 = [ R1 (Vout – Vref) ] / [ Vref + (Iadj x R1) ] To produce Vo= 5.0 V, and by assuming R1 = 100 Ω, We find R2= 297.6 Ω. = 300 Ω. LM317T is a 3-terminal floating regulator. In operation, the LM317T develops and maintain a nominal 1.25V reference voltage (Vref). Capstone Design Project: Self Heating Coffee Mug

  41. Power Converters: List of Parts used Capstone Design Project: Self Heating Coffee Mug

  42. Block#2: Power Converters Commercial Plug (NEMA) Block#1 Charging Circuit Block#1 Car Adapter Block#1 Batteries 120 VAC 60Hz 6VDC 1400mA 12VDC 12VDC 1500 mA AC-DC Converter Switching Circuit 12VDC 1500mA VR VR 6 VDC 1400mA Or 12 VDC 1500mA 2.0 VDC 5.0 VDC Touch Pad Dot Matrix CPLD Heat Sensor Heating Coils Block#4 Block#5 Block#3 Block #6 Block#8 Capstone Design Project: Self Heating Coffee Mug

  43. Safety Standards and EMC Tests • UL 231: Power Outlets. • IEC 61000-4-2: Electrostatic Discharge (ESD) immunity. • EN 61204-3: Low voltage power supplies with DC output. Capstone Design Project: Self Heating Coffee Mug

  44. Digital Control Unit Capstone Design Project: Self Heating Coffee Mug

  45. Blocks Diagram Car cigarette / lighter Socket Commercial Plug (NEMA) 120 VAC 60Hz 120 VAC 60Hz 12 VDC 12VDC Block #1 Power Suppliers Block #2 Power Converters Block #3 CPLD Block #9 Mechanical Design 6VDC 1400mA 5VDC 12 VDC 1500 mA 6VDC 1400mA 12VDC 1500mA 2VDC 2VDC 5VDC Block #4 Touch Pad Block #5 Dot-Matrix LED Block #8 Heating Coils Block #6 Heat Sensor Block #7 Liquid Level Subroutine Capstone Design Project: Self Heating Coffee Mug

  46. Purpose and Definition • Receive digital input from the touch pad by the user, to trigger the desired temperature. • Receive analog data inputs from the heat sensor to control the temperature of the beverage. • The Liquid Level subroutine will be a VHDL coded module that will use the inputs from the heat sensor. • Convert the analog signals with an ADC unit • Output digital data to the dot-matrix display for the user. • Output to the heating coils to control the heat. Capstone Design Project: Self Heating Coffee Mug

  47. Performance Requirements Electrical Interfaces Digital Signals Supply voltage (VCC): +4.75 to +5.25 V Output supply voltage (VCCO): +4.75 to +5.25 V Input low voltage (VIL): 0.8 V Input high voltage (VIH): 2.0 V Input leakage current (IIL): -10 µA Input leakage current (IIH): 10 µA Output low voltage (VOL): 0.5 V Output high voltage (VOH): 2.4 V Output current (IOL): 24 mA Output current (IOH): -3.2 mA Analog Signals None User Interfaces None Operation Modes ON/OFF to heat or warm the beverage Capstone Design Project: Self Heating Coffee Mug

  48. External Signal Table Capstone Design Project: Self Heating Coffee Mug

  49. DC Drive Analysis Table Vxx in Volts, Ixx in mA Source Currents Listed as Negative Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger Capstone Design Project: Self Heating Coffee Mug

  50. Timing Analysis Table Capstone Design Project: Self Heating Coffee Mug

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