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Subsystem Design Review
P16203
Andre Pelletreau, Kerry Oliviera, Jeremy Willman,
Vincent Stowbunenko, Kai Maslanka
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Recap of Last Review
• Functional Decomposition
• Morphological Chart and Concept Generation
• Concept Selection
• Engineering Analysis
• System Architecture
• Feasibility Analysis
• Risk Assessment
• Test Plan
• Next 3 Weeks…
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Agenda System Architecture
Requirements Flow Down
Subsystem Interaction
Constant Current and Constant Voltage Loads
Thermal Analysis of Enclosure
Stress Analysis
UML Diagrams
RS-232 Proof of Concept
Stress Analysis for Enclosure
Design of Enclosure and Safety Shield
Air Flow Analysis
Preliminary BOM
Updated Test Plan
Next 7 Weeks…
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Subsystem Interaction
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Subsystem Engineering Requirements Sub-
System ER
Physical Enclosur
e
Transparent Safety
Enclosure
AC disengaged when lid is
open
AC voltage
not accessibl
e
Able to withstand
UUT failure
1.5’ x 1.5’ x 1’
Quick (dis)connec
t wires
Difficulty to set up / lock in
Time to set up < 1 minute
Loads
Length of test <
5 minutes
Output 1 –
Active Load
Output 2 – Resistive
Load
Data Storag
e
Store Test Data
Feedback
AC disengaged when lid is
open
AC voltage accessibilit
yPass/fail
indicationReason
for failure
UUT on indicatio
n
Test Bench on indicatio
n
Number of test steps
under 5
Cooling
Internal Temperature < 50 ˚C
Processing
Length of test < 5 minutes
Successfully calibrate
UUT
AC disengaged when lid is
open
Tx and Rx data to/from
UUT
AC voltage accessibility
Establish communicatio
n with UUT
Safety
Internal Temperature < 50 ˚C
AC disengaged when lid is
open
Transparent safety
enclosure
Able to withstand
UUT failure
AC voltage accessibilit
y
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Constant Voltage Load
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Constant Current Load
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Stress Analysis for Enclosure Metal
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Thermal Analysis
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UML Diagrams
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UML Diagrams
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UML Diagram Cont’d
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UML Diagram Cont’d
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RS-232 Proof of Concept
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Autotransformer Mathematical Proof of Concept
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AC Inputs
Two autotransformers were needed to satisfy AC input specifications
The outputs of the transformer will be controlled by a relay
The relay will be controlled by the Arduino Microcontroller
The Hammond Manufacturing Hard Wired 170 Series autotransformer will step down 115 V to 85 V
E100E SOLA HD autotransformer will step from 120 V to 264 V with the added 24 V winding
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Feasibility Analysis of Design
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Enclosure Material Selection
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Enclosure and Safety Shield
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Enclosure and Safety Shield
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Circuitry and Resistor Layout
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Airflow Analysis
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Airflow Analysis Cont’d
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Preliminary Bill of Materials
Line Item Part Vendor Manufacturer Quantity Price
1 6 ", 200 W Tubular Resistor Farnell Vishay 4 ~40
2 Arduino Mega SparkFun Arduino/ATMEL 1 ~$60
3 21 x 4 (characters) LCD SparkFun N/A 1 $18
4 E075E - Autotransformer (High Line) Newark Sola-HD 1 $51.55
5 168C - Autotransformer (Low Line) Mouser Hammond 1 $77.84
6 25 Ohm Tubular Resistor Newark Multicomp 2 $5.66
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Test Plan
Are the physical measurements ≤ the required dimension?
Measure the physical dimensions of the enclosure
Is the length of the test ≤ 5 min? Time the entire test starting from power supply board set
up finishing with the verification of entire unit test.
Is the Internal Temperature ≤ 50 Celsius? Use a thermometer to measure
Are there indications of passing/failure of the test fixture?
Verify that the GUI lists pass/fail after a test in complete
Does the AC disengage when lid is open? Verify power turns off when Safety Shield is opened
Is the AC voltage accessible? Verify that the AC voltage is not accessible and is within
the enclosure.
Is the safety enclosure transparent? Verify that the Safety Shield is transparent and that the
UUT is visible
Is the enclosure able to withstand a failure of the UUT?
Run stress tests and force tests on the base and the safety shield to see how much heat and force each can withstand
Has communication with the UUT been established?
Verify GUI indicates communication has been made
Has data been transmitted and received to/from the UUT?
Verify from GUI that data is being shared and received through the proper completion of the test
Has the UUT been successfully calibrated?
Verify there is an LED indicator that the UUT
Is there reason for failure feedback?
Verify that the GUI states a failure and where in the test it fails
Is there an indication that the UUT is on?
Verify that there is an LED indicator that the UUT is powered on, and a label saying ‘UUT Power On’
Is there an indication that the Test Bench is on?
Verify there is an LED indicator and a label saying ‘Test Bench Power On,’ and verify that the LED is on
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Test Plan Cont’d Are the number of test steps less than 5?
Complete set up and verify that the number of steps is less than five per each test (PS Board test, Controller Board Test, and Entire Unit Test)
Is there a quick (dis)connect? Verify the connect and disconnect time is less than 5 seconds for each.
Is the time to set up less than 1 minute? Time the setup of the enclosure
Is the set up difficult? Based on time to set up and the number of steps, verify that those
requirements are met, which will indicate ease of setup.
Is the test data being stored? Connect SD card and USB to computer to see if test data is being stored
Is the budget under $1500? Yes/No
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Next 7 Weeks…
• Detailed Design Activities• Updated Test Plan• Finalize detailed CAD• Active Loads• PCB Layout• Final schematics• Bill of Materials• Code Algorithms
• Prototyping Activities• Active Load – Constant
Current• Active Load – Constant
Voltage• RS232 Communications• CNC of Enclosure Materials• Risk Assessment
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Questions/Concerns?