TEAM 2 Remote Control Car

Team #2: Total Resources LPI-Sean Murphy (BSEE) LSD-Russ Diamond (BSEE) LPM-Adam Wozniak (BSEE) LRM-Brad LaCount (BSEE) LMM-Barry Gentz (BSEE)

Project Features The remote control car has a two-way antenna that can transmit to and receive data from the car. Control of the car will come from the controller. The car can turn its lights on and off manually, and automatically if it gets dark enough. The display will tell us the speed and direction of the car, and the battery life remaining.

Estimation Slide As of 3rd Week Manhours-500 Material $500 ~2% for design ~86% for detailed design ~2% for verification ~10% for documentation End of Project Manhours-1702 Material $1031 These values may be off due to overlapping of projects.

Competitor’s Slide Competitors Market Size Average List Price Requirement Units to Specify Traxxus, Tra5510 $600 million, website $200 World-Wide 6 yr. old to adult, boys Home, toy $80 / unit $20 / unit 6 million / yr Included Competitors Market Size Average List Price Market Geography Market Demography Intended Application Material Cost Manufacturing Cost Annual Volume User Manual

System - Std Reqs: Mfg & Life Cycle Requirement Units to Specify 200 Total Parts 100 Unique Parts $80 (Parts+Mfg=Product Cost) $20 (Parts+Mfg=Product Cost) 3 yrs 6 months Repair Max Parts Count Max Unique Parts Count Parts/Mat $ Allocation Asm/Test $ Allocation Product Life, Reliability Full Warranty Period Service Strategy

System - Std Reqs: Production Requirement Units to Specify Max Volume Shipping Container Size Max Mass Max # of PC Bds Max PCB Circuit Area Max Shock 12,000 cm3 18,000 cm3 2 Kilograms 5 500 cm2 Total 50 G force

System - Std Reqs: Power Interfaces Requirement Units to Specify Min Oper Voltage Range Max Power Consumption Max Energy Consumption Car Battery Chemistry Car Battery Capacity Controller Battery Pack Controller Display Segments Controller Accuracy Modes of Operation 5-9.0 V and 5-15.0 V 18.0 Watts Total 6000 mAH Total Nimh 6000 mA-Hrs i.e. AA 1.5V 10 bars 15% battery life On/Off

System - Std Reqs: Enviroment Requirement Units to Specify Min Oper Temp Range Min Oper Humidity Range Min Oper Altitude Min Storage Temp Range Min Storage Humidity Range Min Storage Altitude Max Storage Duration 10-45 Co 10-90% non-condensing 0-3000 Meters 0-80Co 10-90% non-condensing -200-3500 Meters 1 year

System – Perf Reqs: Display LCD Display: Display size: Max. Display Distance: Viewing Environment: Display Char Matrix: Display Size: Display Illumination: Mono Color 150mm x 70mm 1 meter Any 20 Total Char/Row, 4 Total Rows 20cm x 10cm LED

System – Perf Reqs ON/OFF/AUTO Lights None Power Saving Modes ± 3 mph Requirement Definition ON/OFF/AUTO None ± 3 mph 200 ms 0-40 mph 8 Directional Units 0-5V logic levels .005 s 300 ft Lights Power Saving Modes Speed Accuracy Microprocessor Updates Speed Range Controller Accuracy Response Time Input/Output Max. Delay Min EM Transmission Distance

System – Perf Reqs: Safety Standards We will be using the standards UL 2202 1.5, UL2111 1.5, UL 1977, Cispr 61000-6-3, EMC 61000-4-2, EMC 61000-4-4, and EMC 61000-4-5 in order to make sure that our product is safe. These standards insure that there is no risk to the user from the product and vice versa. The EMC standards protect our product from ESD and power surges.

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Designed by: Barry Gentz Signal Input Designed by: Barry Gentz

Block 1: Signal Input Theory Of Operation: Signal input takes in the users desires for the speed, direction and light position and implements them to the car’s motion, direction or state.

Block 1 - Std Reqs: Environmental Requirement Units to Specify Min Oper Temp Range 10-45 Co Min Oper Humidity Range 10-90% non-condensing Min Oper Alt or Press Range 0-3000 Meters Min Storage Temp Range 0-80Co Min Storage Humidity Range 10-90% non-condensing Min Storage Alt Range 0-3000 Meters

Block 1 - Std Reqs: Safety Requirement Units to Specify Max Storage Duration 1 year Safety Standards 61000-4-2 61000-4-4

Block 1 - Std Reqs: Power Interfaces Requirement Units to Specify Source Connection List Permanent Operating Voltage Range 4.9-5.1 V Max Power Consumption 3.0 Watts Max Energy Consumption 100 mAH Max Potential 0V

Block 1 - Std Reqs: Mechanical Requirement Units to Specify Max # of PC Bds 1 Max PCB Circuit Area 100 cm2 Total Max Volume 200 cm3 Total Max Weight .5 lbs Max Shock 50 G force

Block 1 - Std Reqs: Manufacturing Costs Requirement Units to Specify Parts/Mat $ Allocation $25 Asm/Test $ Allocation $50

Block 1 - Std Reqs: Parts Count & Reliability Requirement Units to Specify Max Parts Count 30 Total Parts Max Unique Parts Count 10 Unique Parts Product Life, Reliability 3 yrs Full Warranty Period 6 months Product Disposition Dispose Service Strategy Dispose or Repair

Block 1 – Perf Reqs: I/O Requirements-Modes Requirement Definition Max Error Voltage .25V Operational Modes - Fast/Slow/Stopped - Left/Right/Straight - On/Off/Auto

Block 1 – Perf Reqs: Signal Interface Req’s Response time < 250ms Digital Signals Vol max Voh min Iol Ioh Min .4 2.4 8mA -.4mA Analog Signals Noise must be -40dB at 10 Hz Power input = Vref [DC (AA batteries)]

Block 1 – Perf Reqs: User Interfaces Requirement Type Speed Control Vertical Pot wheel Direction Control Vertical Pot trigger Light Switch 3 position switch

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Block 1- Detailed Design: Sub-Block Design Analysis Plan Steering1 5K Pot ESD LP Filter Speed1 Processor 5K Pot ESD LP Filter Lights Switch ESD De-Bounce S.T. Digital Signal Analog Signal Power Signal Power

Block 1- Detailed Design: Signal Type Digital Analog

Block 1- Detailed Design: Speed & Direction

Block 1- Detailed Design: Filter Calculations Transfer Function: 2nd order filter is need to increase the steepness of curve.

Block 1- Detailed Design: Filter Calculations Transfer Function: Since R1=R2=130k and C1=C2=1.5uF (1/R2C2)/[s2 + s(3/RC) + (1/R2C2)] fc = .816 Hz

Block 1- Detailed Design: Light Switch Switch logic Debounce Calculations: TDB = RC = 20000*10^(-6) = 20ms

Block 1- Detailed Design: Schmitt Trigger 74HS14 Vutp = 2.85V Vltp = 1.85V VHYST max = 1.5V VHYST min = 1.0V

Block 1- Detailed Design: DFM-Worst Case Analysis Plan

Block 1- Detailed Design: DFM-Power Dissipation Analysis Passive Discrete Specifications Nominal Value or Max Value Adjustment Range, %/Turn Tolerance Around Nominal Derated Power Capacity Maximum Working Voltage Composition Dielectric or Form Package Component Resistor 130KΩ   5% 1/8W 250V Thick Film 0805 20KΩ Fixed Capacitor .1uF 10% 10V Tin/Nickel Axial 1uF Ceramic 1.5uF Potentiometer 5kΩ 0.5 20% 1W 6mm Rnd Key: Not Applicable

Block 1- Detailed Design: DFM-Capacitor Specs Rated to 10V 10% tolerance in Capacitance rating Axial packaging

Block 1- Detailed Design: DFM-Packaging Selections The switch is mounted on the PCB. The pot’s are aux mounted on the controller. All other parts are SMT.

Block 1- Detailed Design: Safety Features Provided Shock Protection ESD > 15 kV Over Voltage Protection Diode > 20 kVR Safety Standards 61000-4-2 61000-4-4

Block 1 – Mfg Design: BOM

Block 1- Detailed Design: Light Switch

Block 1- Detailed Design: Reference Voltage Bandgap Vref

DC Drive Device Parameters Block 1- Detailed Design: DFM-DC Drive Analysis Table Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh Min Checked S.T. Std TTL 1.2 3.5 -.4m 20u .5V 2.7 8mA -.4mA Switch na .4V 2.4 Vxx in Volts, Ixx in mA Source Currents Listed as Negative Std = Standard

Block 1 – Mfg Design: PCB Layout

Block 1 – Mfg Design: Flow Chart/Assembly Order/Receive Parts Initial Assembly Testing Final Assembly Final Testing Ship to Customers/Stores

Block 1 – Mfg Design: Testing Functional tests are needed after initial assembly which include : Checking outputs of block to look for desired voltage levels. Make sure all Functions work before final assembly

Block 1 – Reliability Analysis: Summary Table

Block 1 – Reliability Analysis: Unreliability Worst parts: (According to Calculated FITS) Resistors at 72.8 Potentiometers at 50 OP-Amp’s at 38

Block 1 – Obsolescence Analysis: Summary Worst part

Block 1 – Legal/Societal/Ethical Aspects: Summary Entire Block is ROHS compliant. Block includes no Hazardous materials. Due to automated placement of parts, block can be assembled anywhere. Most common failure i.e. pot breaking, will result if abused.

Controller Power Supply Designed by: Brad LaCount

Controller Power Supply Description Converts a 9V DC input into a regulated 5V DC output. Distribute the output to the display, CPU, Rec/Tran circuit, and input signals.

Controller Power Supply Std Reqs: Life Cycle Requirement Units to Specify Product Life, Reliability Full Warranty Period Service Strategy 3 yrs 6 months Repair

Controller Power Supply Std Reqs: Parts Allocation Percent of Total 5% 1% 15% 2% Allocation Component Count Component Cost Mfg Cost PCB Area Volume Mass Amount 10 $4 $1 50 cm2 72 cm3 50 g

Controller Power Supply Std Reqs: Operation Requirement Units to Specify Min Oper Temp Range Min Oper Humidity Range Min Oper Alt or Press Range Min Storage Temp Range Min Storage Humidity Range Min Storage Alt or Press Range Max Storage Duration Standards 10-45 Co 10-90% non-condensing 0-3000 Meters 0-80Co 10-90% non-condensing 1 year UL 1977

Controller Power Supply Std Reqs: Voltage and Current Requirement Units to Specify Max Input Voltage Min Input Voltage Max Input Current Max Output Voltage Min Output Voltage Max Output Current 9.0 V 6.0 V 1000 mA 5.05 V 4.95 V

Controller Power Supply Perf Reqs: Block Safety Features: Reverse Voltage Protection Reverse Battery Protection Contain Two Operational Modes: On/Off Power Input Type: Six AA Batteries (1.5V) Power Input Minimum Life: 4 Hours

Controller Power Supply Perf Reqs: Power Signals

Controller Power Supply Perf Reqs: Mechanical All but one power supply connection will be contained on the controller circuit board. The power connection to the display will be made using a 6 pin board to wire connector. It will contain the power and control lines.

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Controller Power Supply Design: Bill Of Materials

Controller Power Supply Design: Block Diagram

Controller Power Supply Design: Passive Components

Controller Power Supply Design: DFM Plan Sub Circuit Type Applicable Worst Case Analysis Plan Task 1 Task 2 Task 3 5VDC Regulator Power Dissipation Junction Temperature Battery Life

Controller Power Supply Design: Calculations Worst Case Power Dissipation of Regulator: Input Voltage(Vin) = 8.3V Output Voltage(Vout) = 5V Input Current(Iin) = 1000mA Ground Pin Current(IAD) = 10mA Power Dissipated(PD) = (Vin – Vout)(Iin) + Vin (IG) = 4.2W

Controller Power Supply Design: Calculations Junction Temperature Junction Temperature With Heat sink

Controller Power Supply Design: Calculations Battery Life Calculations: Using a standard 2500mAh battery we obtain the following results for battery life: BLOCK TYPICAL MAX Light Switch 500uA 800uA CPU 2.5A 4.0mA User Input Display 6.0mA 525mA TOTAL 9.5mA 530.6ma CURRENT DRAW PER BLOCK

Controller Power Supply Block Reliability Analysis

Controller Power Supply Manufacturing Process Trace: Width = 5mils Spacing = .1 mm

Controller Power Supply Manual Manufacturing Processes Manual Attachment: Place heat sink on regulator and secure with a screw. Attach the circuit board to the controller housing Create a 5 inch wire harness. Six wires – Female connector on both ends Attach one to J1 on the controller’s main circuit board and the other end to the display

Controller Power Supply Manufacturing Test Process Test 1 Battery Power Verification: Action 2: Apply 9V to the power supply input Verify: Output voltage 4.95-5.05 VDC

Controller Power Supply Block Obsolescence Analysis QTY Part Sigma V V+2.5(Theta)-P V+3.5(Theta)-P   SIGMA 1 Fixed Regulator 2004 6.5 3010.6 5014.6 2 Tantalum Capacitor 1985 10 2966.6 4951.6 Diode 1975 12.5 2944.1 4919.1

Controller Processor and Display Designed by: Brad LaCount

Controller CPU and Display Description The Processor is used to coordinate and executed the functions of the Controller: Display Four line display Mounted on the controller Used to relay information to the user Able to view in dim/dark environment – backlight

Controller CPU and Display Std Reqs: Operation Requirement Min Oper Temp Range: Min Oper Humidity Range: Min Oper Alt or Press Range: Min Oper Range (Distance): Min Storage Temp Range: Min Storage Humidity Range: Min Storage Alt or Press Range: Max Storage Duration: Value 0-45 Co 10-90% non-condensing 0-3000 Meters Line of Sight 0-80Co 10-90% non-condensing 1 year

Controller CPU and Display Std Reqs: Voltage and Current Requirement Units to Specify Max Input Voltage Min Input Voltage Max Input Current Max Output Voltage Min Output Voltage Max Output Current 5.1 V 4.9 V 600 mA 0 V 5 mA

Controller CPU and Display Std Reqs: Mfg & Life Cycle Percent of Total 13.5% 50% 15% 11% 1% 2% Allocation Component Count Component Cost Mfg Cost PCB Area Volume Mass Product Life, Reliability Full Warranty Period Product Disposition Service Strategy Amount 27 $40 $3 36 cm2 72 cm3 50 g 3 yrs 6 months Dispose Repair

Controller Power Supply Perf Reqs: User Interface Lcd Screen Characters: 20 characters X 4 Lines Resolution: 120 X8 Dots per line Color: Backlight - Green Characters - Black

Controller CPU and Display Perf Reqs: Interface Signals Analog Digital Power

Controller CPU and Display Perf Reqs : Mechanical The power and control lines will be connected to the display using a 6 pin board to wire connector. The display will need to be mounted to the controller housing

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Controller CPU and Display Bill of Materials

Controller CPU and Display Design: Block Diagram

Controller CPU and Display CPU Flow Chart

Controller CPU and Display Design: Passive Components

CPU and Display DFM Plan Sub Circuit Type Applicable Worst Case Analysis Plan Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 8 Bit A-D Converter R & C Tol RC Specs Max Offset Error Max Gain Max DNL Max INL Input Impedance Worst Case Total Error Bits, Volts Sample/Hold Required? Conversion Speed Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min CFA634-NFA-KS Std .8 2.0 1uA NA PIC16F77 .75 .6 4.3 3mA

CPU and Display DFM Plan Digital Timing Analysis Table Dig Signal Output Type Input Type Timing Parameters Tsu Setup Th Thold Margin Fmax F Tpulse Min CPU Siganl Std 200n 400n .1 20M 5M .01

Controller Power Supply Block Reliability Analysis

Controller CPU and Display Manual Manufacturing Processes Soldier 6 pin surface to cable connector Manual Attachment: Mount the Display to the controller housing

Controller Power Supply Block Obsolescence Analysis QTY Part Sigma V V+2.5(Theta)-P V+3.5(Theta)-P   SIGMA 1 PIC 1990.5 9.2 2979.55 4970.05 Tantalum Cap 1985 10 2966.6 4951.6 2 Polyester Cap Crystal Oscillator 1975 12.5 2944.1 4919.1 24 Film Resistor

Designed by: Sean Murphy RF Transceivers Designed by: Sean Murphy

Block 4 - RF Two way real time digital communication between controller and car processors Feeds information to car such as speed, direction, and light control Feedback information to controller on battery life, speed, and direction Server - client configuration 50% Tx/Rx

Block 4 - RF Standard Requirements Value 10 - 45 Co 10-90% non-condensing 300ft 0-80 Co 10-90% non-condensing 1 year 0 - 80 Co Requirement Min Oper Temp Range: Min Oper Humidity Range: Min Oper Range Min: Storage Temp Range: Min Storage Humidity Range: Max Storage Duration: Max Storage Temp Range:

Block 4 - RF Standard Requirements Continued Requirement Value % Of Total Total Parts: <15 5% Area: 64cm2 20% PCB Area 75cm2 22% Weight: 16oz 13% Product Mat. Cost: -- 30%

Block 4 Performance Requirements Modes: Input Power: Current Consumption: Packet Size: Operating frequency: Antenna: Regulations: Standards: Connectors: Value On/Off &Tx/Rx 5V DC ±2%, 50mVpp ripple 115mA 3 bytes 2.4GHz ½ Wave Dipole FCC Parts 15 and 27 CISPR 61000-6-3 IEC, 47CFR2 20 Pin Mini Connector MMCX

Antenna Current consumption Input Characteristics Sensitivity: -90dBm Transmit: 115mA Receive: 85mA Input Characteristics Sensitivity: -90dBm Gain: 3dBi Output Power Conducted: 10mW EIRP: 20mW (Effective Isotropic Radiated Power)

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Car Processor Power RF Transceiver Supply Power RF Transceiver Supply Block 4 Signals RF Car Processor Digital Power Supply 5V DC Transmitted Bit Package Car To Controller: Speed Indicator Direction Indicator Battery Life RF Transceiver Digital Transmitted Bit Package Controller To Car: Speed From User Dir From User Lights On/Off/Ambient Power Supply RF Transceiver 5V DC Digital Ctrlr Processor

Transmit/Receive Flow Chart Processor Demodulation, Decoding 8 data bits 1 start bit 1 stop bit CTS Condition Buffer Buffer Modulation, Encoding RTS Low 24 bits 8 data bits 1 stop bit 1 start bit Transmit Data Processor Hop Frame Receive Data Full duplex mode prevents transceivers from transmitting at the same time

Block 4 BOM Total Cost: $205.72

Block 4: Transceiver, Processor, and PS Interface

Block 4 - Timing Analysis Interface time out specifies byte gap, adjustable in decrements of 160µs. RF Mode Interface Baud Rate Duplex Direction Throughput (bps) Acknowledge 115,200 Full Both Ways 40k

RF Transceiver : Digital RF Transceiver : Power RF Transceiver : Digital

Block 4 - RF

Block 4 Reliability

Designed by: Sean Murphy Power Source Designed by: Sean Murphy

Theory Of Operation Monitors voltage drop across sense resistor to determine discharge activity. The fuel gauge is a coulomb counter, initial nominal capacity is preprogrammed. Recalibrated after full discharge cycle. Accounts for temperature, self-discharge, and rate of discharge. Capacity is recalibrated in course of discharge. Nominal capacity is indicated through serial link. Registers include energy, temp, voltage, current, and status.

Block 5: Car Power Source Provides power to all on car devices and functions Indicates battery life remaining to processor Will require voltage regulation

Standard Requirements: PS Type: Source Type & mAh: Oper Temp Range: Storage Temp Range: Vo Regulator: Vp-p Ripple Max: Io(Max): Connection: Safety: Nimh Battery Pack DC, 6000mAh max 10 - 45 Co 0 - 80 Co 5V ±2% 50mV 350mA Temporary UL 2054,1989 (Batteries)

Standard Requirements Continued Requirement Value % Of Total Total Parts: <25 15% Area: 200cm2 50% PCB Area 100cm2 30% Weight: <16oz 13% Prdct Mat. Cost: <$80 10%

Performance Requirements: Voltage Regulator VR Type: LDO High Discharge Vin Min/Max: 5.3V/10V Vo Nominal: 5V Vo Max Tol: 2% Vp-p Ripple Max: 50mV Io Max: 200mA Dropout Voltage: 300mV Fuel Gauge Type: Gas Gauge Vin Battery Min/Max: 5V/10V Vin Supply: 4.95/5.05V Accuracy: 15%

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Block 5: Car Power Source Block Diagram Nimh Battery Pack 0-9.6V Fuel Gauge 3.8V Back-up Battery Voltage Regulator (5V Nominal) Car Processor 5.5-9.6V Direction Sensor Speed Sensor Lights RF Trans / Rec 0-9.6V For Motor Electromechanical Control

Block 5: Voltage Regulator Detailed Design Want Cout large due to large changes in current. Want ESR low to reduce ripple Start up time inversely α CBYP (15ms CBYP= .01µF, COUT=10µF) With CBYP= .01µF, output settles within 1% for 10mA to 500mA load step in less then 10µs.

Voltage Regulator

Block 5: Fuel Gauge Detailed Design Rsense is chosen by looking at the lowest current representing the majority of the battery drain so that the voltage across it is 5-7mV: 85mA @ 6mV, Rsense = .0705 RB1 and RB2: Back-up battery: 3V 170mAh 1.5V 163mAh Storage cap: 4F ~ 24.7hrs

Block 5: Fuel Gauge Detailed Design PFC = BatCap*Rsense=231

Fuel Gauge Operational Overview

Block 5 BOM Total cost: $66.00

Power Source: Power Fuel Gauge : Digital

Block 5 – Car Power Supply

Block 5 Reliability Component Type FIT πT πV πE πQ Total FIT Qty Total Resistor-10V Metal Film 0.7 1.48 0.82 5 1.25 5.31 4 21 Resistor-5V Carbon 18.2 1.96 0.83 185 3 555 Capacitor: Va=5V,Vr=100 Ceramic 2 2.11 0.86 24 1 Capcitor-Va=10V,Vr=100V 0.91 120 Va=5V,Vr=50V Capacitor Tantulum 15 10.6 2.22 2081 Diode-5V Schottky 2.4 1.55 2.23 51.8 Diode-10V Battery Nimh&Li-ion 7 35 70 LED Bulb 9 0.818 488 Fuel Gauge Gas Gauge 19 270 9.97 5179 Voltage Reg. Linear 14 328 Total FIT: 8946

Designed by: Russ Diamond Car Processor Designed by: Russ Diamond

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Block 6: Car Processor – Function and Purpose Interprets signals from the transceiver and outputs control signals to the rest of the board. Data sensed on the car is sent to the transceiver.

Block 6: Car Processor - Standard Requirements Parts Count Block Area Block Weight Voltages and current requirements EMC standards < 25 parts < 15 cm2 < 1 ounce 1%, 5V input Imax = 10mA Radiated Emissions CISPR11

Block 6: Car Processor - Standard Requirements Environmental 10-45 Co 10-90% non-condensing 0-3000 Meters 0-80Co 10-90% non-condensing 1 year Min Oper Temp Range Min Oper Humidity Range Min Oper Alt or Press Range Min Storage Temp Range Min Storage Humidity Range Min Storage Alt or Press Range Max Storage Duration

Block 6: Car Processor – Performance Requirements Operational modes Mechanical Interfaces Serial interface CPU Frequency Maximum interrupt length On, Off Transceiver 115,200 KBaud interface 20 MHz 50 inst. cycles = .00001s

Block 6: Car Processor – Performance Requirements Signal Table

Block 6: Car Processor – Detailed Design Block Diagram Inputs Outputs 5V from Power Supply CPU for Car DO to steering servo Analog Input from Battery Sense circuit DI Speed Indicator 3 DO for Lights DI data from Transceiver Transceiver Data Request DI from Compass 4 DO for Motor Control DI from Photocell Clock signal from Crystal DO to Transceiver

Block 6: Car Processor - Detailed Design Schematic

Block 6: Car Processor – Detailed Design Theory of Operation Main Processor tasks Control Motor Speed and direction. Output servo control pulse for steering system. Receive and transmit data to transceiver. Poll compass for direction data and translate received data to direction in degrees. Count pulses from speed sensor. Communicate with fuel gauge for battery life readings. Check photo sensor input when in automatic lighting mode.

Block 6: Car Processor – Detailed Design Receive and transmit data to transceiver Calculations The PIC16F777 has a built in AUSART. Used asynchronously Timing based off the 20 MHz oscillator Required 115,200 +-3% Baud Rate to communicate to the transceiver. Set up –> SPBRG = (Fosc/(16*115,200))-1 = 10 BRGH = 1 Baud Rate = 113636.36 = 1.4 % difference acceptable Data is packaged 8 data bits, 1 start bit, 1 stop bit = 10 bits Timing calculations 8.89u seconds/bit *10 = 88.9u seconds till possible overflow occurs or 444 instruction cycles.

Block 6: Car Processor – Detailed Design Receive data from transceiver Flowchart and Code Receive: btfsc Rec_Data_Counter, 1 goto lights btfsc Rec_Data_Counter, 0 goto steering Speed:

Block 6: Car Processor – Detailed Design Data Requested by Transceiver/TXREG Interrupt Theory of Operation Interrupt from PORTB interrupt on change pin Interrupt generated when CTS pin from transceiver goes low Outputs first byte of data to the AUSART Starts secondary interrupt TXREG request Interrupt occurs when TXREG empties after data is sent Timing Calculations 10,000 instruction cycles between data being sent by transceiver. .002 / 2e-7 444 inst. Cycles between bytes loaded into register 8.89e-6 s / bit at 115,200 baud = 225 bits sent possible

Block 6: Car Processor – Detailed Design Data Requested by Transceiver/TXREG Interrupt Transceiver requests data

Block 6: Car Processor – Detailed Design Data Requested by Transceiver/TXREG Interrupt TXREG requests next byte

Block 6: Car Processor – Detailed Design DFM Analysis Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Crystal oscillator Voltage vs Freq Phase vs Freq Slew rate BW Step Resp Input Impedance Output DC Offset V Total Noise Input Capacitor C Tol C spec

Block 6: Car Processor – Detailed Design DFM Analysis Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked Micro TS .75 2.0 -1u 1.0u .6 4.3 8.5m -.3m 1.25 Dig Signal Output Type Input Type Timing Parameters Other Tsu Setup Th Thold Margin Fmax F Tpulse Min Checked Micro signals TS 200n 400n .1 20M 5M .01

Block 6: Car Processor – Detailed Design Component DFM Analysis

Block 6: Car Processor – Detailed Design Analog DFM Analysis

Block 6: Car Processor – Manufacturing Bill of Material

Block 6: Car Processor – Reliability Block Summary The crystal oscillator is the main driver of unreliability. A larger temperature range would improve it’s reliability. The CPU also has low reliability. It could be improved by operating it at a lower voltage.

Block 6: Car Processor – Reliability Obsolescence Block 6 Obsolescence   v sigma p 2.5 3.5 CPU 1994.5 7 2005.9 6.1 13.1 crystal 2001.5 7.8 15.1 22.9 Capacitor 1980 14 9.1 23.1 Resistor 8.5 -4.65 3.85

Electromechanical Control Designed by: Russ Diamond

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Block 7: Electromechanical Control Function and Purpose Generates an analog voltage across the voltage terminals of the motor Controls the steering of the car

Block 7: Electromechanical Control Standard Requirements Parts Count Block Area Block Weight Voltages and current requirements EMC standards < 20 parts < 15 cm2 < 2 ounces 5V, 1% input, Imax = 10mA Vbatt input, 5.3V – 12V Imax = 10A Radiated Emissions CISPR11

Block 7: Electromechanical Control Standard Requirements - Environmental 10-90% non-condensing 0-3000 Meters 0-80Co 10-90% non-condensing 1 year Min Oper Temp Range Min Oper Humidity Range Min Oper Alt or Press Range Min Storage Temp Range Min Storage Humidity Range Min Storage Alt or Press Range Max Storage Duration

Block 7: Electromechanical Control Performance Requirements Operational modes Mechanical Interfaces Safety features Digital interface PWM Frequency Maximum pulse width error Forward, Reverse, Stopping Stopped Motor Warning labels 50 Hz interface 15 kHz .00001s = 1%

Block 7: Electromechanical Control Performance Requirements – Signal Table

Block 7: Electromechanical Control Detailed Design - Block Diagram Motor Control Circuit 4 Digital inputs 2 Analog outputs To Motor 1 Digital Input Steering Servo

Block 7: Electromechanical Control Detailed Design–Motor Drive Schematic (H-bridge)

Block 7: Electromechanical Control Detailed Design – Theory of Operation State Table This system creates an analog voltage across a permanent magnet DC motor using Pulse Width Modulation. The n-channel mosfet’s are driven with a variable duty cycle 15KHz signal. Direction control is achieved by turning on the correct mosfet pattern. This method achieves continuous current through the motor and a very high efficiency. The BJT transistors provide a simple method of controlling the upper p-channel mosfet’s.   Q1 Q2 Q3 Q4 Forward off on Reverse Coast Brake

Block 7: Electromechanical Control Detailed Design – Calculations Rise time N-channel = 180ns Fall time N-channel = 80ns Power loss calculations I = 10A, F = 15KHz On time = .6W at 100% dc Off time = 0W Turning off = .135W Turning on = .12W Max power dissipation = .6W Heat rise = 62.5*.6 = 37.5C

Block 7: Electromechanical Control Detailed Design – Calculations The TMR2 module controls the PWM frequency Desired frequency = 15KHz Period = [(PR2)+1]* 4 * Tosc * TMR2prescale TMR2prescale = 2, PR2 = 165 Achieved frequency = 15060Hz

Block 7: Electromechanical Control Detailed Design – Flowcharts Forward Reverse

Block 7: Electromechanical Control Detailed Design – Flowcharts Forward

Block 7: Electromechanical Control Detailed Design – Code Speed: movf RCREG, 1 ; RCREG -> W movwf speed_var ; W -> speed_var btfss speed_var, 7 ; test bit seven to check direction goto Reverse ; if bit is clear direction is reverse Forward: btfsc F_R, 0 ; test bit 0 to see if unit is stopped goto drive_f ; if bit 0 is set goto forward drive btfsc F_R, 1 ; test bit 1 to see if unit is stopping goto F_PSS ; if bit 1 is set goto further checks btfss F_R, 2 ; test bit 2 to determine current direction goto stop ; if bit 2 is clear stop the car goto update_FPWM ; if bit 2 is set update the duty cycle Reverse: goto drive_r ; if bit 0 is set goto reverse drive goto R_PSS ; if bit 1 is set goto further checks btfsc F_R, 2 ; test bit 2 to determine direction moving goto stop ; if bit 2 is set stop the car goto update_RPWM ; if bit 2 is clear update the duty cycle F_PSS: btfss F_R, 2 ; test bit 2 to check direction moving goto end_speed ; if bit 2 is clear continue stopping drive_f: ; if bit 2 is set drive car forward bsf PORTD, RD1 ; turn off Q4 has inverted logic movlw clear ; put 0 into CCPR2L movwf CCPR2L bcf PORTD, RD0 ; turn on Q3 update_FPWM: subwf speed_var, 0 ; subtracts 128 from speed_var movwf speed_var ; puts result in w and speed_var addwf speed_var, 0 ; adds w and speed_var result in w

Block 7: Electromechanical Control Detailed Design – more Code movwf CCPR1L ; puts reult in CCPR1L to set duty cycle of PWM clrf F_R ; clear F_R bsf F_R, 2 ; set forward bit goto end_speed R_PSS: btfsc F_R, 2 ; test bit 2 to check direction moving goto end_speed ; if bit 2 is set continue stopping drive_r: ; if bit 2 is clear drive car reverse bcf PORTD, RD0 ; turn off Q3 movlw clear ; 0 -> W movwf CCPR1L ; put 0 into CCPR1L bsf PORTD, RD1 ; turn on Q4 update_RPWM: movf speed_var, 0 ; puts temp_variable into w addwf speed_var ; doubles speed_var comf speed_var, 0 ; complements speed_var movwf CCPR2L ; puts result in CCPR2L to set duty cycle of PWM clrf F_R ; update info in F_R - clear all bits in this case stop: movlw all_on ; 255 -> W bcf PORTD, RD1 ; turn off Q4 movwf CCPR1L ; turn Q1 and Q2 on full movwf CCPR2L ; update info in F_R bsf F_R, 1 ; set stopping bit bcf F_R, 0 ; clear stopped bit - shouldn't be on anyway end_speed: incf Rec_Data_Counter btfsc F_R, 1 ; check stopping bit in F_R bcf PORTD, RD5 ; if set turn on brake lights bsf PORTD, RD5 ; if not set turn off brake lights goto end_Receive

Block 7: Electromechanical Control Detailed Design – Steering Schematic Position Control is achieved by sending a pulse to the servo every 20ms. The length of the pulse determines the positioning of the servo.

Block 7: Electromechanical Control Detailed Design – Theory of Operation This system receives a control signal in from the CPU in the form of a pulse from 1 to 2 ms in length at a rate of 50Hz. How it’s Implemented TMR1 is set up to overflow every 20ms. TMR0 is then preloaded with a value that will cause it to overflow between 1 and 2ms based on input. When TMR0 overflows it is turned off until TMR1 overflows and sets it again. Maximum interrupt length is set to 50 instruction cycles to keep error of output pulse 1% or less.

Block 7: Electromechanical Control Detailed Design – Calculations TMR1 increments every instruction cycle. It is a 16 bit timer so with a pre-scaler of 2 it will overflow every 26.2ms. Preload the upper byte of the timer with 15616 = b’00111101’ -> TMR1H Setup TMR0 using a pre-scaler of 64. 2^8 * 2e-7 * 64 = overflows after 3.28 ms Input = 78 = .9984 ms (full right steering) Input = 156 = 1.997 ms (full left steering)

Block 7: Electromechanical Control Detailed Design – Code steering: movf RCREG, 1 ; RCREG -> W movwf steering ; W -> steering end_steering: incf Rec_Data_Counter goto end_Receive ; this routine turns off the servo output after a specific time TMR0_int: bcf PORTB, RB1 ;turn off output pin bsf OPTION_REG, 5 ;turns off tmr0 end_TMR0: ; reset interrupt goto end_isr ; this routine starts the servo output and checks the lights if they're in auto mode ; this routine moves temp_speed to speed_sensor and resets temp_speed ; this routine causes an interrupt every 20 ms TMR1_int: movf temp_speed, 0 ; temp_speed -> W movwf speed_sensor ; W -> speed_sensor btfsc status, Z ; check zero bit in status register bsf F_R, 0 ; if temp speed = 0 set stopped bit in F_R clrf temp_speed ; clear temp_seed for next period movf steering, 0 ; steering -> W movwf TMR0 ; W -> TMR0 bsf PORTB, RB1 ; set servo output pin bcf OPTION_REG, 5 ; turns tmr0 on

Block 7: Electromechanical Control Detailed Design - DFM Analysis Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Mosfet Drivers R, L & C Tol RLC Specs Gain vs Freq Phase vs Freq Slew rate BW Step Resp Input Impedance Output DC Offset V Total Noise Current Diodes Resistor Max Offset Error Max Gain Max DNL Max INL Worst Case Total Error Bits, Volts Sample/Hold Required? Conversion Speed

Block 7: Electromechanical Control Detailed Design - DFM Analysis Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked Traxxas 2015 servo Mec Std. .80 3.5 -.1m .1m n/a 2.7 Digital Signal Output Type Input Type Timing Parameters Other Tsu Setup Th Thold Margin Fmax F Tpulse Min Checked Q1 Std. n/a 15KHz Q2 Q3 DC Q4 Servo 1m 2m 50 Hz

Block 7: Electromechanical Control Detailed Design - Component DFM Analysis Analog DFM Analysis

Block 7: Electromechanical Control Detailed Design - Safety The largest safety concern is the motor which can get extremely hot after continued use. There are warning labels on it ,but a guard around it may be a good idea. Justify wire gauge 10 gauge wire to the motor to handle the current demands Board trace width between the motor and power and ground = 200 mills

Block 7: Electromechanical Control Manufacturing – Bill of Materials

Block 7: Electromechanical Control Reliability - Block Summary The main driver of unreliability in this situation is the servo. A higher maximum voltage rated part would improve it’s performance.

Block 7: Electromechanical Control Reliability - Obsolescence Block 7 Obsolescence   v sigma p 2.5 3.5 Resistor 1980 8.5 2005.9 -4.65 3.85 MOSFET 2004.5 8.3 19.35 27.65 BJT Capacitor 14 9.1 23.1 servo 2001.5 7.8 15.1 22.9

Designed by: Adam Wozniak Car Signals Designed by: Adam Wozniak

Signals if the lights are on or off Block 6: Car Sensing Signals if the lights are on or off Uses light detection to determine if lights should turn on or off Signals how fast the car is going Signals in which direction the car is moving

Standard Requirements Conforms to EMC Standard EN 61800-3 (Adjustable speed electrical power drive systems )

Standard Reqs: Car Sensor Requirement Definition Max # of PC Boards Max PCB area Max Parts Count Operating Temp Storage Temp Operational Mode Mechanical Interface Safety Feature Voltage Range Max Current 3 (10%) 30 cm2 (4%) 20 (5%) 10-60 C 0-80 C ON Sensors Withstands up to 50G’s 5.7 V 7mA

Performance Reqs: Car Sensor Requirement Definition Direction Sensor Accuracy Response Time Speed Sensor Updates Speed Range Light Sensor Sensitivity 8 Directional Units 200 ms + 3 mph 0-40 mph 100fc

Team #2: Project 1 Block Assignment Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Block 8: Car Sensing Direction Sensor Car Processor Digital Car Processor Controller Processor Transmit to/from Processor Speed Sensor Speed digital Lights digital Comparator Light Sensor Lights digital Power Lights Lights digital

Bill Of Materials I have approximately 10% of the budget for Parts

Diagrams CLK from Processor

Block 6: Car Processor – Detailed Design Speed Sensor Calculations Miles per pulse = 2*pi*radius / 36*63360 Time period = TMR1 rollover = 19.97ms Speed per pulse = miles per pulse / time period (hrs) = .993 mi/hr Theory of Operation Every time a pulse occurs the firmware increments a variable. Every time TMR1 overflows the variable is saved as the car’s speed. If the variable = 0 set the stopped bit in the F_R variable. Max interrupt frequency 2000 Hz 40 mph max = 40 pulses / .02 seconds

Car Sensor: Power Car Sensor: Digital

DC Drive Device Parameters Digital Block DFM - DC Drive Analysis Table Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked Direction Sensor Std NA TTL 5.2V 4.8V 7mA 3mA Speed Sensor Comparator Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Passive Component Specifications

Digital Block DFM - Timing Analysis Table Dig Signal Output Type Input Type Timing Parameters Other Tsu Setup Th Thold Margin Fmax F Tpulse Min Checked HM55B Std 30ns 100ns 5MHz 1MHz 30mS 40mS

Reliability Slide

Reliability Conclusions Block 8 The total FIT’s are 204, thus the MTBF is 559 years The most unreliable parts are the resistors, and the comparator The reliability could be better if we could get better resistor reliability

Component Life Parameters

Obsolescence Table None of my parts are obsolete The capacitors are going to be obsolete BUT we have many vendors for that part

Special Mfg and Testing The Photocell will need to be mounted such that it is able to sense outside light. The speed sensor will need to be mounted within a ¼ inch of the wheel gear

Prototyping Slides

Product Assembly We will try to use as many SMT components as we can. We will use a Perfboard to connect all components.

Master Parts List

Master Parts List

Assembly Steps Step 1- Program processors Step 2- Assemble components on PCB1/PCB2 Step 3- Construct Car, Mount Battery, Mount PCB, Mount sensors to appropriate locations, Mount Display on Controller Step 4- Perform performance tests Step 5- Place car and manual in package

Life Stress Model Over 1 year the product will be turned on and off 365 times It will go through 100 thermal cycles ranging in Temperature from -20C – 80C It will go through 3650 shock cycles on the magnitude of 20 G’s

Reliability Growth Plan

Reliability Conclusions The total FIT’s are 17909, thus the MTBF is 6 years and 4 months 7.5% of products will fail in the warranty period The most unreliable parts are the servo and the crystal oscillator

Patents Radio-controlled toy car, United States Patent 4457101 Matsushiro, Yukimitsu Remote-control toy car set , United States Patent 6746304 Liu, Shu-Ming Remote control toy car control system , United States Patent 6585618 Lu, Ke-Way

For their help with this project We would like to thank Jeff Kautzer Chris Merkl For their help with this project

Any Questions?

The End