Critical design review
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Critical Design Review. Ahmad Alawadhi Eric Willuweit Kegan Grimes Kyle Chessman Sean Flodberg. Team Iron Chefs. Eric. CDR Agenda. The Design Project Status and Goal. Eric. The Design. Eric. PDR Review. Sense (appropriate ferromagnetic) cookware.

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Critical Design Review

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Critical design review

Critical Design Review

Ahmad Alawadhi

Eric Willuweit

Kegan Grimes

Kyle Chessman

Sean Flodberg

Team Iron Chefs

Eric


Cdr agenda

CDR Agenda

  • The Design

  • Project Status and Goal

Eric


The design

The Design

Eric


Pdr review

PDR Review

  • Sense (appropriate ferromagnetic) cookware.

  • Turn on a PWM signal and LED indicator to corresponding coils.

  • Test multiple types of sensors

    • Photodiodes, induction, infrared, and pressure mapping

  • One coil sub-system

Eric


Concept overview

Concept Overview

  • Adjusted approach

    • Hardware and Software Interaction

  • Sub-systems

    • Sensor

    • Power Stage

    • Gate Stage

    • Feedback

Eric


Adjusted approach

Adjusted approach

  • Utilize seven smaller copper coils in place of a large single coil.

  • Sense cookware’s location on the range via induction sensing.

  • Supply power to the coils that sensed the cookware.

Eric


System flow diagram

System Flow Diagram

Eric


Preliminary sub system implementation

Preliminary Sub-system Implementation

  • Systems

    • Indicator LEDs

    • Sensors

    • Copper coils

Eric


Current sub system implementation

Current Sub-system Implementation

  • Systems

    • Indicator LEDs

    • Induction sensing

    • Power Supply

    • Resonant Circuit

    • Gate Driver

    • Microcontroller

Eric


Led indicator sub system

LED Indicator Sub-system

Kegan


Critical design review

  • LEDs indicate which coils are being supplied with power.

  • LEDs on temperature knobs lit with same color LED as the powered coils to display which cookware the knobs correspond to.

Kegan


Led location

LED Location

Each coil has at least five LEDs

LEDs on

LEDs off

Kegan


Led use cases

LED Use Cases

LEDs on

LEDs off

Kegan


Led use cases1

LED Use Cases

LEDs on

LEDs off

Kegan


Led use cases2

LED Use Cases

LEDs on

LEDs off

Kegan


Sensor sub system

Sensor Sub-system

Kegan


Sensor sub system circuit

Sensor Sub-system Circuit

  • Coils are also used as induction sensors.

    • Placing ferromagnetic cookware above the coil, its measurable impedance changes .

    • Impedance change, affects measurable power.

Kegan


Sensor sub system circuit1

Sensor Sub-system Circuit

A bridge rectifier and low pass filter turns the AC signal across the coil into a DC signal.

Kegan


Sensor sub system1

Sensor Sub-system

  • The DC signal is fed into an analog to digital converter to be processed by the microcontroller.

  • When the voltage across the coil drops below a threshold, the LED turns on and a varying frequency PWM is initiated.

Kegan


Testing potential sensors

Testing Potential Sensors

  • Photodiodes

  • Induction sensing

  • Infrared LEDs

  • Pressure sensing / Mapping

Kegan


The transitron

The “Transitron”

  • JB Saunders

  • A three terminal device

  • Light enters the base region and causes electrons to be injected into the emitter.

Kegan


Transitron evaluation

Transitron Evaluation

  • Voltage change of only ~10mV

  • Fed into an Op-Amp

  • Amplified signal fed to ADC on the Arduino Uno (used for demo)

  • Turned on the LED when transitron is covered

Kegan


Transitron pros and cons

Transitron Pros and Cons

  • Pros

    • Inexpensive

    • Availability

    • Easy Implementation

  • Cons

    • Requires an amplifier

    • Unreliable

    • Cover with ANY object and the coil supplies a magnetic field

Kegan


Critical design review

Consensus:

No thank you, transit-tron

Kegan


Total circuit simulation

Total Circuit Simulation

Sean


Critical design review

Sean


Power supply

Power Supply

Sean


Critical design review

  • Input Power

    • 120VAC at 60Hz

  • Common mode choke

  • Bridge Rectifier

Sean


Gate circuit

Gate Circuit

Sean


Critical design review

  • Gate Drivers

  • High power IGBTs

Sean


Power igbts

Power IGBTs

  • ON Voltage – 15V

    • Supplied from gate driver

  • Rated For:

    • 1200V

    • 40A

  • Reverse conduction diode

  • Heat:

    • Cool using an aluminum heat sink

Sean


Resonant tank

Resonant Tank

Sean


Critical design review

  • Matching Impedance

  • LC Tank:

    • Resonant Frequency

  • Matches switching frequency with resonant frequency to maximize power output

SW

Sean


Critical design review

Sean


Testing hardware

Testing Hardware

  • Variable Auto-Transformer

  • Audible IGBT switching

    • Cast iron pan warmed up

  • Observed Risks

    • Current regulation

      • 8 fuses blown

    • Capacitor sustaining charge

Sean


Microcontroller

Microcontroller

Kyle


Critical design review

  • HW-SW Bridge

  • TOPREF – Top reference

  • SWREF – Feedback

    • Compare the two references

PWM

Kyle


Texas instruments c2000

Texas Instruments C2000

  • Output:

    • Seven PWM signals for the final design

      • A variable frequency PWM to find resonance of cookware and contents

    • LED power to covered coils

  • Input:

    • Read analog signals through ADC from the feedback circuit and adjust PWM output accordingly

  • Additional:

    • Check resonant frequency approximately every 10 seconds

Kyle


Results

Results

Kyle


Induction sensor

Induction Sensor

  • No cookware: 3.2VDC

  • With 15in cast iron pan over coil: 1.77VDC

  • With 6in aluminum pot over coil: 1.69VDC

  • Set ADC threshold to turn on LED and supply PWM only for cast iron pan

Kyle


Coil without cookware

Coil without cookware

Kyle


Coil with 15 cast iron pan

Coil with 15” Cast Iron Pan

Kyle


Prototype board

Prototype Board

Common Mode Choke

IGBTS

Driver Circuit

Resonant Tank

Bridge Rectifier

Ahmad


Analog feedback circuit

Analog Feedback Circuit

Ahmad


Complete one coil system

Complete One Coil System

Ahmad


Future milestones

Future Milestones

  • Finish one-coil subsystem

  • Design seven-coil system

  • Design software to accommodate seven coils

  • Integrate subsystems

Ahmad


Potential risks

Potential Risks

  • Magnetic Field

  • Connecting to mains

  • Probing High voltages

  • High current pollution back to the auto-transformer

Ahmad


Spent budget

Spent Budget

Ahmad


Preliminary parts list

Preliminary Parts List

Ahmad


Updated schedule

Updated Schedule

Ackhmad


Member roles

Member Roles

Primary

Secondary

Ahmad


Questions

QUESTIONS?

Ahmad


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