Functional Specs

Summary Table

Spec ID Requirement Threshold Objective Validation Method
ES01 Component Voltage Rating Powerpath rating for at least 50V, control circuitry rating for at least 20V. Powerpath rating for at least 70V, control circuitry rating for at least 30V. Derating of individual components, assuming “worst case” operation parameters.
ES02 Component Current Rating Powerpath rating for at least 60A, control circuitry rating for at least 12A. Powerpath rating for at least 70A, control circuitry rating for at least 20A. Derating of individual components, assuming “worst case” operation parameters.
PT01 Ripple Voltage Limit Ripple Voltage will not be in excess of 2Vpp, at 4-15kHz.   Use oscilloscope to measure ripple voltage in circuit.  Report the average of 5 measurements.
PT02 Directional Operation Unidirectional Bidirectional Supplying loosely conditioned input of 20.5-35.5VDC to input to expect a nominal output as specified in OP04-OP06.
PT03 Power Dropout Duration 500ms 50ms An oscilloscope will be used to read output voltage with respect to time. Power transfer direction will be changed 3 times.  The average of the 3 dropout times is reported as the system dropout time. 
OP01 Constant Current Output Constant current output of 50A ± 5%. Constant current output, based on battery charging algorithm via RS-485 signal interface delivering 50A ± 1%. Oscilloscope measurements of output, once every 10 seconds for 2 minutes. Average of all measurements reported. If the average current is within the stated tolerance (±5% or ±1%) then current is considered constant.
OP02 Constant Voltage Output Constant voltage output delivering 28.5-32V ± 5%. Constant voltage output, based on battery charging algorithm, via RS-485 signal interface, delivering 28.5-32V ± 1%. Multimeter measurement of output, once every 10 seconds for 2 minutes.  Average of all measurements, reported.  If the average voltage is within the stated tolerance (±5% or ±1%) then voltage is considered constant. 
OP03 Phase Margin < 70° phase margin at full load, in excess of 45° phase margin across any load.   Oscilloscope measurement of phase margin. Average of 3 phase measurements reported.
OP04 Max Voltage Output Voltage output will not exceed 32VDC.   Multimeter measurement of output once every 10 seconds for 2 minutes. Maximum measurement reported.
OP05 Boost Mode Operation 30VDC ± 5% output. 30VDC ± 1% output. Loosely conditioned input of 21VDC is supplied to the input where the output voltage is expected to be roughly 30VDC ± stated voltage. Multimeter will measure output voltage at 10 second intervals for a span for 2 minutes.  Average of all measurements is reported as output voltage. 
OP06 Buck Mode Operation 30VDC ± 5% output. 30VDC ± 1% output. Loosely conditioned input of 35VDC is supplied to the input where the output voltage is expected to be roughly 30VDC ± stated voltage. Multimeter will measure output voltage at 10 second intervals for a span for 2 minutes.  Average of all measurements is reported as output voltage. 
OP07 TR Mode 28VDC ± 5% output. 30VDC ± 1% output. Loosely conditioned input of 35VDC is supplied to the input where the output voltage is expected to be roughly 28VDC ± stated voltage. Use of a multimeter to measure output voltage at 30 second intervals for a 5-minute continuous operation period.  The average of these recorded measurements is reported as the output voltage, in TR mode.
UI01 Signal Interface RS-485. RS-485 capable of accepting Turn-On/Turn-Off commands, Charge vs TR mode, Current Limit, Charge Mode Topping Voltage limit, and Power Direction Commands. RS-485 signal interface must be present on the power converter, where the signal is connected to the FPGA/powertrain. Simulations will be a secondary means to analyzing data streams/sent commands for this spec.
MS01 System Mass Full system mass less than 5.44kg. Full system mass less than 4.45kg Final prototype will be placed on a weight scale. Any components, which are shown in the CAD models and drawings, but are not present at the time the system mass is recorded, must be analytically determined and added to the mass recorded by the scale.  Sum of the scale mass, and any masses which are analytically determined, which is reported as the final as-designed system mass. 
MS02 Enclosure Type Full CAD package, containing models, drawings, part numbers for ARINC600 4MCU enclosure. Power Converter housed in ARINC600 4MCU enclosure. Primary Analysis is dimensional CAD analysis.  Secondary Analysis is to take three measurements for each dimension (length, width, height) and report the average of the 3 measurements as the final dimension.  
MS03 Full System Volume External dimensions will not exceed 5.01” ±0.05” x 7.25” ±0.05” x 14.95” ±0.05.”   Primary Analysis is dimensional CAD analysis.  Secondary Analysis is to take three measurements for each dimension (length, width, height) and report the average of the 3 measurements as the final dimension.  
MS06 Thermal Management – Maximum Internal Temperature Internal Temperature < 90 °C at bulk temperature > 65 °C Load Reduction to 30 A allowed Internal Temperature < 90 °C at bulk temperature > 65 °C Full Load   SolidWorks Thermal Simulations or ANSYS FEA tools will be used to determine theoretical values; thermocouples to measure physical values for a length of 45 min for 30A/50A.
MS07 Internal Temperature – Medium  Internal Temperature < 90 °C when 50 °C < bulk temperature < 65 °C Load Reduction to 30 A allowed Internal Temperature < 90 °C when 50 °C < bulk temperature < 65 °C Full Load SolidWorks Thermal Simulations or ANSYS FEA tools will be used to determine theoretical values; thermocouples to measure physical values for a length of 60 min for 30A/50A.
MS08 Internal Temperature – Steady State Internal Temperature < 90 °C when bulk temperature < 50 °C Full Load Internal Temperature < 70 °C when bulk temperature < 50 °C Full Load Transient Thermal Simulations using SolidWorks Thermal Simulations or ANSYS FEA tools will be used to determine theoretical values; thermocouples within the enclosure will measure physical values for a length of 60 min for full load.