programmable power relay senior design ii final presentation april, 23 2009
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Programmable Power Relay
Senior Design IIFinal Presentation
April, 23 2009
Team Members
Jameson Mitchell Electrical Engineering PC to PIC communication GUI Design
David Null Electrical Engineering TRIAC control Firmware Design Schematic Design PCB Layout
Rick Wolbrecht Electrical Engineering Packet Encoding GUI Design
Lane Simmons Electrical Engineering Team Leader Firmware Design Website Design
Overview• Introduction• Problem• Solution• Final Product• Practical Constraints• Bill of Materials• Technical Constraints• Software Testing• Hardware Testing• Questions
Introduction
What is the PPR supposed to do?• Control device power using schedule• Allow automated control• Minimize need for user input after schedule is
set
+
Problem
• Current power strips have limited features
No programmable timing schedule No interactive user interface No dimming capability No battery backup
Solution
• "Smart" power strip with enhanced features
o Programmable Timing Schedule for AC-switchingo PC software applicationo Dimmingo Battery Backup
• Possible Target Markets• Task Automation• Security
Final Product
Pre-Build Concept
Finished Design
Practical Constraints
Health and Safety
• Must conform to Underwriters Laboratories (UL) standards for safetyoNon-conducive Casingo Fused Overcurrent Protection
Economic• Must be manufactured for less than $50
Bill of MaterialsDescription Part
NumberPrototype Cost
Production Cost
1000 units
Advanced Electronics PCB 2247819 33.00 5.21
PIC24HJ64GP502 PIC24HJ64GP502-I/SO-ND 5.82 3.81
MODULE USB - SERIAL MODULE MINI
768-1022-ND 17.5 13.12
IC RTC SERIAL 512K 8-DIP DS1307+-ND 3.74 1.69
IC AC/DC CONV 5V 200MA SIP10 BP5063-5-ND 6.72 4.2
FUSEHOLDER ATO 20A IN-LINE F1086-ND 3.9 1.74
BATTERY LITHIUM COIN 3V 16MM P034-ND 1.00 0.53
HOLDER COIN CELL FOR 16MM CELL
BH600-ND 0.83 0.45
TRIAC ISOL 600V 25A TO-3 Q6025P5-ND 11.92 5.4
CAP .1UF 200V 10% CER RADIAL 399-4387-ND 0.96 0.28
Description Part Number Prototype Cost
Production Cost
1000 units
Optocouplers 6Pin 250V 512-MOC3011SR2M 1.52 0.668
CAP 22UF 200V ELECT VR RADIAL
493-1178-ND 0.47 0.16
ZERO CROSSING512-FOD8143S 0.38 0.134
USB MINI B CONNECTOR798-UX40-MB-5P 1.18 0
USB MINI B PANEL MOUNT523-MUSB-B151-34 11.66 0
RECTIFIER 400V 1A DO-41 1N4004DICT-ND 0.3 0.02
INDUCTOR HIGH CURRENT 820.0UH DN7786-ND 2.63 1.05
SUR ABSORBER 5MM 360V 600A ZNR P7243-ND 0.25 0.1
CRYSTAL 32.768KHZ CYLX801-ND 0.3 0.16
4.7 x 3.5 x 3.2 Polycarbonate Enclosure 546-1554G2GYCL 18.29 5.5
MOD PWR NEMA OUTLETS SNAP-IN PNL 486-1082-ND 1.9 1.06
Total: $122.37 $45.28
Technical Constraints
Technical Constraints
• Real time clock must operate at all times, under all power conditions
• Timing schedule accuracy must include Years, Months, Days, Hours, Minutes, Seconds
• PC is required to operate user interface
• Must supply power to internals from 120VAC
• Switching power must operate up to 120VAC at 15A (NEMA 5-15 Standard) [1]
• Must support output dimming
Technical Constraints ResultsFrom Design I
RTCC Operation PassTiming Schedule Accuracy Pass
PC Operation Pass
AC/DC Power Supply Pass
Power Output Pass
Output Dimming Fail
Technical Constraints Resultsin Design II
RTCC Operation PassTiming Schedule Accuracy Pass
PC Operation Pass
AC/DC Power Supply Pass
Power Output Pass
Output Dimming Pass
Software Tests• Text File I/O• Serial Port I/O • Conversion Method• Exception Handling• Event Deletion Method
Text File Test• Enter Event into GUI• Event is saved to text file
Text File Test• Text file data is loaded
into memory upon opening of application
Serial Port Test
• Serial Port was scoped to see if packet is being sent
Error Checking Test
Conversion Test• Convert Event class
data into packet format
Conversion Test
Conversion Test
Event Deletion Test
Event Deletion Test
Hardware Tests
PCB Testing
• Populate in sections• Test each section directly after population• Exception with surface mount(PIC)• Tests:
– Power (AC/DC 120VAC to 5VDC, 5VDC to 3.3VDC, Zero Crossing)
– PIC communication(programming)– RTCC– TRIAC control
PCB Power
ZERO CROSSING
AC/DC 5VDC
3.3VDC
PCB Communication
ICSP USB
RTCC and TRIAC Control
TRIAC Header on Bottom of Board
TRIAC Output / Dimming Tests
Finished PCBBefore Population
Populated and Tested Fully Functional Board
Single Event (Constant Power)
Repeating Event (Constant Power)
Single Event (Interrupted Power)
Repeating Event (Interrupted Power)
Single Event (Constant Power)*Dimmed*
Repeating Event (Constant Power)*Dimmed*
Single Event (Interrupted Power)*Dimmed*
Repeating Event (Interrupted Power)*Dimmed*
Outlet 1
Outlet 2
Simultaneous Startup/Shutdown Outlets 1&2
Offset Startup/Shutdown Outlets 1&2
Test Cases
Questions ?
References•[1] Powercords Online, "IDC Plugs - Standards," [Online]. Availible http://www.powercords.co.uk/standard.htm
•[2] "Appliance Wiring Material, UL 758." Underwriters Laboratories. http://ulstandardsinfonet.ul.com/scopes/0758.html. Accessed September 16, 2008.
•[3] “Isolé® IDP-3050 Plug Load Control.” WattStopper. http://www.wattstopper.com/products/details.html?id=74&category=122&type=Commercial. Accessed August 27, 2008.
•[4] “Bits Energy Saving Smart Strips.” Bits Limited. http://catalog.bitsltd.us/power_strips/. Accessed August 27, 2008.
•[5] “6-PIN Dip Random Phase Optoisolators Triac Driver Output.” Programmable Power Relay Datasheets. http://www.ece.msstate.edu/courses/design/2008/smartcord/downloads/MOC3011-M.pdf. Accessed December 1, 2008.
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