Przebieg r20261030-0412-v000-zadymiarka-concept-3

Derived and refined requirements (design-to values of concept C1)

These are the engineering requirements the concept imposes on its subsystems so that the customer requirements above can be met. Each traces to its parent ids. Values are design choices (ASSUMPTION) or CALCULATION results from ../02-concept/estimates/concept_estimates.results.json; verification is by the named analysis or prototype test.

ZAD-1000 — Requirements designed to (concept revision C1.1)

Generated by build_requirements.py from INPUT/requirements.md (verbatim ids, metrics, targets, thresholds, priorities and verification methods) plus the concept responses. Values: CALCULATION from 02-concept/estimates/concept_estimates.results.json unless the note says ASSUMPTION; tests are NOT RUN at the concept tier.

Status rule: met = target achieved by the concept evidence · partly = threshold achieved but not the target, or the concept-tier evidence cannot yet prove it (needs CAD, detailed design or test) · not_met = threshold missed · not_addressed = no design response.

Status count: met 30, not_met 3, partly 23 (of 56).

Performance

Size

Weight

Power

Functions

User experience

Safety

Certification and compliance

Cost and price

Manufacturing

Reliability

Service and maintenance

Derived and refined requirements (design-to values of concept C1)

These are the engineering requirements the concept imposes on its subsystems so that the customer requirements above can be met. Each traces to its parent ids. Values are design choices (ASSUMPTION) or CALCULATION results from ../02-concept/estimates/concept_estimates.results.json; verification is by the named analysis or prototype test.

ZAD-1000 — Concept alternatives, decision and rationale

Numbers labelled CALCULATION come from estimates/concept_estimates.py → estimates/concept_estimates.results.json (re-runnable with ddpy concept_estimates.py). Cost figures come from ../09-bom-cost/ (concept-level BOM).

1. The engineering problem in one paragraph

Fog output is fluid vaporised per minute. Vaporising the reference standard fluid (fluid S: 70 % water, 20 % propylene glycol, 10 % triethylene glycol by mass, ASSUMPTION representative of ANSI E1.5 fluids) from 20 °C to 230 °C vapour takes 2.40 kJ/ml (CALCULATION; 2.61 kJ/ml for a water-rich quick fluid, 2.27 kJ/ml for a dense fluid). With the EU rated input capped at 1000 W (ZAD-PWR-02 target), the continuous rate is fixed by an energy balance, not by the pump: (heater − losses − control reserve) / energy per ml. Budget machines spit and pause because they pump faster than this balance allows until a thermostat stops them. The design therefore has to (a) waste as little heat as possible, (b) store just enough heat for a strong burst without slowing warm-up, and (c) let the pump follow the available heat.

2. Requirement tensions found before choosing

3. Morphological chart (options per sub-function; chosen option in bold)

4. Integrated concepts evaluated

• A — Classic thermostat block (budget architecture, improved): 1.0 kg block (1.25 kJ/K), one 1000 W element, bimetal thermostat, pump full strokes with thermostat lock-out, 433 MHz one-way remote, 3-pin DMX non-isolated. Warm-up ≈ 5 min (1.25 kJ/K × 230 K / 0.95 kW, CALCULATION by hand); strong 30 s burst; but output stops for reheating when the block falls below the thermostat band → fails the ZAD-PRF-03 threshold (≤ 10 s). Cheapest.
• B — Low-mass flash evaporator: ~0.25 kJ/K thick-film or brazed evaporator, fast thermocouple loop, DC gear pump with speed control, 2.4 GHz remote. Warm-up ≈ 1 min; continuous rate as C; but only ≈ 17 ml in the first 30 s (0.25 kJ/K × 50 K + 27.9 kJ over 2.40 kJ/ml, CALCULATION by hand) → misses the ZAD-PRF-04 target; very high wall heat flux raises coking risk (ZAD-REL-03); gear pump and new evaporator raise unit and one-off cost; least proven.
• C — Power-matched compact exchanger (chosen): compact die-cast block 0.72 kJ/K with two cast-in 485 W elements and a 1.5 m stainless coil, outlet-zone spit guard, heat-matched AC vibratory pump control with gravimetric trim, independent hardware protective chain, two-way 2.4 GHz remote, isolated DMX/RDM.
• (Screened out early) D — Two-stage preheater + vaporiser: two heated parts, more mass and cost; its main benefit (no spitting) is obtained in C by control.

Weighted decision matrix (score 1 = poor … 5 = excellent; weights from requirement priorities)

Scores are engineering judgement (ASSUMPTION) supported by the calculations above. A is also eliminated by a threshold failure (ZAD-PRF-03). Decision: concept C. It is the only concept that meets every performance target on paper while staying on mature, low-cost hardware (die-cast block, vibratory pump, triacs); its novelty is in control and sensing, which is cheap to iterate in firmware.

5. Sub-decisions and rationale

6. What would change the decision (tripwires for the prototype)

• Measured READY losses > 45 W or e_ml of popular brand fluids > 2.45 kJ/ml → continuous target at risk: first try aerogel insulation, then accept 1050 W rated input (PWR-02 target lost, threshold kept).
• Partial strokes not repeatable below ~0.06 ml or pump noise > 45 dB(A) at the continuous rate → switch to a DC peristaltic or gear pump (cost +EUR 8–20, ASSUMPTION) and drop the US/EU pump variant.
• Load cell drift/vibration error > 0.5 g over 1 min → fall back to a capacitive level electrode + open-loop calibration (ZAD-PRF-06 then likely ≤ 10 % instead of ≤ 5 %).
• Floor-level radio range < 50 m in the hall test → add an external antenna stub on the rear panel or a module with an RF front end.
• Mass reduction to reach ≤ 3.0 kg: 1.0 mm cover (−0.12 kg), lighter pump (−0.1 kg), 0.2 mm can (−0.05 kg), smaller bezel (−0.03 kg) — about −0.3 kg combined (ASSUMPTION).

ZAD-1000 — System architecture (concept revision C1)

Status: concept tier. Nothing here is built, simulated in CAD/FEM/CFD or tested; every number carries a label. Numbers marked CALCULATION come from estimates/concept_estimates.py (results in estimates/concept_estimates.results.json, inputs and their labels in estimates/concept_estimates.inputs.json).

1. What the product is

A compact (295 × 165 × 195 mm bounding box, CALCULATION 9.49 L) mains fog machine for ANSI E1.5 water-based glycol/glycerin fluids. A small, well-insulated die-cast heat exchanger (0.72 kJ/K at 250 °C, CALCULATION) with two 485 W elements reaches READY in 2.75 min (CALCULATION, standard fluid, 230 V) and is never allowed to cool below the fluid's vaporising temperature: the pump rate follows the heat that is actually available, so the output derates smoothly from a 30 s burst (25.6 ml, CALCULATION) to the continuous rate (22.5 ml/min, CALCULATION, fluid S, 230 V) instead of stopping to reheat. Control from the unit (OLED + encoder), from DMX512-A/RDM (isolated, 5-pin and 3-pin) and from an included two-way 2.4 GHz remote that shows each machine's state. Two mains variants (EU 220–240 V, US 120 V) share everything except heater elements, pump, fuse, cord and labels.

2. Block diagram

Rendered diagram: block-diagram.svg (PNG copy block-diagram.png), generated by block_diagram.py. Text form (Mermaid):

flowchart LR
  subgraph MAINS["Mains side (hazardous voltage)"]
    INLET["IEC C14 inlet + switch + fuse<br/>EU T6.3 A / US T10 A"] --> EMI["EMI filter<br/>X2 + CM choke + Y2 1 nF"]
    EMI --> PSU["Certified 5 V AC-DC module<br/>(reinforced, <0.075 W no-load)"]
    EMI --> MET["Mains metering IC<br/>V_rms, I, zero-cross"]
    EMI --> K1["Safety relay K1 16 A, 2-pole<br/>(held by protective circuit)"]
    K1 --> TCO["Thermal cut-outs TCO-A/B ~300 °C<br/>both leads, non-self-resetting"]
    TCO --> Q1["Triac Q1 zero-cross"] --> H1["Element H1 485 W"]
    TCO --> Q2["Triac Q2 zero-cross"] --> H2["Element H2 485 W"]
    TCO --> Q3["Triac Q3 + diode<br/>phase-controlled"] --> PUMP["Vibratory pump<br/>EU 230 V 50 Hz / US 120 V 60 Hz"]
  end
  subgraph SELV["SELV side (reinforced insulation from mains)"]
    MCU["MCU STM32G0<br/>control, DMX/RDM, UI, logs"]
    SAFE["Protective circuit, no software<br/>OT/open/short on S1+S2, watchdog,<br/>pump limiter, cold interlock -> K1"]
    S1["PT1000 S1 outlet zone"] --> MCU
    S2["PT1000 S2 heater zone"] --> SAFE
    S2 --> MCU
    LC["Load cell under tank<br/>24-bit ADC"] --> MCU
    ACC["3-axis accelerometer"] --> MCU
    DMX["Isolated RS-485<br/>5-pin + 3-pin XLR in/thru"] <--> MCU
    RF["nRF52833 module 2.4 GHz<br/>Coded PHY, AES-CCM"] <--> MCU
    UI["1.3in OLED + encoder + FOG/MENU<br/>RGB status light, lit tank"] <--> MCU
    USB["USB-C service port<br/>DFU + log export"] <--> MCU
  end
  PSU --> SELV
  MET -. "2 x reinforced optocoupler" .-> MCU
  MCU -. "opto-triac drivers" .-> Q1 & Q2 & Q3
  SAFE -. "relay coil" .-> K1
  MCU -. "watchdog toggle" .-> SAFE
  subgraph FLUID["Fluid path"]
    TANK["Tank 1.40 L PP, usable 1.25 L<br/>wide cap + EPDM seal + PTFE vent"] --> FILT["Weighted pick-up<br/>100 µm inlet filter"] --> PUMP
    PUMP --> CV["Check valve 0.3 bar, PS 160 bar<br/>+ relief valve to tank"] --> COIL["Cast-in stainless coil 1.5 m<br/>in Al block 0.55 kg"] --> NOZ["Nozzle Ø3.5 mm<br/>+ stainless guard"]
  end
  REMOTE["Remote: nRF52833, 2 x AAA<br/>select 1-4 / ALL, status LEDs"] <-. "2.4 GHz two-way" .-> RF
  DESK["Lighting desk / DMX"] <--> DMX

3. Physical layout (concept)

 SIDE VIEW (section)                                         REAR PANEL (165 x 170 mm)
 front                                          rear        +-------------------------------+
  ___________________________________________________       | [OLED]  (enc)  [FOG] [MENU]   |
 |guard|  EXCHANGER MODULE   | heat  |  handle/cap  ==|      |                               |
 | ((o))  140x100x80 can     | shield|   TANK 1.40 L  |     | (5-pin IN) (5-pin THRU)       |
 |nozzle  Al block+coil      |       |   PP, lit level|     | (3-pin IN) (3-pin THRU)       |
 |_____|_____________________|_______|   on LOAD CELL |     |                               |
 |  vents   PUMP on silicone   MAIN PCB (SELV + mains |     | [IEC C14+switch+fuse]  [USB-C]|
 |__________mounts_____________zones, heat-shielded)__|     +-------------------------------+
   foot                                          foot

• Hot zone (front-top): insulated exchanger module (AES-wool blanket 20 mm in a 0.3 mm stainless can) on four steatite stand-offs; replaceable stainless nozzle insert (Ø3.5 mm, screwed into the block outlet with a graphite seal, ZAD-SRV-01) behind a perforated stainless guard; no part hotter than 70 °C reachable with IEC 61032 probe B (design intent, ZAD-SAF-03, to be checked in CAD).
• Cool zone (bottom, rear): main PCB on the floor plate under a heat shield with a 10 mm air gap; pump on silicone grommets on its own bracket; tank on a single-point load cell at the rear; all fluid connections are below or beside the module, never above live parts; a drip channel in the floor leads any leak to a drain hole away from the PCB.
• Rear: all connectors and the UI (operators reach the rear of a floor machine; on truss the display faces the rigger). Handle at the top rear, ≥ 200 mm from the outlet (requirement ≥ 150 mm). Tank cap on top at the rear.
• Natural convection only: bottom inlet louvres, rear/top outlet louvres; no fan (ZAD-UX-02).

4. Fluid path and anti-spit design

Wetted materials: PP/HDPE tank, EPDM cap seal, silicone (VMQ) hoses, PTFE vent membrane and pump seals, AISI 304/316 check valve and coil, pump body per the pump datasheet (brass/PA class, ASSUMPTION until datasheet check). All are generally rated for glycols/glycerol (to be confirmed with the fluid makers' compatibility tables).

5. Heat exchanger and protective chain

• Block: die-cast AlSi (EN AC-46000/ADC12 class) 0.55 kg with cast-in AISI 304 coil 5.0 × 0.6 mm × 1.5 m and two cast-in tubular elements (EU 2 × 109 Ω hot, US 2 × 29.7 Ω hot, CALCULATION from 485 W each). Heat capacity 0.66 kJ/K at 20 °C, 0.72 kJ/K at 250 °C (CALCULATION). Losses at READY 40 W design value (31 W model × 1.3 margin, CALCULATION).
• TCO selection constraint (open issue raised by the reliability review): a thermal link must not age or trip while the block sits at up to 265–290 °C for thousands of hours, i.e. its holding temperature must exceed ~295 °C. If no qualified link with that holding temperature is available, use a manual-reset capillary safety limiter (oven/fryer class) on the block, or mount the link on a calibrated thermal bridge that sees a known fraction of the block temperature (ASSUMPTION; decided in detailed design with the supplier's data).
• Sensors: S1 PT1000 in the outlet zone (control and spit guard), S2 PT1000 near the elements (independent safety comparator and plausibility). Two separate bores, separate wiring.
• Protective chain, independent of the main firmware: (1) window comparators on S1 and S2 (over-temperature 300 °C, sensor open or short; rev C1.1) and (2) an external window watchdog that needs a periodic MCU toggle both hold K1; either one drops K1 and latches until the mains switch is cycled; (3) non-self-resetting TCOs (≈ 300–310 °C) on the block in both supply leads as the final protection (rev C1.1). The main firmware also limits at 280 °C and opens K1 on plausibility faults (S1 vs S2 > 40 K, current when triacs are off, element current missing), but no protective function relies on it, so EN 60335-1 Annex R software class B is not claimed for the main firmware (the protective electronic circuit is tested under clause 19.11, see safety-concept.md).
• Heater switching: whole-cycle burst firing, the two elements are never switched in the same second; ≤ 1 switching event per element per second. Flicker Pst ≈ 0.48 for one-element steps vs 0.95 if both switched together (CALCULATION, EN 61000-3-3 analytical method, reference impedance) — hence the staggering rule.

6. Control strategy (ZAD-PRF-02/03/04/06/07, ZAD-SAF-07)

1. Temperature loop on S1: PI with feed-forward of the fluid heat demand (Q × e_ml, e_ml = 2.40 kJ/ml for fluid S, CALCULATION) and of the measured mains voltage (heater power ∝ V²).
2. Heat-matched pump loop: Q_pump = min(Q_user, Q_avail) with Q_avail = Q_cont(V_rms, fluid) + Kp·(T_S1 − T_guard) + Ki·∫(T_S1 − T_guard), T_guard = T_min + 10 K. From READY the stored heat lets Q_avail exceed Q_cont (burst, up to the 60 ml/min ceiling); as the block droops toward T_guard the output slides down continuously to Q_cont — there is no step to zero in normal operation, so the 30-min 100 % run has no interruption (design intent ZAD-PRF-03 target 0 s). Below T_min the pump stops (would count as a gap; only reachable with a fault or an out-of-range supply, and it is logged).
3. Metering: a stroke scheduler turns Q_pump into mains-synchronous half-wave strokes: full strokes (0.167 ml, ASSUMPTION from the pump curve) above ~10 ml/min; partial strokes (late phase angle, ~0.04 ml, ASSUMPTION) below, giving a stroke every 1.2 s at 2 ml/min (CALCULATION). Stroke volume is corrected for V_rms by a calibration table and trimmed by the gravimetric loop.
4. Gravimetric loop: tank mass from the load cell (tilt-corrected with the accelerometer) gives the true 1-minute flow (CALCULATION: ±1.6 % at 22 ml/min, ±3.5 % at 10 ml/min, ±17 % at 2 ml/min over 1 min, so below ~8 ml/min the trim uses 5-minute windows), the fluid level, refill detection, the low-fluid stop and blocked-outlet detection (pump running, no mass loss for 20 s → pump stop, code E11; fault-code table in reliability-service-production.md §7.1).
5. Loss of control: DMX loss detected after 1.0 s without a valid packet → pump stopped ≤ 1.3 s after the last valid packet (unless the user selected HOLD); remote momentary fog is hold-to-run (frames every 100 ms; 3 missed frames → stop); remote continuous mode auto-off (default 10 min, 1–60 min); no pumping unless READY; tilt > 45° → pump and heater off.

7. Firmware state machine

8. Control interfaces

• DMX512-A (ANSI E1.11): isolated RS-485 (digital isolator + transceiver + low-power isolated supply), 5-pin XLR IN/THRU (standard) and 3-pin XLR IN/THRU (DJ market), passive thru that stays connected unpowered, no internal termination (user terminates the line). Personalities: 1-ch (output 0–100 %) and 2-ch (ch1 output; ch2 mode: 0–49 direct, 50–99 on-unit timer with ch1 level, 100–149 continuous-only (no burst, steadiest output for video), 150–199 burst allowed, 200–255 reserved). Start address on the OLED; no DIP switches.
• RDM (ANSI E1.20) responder: DEVICE_INFO, DMX_START_ADDRESS, DMX_PERSONALITY(_DESCRIPTION), IDENTIFY_DEVICE (status light flashes), SENSOR_DEFINITION/SENSOR_VALUE (S1, S2, fluid %, mains V), STATUS_MESSAGES (heating, ready, low fluid, faults), DEVICE_HOURS, DEVICE_LABEL, SOFTWARE_VERSION_LABEL, SUPPORTED_PARAMETERS, RESET_DEVICE, plus manufacturer PIDs for fog hours, fluid type and fault log.
• Radio: nRF52833 pre-certified modules both ends; proprietary frames on the BLE Long-Range (Coded PHY 125 kbps) modulation, 3 channels with frequency agility, AES-CCM-128 with 32-bit frame counter (replay protection), unique 32-bit IDs; pairing by holding MENU+FOG on the machine (30 s window, key exchange at −20 dBm within ~1 m). Remote keys: FOG (hold), CONT on/off, LEVEL +/−, TIMER start/stop, machine select 1–4 and ALL; one bicolour LED per machine (amber pulsing = heating, green = ready, amber blinking = low fluid, red = fault) refreshed from the ACK payload. Link budget: 219 m free space, 160 m two-ray with the machine on a 3 m truss, 46 m two-ray with the machine on the floor (antenna 0.25 m), all with a 15 dB fade margin (CALCULATION). No internet connection, no app, no account.
• On-unit UI: 1.3" 128×64 OLED, encoder with push, FOG (manual) and MENU keys; shows warm-up %, READY, output %, DMX address/personality, timer, fluid type and level, fault codes; settings in MCU flash (survive power-off); front RGB status light visible from > 5 m; backlit translucent tank level window visible from 3 m.
• Service: USB-C (SELV) for DFU firmware update and export of the operating-hours and fault log.

9. Mains variants (ZAD-PWR-01)

Rated input 980 W (declared; calculated 979 W = 970 W heater + 5.8 W pump at the burst ceiling + 3.3 W electronics); 4.26 A at 230 V and 8.17 A at 120 V (CALCULATION), below the 12 A US continuous limit of ZAD-PWR-02.

11. Revision C1.1 — safety-driven changes adopted by the manager

The safety review (safety-concept.md §13, SR-01…SR-15) found gaps in the C1 power and fluid path. The manager adopts them; they supersede the C1 text above where they differ (the block diagram already shows them):

Cost impact of SR-01…SR-06 (2-pole relay, second TCO, pressure-rated check valve, relief valve, extra comparator channels): about +EUR 3–5 per unit at 1,000 (ASSUMPTION); see the cost notes in ../09-bom-cost/cost.md and §7 of ../REPORT.md.

10. External interfaces summary

Concept estimates - generated by concept_estimates.py (do not edit by hand)

All results are CALCULATION from the inputs below. Inputs carry their own label.

Results

Inputs

ZAD-1000 — Key estimates (concept revision C1)

All values below are CALCULATION results of estimates/concept_estimates.py (run ddpy concept_estimates.py in estimates/; offline, ~5 s). Results: estimates/concept_estimates.results.json; every input with its label (SOURCE or ASSUMPTION) and basis: estimates/concept_estimates.inputs.json; full table: estimates/concept_estimates.table.md. These are first-order engineering estimates, not simulations or measurements.

1. Energy needed per ml of fluid (basis of every output claim)

Enthalpy from 20 °C liquid to vapour at the exchanger exit (setpoint − 20 K), water from CoolProp, glycols from thermo correlations (heat liquid to 100 °C, vaporise at 100 °C, heat vapour), ideal volume mixing +1 % density correction.

Sensitivity (fluid S): vapour exit at 150 °C → 2.24 kJ/ml; at 250 °C → 2.44 kJ/ml. Water dominates: the more water, the more energy per ml, so quick-dissipating fluids give the lowest continuous rate.

2. Heater, rating and mains (ZAD-PWR-01/02)

3. Exchanger thermal model

4. Performance (fluid S unless stated)