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High-Efficiency DC Servo Motor Controller for Trolling Motor Application

This project entails developing a DC servo motor controller for a trolling motor, featuring high efficiency motor control, temperature sensor, and battery charge indicator. The team comprises experts in microprocessors, power electronics, and signals & systems. They plan to use Gantt charts and follow a consensus-based decision-making approach. The proposed product is a 2hp brushless servo motor with a 12VDC supply, designed for consumer use. The project's system level requirements include high efficiency (>85%), extended lifetime, and various power modes. The ethical considerations focus on quality, safety, legal compliance, and environmental responsibility. The project also considers intellectual property rights and safety standards like UL 1004 and EN 60204-1.

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High-Efficiency DC Servo Motor Controller for Trolling Motor Application

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  1. TEAM 2Project • DC servo motor controller applied to a trolling motor application. • Features include a high efficiency motor control, water temperature sensor, and a battery charge level indicator.

  2. 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

  3. Project Team Roles • LPI : Dan Drews • LSD: Wayne Stollenwerk • LPM: Anthony Camomilli • LRM: Anthony Camomilli • LMM: Bhavi Mistry

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

  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. 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

  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 (>85%) • 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 • Operating voltage range: 10.2 – 14.0V • U.S. Market (Low Budget Consumer) • Max Power Consumption: 740 Watts

  11. Business case(estimated values) • Average selling price • $225 • Annual sales volume • 150,000 Units • Per unit cost of parts • $125 • Per unit cost of assembly, test & manufacturing • $50 • Total development cost • $100,000

  12. Usable Battery Life Operating Voltage Range Based on (+/- 10%)

  13. Block Diagram 12V Battery User Input/Display 3 PWM(Dan) 1 Temp Sensor w/ display (Anthony) 2 4 Battery Sensor (Bhavi) H-Bridge (Wayne) Motor

  14. Block Diagram Descriptions

  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. 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 • 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

  17. 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 • It will be necessary to carefully examine the patent’s asserted claims, and specifically target the language and structure of those claims.

  18. Safety Hazards and Mitigations

  19. Safety Test Standards Used in DC Motor Controlers • 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)

  20. 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

  21. 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

  22. 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

  23. 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

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

  25. EMC Hazards and Mitigation

  26. EMC Standard Tests Used in DC Motor Controllers • IEC:6100-4-2: ESD Immunity • IEC:6100-4-3: Radiated Radio Frequency Immunity • CISPR-11: Limits and Methods of Measurement of Electromagnetic Disturbance Characteristics of Industrial, Equipment • IEC:6100-4-6: Conducted Radio Frequency Immunity • IEC:6100-4-9: Pulsed Magnetic Field Immunity

  27. 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

  28. 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

  29. 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

  30. Interference with Other Electronic Systems • Mitigation Design/Devices/Materials/Packaging • Minimize circuit paths to prevent loops • Proper Shielding • Affected Blocks • H-Bridge, PWM and Battery charger circuit • Tests Required to Verify Protection • Secured lab testing

  31. Product Level Design

  32. Block Prototyping Plan

  33. Individual Block Detail

  34. Temp sensor and display

  35. Block 1 Description and Purpose • Block 5 consists of a temperature sensing circuit and a user display. • It is intended that this should allow the user to choose a more ideal location for fishing. • Operates independent of other blocks

  36. Block 1 Performance Requirements • Low power consumption (<5 watts) • Limited power available • Heat dissipation • Temperature sensing accuracy (+/- 1°) • 12VDC Input • Small Footprint • User Display

  37. Block 1 Standards 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: 10.2 – 14.0V • U.S. Market (Low Budget Consumer)

  38. Block 1 Diagram Breakdown 12V Battery User Input/Display 3 PWM(Dan) 1 Temp Sensor w/ display (Anthony) 2 4 Battery Sensor (Bhavi) H-Bridge (Wayne) Motor

  39. Block 1 Diagram Breakdown Voltage Regulator 12V Battery Regulated 9VDC Full Scale Reference Dual Slope Converter Scaling User Input/Display LCD LCD Driver Sensor Oscillator Auto-Zero Cycle

  40. Block 1 Preliminary Schematic

  41. Block 1 Theory of Operation • The basic theory of operation for block 5 is simple • The LM34 outputs a analog signal that varies by 10mV / °F • That signal is captured by the 7106 • The 7106 measures the input, stores the input, and sends this value out to the LCD display • It will then repeat this process based on the internal clock • As an option you can have the 7106 zero the inputs before each measurement

  42. Block 1 Component Selection:The 7106

  43. Block 1 Component Selection Cont. • The 7106 is a direct drive LCD driver with integrated differential inputs • No current limiting required for LCD to function • Allows for direct sensor input • Reduced IC count and wide operating range • Requires External Oscillator for Clock • A 48kHz clock can be created using a 100K resistor and a 100pF Cap • LCD backplane Is driven at 1/800 clock or ~60Hz • Requires Range Specific components for Dual Slope Conversion • Auto Zero Cycle allows for offset voltage error correction on inputs • Works similar to a sample and hold circuit • Voltage scaling accommodated by reference voltage input • 100mV => 199.9 (200 mV full scale) • 1V => 1.999 (2V full scale)

  44. Block 1 Component Selection Cont. • The temperature sensing is accomplished by collecting the output of a LM34 Fahrenheit sensor • Easily Measured 10 mV/°F • Sensitive (+/- 1°F) Can be compensated for greater Accuracy • Expensive $5-$12 • All resistors and capacitors that are task important will require 5% tolerance or better

  45. Block 1 Preliminary Bill of Materials

  46. Block 1 Prototype PCB Layout

  47. Block 1 Prototype PCB Cost

  48. Block 1 Prototype (Actual) Bread Board Prototype PCB Prototype

  49. Block 1 Detailed Package Selection • Device Package Type Rationale • Package for LM2940 (T0-220) was determined by cost, ease of prototype, heat disipation, and availability • Package for LM34 (T0-92) was determined by size since it needs to be compact enough to be fitted to a small metal cap for production • Package for 7106 (DIP 40 Pin), was selected for pure ease of use, easy to solder with fair room to work • Nominal Resistance, Capacitance, Inductance Values & % Tolerance Calculations • Capacitor values chosen at 5% to reduce error in 7106 timing • Resistors chosen at 5% to reduce part count between blocks • 1% resistor values would decrease error in critical applications

  50. Block 1 Proposed Production BOM

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