[HELP NEEDED] Power Surge Protector w. Wattage Meter Prototype  - Page 1
Forum section: electronics / projects

author: RalfSchooneveld
author_rank: Contributor
timestamp: November 23, 2016, 12:42:08 am
content: Gentlemen,I have had a prototype on paper (concept) for a while and have been unable to find someone to build it for me.Therefor I would very much love step to step help from willing and experienced people to be able to do it myself; as to what certain things are and where to buy them.To start. If anyone could tell me what the parts are on the board of the wattage meter I have opened up, that would go a long way as I have no idea what parts I need, or are called so as to google them and purchase them.After I know what parts to get and purchase I am wanting and have found someone to potentially make the custom housing.The main use of it will be in my filmstudio, to monitor the wattage of lamps and devices. Through AC from a building or from the Arkpak 730.I have the intention of making a large bulk (+- 100) after prototype for reselling in Europe........that's the idea at least.Thanks in advance.

author: RalfSchooneveld
author_rank: Contributor
timestamp: November 23, 2016, 12:48:04 am
content: Wattage Meter opened up.Brennenstuhl PM 231 Ehttp://www.bax-shop.nl/bliksem-overspanningsbeveiliging/brennenstuhl-pm-231-e-primera-line-wattage-en-stroommeter?gclid=CjwKEAiA9s_BBRCL3ZKWsfblgS8SJACbST7D-NGKsh3wCS8PzJqLUrJYq38HnkPW9HMBagKnxLnICxoC8lnw_wcBHow would I backwards engineer this for myself so as to understand how this works, so that I might be able to know what parts to get?Thanks in advance.

author: jeroen79
author_rank: Frequent Contributor
timestamp: November 23, 2016, 03:34:45 am
content: How much do you know at all about electricity and electronics?And what data do you want to measure? Just current (Amperes)?Or the power as well? Do you know the difference between VA, VAR and Watts? Or what power factor is? Are you interested in that at all?Is the drawing you attached the prototype?If you want to make a powermeter yourself then you would need to measure the voltage and current and the phase between the two.Then feed that through a analog-digital-converter to a microconroller and let the microcontroller calculate the things you want to know and output it to a screen.You mention production of a large bulk of about 100 units.100 is NOT a large bulk for this kind of stuff.You won't get the benefits of large scale production and stuff like safety certification would be a big part of the cost.For your own use you would be better off getting some ready made panelmeters, mains sockets and switches and putting them in a box.A simple DIY solution would be to get some cheap chinese metersYou can get them from China from €5 to €15, depending on what functions you desire.'Proper' industrial meters would cost more.You could even cannibalize some of these units from Brennenstuhl if you prefer it over chinese stuff.They're €12 on amazon.de.(For personal use only)Your photo of the brennstuhl unit is too little info for reverse engineering.The big yellow thing is probably a capacitor to reduce the voltage to power the unit, but that is a guess. And it seems like current is measured through a shunt rather than through a current transformer. (another guess)For starters, we would need face on photo's of all the PCBs from both sides, with and without components.

author: mjkuwp
author_rank: Unknown
timestamp: November 23, 2016, 03:42:02 am
content: a few questions - there are commercial devices available and I wonder why you want to make your own?member blueskull mentioned the math behind the measurement. Often this is done with a dedicated ic that handles the integration. A good example is ADE7953 from Analog Devices. You need.1. AC-DC power supply to obtain power supply for the meter.2. current shunt or rogowski coil or current transformer for measuring the current3. voltage divider (very simple!) for the volt signal4. magical ic such as the one I mentioned above. It samples the signals near 7 khz and handles all of the math.5. digital signal connection such as UART, i2c or SPI6. Some microcontroller- and software!7. optional - display and interfaceThis is getting a bit old now, but perhaps you can find something from this blog page documenting my design. It is wifi usingelectric imphttp://themzlab.tumblr.com/wattmeterThe one that I made is designed as a closed case which helps in that since I don't allow the user to touch anything it is easier to achieve a safe design.EDIT, add this linkhttps://upload.wikimedia.org/wikipedia/commons/1/17/Brennenstuhl_PM_230.JPGin this picture the current shunt can be seen inline with the RED wire.

author: RalfSchooneveld
author_rank: Contributor
timestamp: December 14, 2016, 11:28:04 am
content: Hey guys, many thanks for the help so far.I have found someone who can make me a prototype for about € 2842,-. Still I want to get into all this, but you guys use terms and equations I simply am not familiar with.But either way, you are giving me stuff to research on and I thank you for the effort.

author: jeroen79
author_rank: Frequent Contributor
timestamp: December 15, 2016, 06:50:17 am
content: A €2800 powerstrip?

author: Dave
author_rank: Super Contributor
timestamp: December 17, 2016, 07:25:05 am
content: A 400€ power strip and 2k€ development cost. Seems rather reasonably priced, TBH.I'm more surprised that the guy is capable of designing the whole thing in a single work week and program it in half that time.

author: Jeroen3
author_rank: Super Contributor
timestamp: December 23, 2016, 01:13:03 pm
content: Maybe the guy already invented flux-capacitors so he can work very time-efficiently.

author: RalfSchooneveld
author_rank: Contributor
timestamp: December 31, 2016, 06:10:20 am
content: This specific model with the multiple LCD's is for me. I am aware of the fact that it would be very expensive to mass produce.In the latter case I might have to make a more economic model like the american Kill-O-watt.Either way, I am wanting to have this made for myself, and later on, or as time goes by, I can think up other versions. I might want to add an option for an sd card slot so as to keep track of energy consumption and all that.I have no money to fund this out of my own pocket, as I am still getting funds to get multiple other things started, for which I already have potential clients (like our record label for instance).I am looking for people I can lend money so as to have this built. Donations would be great, but I am aware of the fact very few people would see the use of this, not knowing the other inventions I am working out.Sometimes in life, you've got to do what you got to do.https://www.gofundme.com/CFP-PrototypeMany thanks for you guys' support. I appreciate it.