EPS Preliminary Design

Introduction

This design document is broken down in to multiple sections: the Preliminary Design Criteria Review, the Preliminary Schematic, the Preliminary Bill of Materials, and finally the Preliminary Budget. Each of these sections has information which is preliminary in nature, yet attempts have been made to make these as accurate as possible.

Preliminary Design Criteria Review

Preliminary Schematic

Preliminary Bill Of Materials

Control Board
Schematic Description Package
C1 68uF Capacitor SMD
C2 120uF Capacitor Axial
D1 1N5817 Schottky diode SMD
L1 100uH Inductor SMD
Rb1 47k Ohm .25W Resistor SMD
Rb2 47k Ohm .25W Resistor SMD
U1 LM2594M-3.3/NOPB Voltage regulator SSOP-8
CN1 Molex70555-0038 Locking connector thru hole
CN2 Molex70555-0038 Locking connector thru hole
CN3 Molex70555-0038 Locking connector thru hole
CN4 Molex70555-0038 Locking connector thru hole
CN5 Molex70555-0038 Locking connector thru hole
J1 5mm barrel jack, 2.1mm center pole Std
EPS Board (MSP430 MCU and MAC IC) Board
Current Sensor Board
Schematic Description Package
CN1 Molex70555-0038 Locking connector Thru hole
Cf1 1uF capacitor SMD
2 position screw terminals Std
Rf1 4.7 Ohm .25W resistor SMD
Rf2 4.7 Ohm .25W resistor SMD
RL1 220 Ohm .5W resistor SMD
Rs 3.9 mOhm 5W resistor Axial
Ra1 47k Ohm .25W Resistor SMD
Ra2 47k Ohm .25W Resistor SMD
S1,2 2 pos DIP switch Thru hole
U3 INA226 Current and voltage sensor SSOP-10
Current Sensor PC Board Board
Molex 50-57-9404 (mating connector for cable) Cable
Molex 50-57-9404 (mating connector for cable) Cable
Alpha Wire 1174c SL005 4cond 22ga Cable
Temperature Sensor Board
Schematic Description Package
CN1 Molex70555-0038 Locking connector Thru hole
U2 TMP102 Temp sensor (I2C) SSOP-6
Temperature Sensor PC Board Board
Molex 50-57-9404 (mating connector for cable) Cable
Molex 50-57-9404 (mating connector for cable) Cable
Alpha Wire 1174c SL005 4cond 22ga Cable

Preliminary Budget

Control Board
Schematic Description Prototype Cost Production Cost
C1 68uF Capacitor $0.49 $1.15
C2 120uF Capacitor $0.62 $0.62
D1 1N5817 Schottky diode $0.27 $0.19
L1 100uH Inductor $0.18 $0.09
Rb1 47k Ohm .25W Resistor $0.37 $0.03
Rb2 47k Ohm .25W Resistor $0.37 $0.03
U1 LM2594M-3.3/NOPB Voltage regulator $2.70 $2.70
CN1 Molex70555-0038 Locking connector 0.97 $0.96
CN2 Molex70555-0038 Locking connector $0.97 $0.96
CN3 Molex70555-0038 Locking connector $0.97 $0.96
CN4 Molex70555-0038 Locking connector $0.97 $0.96
CN5 Molex70555-0038 Locking connector $0.97 $0.96
J1 5mm barrel jack, 2.1mm center pole $4.95 $1.12
EPS Board (MSP430 MCU and MAC IC) $0.00 $12.00
Populated Ethernet Booster Pack (MSP430 MCU) $25.00 $25.00
Labor $1,362.50 $120.12
SUBTOTAL $1,402.30 $167.85
Current Sensor Board
Schematic Description Prototype Cost Production Cost
CN1 Molex70555-0038 Locking connector $0.97 $0.96
Cf1 1uF capacitor $0.14 $1.15
Phoenix Contact 1714971 two position screw terminals $1.34 $1.31
Phoenix Contact 1714971 two position screw terminals $1.34 $1.31
Rf1 4.7 Ohm .25W resistor $0.37 $0.03
Rf2 4.7 Ohm .25W resistor $0.37 $0.03
RL1 220 Ohm .5W resistor $0.37 $0.03
Rs 4 mOhm 4W resistor Ohmite 14AFR004E $1.98 $1.23
Ra1 47k Ohm .25W Resistor $0.37 $0.03
Ra2 47k Ohm .25W Resistor $0.37 $0.03
S1,2 2 pos DIP switch $0.53 $0.49
U3 INA226 Current and voltage sensor $6.33 $3.38
Current Sensor PC Board $0.00 $4.00
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Alpha Wire 1174c SL005 4cond 22ga $1.00 $1.00
Labor $225.00 $62.09
SUBTOTAL $241.84 $77.81
Temperature Sensor Board
Schematic Description Prototype Cost Production Cost
CN1 Molex70555-0038 Locking connector $0.97 $0.96
U2 TMP102 Temp sensor (I2C) $5.95 $1.69
Temperature Sensor PC Board $0.00 $2.00
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Molex 50-57-9404 (mating connector for cable) $0.68 $0.37
Alpha Wire 1174c SL005 4cond 22ga $1.00 $1.00
Labor $75.00 $29.21
SUBTOTAL $84.28 $35.60
Completed Assembly as Specified
Board Prototype Cost Production Cost
Control Board $1,402.30 $167.85
Current Sensor Board $241.84 $77.81
Current Sensor Board $241.84 $77.81
Temperature Sensor Board $84.28 $35.60
TOTAL COST $1969.96 $359.07