P16203: Smart Power Supply Test Bench
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Preliminary Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase

The goal for this phase of our design is used to get feedback from our customer and guide on our pseudo code, schematics, mechanical enclosure, and the Engineering Requirements Test Plan. The feedback from this review will be used to revamp and change anything that was wrong or seen as a better fit for our design and end goals. Things to be changed might be:

Mechanical Enclosure Analysis

Below are the mechanical slides presented at the preliminary detailed design review.

Safety features such as an emergency shut off button designed to instantly turn off the AC voltage when pressed, and a reed switch designed to instantly shut off power if the scatter shield or enclosure are opened while running were planned to be installed to keep operator safety as a high priority. These are shown below.

Reed Switch and Emergency Shutoff

Reed Switch and Emergency Shutoff

The Cooling calculations were done using Excel, taking into the account the worst case scenario of the maximum power and heat being displaced by the board.

Cooling Calculations

Cooling Calculations

From the cooling calculations and airflow analysis, it was seen that with 40 CFM fans on the intake side of the enclosure, exhaust fans on the enclosure and separate fans on the heat sinks related to the constant current and constant voltage of the load boards, enough cooling could be obtained for any scenario experienced with the boards.

Cooling Design

Cooling Design

At this point the SolidWorks 3D model of the enclosure was completed. This is shown below, with screen shots of the Aluminum enclosure at open and closed states.

Barrel Bolt locks, friction hinges and butterfly locks are planning on being used at this point to secure the scatter shield and aluminum enclosure from being opened physically as well as friction hinges to assist the operator in holding the scatter shield open at any point.

Enclosure Design (Closed)

Enclosure Design (Closed)

The slide below shows the aluminum enclosure and how it will mechanically open for troubleshooting and repair of the boards underneath. Piano hinges and supporting hinges will be used to make the opening of the top aluminum sheet easy and effortless.

Enclosure Design (Open)

Enclosure Design (Open)

Main Board, Load Board, and Relay Board Schematics

Purpose

Instructions

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Main Board Schematic

Load Board Schematic

Load Board Schematic

Load Board Schematic

Load Board Schematic

Load Board Schematic

Load Board Schematic

Relay Board Schematic

Relay Board Schematic

Bill of Material (BOM)

A copy of the Preliminary BOM can be found here.

Test Plans

A PDF copy of the Engineering Requirements Test Plan can be found here.

Purpose

The purpose of this document is to properly test that the Engineering and Customer Requirements are met throughout building the system and to verify that upon completion the requirements have been met. This document will also serve as a reference to the customer for trouble shooting purposes as well as a guideline in the event another test fixture is to be made.

Inputs and Source

A downloadable copy of the Engineering Requirements Excel Sheet can be found here for better viewing.
Engineering Requirements

Engineering Requirements

Risk Assessment

A PDF copy of the Risk Assessment can be found here.
Risk Assessment

Risk Assessment

Design Review Materials

Include links to:

(Use the individual 3-week plan template for this)


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