Blog Archives

3rd Qtr 2011

(c) 2011 Design/Analysis Consultants, Inc.
Newsletter content may be copied in whole or part if attribution
to DACI and any referenced source is prominently displayed with the copied material

This Issue: NEWS BITE: Mutant Singing Cantaloup Wins Karaoke Contest! / MORE UNINTENDED CONSEQUENCES: Hands-Free Faucets / DESIGN MASTER TIP: AC Rectifier Worst Case Analysis Made Easy / ART MEETS ENGINEERING: The Invisible Man / STATISTICAL DESIGN PITFALLS: Monte Carlo Is Not Worst Case Analysis

NEWS BITE: Mutant Singing Cantaloup Wins Karaoke Contest!

Freaky Robot Mouth Learns to Sing,”
Evan Ackerman, 13 July 2011, IEEE Spectrum

MORE UNINTENDED CONSEQUENCES: Hands-Free Faucets Harbor More Germs Than Standard Faucets

Details here.

DESIGN MASTER TIP: AC Rectifier Circuit Worst Case Analysis Made Easy

In our previous Newsletter we provided a pretty good estimate for the ripple current for the bulk capacitor in an AC rectifier circuit. But what if you have a large volume product and you need a full worst case analysis to ensure high reliability, but one that is not overly pessimistic so that you can minimize cost? Design Master can help you achieve that optimum balance.

As readers are aware, we’ve started to release some DMeXpert “fill in the blank” WCA templates to make the design engineer’s life a bit easier. One of these is our AC Bridge Rectifier Analysis (ACBR1 $19) which allows the designer to determine all of the worst case component stresses within a minute or two. The analysis includes the effects of source impedance Rs (such as transformer secondary winding ohms), which if present can be used to reduce capacitor ripple current requirements, hence reduce capacitor cost.

As those who have studied AC rectifier circuits are aware, this seemingly simple circuit has resisted for decades all of the attempts to generate a single-formula solution, until recently, which we’ve included in ACBR1. Based on Keng Wu’s article, “Analyzing Full-Wave Rectifiers With Capacitor Filters” (1 Jan 2010, Power Electronics Technology), Wu’s formula allows a straightforward circuit solution, greatly reducing computational time. So with ACBR1 you can just fill in the blanks, click Calculate, and let Design Master do the rest.


Engineers who work for the military are sometimes required to design clothing, equipment, or even entire shelters to be “invisible” to various detection means. Chinese artist Liu Bolin has a gift for applying such camouflage in a non-technological way, as seen below. Hint: If you can’t spot Liu, look for his shoes first.

From “The Invisible Man: Dragon Series,” Vurdlak, 28 June 2011,

Some more fascinating photos here and here.

STATISTICAL DESIGN PITFALLS: Monte Carlo Is Not Worst Case Analysis

A lot of folks like to let a simulator crank out “worst case” results, using Monte Carlo statistical methods. But as we’ve explained previously (“Design Master vs Extreme Value, RSS, Monte Carlo, & Simulation,” and “Design Master vs Monte Carlo“), this can be not only time consuming, but risky. For example, Monte Carlo can easily miss small but significant errors (see example below). In addition, if the Monte Carlo runs are improperly implemented (such as including temperature or other dynamic variables) you will likely obtain wildly inaccurate results.

The Design Master Advantage

Instead of statistical sampling, Design Master uses a top-down approach to achieve safer and more cost-effective results, by (a) detecting the extreme limits of performance, and then (b) using a proprietary probability algorithm to estimate how often those results will exceed the specification limits.


Design Master results at 2 samples/variable versus
Monte Carlo at 10,000 samples/variable, for the gain of an 8-variable filter

As can be seen, the Monte Carlo analysis detected a minimum of 8.42 versus the actual minimum of 7.86, a 7% error, and a maximum of 16.0 versus the actual maximum of 18.8, a 15% error.

AC Full Wave Bridge Rectifier DMX Analysis File Released

AC Bridge Rectifier DMX Worst Case Analysis File
ACBR1 $19

(DMX files are available free to Design Master™ Professional Edition users who purchased or upgraded DM not more than one year prior to the DMX file release date.)

This updated and easy-to-use analysis provides all of the key waveforms, voltages, and currents for the AC full wave bridge rectifier circuit, including the effects of source ohms. Output includes average input amps, rms input amps, input watts, Rs watts, capacitor rms amps, average load volts, average load amps, and output watts.

Capacitor Current

DMeXpert™ (DMX) files guide the user with pop-up instructions, component selection lists, standard part values, important formulas, and a variety of other tips that are activated when entering a Formula cell. It’s like having a design/analysis expert at your side.

4th Qtr 2010

(C) 2010 Design/Analysis Consultants, Inc.
Newsletter content may be copied in whole or part if attribution
to DACI and any referenced source is prominently displayed with the copied material

This Issue: NEWS BITE: Reporters Scramble To Adapt To Cameramen Layoffs During Economic Downturn! / DM V8 And DMX Released / REVIEW: The Social Network: Entertaining But Not True / NEWS BULLETS: Unintended Consequences (Reusable Grocery Bags) / RECREATION: Having Fun With Fantasy Football

NEWS BITE: Reporters Scramble To Adapt To Cameramen Layoffs During Economic Downturn!




Teleactor Annamarie Ho. Photo: Bart Nagel
Q&A: Ken Goldberg Discusses Telerobots, Androids, and Heidegger,” by Erico Guizzo, IEEE Spectrum, 1 Oct 2010

DESIGN MASTER: DM V8 with DMeXpert™ (DMX) Released

DMX provides expertly-designed “fill in the blanks” templates for thorough and efficient worst case analysis. Click here for details. If you purchased Design Master on or after October 4 2009, you can obtain an update at no charge; please contact us for download instructions (new install required for V8).

REVIEW: The Social Network: Entertaining But Not True
“Mark Zuckerberg, Facebook’s young and intrepid creator, is portrayed as a geek who starts his path to dot com glory after getting dumped by a girl … If it were true it would be a lot more compelling.  Back in 2005 and 2006, shortly after the film is set, I interviewed Zuckerberg on several occasions, and he wasn’t much like the guy on-screen.  In addition to actually having a girlfriend, a fact left conveniently out of the film, he had a lot of thoughtful things to say about the world he was creating online. ”
The Social Network’s Science Fiction,” by David Kushner, IEEE Spectrum, 7 Oct 2010

The Bozo Award is presented to screenwriter Aaron Sorkin and the movie’s producers for their lack of integrity, as demonstrated by their willingness to damage reputations through false representations of actual events.

NEWS BULLETS: Unintended Consequences Strike Again

“The CALL7 Investigators tested several reusable bags used by 7NEWS colleagues and another from a woman going into a Denver grocery store. Marchetta took the lab results to Dr. Michelle Barron, the infectious disease expert at the University of Colorado Hospital. ‘Wow. Wow. That is pretty impressive,’ said Barron. Barron examines lab results for a living. ‘Oh my goodness! This is definitely the highest count,’ Barron commented while looking at the bacteria count numbers.”
-“Reusable Grocery Bags Breed Bacteria” By Theresa Marchetta, 28 Sep 2010 Denver News

RECREATION: Having Fun with Statistics and Fantasy Football
Design Master™ is used by engineers to help create highly reliable products, but it has been suggested to us that it can be used for some fun, too, such as fantasy football or other games that use statistics. It might even provide a bit of an edge, because its probability models provide more information than simple statistical averages.

For example, you can define a group of players in the Variables Library, enter the raw stats for each player, and let Design Master generate their “player strength” probability models (Tools/Make A Model From Raw Data).

In the worksheet, you create a simple Team formula that defines the strength of the team, using a weighted sum of all the players —

TeamA = 0.2*Player1 + 0.10*Player2 + 0.15*Player3 + …

— where the weights add to 1.0 (100%).

Then press Calculate to generate the team’s probability model.

Repeat this for a competing TeamB and its players, and then compare the team models:



TeamA strength = 5 to 10                                                TeamB strength = 4 to 16

There are many ways to make a  comparison, but a simple way would be just to subtract the teams. For example, to determine the probability of TeamA losing to TeamB,

TeamAWin = TeamA – TeamB

where the minimum limit is set to zero (i.e. the case where TeamA is less strong than TeamB).

Probability models help guard against counter-intuitive bets. In this example, it may appear that TeamB (max strength of 16) is superior to TeamA (max strength of 10). But if you look at average strengths, TeamA comes out on top (8 to 7). How should these factors be evaluated?

Press calculate, and the resultant probability distribution indicates that the “weakling” Team A only has about a 12% chance of losing to TeamB:

Furthermore, knowing the actual probability of 12% provides an added edge for intelligent odds-making … all in fun, of course.

Q&A: Ken Goldberg Discusses Telerobots, Androids, and Heidegger