EE-595 Capstone Design Project Overview

Capstone Design Project DESCRIPTION   Course Description: Capstone Design Project . 4 Credits U/G. Lecture/Laboratory. Team based design using real-world industrial constraints of an electronic based product including requirements capture, detailed design, prototyping, verification, safety, manufacturing, reliability, and sustainability. Major deliverables; Oral presentation Project Report Prototype The term Capstone is used to describe the “finishing” aspect of this course, just as a capstone or keystone is the finishing stone in an archway support

Capstone Design Project PREREQUISITES   Senior Standing ElecEng 335(P) or 332(P) ElecEng 367(P) Prerequisites by Topic   ·         Design of basic linear and non-linear analog circuits including amplifiers, filters, oscillators, comparators, timers, pulse generators, and detectors ·         Design of basic linear power conversion circuits including basic transformer voltage conversion, passive ripple filtration and linear regulation ·         Design of basic digital logic circuits including multi-input/output combinatorial circuits and multi-input/output sequential state circuits ·         Design of basic microprocessor based circuits including interface of memory and I/O devices ·         Basic time domain and frequency domain simulation analysis utilizing Pspice ·         Prototyping (bread boarding) of simple analog and digital circuits ·         Verification of circuit functionality utilizing standard test equipment including DMM, DSO, logic analyzer, waveform generator, and frequency counter

Capstone Design Project TOPICS COVERED   ·         Basic Business Organization, Annual Cycles, Financial Flow, Costs and Contribution Margins ·         Business Cases for Product Development Justification ·         Product Development Processes, Life Cycles, Requirements, Verification and Validation ·         Requirement Allocation, Association and Flowdown ·         Safety Standards, Testing Labs and Regulatory Bodies ·         Electromagnetic Compliance and Global Power Standards ·         Review of Statistics and 6 Sigma Quality ·         Reliability distributions, predictions methods, growth strategies and product warranties ·         Task Estimating, Project Planning and Management ·         Prototyping Methods ·         Basic Thru Hold and Surface Mount Electronic Component Packaging ·         Printed Circuit Fabrication, Surface Mount and Thru Hole Electronic Assembly Processes ·         Printed Circuit Board Testing Strategies, IPC Electronic Assembly Quality Standards ·         Analog Circuit Design for Mass Production, Worst Case Analysis and Component Data Sheets ·         Mixed Signal Circuits, Analog to Digital Conversion Architectures and Component Data Sheets ·         Digital Circuit Design for Mass Production, Families, I/O Structures, and Worst Case Analysis ·         Sequential Logic Timing Analysis, Bus Cycles, Meta-stability, PLD Architectures ·         Obsolescence, Life Cycles and Sustainability of Electronic Designs ·         Technical Reports, Presentations and Communication

Capstone Design Project 12 LEARNING OUTCOMES - Preliminary   1.     Students will gain familiarity working in an industry engineering team environment including requirement formulation and flowdown, project planning, constraints, interface specification, and prototype integration 2.     Students will learn introductory project management estimating their team resources, project tasks and generating a basic project plan 3.     Students will gain experience in preparing and giving technical multi-contributor presentations including integration of their contribution to the team project 4.     Students will gain experience in authoring a multi-contributor technical report including documenting and integrating their design contribution 5.     Students will gain ability to design and analyze analog and digital circuits for mass production using worst case performance including error voltages, bandwidth, interface compatibility and timing validations as specified in commercial environments 6.     Students will be able to assimilate industry device data sheets, find relevant parameters for typical versus worst case operation over an operating environment 7.     Students will learn to perform basic cost modeling of designs and perform component package-manufacturing cost and process tradeoffs 8.     Students will understand the basics of surface mount and thru hole electronic assembly processes and industry standard electronic assembly quality standards 9.     Students will understand the basic elements of a multilayer printed wiring board and ECAD design 10. Students will learn introductory reliability modeling, estimation and stress testing strategies 11. Students will learn about basic product safety and regulatory standards including electromagnetic compliance, testing labs, US government agencies and global standards bodies 12. Students will learn about ramifications of designing products for a global market including commercial power and environmental differences

Critical Success Factors Capstone Design Project 318-595 Requirements Management Teamwork & Presentation Capstone Project Planning & Communication Prototyping & Testing Electrical Eng Design & Sim Critical Success Factors

Capstone Design Project EE-595 Staff   LC 401, THURS 7:00-9:00PM, E225 Jeffrey A. Kautzer Senior Lecturer Office: EMS-E222 Phone: 229-5189 Hrs: Tues 7:00-8:00 PM, Thurs 9:00-10:00 PM Email: kautzer@uwm.edu g GE Healthcare _________________________________________ Jeffrey A. Kautzer Manager, CT Detector Engineering 3000 Grandview Blvd, W1180, Waukesha, WI 53188 Email: jeffrey.kautzer@med.ge.com GE: 25 Years Industry Electronic Design & Management UWM: Senior Lecturer in Dept of EE, 25+ Years RF, CPU, Mixed Signal, Motion Control EMC, Micro-electronics, Electronic Assembly, Regulatory Senior Member IEEE 20 Filed Patents

Capstone Design Project LAB ASSISTANT   Mr. Kalu Bhattarai Office: EMS-W387 Phone: 229-5861 Hrs: Wed 5:00-6:30PM, Thu 4:30-6:30PM Email: kalu@uwm.edu Experienced Lab Assistant for 595 Experience TA for other Electronics Labs Electronics Undergraduate New Baby

Capstone Design Project 318-595 1. Electronics Project Management & Design by Stadtmiller, 2nd Edition, Prentice Hall, ISBN 0-13-111136-1 (Earlier 1st Edition pictured may also be used) 5. 318-355 Electronic Design Laboratory - Handbook of Design by Kautzer, ISBN 0-900-00701-B (on line) Main Texts

Supporting Texts (from 318-335) Capstone Design Project 318-595 2. Electronics by Hambley, 2nd Edition, Prentice Hall, ISBN 0-13-691982-0 3. Schematic Capture With Cadence Pspice by Marc E. Herniter, 2nd Edition, Prentice Hall Inc, ISBN 0-13-048400-8 (Earlier Edition may also be used) Supporting Texts (from 318-335)

Capstone Design Project 318-595 4. Strategies for Engineering Communications by Stevenson, 1st Edition, Wiley, ISBN 0-471-12817-1 Secondary Text

Capstone Design Project 318-595 Printed Circuit Assembly Design by Marks and Caterina, 1st Edition McGraw Hill, ISBN 0-07-014107-7 Reference Text

Capstone Design Project Web Info 595 WEBSITE   http://www.uwm.edu/course//318-595 The website is password protected. Login name = ee595, Password = xxxxxx.   On-Line Component & Project Information   http://ee.cleversoul.com/ http://www.datasheetlocator.com/ http://cmpmedia.globalspec.com/

Capstone Design Project E203 “McPherson” Lab ·         Agilent 54622D/54641D Dual Analog CH, 16 Dig CH, 100/350 Mhz DSO w/2 probes (in cabinet)   Backup Scopes: ·         Tektronix TDS350, 1 GSPS dual trace DSO w/2 probes (all probes are locked in cabinet) ·         Hitachi, V-660, 60 Mhz dual trace analog oscilloscope with NTSC TV-V and TV-H triggering ·         NEW!! Fluke 179 Portable DMM, V: 100uV–1Kv, Cap:1000pF -10,000uF, Freq: 2hz-50 KHz, Temp: 40-400oC Backup DMM: ·         Tenma 74-4020 including capacitance meter and frequency counter ·         Heathkit Triple DC power supply (may not be on bench due to space constraints) ·         Elenco Dual Variable Regulated DC power supply, XP-650 (2 at each bench) ·         Hewlett Packard HP33120A Waveform, AM, and FM Generator ·         120 VAC power with 20 AMP circuit breaker protection on corner panel ·         4 conductor wire distribution to Blue, Grey, Red and Black terminals via 30 AMP circuit breaker protection All Analog Scope and DSO probes, BNC-BNC cables, BNC-Clip cables, Banana Jack Wires, and Aligator Clips are kept locked in metal cabinet and must be supplied by the TA.

Dedicated Prototyping and Design Lab Times ! 10 Weekly Lab Assignments Entirely Devoted to Project Lab Assignments are due at End of Lab as Shown Lab 1, 4, 6, 10 are Presentations or Slide Package Submissions 2 Exams MONDAY MAY 7 (& May 8) Faculty Presentation Day(s) THURSDAY MAY 10 Project Reports Due Dedicated Prototyping and Design Lab Times !

318-595 Grade Composition Final Grade 0-100 Pts Exams 25% Project Labs Final Grading Scale ═════════════════════════════════════════════════════════ 94.0 - 100.0 ..... A 78.0 - 83.99 ..... C 93.0 - 93.99 ..... A - 77.0 - 77.99 ..... C - 92.0 - 92.99 ..... B + 76.0 - 76.99 ..... D + 86.0 - 91.99 ..... B 70.0 - 75.99 ..... D 85.0 - 85.99 ..... B - 00.0 - 69.99 ..... F 84.0 - 84.99 ..... C + Final Grade 0-100 Pts Exams 25% Project Labs 20% Design Project 50% Lab Performance 5%

Design Project Grade Capstone Design Project MSWord Report Score 35% Peer Evaluations 15% Design Project Grade Faculty Team Evaluation 10% Prototype Demo 15% Faculty Individual Evaluation 15% Lab Assistant Evals 10% Individual Components Team Components

Project Faculty Eval Criteria Faculty Evaluation Criteria for Oral Presentations   Capstone Design Project   Project Faculty Eval Criteria Rate the presentation on a scale of 1 (= Poor) to 5 (= Excellent) 1 Identification and formulation of the problem 2 3 4 5 Level of analysis of the problem and the solution(s) Application of knowledge of math and science Application of engineering knowledge Use of tools and techniques appropriate for modern engineering analysis 6 Consideration of economic aspects 7 Consideration of societal aspects (e.g. accessibility, cultural, gender issues) 8 Consideration of environmental, and health and safety issues

Project Faculty Eval Criteria Faculty Evaluation Criteria for Oral Presentations   Capstone Design Project   Project Faculty Eval Criteria 9 Consideration of ethical, political and legal issues 1 2 3 4 5 10 Consideration of manufacturability and sustainability 11 Appropriateness of the scope and level of the project for a capstone experience 12 Quality of visual aids (slides, transparencies, models) 13 Use of audience-appropriate content, detail, style and vocabulary 14 Use of charts, graphs and figures in the presentation 15 Language usage (grammar, spelling) Non Technical Areas

Project Faculty Eval Criteria Faculty Evaluation Criteria for Oral Presentations   Capstone Design Project   Project Faculty Eval Criteria 16 Clarity and volume of speech 1 2 3 4 5 17 Technical credibility of material and effectiveness of responses to questions and comments 18 Presenter’s contribution level versus team member peers and overall project tasks 19 Presenter’s professionalism including appearance, organization and manner 20 Presenter’s eye contact and ability to address the audience Presentation Skill Areas

Project Team Logistics Capstone Design Project Project Team Logistics Project Teams must be comprised of students from same lab section Project Teams are comprised of 4-6 students, no more than 3 project teams per lab section Project Team members are asked to communicate outside of normal class times Project Teams should plan on meeting at least 1/week outside of normal lecture/lab and office hour times Project Team members will assess their teammates at semester end anonymously as part of the project grade

Project Team Roles LPI: Lead Project Integrator LSD: Lead System Designer LPM: Lead Presentation Manager LRM: Lead Report Manager LMM: Lead Manufacturing Manager In limited cases of teams with only 3 or 4 members, students must take on 2 of the above roles

Industry Terminology: “Ownership” Definition: To have primary responsibility of a deliverable Ownership does not necessarily mean you are the only contributor but… in general if you own the deliverable, you need to make sure it gets done

Roles to Define & Assign Lead Project Integrator (LPI): 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. Submits attendance records as part of P1, P2, P3 and P4 slide packages 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): 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): 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 Page Numbering 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 electronic files for all Prelim Presentations P1-P4 and Final Presentation

Roles to Define & Assign Lead Report Manager (LPM): 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 Page Numbers Table of Contents & Chaptering Font sizes & font styles Colors Header/footers Revision 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 electronic file and bound paper copy of Final Project Report

Roles to Define & Assign Lead Manufacturing Mgr (LMM): 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 gluing.

Project/Product Requirements 1.      Standard Requirements: Those common to all projects including power consumption, voltage/frequency range, mass production cost, parts count, physical size, weight, operating temp range, etc.   2.    Performance Requirements: are those that differentiate your design from a competitive design. This includes a list of all requirements that describe the intended functionality including all operating controls/displays, electrical inputs/outputs, mechanical inputs/outputs, operational modes, and differentiating performance requirements. Performance attributes may includes speed, accuracy, ease of use, display readability, safety, ergonomics, etc. Performance Requirements are key to Successful Projects ! DO: Design to Requirements ! DO NOT: “Find” Your Requirements from Your Design or Components !

595 File Formats General Filename Format: Team#-SemesterXX-Docname.ext   General Filename Format: Team#-SemesterXX-Docname.ext Where: # = the team number (assigned during week 1) Semester = Fall or Spring XX = 2 digit year Docname = Requirements, Project-Plan, Presentation, Project-Report, User-Manual or Lab# ext = doc, xls, ppt or other proper file extension name Examples: Team3-Spring03-Lab7.doc (Team 3, Spring 2003, 7th Lab file) Team2-Spring07-Requirements.xls (Team 2, Spring 2007, Requirements Spreadsheet) Team6-Fall05-Project-Report.doc (Team 6, Fall 2005, final project report file) Team5-Fall04-Presentation.ppt (Team 5, Fall 2004, final ppt presentation file)

Capstone Design Project Safety Safety Glasses Must be Worn When ……. Soldering, Drilling, Sawing, Sanding, Gluing and Filing Using of heat gun or other heat sources for tubing shrinkage or other assembly When trimming leads of wires particularly on soldered connections When using any type of power tools AC Power in E203 Standard Grounded Outlets on 20AMP Breakers, Caution: NO GFCI’s Food/Drink Lab bench areas are used for soldering lead based alloys Keep food/drink away from of lab bench areas. ESD Lab bench areas are equipped with ESD grounding pads

Lecture & Lab Attendance Capstone Design Project Lecture & Lab Attendance Lab Assistant will keep attendance records Advance notice of absence is requested whenever possible so we can inform your team members Whenever possible you should also contact at least one other team member for advance notice of absences Project Teams will also keep attendance records for all Team meeting times outside of scheduled classes. (LPI Role) Absentee’s responsibility to obtain missed material from lecture/lab and team meetings