P Charging Dock & Power Control. Sustainable Energy System for Education

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Helena Ray
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1 P12402 Charging Dock & Power Control Sustainable Energy System for Education Most recent prototype (March 2011) of a portable & sustainable charging system for a battery pack. Team Members Matt Cappello Dave Herrera Ryan Legault Thomas Mittner Matt Owens David Sonneborn

2 Exported on November 01, 10:50 PM EDT Page 1 of 1

3 ME Bill of Materials Item Description Manufacturer Manufacturer Part # Vendor Vendor Part # Price / Unit # Required Total Price Shipping 3 1/2" Cabinet Pull Liberty P604DBC-SC-C5 Home Depot Store SKU # $ $5.92-1/8" x 12 x 12 Aluminum Sheet (3003) McMaster-Carr 8973K89 $ $13.42 * 1/4" x 12" x 24" Polycarbonate Sheet McMaster-Carr 8707K132 $ $ /2" x 12" x 24" Polycarbonate Sheet McMaster-Carr 8707K152 $ $ /2" 90 Deg Polycarbonate - 4ft length McMaster-Carr 1755K61 $ $3.03 Aluminum Male-Female Threaded Standoff McMaster-Carr 93505A113 $ $1.76 * Sealing Flat Machine Screws [6-32] McMaster-Carr 98070A270 $ $23.12 Round Hole Size 6 Nylon Washers McMaster-Carr 90295A075 $ $3.50 Machine Screw Nuts [6-32] McMaster-Carr 90480A007 $ $1.16 Grab Latches McMaster-Carr 1659A7 $ $10.28 Weatherproof Enclosure $0 Handle $0 Silicone $0 Assembly $0 Waterjetting $0 $ Total: $177.62

4 EE Bill of Materials Item Description Manufacturer Manufacturer Part # Vendor Vendor Part # Price / Unit # Required Total Price Shipping Lead Time Regulators (Batteries) Linear Technology LT1086CM Linear Technology LT1086CM $ $21.20 $ Regulators (µcontroller) Linear Technology LT1086CM-3.6 Linear Technology LT1086CM-3.6 $ $2.65 * 7 AC/DC Converter Mini-Box PWR-ACDC-12V-8.5A-102W Mini-Box $ $35.95 $ Micro Controller Texas Instruments MSP430G2231IN14 Digi-Key ND $ $13.51 $ Micro Controller Dev Board Texas Instruments MSP-EXP430G2 Digi-Key ND $ $4.35 * 10 Switches (Relays) Omron Electronics G6L-1FDC3 Digi-Key Z1230-ND $ $44.16 * 7 Resistors (1W, 1% 75KΩ) Vishay/Dale CRCW251275K0FKEG Digi-Key KAFCT-ND $ $4.00 * 7 Resistors (1W, 1% 10KΩ) Vishay/Dale CRCW251210K0FKEG Digi-Key 541-1KAFCT-ND $ $4.00 * 7 Resistors (1W, 1% 47mΩ) Yageo RL2512FK-07R047L Digi-Key TCT-ND $ $10.80 * 7 LEDs (Red) Xicon RC Mouser RC $ $2.08 $ LEDs (Green) Xicon RC Mouser RC $ $2.00 * 7 PCB (6x4) Barebones PCB $ $24.80 $20 7 Power Barrel Connector (2.5x5.5mm) CUI Inc PJ-063BH Digi-Key CP-063BH-ND $ $3.56 * 30 Female Tamiya Connector Housing CN-TMFM-Housing $ $3.84 $ Receptacle Pin for Female Tamiya Housing (x2) CN-TMFM-Pin $ $1.52 * 7 IC Socket 14 Pin Mill-Max Digi-Key ED2129-ND $ $10.56 * 7 14 Gauge Wire QC Supply QC Supply $ $0.60 $ Fuse Holder Littelfuse/Wickmann Digi-Key WK6245-ND $ $0.90 * 7 Fuse Littelfuse Inc HXP Digi-Key F2401-ND $ $0.34 * 7 $ $73.72 Total: $264.54

5 Sheet1 Function or Requirement Potential Failure Modes Potential Causes of Failure Occurrence Local Effects End Effects on Product, User, Other Systems Severity R P N Accept Energy no energy transferred loose connection 1 batteries don't charge LVE cannot be powered 8 8 component failure short 1 batteries don't charge LVE cannot be powered 8 8 Convert AC to DC overheats fan breaks 2 batteries don't charge LVE cannot be powered 8 16 short 1 batteries don't charge LVE cannot be powered 8 8 Regulate Energy too much current short 1 component failure battery lifetime decreases 7 7 too little current design flaw 1 batteries don't charge LVE cannot be powered 8 8 blown fuse 3 no currnet dock requires maintainance 8 24 low voltage battery doesn't supply enough 4 regulator will not work LVE cannot be powered 8 32 place batteries on floor of Dock Batteries cannot place batteries on dock sliding tray breaks off 6 housing batteries are not well secured 3 18 Connect Tamiya Connectors terminals don't connect material jammed in ends 5 can't secure connection must clean out terminals 3 15 Indicate Status of Charge signal not generated led shorts 3 can't tell if battery is being charged user thinks battery is broken 4 12 Charge Batteries batteries overcharge micro controller fails 2 fails to control switch damage batteries switch failure 2 stuck in wrong charge mode damage batteries resistor tolerance issue 1 too much current damage batteries batteries don't charge micro controller fails 2 fails to control switch LVE cannot be powered 8 16 switch failure 2 too little current LVE cannot be powered 8 16 House Components gaps in casing loose bolts 6 not aesthetically pleasing structure falls apart 6 36 loose silicon 7 case is wobbly structure falls apart 6 42 Page 1

6 Row # Maximum Relationship Customer Needs (Explicit and Implicit) Functional Requirements Our Product Tenergy SUC Tenergy BC Customer Competitive Assesment Row # Target Max Relationship Technical Importance Rating Relative Weight 3% 3% 12% 1 1 5% 1 4% 4% 4% 4% 4% 4% 23% Weight Chart Weight Chart Relative Weight Customer Importance Column # Direction of Improvement 1 MTBF 2 3 Decrease disassembly time Minimize training time Minimize troubleshooting time Ambient temperature range to operate Minimize operating heat output Must operate in humidity range Charging time % 9 9 Powers the LVE batteries % 3 1 Withstands a drop % 9 9 Must operate outdoors % 9 9 Easy to use % 9 3 Provides current charging status % 1 3 Aesthetically pleasing % 3 9 Small in size and weight % 3 9 Quick to recharge batteries % 3 9 Easy to maintain Our Product 10 15% 9 9 Charge multiple batteries Tenergy SUC 11 2% 1 1 Modular Tenergy BC 11 Storage size requirements Operating size requirements Weight requirements Target input current 13 Target output current # of batteries charged 50,000 hours 15 minutes 2 hours 10x10x6 inches 6x6x3 inches 1.5 lbs 35 amps 3 amps 5 to 10 batteries.25 hours 5 minutes 10 to 90 deg. F < 100 deg. F 0 to 95 % rel. humidity

7 PHASE II QFD Charging Dock Part Characteristics Phase I Relative Weights Battery Regulators µ controller Regulators AC/DC Converter Micro Controllers Developer Board for µ cont. Relay switchers 75 KΩ Resistor 10 KΩ Resistor 47 mω Resistor Red LEDs Green LEDs PCB Power Barrel Connector Female Tamiya Connector Housing Receptacle Pins for Tamiya Connector Engineering Metrics MTBF 3% Dissassembly Time 3% 1 1 Training Time 12% Troubleshooting Time 1 Ambient Operating Temperature Range 1 Operating Heat Output 5% Operating Humidity Conditions 1 Charging Time 4% 3 9 Storing Size of Unit 4% Operating Size of Unit 4% Weight 4% 3 1 Input Current 4% 1 9 Output Current 4% 3 Number of Batteries Dock can Charge 23% Raw score Relative Weight 4% 4% 1 5% 3% 5% 3% 3% 19% 36% 3% 4% 1

8 QFD Cost - Worth Diagram (based on "Total Part Cost" as divisor) 3 Microcontroller Regulators Relative Cost 2 Battery Regulators PCB Microcontrollers 1 47 mohm Resistor Power Barrel Connector Relative Worth 11/2/11

11 Single Battery Charging Circuit (x8) November 2, 2011 Green LED Out 1 120Vac LTI1086CM-3.6 SW1 Out VCC SW2 Out Out 2 ADC IN Red LED Converter 120VAC - 12VDC 3.6V Microcontroller (TI MSP430) 12VDC Power In (2.5/5.5mm Barrel Connector) 12V Relay 3.6V LTI1086CM 10.62V 47mΩ 47mΩ Relay 3.6V 10.5V Battery 10kΩ P kΩ All Devices Repeated after this point (8x) Page 1

EZTRIM - Data and Specifications 2019

EZTRIM - Data and Specifications 2019 EZTRIM - Data and s 2019 Debudder - Tabletop Aluminum 6061 - FG Control Box 120 or 240VAC Weight: 75 lbs. Stainless Steel - FG Motor 60 HZ Ship weight: 90 lbs. Silicone - FG Power Cord 3 Phase Assembled