Design Review

Video Lecture

Video, Slides

updated Fa 2020

Description

The design review is a 30-minute meeting intended to make sure that the team has a successful project. Students will present and defend their design while instructors and TAs critique it, identifying any infeasible or unsafe aspects and steering the team toward success. Instructors and TAs will ask questions throughout and may choose the order of blocks to be discussed. Specifically, here is what the course staff are looking for:
  1. Evidence that the overall design and high-level requirements solve the problem stated.
  2. Check if the overall design has suitable difficulty for course standards and completion in one semester. Scope may need to be adjusted if otherwise.
  3. Check team members' engineering preparedness to implement each module.
  4. Check that each team member is assigned an equal portion of the project effort.
Prepare for the following sequence.
  1. Promptly project the design document on projector.
  2. Introduce team members (name, major, and the project part each is in charge of).
  3. Present problem statement and proposed solution (<1 minutes) following the template in DDC (see Description 1.a)
  4. Present design overview (<5 minutes)
    1. High-level requirements: check DDC
    2. Block diagram: check DDC
    3. Physical design
  5. For the remainder of the review, you will participate in a detailed discussion of the design. Plan to cover each block, one at a time, beginning with the most critical. The course staff will ask questions and may step in to guide the discussion. Be prepared to discuss all aspects of your design with a focus on the following.
    1. Requirements & Verification: (see DDC); We'll look at all the important block requirements. Prepare to justify the components chosen and compare with important alternatives.
    2. Evidence that the design meets requirements (use the following as applicable)
      • Simulations
      • Calculations
      • Measurements
      • Schematics
      • Flowcharts
      • Mechanical drawings
      • Tolerance analysis: check DDC
      • Schedule: Suggestions:
        1. Think about what you can do in parallel, what has to be sequential;
        2. Work on hardware before software;
        3. Perform unit testing before system testing;
        4. Unit test each module on a breadboard before starting PCB design);
        5. Leave margin for unexpected delays or accidents. You are mostly responsible for those exceptions, just as if you were the owner of this senior design business;
      • Cost:hourly rate is ~$50 not $10. In addition, apply the 2.5x overhead multiplier ($125/hr is the cost of your senior design business), which includes the cost of salaries of you, your boss, CxOs, sales, janitors, etc.

Grading

The DR Grading Rubric is available to guide your DR preparation. Two sample Design Review documents are available as examples of what we expect: a Good Sample DR, a Moderate Sample DR, and a good example R&V table as it was presented in a final report. Notes are made in red type to point out what is lacking. Note that the grading rubrics and point structure may have evolved since these reports were generated, so use them only as a guide as to what we are generally expecting.

Submission and Deadlines

Your design document should be uploaded to PACE in PDF format by Midnight the Friday before design review. If you uploaded a mock DR document to PACE, please make sure that it has been removed before uploading the final DR..

Tech must-know and FAQ for design

Here is the link of "Tech must-know and FAQ for design" which is accessible after logging into g.illinois.edu.

Over semesters, ECE445 course staff have encountered repeated mistakes from students. The document above is designed to provide students with the essential knowledge needed in order to have a good design. Spending 5 min reading it might save you 15 hours later. Also, there might be some quiz questions in your DDC or Design Review. Please help us improve this document. We value your feedback!

Tesla Coil Guitar Amp

David Mengel, Griffin Rzonca

Featured Project

# Tesla Coil Guitar Amp

Team Members:

* Griffin Rzonca (grzonca2)

* David Mengel (dmengel3)

# Problem:

Musicians are known for their affinity for flashy and creative displays and playing styles, especially during their live performances. One of the best ways to foster this creativity and allow artists to express themselves is a new type of amp that is both visually stunning and sonically interesting.

# Solution:

We propose a guitar amp that uses a Tesla coil to create a unique tone and dazzling visuals to go along with it. The amp will take the input from an electric guitar and use this to change the frequency of a tesla coil's sparks onto a grounding rod, creating a tone that matches that of the guitar.

# Solution Components:

## Audio Input and Frequency Processing -

This will convert the output of the guitar into a square wave to be fed as a driver for the tesla coil. This can be done using a network of op-amps. We will also use an LED and phototransistor to separate the user from the rest of the circuit, so that they have no direct connection to any high voltage circuitry. In order to operate our tesla coil, we need to drive it at its resonant frequency. Initial calculations and research have this value somewhere around 100kHz. The ESP32 microcontroller can create up to 40MHz, so we will use this to drive our circuit. In order to output different notes, we will use pulses of the resonant frequency, with the pulses at the frequency of the desired note.

## Solid-state switching -

We will use semiconductor switching rather than the comparably popular air-gap switching, as this poses less of a safety issue and is more reliable and modifiable. We will use a microcontroller, an ESP 32, to control an IR2110 gate driver IC and two to four IGBTs held high or low in order to complete the circuit as the coil triggers, acting in place of the air gap switch. These can all be included on our PCB.

## Power Supply -

We will use a 120V AC input to power the tesla coil and most likely a neon sign transformer if needed to step up the voltage to power our coil.

## Tesla Coil -

Consists of a few wire loops on the primary side and a 100-turn coil of copper wire in order to step up voltage for spark generation. Will also require a toroidal loop of PVC wrapped in aluminum foil in order to properly shape the electric field for optimal arcing. These pieces can be modular for easy storage and transport.

## Grounding rod -

All sparks will be directed onto a grounded metal rod 3-5cm from the coil. The rest of the circuit will use a separate neutral to further protect against damage. If underground cable concerns exist, we can call an Ameren inspector when we test the coil to mark any buried cables to ensure our grounding rod is placed in a safe location.

## Safety -

Tesla coils have been built for senior design in the past, and as noted by TAs, there are several safety precautions needed for this project to work. We reviewed guidelines from dozens of recorded tesla coil builds and determined the following precautions:

* The tesla coil will never be turned on indoors, it will be tested outside with multiple group members present using an outdoor wall outlet, with cones to create a circle of safety to keep bystanders away.

* We will keep everyone at least 10ft away while the coil is active.

* The voltage can reach up to 100kV (albeit low current) so all sparks will be directed onto a grounding rod 3-5cm away, as a general rule of thumb is each 30kV can bridge a 1cm gap.

* The power supply (120-240V) components will be built and tested in the power electronics lab.

* The coil will have an emergency stop button and a fuse at the power supply.

* The cable from the guitar will use a phototransistor so that the user is not connected to a circuit with any power electronics.

# Criterion for Success:

To consider this project successful, we would like to see:

* No safety violations or injuries.

* A tesla coil that produces small visible and audible 3-5cm sparks to our ground rod.

* The coil can play several different notes and tones.

* The coil can take input from the guitar and will play the corresponding notes.

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