Remote Controlled Car

Team #: 4 BSEE Jordan Acevedo Phosay Bouapha Corey Preuss Ben Reider Lee Strauss

Team #4: Expertise & Experience Jordan Acevedo Phosay Bouapha Corey Preuss Ben Reider Lee Strauss Expertise: Digital: PLD/FPGA VHDL, Soldering, Troubleshooting Experience: 2 Year Internship at Rockwell Automation Expertise: Analog: Amplifier, Filter Design Experience: None Expertise: Hardware, Software Validation, Mathematics Minor Experience: 3 Internship Terms at GE Healthcare Expertise: Power Supplies & Systems, Soldering, Business Minor Experience: 2 Co-Ops at Kohler Corp. Expertise: Power Supplies & Amplifiers

Team #4: Total Resources 10 Manhours/week $200 budget

Proposed Product Summary Selected Product Remote Controlled Car Entertainment Details Miniature toy replica of a car, controlled remotely. Primary use of product is for entertainment and educational purposes. With proximity sensors, user is less likely to break product by running it into a wall. Yes there are similar products, but not identical due to fact of added damage protection and intended future use. Major industry family the product belongs to is consumer toys.

Project Selection Overall Selection Process The remote controlled car project provided more challenges and involved more complex aspects than the other projects. Major risks involve making sure all of our components work together well. Because our product contains moving parts, it is important that they work according to our specifications because safety concerns. Our other projects were rejected because they did not have enough blocks in the diagrams to satisfy our electronic requirements. This project was unanimously supported by all five members of our group.

System Level Performance Requirements Remote controlled (frequency band) Forward and Reverse, left and right steering, power Proximity sensors Detection of distance from nearby objects and emergency power shut off if car gets too close Headlights Headlights attached to front of car for illumination purposes. Can be turned on or off by the user from the remote control. Lights will also have dimming capability. Blinkers Array of 10 LEDs will click on or off based on user input to represent turn direction.

System Level Standard Requirements 100 Total Parts 30 Unique Parts $150 (Parts+Mfg=Product Cost) $50 (Parts+Mfg=Product Cost) 4 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 Level Standard Requirements 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 0-60 Co 20-95% non-condensing 0-3500 Meters 10-65Co 0-90% non-condensing 1 year

System Level Standard Requirements Estimated Annual Income Min List Price Max Product Material Cost Max Product Mfg Cost Estimated Annual Contribution Operating Voltage Range $100000 300 $80 $30 $50000 12V to 48V

Team Block Diagram DC-DC Converters Battery Motor PWM Microprocessor Proximity Sensor Dimming HeadLights Blinkers RF Signal

Block Diagram Description Block Name Owner Brief Description Of Block Function Power Interfaces Digital Analog 1 Power Supply Lee Converts Battery 12-48VDC Power to 5, 12, -12 VDC In: DC12-48V Out: 5 VDC Out: 12 VDC Out: -12VDC None 2 PWM Controller/ Micro-Processor Jordan Receives the RF signal controls the PWM signal to relate to the speed and direction desired by the user. In: 5VDC Out: 5VDC PWM Signal 3 Blinkers Ben Receives the RF signal and controls the cars blinkers. In:5VDC Out:5VDC On/Off pulse 4 Proximity Sensor Corey P. Senses distance from nearby objects and stops the car through the main PWM signal. On/Off 5 Dimming Headlights Phosay Brightness of the headlights controlled external environment. Photo Sensor

Ethics Considerations Since this is an entertainment product, the group did not see much room for conflicts of interest, bribery, and kickbacks. Safety can be an issue though; since children could play with the car, we’d have to make sure that the moveable parts are safe. While driving the car, someone could be hit, which could cause potential injury. To mitigate this, we need to make sure our proximity sensor switch works effectively. Legally, our remote controlled car could have problems if it is not differentiated enough from other cars in the market. Since remote controlled cars have been being manufactured for years, the idea is probably in the public domain. To stray from this, we will be using a remote controlled car of a larger size. Environmentally, the group doesn’t see any major considerations that must be made. We could try to find a more efficient power source, since batteries must be thrown away or recharged. Also, we could use more environmentally friendly solder and materials to minimize the effects of lead and other hazardous materials found in many components.

Applicable Patents Title: Radio control car Document Type and Number: United States Patent 5334076 There is no work around with this patent, royalties will be determined. Title: Recreational electric vehicle Document Type and Number: United States Patent : 7243746 This patent involves an indoor or outdoor vehicle for one or two people with a space for personal goods.. REV is driven using a joystick and is able to turn on the spot. Our design will not use a joystick that can control the vehicle in a 360 degree manner, but only in forward and reverse. Also our vehicle will not be primarily used for people to ride Title: Children's ride-on vehicle Document Type and Number: United States Patent: D393888 This is the actual patent for a power wheels vehicle that we will be using, therefore we must pay royalties.

Team Gantt Chart

Block 1: Power Supplies Owner: Lee Strauss Power the system that runs and controls the car. Looking for +5 volts for operation Input of 12 volts from battery Buck Regulator used to achieve 5 volt output

Block Diagram

Buck Regulator LM5005 Current: 250mA – 2.5A Operating Frequency: 50kHz to 500kHz Integrated 75V, 2.5A N-Channel Buck Switch Ultra-wide input voltage range from 7V to 75V Internal high voltage bias regulator Current mode control with emulated inductor current ramp Wide bandwidth error amplifier

5V Buck Regulator

Bill of Materials High Voltage Buck Regulator – LM5005 Capacitor 0.022uF – Part#: 08051C223JAT2A Capacitor 1uF – Part#: 08053D105KAT2A Capacitor 0.027uF – Part#: 08053D105KAT2A Capacitor 6.8 uF, 1.8ohms – Part#: EEV-FC1V6R8R Capacitor 10uF, 2ohms – Part#: EEV-FC1H100P Capacitor 0.003uF – Part#: GRM2165C1H302JA01D Capacitor 0.0082uF – Part#: 08055C822KAT2A Diode 0.5v – Part#: B130B-13 Inductor 330uH, 0.574ohms – Part#: DR127-331-R Resistor 1.43K ohms – Part#: ERJ-6ENF1431V Resistor 1K ohms – Part#: ERJ-8ENF1001V Resistor 2.26K ohms – Part#: ERJ-6ENF2261V Resistor 21K ohms – Part#: ERJ-6ENF2102V

Block 2: PWM Controller/ Micro-Processor Owner: Jordan Acevedo

Block 2: PWM Controller/Micro-Processor Description and Purpose The PWM Controller will receive a digital pulse transmitted from remote control and the width of the pulse will determine the desired speed of the car and the width of another pulse will determine the driving direction of the car (forward/reverse). Purpose: Control the speed and direction of the car.

Block 2: PWM Controller/Micro-Processor Block Diagram In From Proximity Sensors Output to Motor Controller Pulse Width Modulation (PWM) Chip Input RF Signals Micro Processor In From Power Supply (+5V) In From Power Supply (+5V)

Block 2: PWM Controller/Micro-Processor Block Signal Definitions Block Name: PWM Controller/Micro-Processor Block Number: 4 Power Signals To - From Type Direction Block-Block Voltage Voltage Range   Block #'s Interconnect Nominal Min Max Power2 5VDC 2 DC Power Input Connector-Cable 5V 4.5V 5.5V Freq Freq Range % V-Reg V-Ripple Current 60Hz 55Hz 65Hz <10% 200mA Digital Signals Dir Output Tech Logic Structure Digital 1 RF Signal Processor Receiver Digital PCB Trace N/A Standard TTL Variable Digital 2 PWM Signal Controller Mot. Contr. Digital 3 Proximity Sensors 5 Cable Input Characteristics Output Characteristics Vih Min Iih Max ViL Max IiL Max Vth Min Vth Max Voh Min Ioh Max VoL Max IoL Max 0-1.8V 0-0.7A 3.7-5.0V 1.4-2.0A

Block 2: PWM Controller/Micro-Processor Theory of Operation As the user presses forward on the remote control, the remote transmits pulses to the receiver. The width of two of these pulses will determine the speed and driving direction of the car. As the control stick on the remote is pressed further, the width of the pulses increases and the car will move faster in the desired direction. If the IR Proximity Sensors are tripped “ON”, the car will no longer be able to drive forward, when the sensors are “OFF” and then full operation will be restored.

Block 3: Blinkers Owner: Ben Reider Description - To receive and interpret a RF signal from controller and output a pulse that blinks either the right or left side blinkers on the car. Purpose – An accessory used to indicate which direction the car turn.

Block 3: Block Level Requirements Must work off of a 5 Vdc power supplied Must be able to handle a max current input of 150mA if needed to meet power supplies min current output. Needs to operate within system temp. requirements of 0-60°C Must read and interpret RF signal Needs to relay power from battery in order to ensure brightness of lights Needs to blink lights once every other second Robustly build to protect against driving collisions Low power dissipation Low cost

Block #3 Blinkers Block Diagram #2 12V Battery #1 5 VDC Power Supply #3 Microprocessor PIC12F509 8 Pin, DIP #6 MOSFET #4 MOSFET #7 Front Light Array 12V #7 Rear Light Array 12V #5 Front Light Array 12V #5 Rear Light Array 12V RF Signal

Block #3 Blinkers Block Specifications

Block #3 Microprocessor Program Flow Diagram Start Check for pulse Signal Read in 5th pulse Measure width of 5th pulse Compare width to nominal value Check zero flag Z=0 LeftBlink=1 Z=1 RightBlink=1 Output Output 1 Sec Delay 1 Sec Delay Output LeftBlink=0 RightBlink=0 Output Interrupt 1 Sec Delay 1 Sec Delay Interrupt

Block #3 Component Selection LEDs Selected because in a series connection they could meet the change in source voltage(12-48V) Low cost and Long Lifetime Robustly built Low Power (144mW each) Transistors 60V Source to drain Voltage which meets the max source voltage of 48V Low power dissipation at 350mW Max Microprocessor Least expensive yet meet programming requirements 6 output/input Can handle the max current input of 150mA Lower Power (800mW Max)

Block #3 Component Specifications

Block #3 Preliminary Schematic

Block #3 Bill of Materials

Block 4: Proximity Sensor Owner: Corey Preuss Part #: GP2Y3A003K0F (from Digikey) Wide Angle Distance Measuring sensor unit (40 – 300cm)

Block 4: Proximity Sensor Preliminary Bill of Materials Part Mfg Part # Description Qty. Package Dimensions 1 GP2Y3A003K0F Wide Angle Distance 1 53x20x18mm Measuring Sensor Unit 2 Capacitor 10uF 1 ---

Block 4: Proximity Sensor Calculations and Specifications Absolute Maximum Values/Limits Measuring Distance Range: 40-300cm # of Outputs/Type: 5 Analog Outputs Detection Angle: 25 Degrees Supply Voltage Range (Vcc): -0.3 to +7V Output Terminal Voltage(Vot): -0.3 to Vcc(+0.3V) Input Voltage(Vin H/L and LED H/L): -0.3 to +Vcc(0.3V) Operating Temperature(Topr): -10 to +60 Degrees Celcius Storage Temperature: -40 to +70 Degrees Celsius

Block 4: Proximity Sensor Calculations and Specifications Electro-optical Characteristics Average Supply Current(Icc Ave./Max.): 30/50mA Ideal Supply Voltage(Vcc): 4.5 to 5.5V Output Voltage(Vo): Min: 2.0 Ave: 2.3 Max: 2.6V Output Voltage Differential(ΔVo): Min: 0.9 Ave: 1.2 Max: 1.5V (between 40cm and 100cm) Input Voltage: VinH: 4.5V(min.) VinL: 0.3V(max.) LED H: 4.5V(min.) LED L: 0.5V(max.)

Block 4: Proximity Sensor Theory of Operation Proximity switch receives input voltage and current from power supply via the microprocessor Sensor measures distance to nearby object If object is close enough to trigger the sensor “ON”, an interrupt will be sent through the microprocessor to the motor disabling the car’s forward position movement Vehicle will be allowed to move in reverse direction until proximity sensor is switched “OFF”, and the car will then be allowed to move forward

Block 4: Proximity Sensor Description and Purpose Sensor used for measuring distance from the car to nearby objects and sending a signal to the motor via the microprocessor to shut off if it gets too close to the object. Car will then only be allowed to move in reverse until it is a safe distance away from the object and will then be allowed to move forward. Operation is used for safety concerns

Block 4: Proximity Sensor Block Diagram Breakdown/Schematic

Block 5: Dimming Headlights Owner: Phosay

Block 5: Dimming Headlights Description – Circuit to dim the headlights when the car is in a bright environment, while operating in a bright environment, the head lights will be at max brightness. Purpose – An accessory used to allow the car to automatically control the headlights by it self.

Block 5: Dimming Headlights Block Diagram P722-5R Block 5: Dimming Headlights Block Diagram +12V Battery +5V Power Supply -12V Power Supply Photo-resister 2 x Inverting op-amps Left Head light Right Head Light

Block #5 Detailed Design Calculations and Component Selection Lights Selected because of price and efficiency. Long Lifetime Low Power (144mW each) Photo-Resistor Type(P722-5R) Resistance range of 15KOhms at 1 lux to 1.1KOhms at 100 lux Has desired performance range Power dissipated (70mW) Op-amp Inexpensive and meets performance requirements

Block 5: Proximity Sensor Preliminary Bill of Materials Part # 276-1657(Radio Shack) LM741CN 1.0KQBK-ND SSL-LX3044YD-12V Description Photo-resistor Op-amp Resistor Lights(LED) Qty.1 2 4 60 Price(each) $0.40 $0.22 $0.054 $0.23 Total cost = $14.86

Bright environment (100lux) max photocell resistance(Rp) Block 5 Bright environment (100lux) max photocell resistance(Rp)

Output Voltage in bright environment (100lux) max photocell resistance Block 5 Output Voltage in bright environment (100lux) max photocell resistance

Dark environment (1lux) min photocell resistance(Rp) Block 5 Dark environment (1lux) min photocell resistance(Rp)

Output Voltage in dark environment (1lux) min photocell resistance Block 5 Output Voltage in dark environment (1lux) min photocell resistance

Output Voltage in medium environment, 7KOhms photocell resistance Block 5 Output Voltage in medium environment, 7KOhms photocell resistance