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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

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

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

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

slide11

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 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

slide24

Consensus:

No thank you, transit-tron

Kegan

slide28

Input Power

    • 120VAC at 60Hz
  • Common mode choke
  • Bridge Rectifier

Sean

slide30

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

slide33

Matching Impedance

  • LC Tank:
    • Resonant Frequency
  • Matches switching frequency with resonant frequency to maximize power output

SW

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

slide37

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

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

prototype board
Prototype Board

Common Mode Choke

IGBTS

Driver Circuit

Resonant Tank

Bridge Rectifier

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

member roles
Member Roles

Primary

Secondary

Ahmad

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