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EE 318-595 Capstone Design Project Spring 2005 Team #3

EE 318-595 Capstone Design Project Spring 2005 Team #3. Nole Martin Paul Simons Eric Ritzke Tom Reuter Steven Krol Murtadha B. Tunis. BSEE BSEE BSEE BSEE BSEE BSEE. Team #3: Staff. Team #3: Total Resources. 1200 Man hours $1000 for material and prototyping

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EE 318-595 Capstone Design Project Spring 2005 Team #3

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  1. EE 318-595 Capstone Design Project Spring 2005 Team #3 1

  2. Nole Martin Paul Simons Eric Ritzke Tom Reuter Steven Krol Murtadha B. Tunis BSEE BSEE BSEE BSEE BSEE BSEE Team #3: Staff

  3. Team #3: Total Resources • 1200 Man hours • $1000 for material and prototyping • Based on our individual experiences and knowledge our team will strive to exceed all project expectations.

  4. Selected Product • Wireless Weather Buoy • Primary Benefit: Real-time Local Weather Information • Intended for use by private water-front property owners. • Product will report air and water temperature, barometric pressure and wind speed via RF communications. • Similar weather stations exist, but not for private use. • Maritime Consumer Market

  5. Similar Existing Product • Features • Wind speed • Wind direction • Barometer • Safety lights • GPS • Solar power • Humidity sensor • Water quality analyzer • Advantages of our product: • Cost effective • Only essential sensors • will be implemented

  6. Block Diagram Solar Recharging Battery Pressure Sensor 4 6 5 1 Microprocessor 2 3 10 LED w/ Controls 7 9 8 11 Outdoor Unit (Buoy) Indoor Unit (Display) Eric – Green Paul - Yellow Murtadha – Orange Steve – Light Blue Nole – Red Tom – Dark Blue Data Lines Wireless Link Power Lines

  7. System Level Requirements System Performance Requirements:

  8. System Level Requirements System Standard Requirements:

  9. System Level Requirements System Standard Requirements:

  10. System Level Requirements System Standard Requirements:

  11. Safety Standards • UL 458 - Power Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles and Marine Crafts • UL 1196 - Standard for Safety for Floating Water Lights • 61010-1 - Electrical Equipment For Measurement, Control, and Laboratory Use • ISO 14000 • ISO 9001

  12. Basic Business Case • Estimated Average Product Selling Price: $700 • Estimated Product Annual Sales Volume: 1000 Units • Estimated Per Unit Cost of Parts and Materials: $300 • Estimated Per Unit Cost of Assembly, Testing and Mfg: $50 • Estimated Total Development Cost (Labor + Material): $494,000 • Calculated Annual Sales (ASP$ x Annual Volume): $700,000

  13. Basic Business Case • Calculated Per Unit Cost Margin (ASP$ - [Parts + Materials + Mfg] x Costs$): $350 • Calculated Cost Margin (Per Unit CM$ / ASP$): 50% • Calculated Annual Cost Margin (CM% x Annual Sales$): $350,000 • Calculated Return On Investment (Est. Dev. Cost$ / Annual CM$): 1.411 Years.

  14. Block #1:Power Block

  15. Block Diagram Solar Recharging Battery Water Temperature Sensor Pressure Sensor Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

  16. Functional Purpose To receive Infra red rays from the sun to charge the solar panels To regulate the solar voltage for the charging circuit To recharge the available power for the battery through an intelligent regulator To output the required regulated voltage for the power conversion circuit

  17. Standard Requirements • Block cost <$120 • Parts count <30 • Unique parts count <20 • PCB Area <350mm2 • Operating temperature range -5 to 70 C • Storage temperature range -20 to 80 C • Reliability MTBF 6 years • Operating Humidity 0 – 100% • Percent Allocations 43% of cost 45% of mass 33% of parts 17% of total area

  18. Performance Requirements • Battery Life 15 years • Battery Type 12V Deep cycle battery • Rated Capacity < 7AH • Supply voltage 12Vdc ± 3% • Supply current <50mA • Solar Panel <17V

  19. Electrical Interface signals

  20. Block Interface Infra-Red Rays SUN Intelligent Voltage Regulator Solar Panels Detail Design of Charging Circuit Voltage Regulator Power Conversion Circuit Deep Cycle Marine Battery

  21. Prototype Plan

  22. Power Regulation and Switching Nole Martin

  23. Block Diagram Solar Recharging Battery Pressure Sensor 4 6 5 1 Microprocessor 2 3 10 LED w/ Controls 7 9 8 11 Outdoor Unit (Buoy) Indoor Unit (Display) Eric – Green Paul - Yellow Murtadha – Orange Steve – Light Blue Nole – Red Tom – Dark Blue Data Lines Wireless Link Power Lines

  24. Functional Purpose • To convert battery voltage from 12V to 5V • To distribute power to sensors, LED display, transmitter, and MPU. • To include a switch so that the processor can power down the sensors. • To include a push-button reset switch with de-bounce components and ESD protection.

  25. Power Regulation and Switching 12V Battery 1 5V DC Switching Regulator 2 LED, Transmitter Switching Circuit MPU 2 Sensors Power Line Control Line

  26. Power Regulation and Switching Standard Requirements • Block Cost <$10 • Parts Count <20 • Voltage Provided 5V +/- 4% • Operating Temperature -5°C to 70°C • Storage Temperature -20°C to 80°C • Reliability Range 5 years • Operating Humidity 0-100%

  27. Power Regulation and Switching Performance Requirements • Output Voltage 5V +/- 4% • Supply Current >800 mA • Regulator Efficiency >75%

  28. Power Conversion and SwitchingElectrical Interfaces

  29. Regulator and SwitchingDetailed Design Schematic

  30. Regulator and Switching Detailed Design DFM Analysis Plan

  31. Regulator and Switching Detailed Design CalculationMax Load Current vs. Max Regulator Output Current Load Max Current Draw Transmitter 15mA CPU 4mA Wind Speed Sensor <1mA Air Temperature Sensor <1mA Water Temperature Sensor <1mA Pressure Sensor 10mA LED Display 30mA Total 62mA (<<1A)

  32. Regulator and SwitchingDetailed Design CalculationWC Analysis Regulator Components Vin=10.5,L1+10%,C2+20% Vin=10.5,L1+10%,C2-20% Vin=10.5,L1-10%,C2+20% *all simulations done using National Semiconductor Websim Software

  33. Regulator and SwitchingDetailed Design CalculationWC Analysis Regulator Components Vin=13.7,L1+10%,C2+20% Vin=13.7,L1+10%,C2-20% Vin=13.7,L1-10%,C2+20% *all simulations done using National Semiconductor Websim Software

  34. Regulator and SwitchingDetailed Design CalculationWC Analysis Regulator Components Results: No significant change in ripple or offset based on WC component tolerances or WC Input Voltage. *all simulations done using National Semiconductor Websim Software

  35. Regulator and Switching Component Specifications

  36. Regulator and SwitchingPrototype Bill of Material

  37. Regulator and SwitchingProduct Bill of Materials

  38. Regulator and SwitchingReliability Table

  39. Regulator and SwitchingSummary of Reliability Table • The dominant parts for unreliability are the electrolytic capacitors. This is due to the method of approximation used as well as the voltage rating selected. • For the capacitors higher voltage rated components could be introduced to improve reliability.

  40. Regulator and SwitchingObsolescence Table

  41. Regulator and SwitchingObsolescence Table • The worst parts for obsolescence is the SMT-voltage regulator. The results do not warrant replacement. • The worst obsolescence window found was 6.5 years. This is above the product life requirement of 5 years.

  42. Regulator and SwitchingVerification

  43. Regulator and SwitchingAssembly Specifications • All components for this block reside on PCB Board #1 • Testing will be performed on the regulator to ensure a clean +5V output.

  44. Microprocessor Nole Martin

  45. Block Diagram Solar Recharging Battery Pressure Sensor 4 6 5 1 Microprocessor 2 3 10 LED w/ Controls 7 9 8 11 Outdoor Unit (Buoy) Indoor Unit (Display) Eric – Green Paul - Yellow Murtadha – Orange Steve – Light Blue Nole – Red Tom – Dark Blue Data Lines Wireless Link Power Lines

  46. Functional Purpose • Read analog outputs of the sensors and convert them to digital. • Process the results to obtain meaningful data. • Send meaningful data to the transmitter. • Control power to sensors.

  47. MPU-Block Diagram 5V DC Push Button Switch Microprocessor Wind Sensor Transmitter Pressure Sensor Switching Circuit Air Temperature Sensor Power Line Water Temperature Sensor Control Signal 5V DC Ref+ Data Signal

  48. MPU Standard Requirements • Block Cost <$7 • Parts Count <10 • Operating Voltage 5V+/- 4% • Operating Temperature -5°C to 70°C • Operating Storage Temperature -20°C to 80°C • Reliability 5 years • Operating Humidity 0-100% • Disposal Throw Away

  49. MPUPerformance Requirements • Operating modes off/sleep/active • A/D Converters 4 • -With accuracy 10bit+ • Transmission capability UART • Timer for sleep/wake-up >10min • DC power (VDD) 5V+/-4% • Reference (VREF+) 5V+/-1% • De-bounce Circuit Time >5ms

  50. MPU Electrical Interfaces

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