Watt You Pay For Group 10 Spring/Summer 2018 Adam Althar Charles Desowitz Anders Hauge Jonathan Killeen Table of Contents 1.0 Executive Summary .................................................................................... 1 2.0 Project Description ......................................................................................... 3 2.1 Project Motivation ........................................................................................ 4 2.2 Goals and Objectives .................................................................................. 4 2.3 Requirement Specifications ......................................................................... 5 2.3.1 Software Functional Requirements .......................................................... 7 2.3.2 Hardware Functional Requirements ...................................................... 8 2.4 Marketing and Engineering Requirements ................................................ 10 3.0 Research ...................................................................................................... 12 3.1 Student Projects ........................................................................................ 12 3.1.1 Watt’s the Matter ................................................................................. 12 3.1.2 S.H.A.P.E.R. ....................................................................................... 13 3.2 Existing Products....................................................................................... 15 3.2.1 TP-Link HS-200 Smart Switch ............................................................ 15 3.2.2 The Kill-A-Watt® PS-10 ...................................................................... 17 3.2.3 Nest Learning Thermostat ................................................................... 18 3.3 Power Monitoring ...................................................................................... 20 3.3.1 Current Sensing .................................................................................. 21 3.3.2 Voltage Sensing .................................................................................. 23 3.4 Analog to Digital Conversion ..................................................................... 24 3.4.1 ADC0804 ............................................................................................ 24 3.4.2 ATmega2560 Integrated ADC ............................................................. 25 3.5 Control Unit Data Transmission Methods .................................................. 26 3.5.1 RS-485 ................................................................................................ 26 3.5.2 Ethernet .............................................................................................. 26 3.5.3 Wi-Fi.................................................................................................... 27 3.6 Operating Systems .................................................................................... 27 3.6.1 Ubuntu Server ..................................................................................... 28 3.6.2 FreeBSD ............................................................................................. 28 3.6.3 Windows Server 2016 ......................................................................... 28 3.7 Power Transformation ............................................................................... 29 3.7.1 Tamura 3FD-320 Power transformer .................................................. 29 3.7.2 Wurth Electronics Midcom 7508110151 SMPS .................................. 29 i 3.7.3 Capacitive Power Supply .................................................................... 30 3.8 Database Management Systems .............................................................. 31 3.8.1 MySQL ................................................................................................ 31 3.8.2 Redis ................................................................................................... 32 3.8.3 Maria DB ............................................................................................. 32 3.9 Microcontrollers ......................................................................................... 32 3.9.1 Texas Instruments MSP430F6638 ...................................................... 33 3.9.2 Microchip ATmega5260 ...................................................................... 34 3.9.3 Parallax P8X32A-D40 ......................................................................... 35 3.10 Web Server Software .............................................................................. 36 3.10.1 NodeJS ............................................................................................. 36 3.10.2 Apache HTTP ................................................................................... 36 3.10.3 Nginx ................................................................................................. 37 3.11 Temperature Sensing .............................................................................. 37 3.11.1 DS18B20 1-Wire Digital Thermometer .............................................. 37 3.11.2 MCP9700A-E/TO Thermistor IC........................................................ 38 3.11.3 LMT86-Q1 Analog Temperature Sensor ........................................... 39 3.12 Displays ................................................................................................... 39 3.12.1 Crystalfontz CFAH1602B-TMI-JT...................................................... 39 3.12.2 Adafruit 0.96” mini Color OLED ......................................................... 40 3.13 PCB Design Software .............................................................................. 40 3.13.1 Altium ................................................................................................ 40 3.13.2 EAGLE CAD ..................................................................................... 41 3.13.3 KiCAD ............................................................................................... 41 3.14 Logic Level Shifter ................................................................................... 41 3.14.1 Voltage Divider .................................................................................. 42 3.14.2 TXB0108 8-Bit Bidirectional Voltage Translator ................................ 42 3.14.3 Bi-Directional Level Shifter ................................................................ 43 3.15 Operation Amplifier .................................................................................. 43 3.15.1 OPA2180-Q1 Operational Amplifier .................................................. 44 3.15.2 INA2128 Instrumentation Amplifier.................................................... 45 3.15.3 INA828 Instrumentation Amplifier...................................................... 45 3.16 Power Relay ............................................................................................ 45 3.16.1 RT1 Power PCB Mechanical Relay................................................... 46 ii 3.16.2 G3NA Solid State Relay .................................................................... 47 4.0 Strategic Components and Part Selection .................................................... 48 4.1 Current Sensor .......................................................................................... 48 4.2 Voltage Sensor .......................................................................................... 49 4.2.1 Final Voltage and Current Sensor ....................................................... 50 4.3 Analog to Digital Converter ....................................................................... 50 4.3.1 Analog to Digital Converter Key Component ....................................... 51 4.4 Microcontroller ........................................................................................... 52 4.5 Capacitive Power Supply .......................................................................... 53 4.5.1 Key Power Supply Components Selection .......................................... 53 4.5.2 Final Power Supply Selection ............................................................. 54 4.6 Digital Temperature Sensor ...................................................................... 54 4.7 PCB Software ............................................................................................ 55 4.8 Display ...................................................................................................... 56 4.9 Main Server Operating System ................................................................. 57 4.10 Main Server Web Server ......................................................................... 57 4.11 Main Server Database ............................................................................. 58 4.12 Control Unit Data Transmission Method .................................................. 59 4.13 Discrete Logic Level Shifter ..................................................................... 59 4.13.1 Key Discrete Logic Level Component Selection ............................... 60 4.14 Operational Amplifier ............................................................................... 61 4.15 Power Relay ............................................................................................ 62 4.15.1 Final Power Relay ............................................................................. 63 5.0 Related Standards