Team #5: Staff Sean Kuter (LPI) Kurt Stonger (LRM) Andrew LaPointe (LSD) Eric Fritz (LPM) Shawn Bostwick (LMM) BSEE

Project Plan Summary Total Manpower Estimated vs. Available Meetings 93.0 man-hours Labs 101.5 man-hours Individual 23.5 man-hours To date 219 man-hours out of 900 total man-hours available Total Material Cost to date $179.98 out of $500.00 total available budget % of Total Manpower System design 14.84% Detailed design 36.30% Verification 10.73% Documentation 38.13% To date there is an overestimate of 61% of man-hours To date there is 64% of material not procured

Selected Project Key Features Reptile Environmental Control Unit: Monitor Environment Ambient Temperature Surface Temperature Humidity Monitor Ambient Temperature Control Surface Temperature Control Humidity Security System to Prevent Escape Cable Management System

Product Applications Exclusive environmental control to support: Snakes (primarily) Turtles, lizards, and other rare reptiles Typical market: Professional/Amateur Breeders and Herpetologists Pet Stores

Hoffer’s Tropical Pet Store

Potential Competitors www.habitatcontrolsystems.com Targeted market Don’t meet all of the key objectives Room for product growth 4 Zone Programmable Controller Made for multiple units Monitors and controls temperature only No security control $249.00 USD

Refined Block Diagram Sean Kuter Shawn Bostwick Kurt Stonger Inputs and Signal Conditioning: Andrew LaPointe Inputs and Signal Conditioning: Sean Kuter Power Distribution: Shawn Bostwick Outputs: Kurt Stonger Surface Temperature Sensors ANALOG Relay Switches Signal Conditioning DIGITAL 29 VAC Foggers Relay Switches DIGITAL 120 VAC Heat Mats Ambient Temperature Sensors ANALOG Signal Conditioning Controller Eric Fritz 4 State Controllers DIGITAL Humidity Sensors ANALOG Signal Conditioning Keypad DIGITAL DIGITAL LCD Display Lights 5VDC Door Sensors Alarm Horn

Out: On/Off signal to outputs Block Assignments Block # Block Name Owner Description Power interfaces Digital Interfaces Analog Interfaces 1 Power conversion & distribution Shawn Bostwick Standard AC input to 5/24VDC and 115 VAC output In:115 VAC Out: 115VAC 5VDC, 24VDC none 2 A/D conv & Signal conditioner Sean Kuter Convert 0-10 VDC analog signals to digital data In: 5VDC Out: Sensor data to Micro Controller In: Analog sensor data 3 Micro Eric Fritz Take in Digital data, perform calculations, output digital On/Off signal Out: On/Off signal to outputs 4 Inputs Andy LaPointe ambient/mat temp, humidity, door sensor, keypad In: 5 VDC Out: 0-5VDC analog 5 Outputs Kurt Stonger Fogger, heat pad, heat lamp, LCD, alarms In: 115Vac, 24Vdc, 5Vdc In: Data Bus On/Off signal

Performance Requirements Display type Temperature Sensors Humidity Sensors Keypad type Key definitions Units to Specify LCD 4 Lines by 20 Characters/Line Accuracy: +/- 1oC Range: 5 - 95oC Accuracy: +/- 5% RH Range: 10 – 90% RH Matrix arrangement up/down/left/right arrows, enter, numbers

Standard Requirements Min Oper. Temp Range Min Oper. Humidity Range Max Dimensions Source Connection List Units to Specify 5 - 45° C 0 – 99% relative humidity 12” x 12” x 6” Temporary, with ability to move unit

Standard Requirements Min Oper. Voltage Range AC power freq range Max Power. Consumption Parts/Material $ Allocation Connector Type Units to Specify 102 – 132 VAC 120 VAC nom. 57 – 63 Hz 60 Hz nom. 850 W 7A $500 (total, $100/member) Type B Plug

Safety Standards IEC 6100-4-2: ESD Immunity IEC 61140 Edition 3.0: Electric Shock Protection IEC 730: Auto. Elec. Controls for Household UL 60730-1A Auto. Elec. Controls for Household UL 60730-2-9 Auto. Elec. Controls for Household Part 2: Particular for Temperature Sensing Controls

Specific Safety Requirements IEC 60335-2-71 Edition 2.0 Household and similar electrical appliances – Safety – Part 2-71: Particular requirements for electric heating appliances for breeding and rearing animals UL 873 Temperature-Indicating and Regulating Equipment UL 60730-2-13A Automatic Electric Control for Household and Similar Use; Part 2: Particular Requirements for Humidity Sensing Controls

EMC Standards 61000-4-2: ESD Immunity Tests IC’s 61000-4-5: Surge Immunity Tests Lightning discharges & switching disturbances 61000-4-11: Voltage dips, short interruptions, and variations Line voltage variances

ECU Technical Risk & Problem Areas Sensors/Sensing Issues Analog sensor output > Digital Processor Programming Pic/Microcontroller selection Programming Hardware Programming Software Power Supply Design Build Safety (explosion, fire, shock)

Individual Reliability Report: Andrew La Pointe Maximum FIT’s: 832.31 MTBF: 137.06 years Most Unreliable Part: Humidity Sensor Suggested Improvement: Find a part with a lower lambda

Individual Reliability Report: Eric Fritz Maximum FIT’s: 6928.5 MTBF: 16.46 years Most Unreliable Part: D-flip flops Suggested Improvement: Use a different part Use fewer parts

Individual Reliability Report: Shawn Bostwick Maximum FIT’s: 1919.00 MTBF: 59.45 years Most Unreliable Part: Zener Diodes Suggested Improvement: Use heatsinks for temperature

Individual Reliability Report: Kurt Stonger Maximum FIT’s: 454.09 MTBF: 251.22 years Most Unreliable Part: Electromagnetic coil relay Suggested Improvement: Use transistorized switch, or SCR

Individual Reliability Report: Sean Kuter Maximum FIT’s: 41.595 MTBF: 2742.57 years Most Unreliable Part Resistors Suggested Improvement None needed

Ambient / Surface Temp Sensing Sean Kuter To provide a controlled temperature scaled inputs to the microcontroller block: Ambient Temperature Surface Temperature Impedance matching Amplified Signals

Sean Kuter Ambient and Surface Temperature Inputs Per Reptile Environmental Unit From Power Dist. Block

Ambient and Surface Temperature Sensors Per Reptile Unit Sean Kuter Standard Requirements IEC 6100-4-2 Electrostatic Discharge Immunity Operating Temperature Range 5 – 45 oC Oper. Humidity Range 0 – 99% RH Performance Requirements Monitor a Temperature Range 5 – 45 oC ( 41 – 113 oF ) Provide a sensor accuracy of +/- 1 oC Provide an Output Voltage Range 0.5 – 4.5 Vdc

Humidity Sensor/Alarm Andrew LaPointe Humidity Sensing Senses humidity Gives proper signal to microcontroller Alarm Senses Door position (open or closed) Gives audible alarm for open door

Andy LaPointe Humidity sensor input and Alarm Circuit Per Reptile Environmental Unit Humidity Multiplexer Microcontroller Block Owned by: Eric Fritz Magnetic Door Switch Ckt 1 Alarm Horn +5VDC 0.05 - 5VDC Magnetic Door Switch Ckt 2 +5VDC +5VDC +5VDC +5VDC +5VDC Power Block Owned by: Shawn Bostwick Humidity Sensor Impedance Matching Network Op-Amp Av = 5 5VDC .01-1VDC .01-1VDC

Humidity Sensor/Alarm Block Standard/Safety Requirements Min Oper. Temp Range 5 - 45° C Min Oper. Humidity Range 0-99 % RH Operating Voltage Range 4.5 – 5.5 VDC Source Connections temporary (hi-density plugs) IEC 6100-4-2 Electrostatic Discharge Immunity

Humidity Sensor/Alarm Block Performance Requirements Humidity sensor has accuracy of +/- 5 % R.H. and range of 0-99% R.H. Humidity sensor outputs 0.5 -4.5 VDC Door switches open to a max of 1” before horn sounds Horn provides 90-100 dB sound @ 2 ft

Humidity Sensors and Alarm Circuit Block Summary Analog Signals Type Direction Coupling Voltage Max Impedance Freq Range Leakage   Amplitude Min uA741 Opamps X4 Analog Output Direct 5.0V 300K 2M N/A Analog1 Door Switch X8 6V 0.1 ohm open Analog2 Humidity Sensor X4 1.0V 200ohm 60uA Power Signals Type Direction Voltage Voltage Range Freq % V-Reg V-Ripple Current   Nominal Min Max Humidity Sensor X4 DC Power Input 5.0V 4.5V 5.5V DC 10.00% n/a 10mA Alarm Horn 3.0V 6.0V 20.00% 60mA uA741 Opamps X4 3.3mA

Outputs Kurt Stonger Control output signals to Fogger, Heat Mat and Light Relay switches Bang Bang control 3 light settings

Outputs Kurt Stonger Component Voltage; Relay Coil Voltage; Microcontroller Component Voltage; Power Block Fogger 24 VAC 24 VAC Relay 5 VDC Heat Mat 120 VAC Relay 120 VAC 5 VDC 5 VDC Relay V-Division Relay Driver 12 VDC 6 VDC 5 VDC Light Relay V-Division 12 VDC 9 VDC 5 VDC Relay 12 VDC 12 VDC

Outputs Kurt Stonger Standards Performance Fogger Heat Mat LEDs Power Surge IEC 6100-4-6 Fogger 24 Vac Heat Mat 132 – 102 Vac LEDs 14 - 6 Vdc & 20 mA Max Solid State Relay 6-4 Vdc Relay Drivers 5 Vdc @ Vcc 4.5 – 16 Vdc Vout & 1.8 A max EM Relays 5 Vdc & 75mA @ coil Performance Fogger Relay Controlled power 0 – 90% Relative Humidity Heat Mat 0 – 30C Range LEDs 4 stages Low 816 Lumens, Medium 1224 Lumens, High 1632 Lumens and Off

Output Block Summary Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current   Nominal Min Max Power1 Fogger AC Input 24V 21.6V 26.4V 60Hz 57Hz 63Hz 15.00% N/A 1A Power2 Heat Mat 120V 102V 132V .111A Power3 LED DC 12V 6V 14V 0Hz .3A

Power Supply Shawn Bostwick Power Supply Block Supply AC Power To: Heating Pads Foggers Supply Rectified DC Power To: Microcontroller Sensors Alarm Lights

Shawn Bostwick Power Supply Power in 120Vac Microcontroller Block Overvoltage/ Overcurrent Protection Transformer 120Vac Rectifiers 5Vdc 120Vac 120Vac Alarm Circuit 5Vdc Voltage Regulator Circuit Transformer 5Vdc/7Vdc/12Vdc Humidity Sensor 5Vdc & +/-12Vdc 24Vac Fogger Control Circuit Ambient Temp. Sensor Heating Pad Control Circuit Lighting Control Circuit Surface Temp. Sensor 5Vdc & +/-12Vdc

Micro Controller Block Eric Fritz Takes Inputs from sensors Performs Calculation Sends Outputs to relays LCD Display Displays data Key Pad Input Allows user to change set points

Microcontroller Eric Fritz Light Logic Terrarium #1 5V Relay Ambient Temperature Sensors 4 x 1 MUX Terrarium #1 7V Relay Analog Input 8 Micro-Controller Terrarium #1 12V Relay Control Signal Light Logic 3 8 8-Bit Latch Surface Temperature Sensors 4 x 1 MUX 4 x 1 MUX Light Logic Control Signal Control Signal D0 D0 Lights Humidity Sensors 4 x 1 MUX 3 x 8 Decoder Light Logic D1 Heaters/Humidifiers Control Signal 3 D2 LCD Display D3 Keypad Input Terrarium #1 Heater Relay D2 Sensor Input Terrarium #2 Heater Relay 5VDC Power 8-Bit Latch 8 D5 Not used Terrarium #3 Heater Relay 8 8-Bit Latch D6 Not used Terrarium #4 Heater Relay D7 Not Used D4 Terrarium #1 Fogger Relay D1 Terrarium #2 Fogger Relay Terrarium #3 Fogger Relay Terrarium #4 Fogger Relay 6 Button User Interface 8 8-Bit Latch 8 8-Bit Latch 8 4 x 20 LCD Display D3 D2

Micro Controller Eric Fritz Standard 4.5-5.5 VDC 0-45oC 0-90% RH IEC 61000-4-2 ESD guideline UL 60730-1A Automatic Electrical Controls for Household and Similar Use; Part 1: General Requirements Performance 40MHz Clock Speed 4 x 20 line LCD 0-5VDC analog input 6 button Keypad interface 8-bit data bus 5 VDC I/O

Individual Reliability Report: Eric Fritz Maximum FIT’s: 6928.5 MTBF: 16.46 years Most Unreliable Part: D-flip flops Suggested Improvement: Use a different part Use fewer parts

Overall Prototype Plan Total Block Area: 462 cm2 Total PCB Area: 432cm2 Substrate Type: Perf-Board w/Pads Comp. Attach. Type: Direct Solder or IC Socket Socketed Components: IC’s, Relays, Rectifiers, and Microcontroller Connector Types: Ribbon cable, Solder, NEC/IEC, and Headers

Block Prototype Plan Block Name Block Area (cm2) Total PCB Area (cm2) Substrate Type Comp Attachment Socketed Components Types of Connectors Eric Fritz 270 260 Perf-Board with pads Direct solder or IC socket ICs, Micro-controller Ribbon cable, Headers, Solid Wire Solder Conn. Shawn Bostwick 120 100 Relays, ICs, rectifiers Ribbon cable, Headers, NEC/IEC power connectors, Solid Wire Solder Conn Andy LaPointe 24 ICs Ribbon cable, Headers Kurt Stonger Sean Kuter

Total Reliability Report Maximum FIT’s: 10246.75 MTBF: 11.13 years Most Unreliable Part D-flip flop Suggested Improvement Reduce number of D-flip flops Change components

Accelerated Stress Model Accelerated 1 Cycle Time Reliability Test Plan Stress 24 Hour Model 10 Year Model Accelerated Stress Model Accelerated 1 Cycle Time Acceleration Factor Max Input Voltage 132 VAC N/A Number of Power Cycles 20 Thermal Range 23-26 c 20-30 c Number of Thermal Cycle 5 Max Shock Grms Number of Shock Cycles 10