EE595 Spring 2007 Group III Project Proposal

Team III: Staff Don Murray Brett Sheleski Ike Butler Mike Baerenwald EE Major CS Minor Ike Butler Brett Sheleski EE Major CS Major Mike Baerenwald

Team III: Expertise & Experience Don Murray Expertise: Embedded Systems Motor Control Experience: ROV Team Electronics Design Microcontroller Programming Ike Butler Analog Systems Linear/Digital Sensors Johnson Controls McNair Scholar Brett Sheleski Expertise: Software development Experience: CAD Drafting IT Intern Mike Baerenwald Power Systems Stora Enso Paper Mill Kohler Co. Co-op

Team III: Contact Info Phone: (414) 305 - 4784 Email: brettjs2@uwm.edu Phone: (920) 213 - 0725 Email: baerenw2@uwm.edu Phone: (262) 689 - 5029 Email: dtmurray@uwm.edu Phone: (414) 248 - 5160 Email: ilbutler@uwm.edu Brett Sheleski Mike Baerenwald Don Murray Ike Butler

Team III: Weekly Availability Worksheet Time 1: MW after 5:00 Time 2: Time 3: R 8:30 – 10:00 Time 4: Time 1: MW before 3:00 Time 2: Time 3: R 8:30 – 10:00 Time 4: Time 1: MW before 3:00 Time 2: TR 11:00-5:30 Time 3: Time 4: Time 1: FSa before 6:00 Time 2: Brett Sheleski Mike Baerenwald Don Murray Ike Butler

Team III: Weekly Project Meeting Plan Weekly Meeting 1: E225, Thursday 2/1/07 8:30-9:00 PM This meeting was to discuss options for the design project. All members were present. Weekly Meeting 2: E225, Monday 2/5/07 9:00 PM This meeting discuss P1. Mike & Don were present, Brett was ill, and Ike was a no show. Note: Meeting Owners Send Weekly Email Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

Team III: Total Resources 10 Man-hours per week, per person $100+ per person for material (if needed) Design and build a solar power supply that adjusts the direction of the solar panels towards the brightest light source to maximize the amount of power generated.

Team III: Decision Making Decisions by consensus If no consensus, consult TA or instructor.

Roles to Define & Assign Lead Project Integrator (LPI): Don Murray (01/23/07 – Present) Owns the MS Excel Project Plan documents Tracks and reports progress to project plan Owns weekly progress reports to TA Owns Logistics and communication of ALL team meetings Keeps Team Attendance at all meetings Owns the Block Diagram Assignments and oversees Design Partitioning Integrates Block design plans Tracks expenditures to budget Helps LMM procure prototype components Keeps a secondary backup of ALL major project deliverable files Identifies contingencies for problems incl team members MIA

Roles to Define & Assign Lead System Designer (LSD): Brett Sheleski (01/23/2007 – Present) Owns the overall product requirements and data sheet Owns the MS Excel Product Requirements document including negotiating and documenting the flowdown of requirements to design block level Owns the Block Diagram Implementation and Design Partitioning Reviews for Completeness ALL Block-Block Interface Requirements Helps integrate and populate Detailed Block design plans including DFM Has primary responsibility for the Safety & Compliance Features in the product Owns project level verification and validation plan Owns capture and documentation of all verification results Owns the MS Word Product User Manual document

Roles to Define & Assign Lead Presentation Manager (LPM): All (01/23/07 – Present) Owns the master MS PPT Presentation slide set for team Keeps backup copy of master slide set and integrates weekly progress submissions from ALL team members Defines and sets ALL slide formats in template form including Logos Font sizes & font styles, Colors Header/footers Slide backgrounds Rev controls Responsible for good visibility of slide presentation Integrates pictures incl schematics, digital photos, animations and other non-PPT file types Checks presentation content against master checklist and communicates gaps Responsible for time allocations and controls during final presentation Submits CD and paper copies for all Preliminary Presentations P1-P4 and Final Presentation

Roles to Define & Assign Lead Report Manager (LPM): Ike Butler (01/23/2007 – Present) Owns the master MS Word Project Report file for team Keeps backup copy of master report and integrates weekly progress submissions from ALL team members Defines within guidelines, report flow including chapter numbering, subchapter numbering, sub-sub chapter numbering, etc. Defines and sets ALL report formats in template form including Logos Font sizes & font styles Colors Header/footers and chaptering Rev controls Responsible for good visibility and proper spelling in report Responsible for integrating data sheets as needed Integrates pictures incl schematics, digital photos, block diagrams and other non-WORD file types Checks report content against master checklist and communicates gaps Submits final file on CD and printed paper copy of Final Project Report

Roles to Define & Assign Lead Manufacturing Mgr (LMM): Mike Baerenwald (01/23/2007 – Present) Owns and documents the product overall assembly and test levels Owns master prototype & product parts lists including integration of design block parts lists Owns procurement of prototype components including identification of long lead components Defines the product and prototyping technologies Owns any required assembly drawings Owns the overall prototype mechanical and electrical assembly Owns the overall PCB layout strategy including Block to PCB mapping, PCB tools, PCB design drawings, and PCB procurement Owns the PCB assembly including any special tools, soldering, wire-wrapping, drilling, and glueing.

Random Number Generator Take readings from various sensors producing a random number Produces random number with testing from Chi Square algorithm. USB/Serial connector getting power either independently or from data cable. Heavy computer science background among group as well as common interest

ROV Sensor Package Distance sensor for ROV-Team’s underwater robot to determine surroundings. Use ROV’s power source (car battery) for powering the device. Don is a member of the ROV team and the project is interesting and challenging.

Traffic Controller A wireless traffic controller to replace manually operated stop signs on UWM campus

Solar Sun Follower Solar panels that automatically adjust so they are always facing the brightest light source so they generate the maximum amount of power possible.

Standard Requirements-Market Estimated Market Size: $100,000,000 Estimated Annual Volume: $1,000,000 Minimum List Price: $50 Max Product Material Cost: $20 Max Product Manufacturing Cost: $10 Estimated Annual Contribution: $600,000

Market Cont. Market Geography: Worldwide Market Demography: Robotics Hobbyists Market Competitors: Power supply manufacturers Market Industry: For Residential Use

Power Energy Sources: 9 Solar Panels 1 Battery

Mechanical 2 Servo Motors Enclosure

Environmental Temperature Range: -40°C to +120°C Humidity Range: 0% to 80% Altitude Range: Unlimited

Safety Primary Safety Standards: “Intelligent” Battery Charger Primary EMC Standards: TBD

Manufacturing Maximum total parts count: 100 Maximum unique parts count: 20 Maximum Parts & Material Cost: $20 Maximum Mfg Assembly/Test Cost: $10

Life Cycle Estimated Max Production Lifetime: 20 yrs Service Strategy: In Home Product Life, Reliability in MTBF: TBD Full Warranty Period: 1 Year Product Disposal: Recyclable

Performance Requirements- User Inputs Enable / Disable solar power Enable / Disable battery Select manual motor control Manual motor controls Display selection

User Indicators & Displays Battery charge meter Status LEDs Voltage meter Current meter

Operation Modes Automatic Manual Automatically tracks light source for maximum power generation Solar panel array is positioned automatically Manual Solar panel array is positioned manually

Safety Battery must not be overcharged Clear safety notifications must be present to prevent use of incorrect batteries

Basic Business Case for the Solar Sun Follower (Inputs) Estimated Average Product Selling Price (ASP$): $50 Estimated Annual Product Sales Volume in Units: 20000 Estimated Per Unit Cost of All Parts & Materials: $20 Estimated Per Unit Cost of All Assembly, Test, and Mfg: $10 Estimated Total Development Cost including Labor and Material: Engineering hours @ $150.00 per hour: 600 Material: $400 Total: $90400

Basic Business Case for the Solar Sun Follower (Outputs) Annual Sales Revenue $ = ASP$ * Annual Volume: $1,000,000 Annual Var Costs $ = (Unit Material $ + Mfg $) * Annual Volume: $400,000 Per Unit CM$ = ASP$ – (Unit Material $ + Mfg $): $30 CM% = Per Unit CM$/ASP$: 60% Annual CM$ = Unit CM $ * Volume = Annual Sales $ - Annual Var Costs $: $600000 ROI (Return on Investment) Time in Years = Est Dev Cost $/Annual CM$: 0.15

Overall Block Diagram

Block Diagram Description Block Name Owner Brief Description Of Block Function Power Interfaces Digital Analog 1 Power Distribution Don Receives power from battery and solar panels and delivers to additional blocks. In: TBD Out: XX VDC None Out: Vbat 2 Solar Panels Mike Nine solar panels that supply power to the power distribution block as well as supplies analog signal to the Solar Logic block. Out: TBD Out: VS1-5 3 User Interface Brett Give user voltage and current readings as well as provide manual override of motors. In: TBD Out: Motor control signal (x2) Out: Power Switches, Voltage/Current readings. 4 Solar Logic Read Voltage readings from 5 panels and convert to digital signal. Out: Binary values of voltage (x5) In: Voltage readings (x5) 5 Motor Control Ike Compare digital signal from the Solar Logic to adjust motors accordingly. Out: Motor Control Signal (x2) In: Off-setting for manual override 6 Motors Motors for adjusting solar panels (x2) In: Motor Control Signal (x2) 7

Three Related Patents Patent number 5169456 Two Axis Tracking Solar Collector Mechanism January 1, 2001 Patent number 5600124 Sun Tracker System for a Solar Assembly February 4, 1997 Patent number 5632823 Solar Tracking System May 27, 1997

Ethical and Societal Issues Charging of the battery presents the greatest potential danger to the user, as overcharging a battery can cause an explosion The battery must be properly chosen for this application, and the type required must be communicated clearly to the end user of the product Any other failures of the product would present a nuisance to the end user, but no specific danger. This product is not intended for use in devices where an exceptionally high level of reliability is required, such as medical devices or industrial controls. This must be communicated to the end user