Team 1: Staff Dan Piessens Henrik Gustavsson David Luu Brent Wellner BSEE / BSCS BSEE

Team 1: Expertise & Experience Dan Piessens Henrik Gustavsson David Luu Brent Wellner Expertise: PLD/FPGA, Microprocessors, Software Experience: 5 yrs software development Expertise: Microprocessors, AutoCAD, Software Experience: 6 semesters consultant @ TetraPak Expertise: AC/DC Conversion, MathCAD, Matlab Experience: N/A Expertise: PLD/FPGA, VHDL Experience: 1.5 yrs Modine Manufacturing

Team 1: Contact Info Dan Piessens Henrik Gustavsson David Luu Brent Wellner Phone: (414)719-0562 Email: piessens@uwm.edu Phone: (262) 818-9325 Email: karlgg@uwm.edu Phone: (414) 423-5643 Email: nghialuu@uwm.edu Phone: (920) 217-0043 Email: bwellner@uwm.edu

Team 1: Weekly Availability Worksheet Dan Piessens Henrik Gusatvsson David Luu Brent Wellner Time 1: M/W 12:30 - …. Time 2: F/S/Su Time 3: T 1:00 - 3:30 Time 4: Time 1: M/W 12:30 - 3:30 Time 2: T/Th - 3:30 Time 3: M/W 6:30 - …. Time 4: F/S/Su Time 1: M/W 1:00 - 3:00 Time 2: F/S/Su Time 3: T …. - 6:30 Time 4: Time 1: M/W …. - 5:00 Time 2: Su Time 3: T/Th …. - 6:30 Time 4:

Team 1: Weekly Project Meeting Plan Weekly Meeting 1: IEEE Office, Thursday 01/27/05 8:30 - 10:30 PM Henrik, All attendees & Purpose: Discuss Project Objectives Weekly Meeting 2: IEEE Office, Tuesday 02/01/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Expand on Project Ideas Weekly Meeting 3: IEEE Office, Tuesday 02/08/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Finalize Project Selection Weekly Meeting 4: IEEE Office, Tuesday 02/15/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Constructed Project Overall Design Weekly Meeting 5: IEEE Office, Tuesday 02/22/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Individual Blocks & Requirements Weekly Meeting 6: IEEE Office, Tuesday 03/01/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Finalized Requirements Spreadsheet Weekly Meeting 6: IEEE Office, Tuesday 03/08/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Finalized Task lists Weekly Meeting 6: IEEE Office, Tuesday 03/11/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Correct Presentation 2 Slides Weekly Meeting 6: IEEE Office, Tuesday 03/1505 1:00 - 3:00 PM Henrik, All attendees & Purpose: Preparation for Lab 5 Weekly Meeting 6: IEEE Office, Tuesday 03/29/05 1:00 - 3:00 PM Henrik, All attendees & Purpose: Note: Meeting Owners Send Weekly Email Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

Team 1: Total Resources 1000 Man-hours (Including: lab, weekly meetings, individual commitments ) $400 or key part availability for material and prototyping

Team 1: Decision Making Decisions will be made through a consensus, based upon: resources, time consumption and cost. Majority vote applies in the event of an irresolvable conflict.

Roles to Define & Assign Project Integrator: Dan Piessens - Owns weekly progress reports to TA. Logistics and communication of team meetings. Develops and Tracks overall project plan. Integrates Block design plans. Tracks expenditures. Owns project level verification and validation plan, capture and documentation of results. Presentation Mgr: Henrik Gustavsson - Owns master MS Powerpoint slide set for team including formats, logos, fonts, colors, header/footer, backgrounds, rev control, submission of master floppy or CD for P1-P4 and Final Presentation. Report Mgr: Brent Wellner - Owns master MS Word document for team including revision control, formats, logos, fonts, colors, header/footer, table of contents, submission of master floppy or CD for Final report. Archive Web Mgr: Dan Piessens - Owns weekly backup of all electronic material generated that week. Backup for Presentation Mgr and Report Mgr. Management of any team Web site resources. Assembly & Proto Mgr: Brent Wellner - Owns overall assembly level definitions, basic assembly drawings, master prototype & product parts lists, collection of block parts lists, procurement of proto components. Overall prototype mechanical and electrical assembly PCB Layout Mgr: David Luu - Owns overall PCB layout, Block to PCB mapping, PCB tools, PCB design drawings, PCB procurement, PCB assembly including special tools, soldering, wire-wrapping, drilling, and gluing.

Catch-a-Buzz Buzzer system: Why is this a good project? This system is designed for users to participate in games like a quiz bowl. Users would be able to hit a button on a remote unit that would transmit the response wirelessly to a center console that indicates who responded and keeps track of a scores. Alternately user can respond to a multiple choice question, the console would then indicate the correct answer and score. Buzzer system: Allows for 1 to N remote units Master console that indicates responses and team scores Two operation modes: First unit to respond Correct answer multiple choice Display team scores either on LCD or TV out Why is this a good project? Large target market: schools, organizations, weddings Easy to use for people, simple remote interface Utilizes the skill of each team member fully

Catch-a-Buzz - Block Diagram Console Unit Remote Unit Power 120V Transformer RF Transceiver Power Battery RF Transceiver Microprocessor CPLD LCD Display / LED Keypad Input LED / 7 Segment Display Button Input

RF controlled Belaying Machine The RF controlled belaying machine is a device intended for use by rock climbers in an indoor rock climbing facility. The primary objective of this device is to substitute the use of a human belayer through the safe use of a belaying machine. The key performance aspect of this device is that it eliminates the use of a belayer when indoor rock climbing. It delivers all control to the climber through a simple RF module which controls the various modes in which the machine can be used. The base/motor drive is powered by a typical 120V power outlet. The remote unit is Li-polymer powered and is recharged through a unit positioned on the base/motor drive. The user interface consists of a pushbutton type user interface with confirmation LED’s for each command. The user interface controls the different modes of operation: belay, slack adjustment, stop and rappel. This project is a good fit for the team due to it’s interesting and practical nature. An RF controlled belaying machine does not exist, it would be the first of it’s kind. It’s marketability is very plausible for all indoor rock climbing centers.

Belaying Machine - Block Diagram Base / Motor Drive Remote Transceiver Remote Charger Transceiver Transceiver Input / LED’s CPU CPLD Power Supply Motor / Drive Power Supply

Enroute - Overview Transit Notification System: This system consists of units at each bus stop that communicate with a remote on every running bus. This allows a bus to only stop at a bus stop if notified by the unit at the station. The users notify the bus via push buttons on the station transceiver. Both Transceivers are programmable via a keypad on their respective units. The station transceiver also contains a taxi call card swipe that sends a request to a server via a network interface.

Enroute - Features Station Transceiver Unit: Bus Transceiver Unit: Ability to request different busses via push buttons Programmable via keypad Network interface for taxi notification and confirmation Powered by 120V AC Source Bus pickup notification Bus Transceiver Unit: LCD & LED display for stop notification Communicates with stations via RF transceiver Powered by 12V DC Source Post-pickup cancellation

Enroute - Block Diagram Bus Transceiver Unit Station Transceiver Unit U.I. 1 Transceiver Transceiver NIC Henrik U.I. 2 CPU1 CPU2 Dan Brent PSU 1 Setup Controls PSU 2 Setup Controls David

Enroute - Justification Why is this a good project? Large target market: useful in any city with a public transit system. No competitive products exist: Unique to the transportation market Easy to use for people, simple interfaces on both ends Reduces ride time and mechanical wear Convenience of notifying taxies Fully utilizes the skill of each team member

Enroute - Product Selection Process Major Risks: Too many blocks - overly complicate design Why were other projects rejected? Other projects were not as closely related to our individual expertise Mechanical challenges with the Belaying machine Lack of marketability for the Catch-A-Buzz product Product Selection: Project selection was unanimous

Standard System Level Requirements Standard Requirements Environmental: Operating Temperature Range: -40 to 70 °C Operating Humidity Range: 2 to 98 % Storage Temperature Range: -30 to 80 °C Storage Humidity Range: 2 to 98 % Storage Duration: 2 Years Energy Sources: 120 VAC (114-126 V, 68-62 Hz) 12 VDC (10-15 V) Over Voltage Protection Circuitry

Standard System Level Requirements Standard Requirements Mechanical: Max Product Volume = 9,000 cm2 Max Product Mass = 5 Kg Max Total PCB Area = 600 cm2 Life Cycle: Production Lifetime = 5 Years Reliability in MTBF = 5 Years Full Warranty Period = 1 Year Service Strategy: Distributor Repair, Return to Mfg.

Performance System Level Requirements Performance Requirements Electrical Functions: Power Modes: On, Off Function Modes: Normal Configure Functional Features: Bus Call Taxi Request Electrical Interfaces: Analog, Digital and Power Signals Bi-Directional RF Transceivers RS232 Network Interface

Performance System Level Requirements Performance Requirements Operator I/F Outputs: LED (1) Momentary Pushbutton (4) 16 Digit Matrix Numeric Keypad (2) 16 x 2 LCD Display (2) Magnetic Card Swipe (1) Mechanical Interfaces: Mounting Brackets RS232 Connectors RJ-45 DIN-5

Performance System Level Requirements Performance Requirements Safety Power Signal Current Limit Max = 1.5 Amps Power Signal Current Limit Max Trip Time = 2 Sec Power Signal Ground Fault Max = 500 mAmps Power Signal Ground Fault Max Trip Time = 8.3 mSec Maximum Potential of User Surfaces = 5 Volts Ground Fault Protection

Performance System Level Requirements Safety Codes IEC 61204 IEC 61204 specifies the safety requirements for power supply units (PSUs) providing DC output(s) with or without auxiliary AC output(s) operating from AC or DC source voltages up to 600 V AC or 1 000 V DC. IEC 61000-6-3 Applies to electrical and electronic apparatus intended for use in the industrial environment for which no dedicated product or product-family emission standard exists. Apparatus designed to radiate electromagnetic energy for radio communication purposes is excluded from this standard. Disturbances in the frequency range 0Hz to 400 GHz are covered. Fault conditioning of apparatus are not taken into account. Also applies to apparatus intended to operate in industrial locations or in proximity to industrial power installations. IEC 61000-6-1 Applies to electrical and electronic apparatus intended for use in the residential, commercial and light-industrial environment for which no dedicated product or product-family emission standard exists designed to radiate. Disturbances in the frequency range O Hz to 400 GHz are covered. EN 61000-6-2 (level 1) No degradation of performance or loss of function is allowed below a performance level specified by the Mfg when the apparatus is used as intended.

Basic Business Case Estimate the Average Product Selling Price (ASP$): $200 (Base) / $100 (Bus) Estimate the Product Annual Sales Volume: 2,000,000 (Base) / 1,000,000 (Bus) Estimate the Per Unit Cost of all Parts and Materials using the above annual volume assumption: $130 (Base) / $50 (Bus) Estimate the Per Unit Cost of all the Assembly, Test and Mfg using the above annual volume assumption: $20 (Base) / $20 (Bus) Estimate the Total Development Cost in $ incl. Labor & Material: $500,000 Calculate the Annual Sales $ = 500 M Calculate the Per Unit CM$ = $150 (Base) / $70 (Bus) Calculate the CM% = 0.75 (Base) / 0.70 (Bus) Calculate the Annual CM$ = $362.5 M Calculate the ROI Time in Years = 0.01 Years

Setup Block Specifications Description: Using a 4x4 keypad, a PIC 16F84 micro detects the manual input producing a digital ascii character output to a 1-wire rs232 interface which is sent to the corresponding CPU. Performance Requirements: Power Inputs: 5 VDC input (nominal) Electrical Interfaces: 4x4 Input Keypad rs232 Network Interface Operator Outputs: Digital ascii character output on a 1-wire rs232 interface to CPU

Setup Block Specifications Standard Requirements: Environment: Operating Temperature Range: -40 to 70 °C Operating Humidity Range: 2 to 98 % Storage Temperature Range: -30 to 80 °C Storage Humidity Range: 2 to 98 % Life Cycle: Production Life 5 Years Full Warranty Period: 1 Year Service Strategy: Distributor Repair Mechanical: Block Mass: .5 Kg Block PCB area: 60 cm2

Setup Block Specifications Internal Block Diagram CPU 1 / 2 6 Data Lines PIC Processor 8 Data Lines 4 x 4 Keypad Power Supply 5V DC

Setup Block: Signal Table Power Digital

Setup Block Specifications Prototyping Plan: Purchase components construct circuit layout build prototype Costs: $12 - Keypad $2 - PIC $2 - Resistors / Capacitors Total for Setup Block ≈ $16 Maximum per Block Cost = $25.20 Maximum Mfg Assembly / Test Cost per Block = $5.60

Setup Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Type Socketed Components Types of Connectors Setup 60 None Plastic pads, no busses Prototype board 0.25 headers

CPU1 Block Specifications Description: Primary processing core for bus Handles processing of RF data Receives Inputs from UI and Setup blocks and responds appropriately Performance Requirements: Power Inputs: 3.3 VDC Input Electrical Interfaces: 10 bit Digital Line Interface to RF Block 6 bit Digital input from Setup Block 8 bit Digital I/O with User Interface 1 Operator Outputs: Digital signal to LCD display

CPU1 Block Specifications Standard Requirements: Environment: Operating Temperature Range: -40 to 70 °C Operating Humidity Range: 2 to 98 % Storage Temperature Range: -30 to 80 °C Storage Humidity Range: 2 to 98 % Life Cycle: Production Life: 5 Years Full Warranty Period: 1 Year Service Strategy: Distributor Repair Mechanical: Block Mass: .5 Kg Block PCB area: 60 cm2

CPU1 Block Specifications Internal Block Diagram UI I/O 8 Data Lines U.I.1 Block Setup Block 6 Data Lines Atmel Processor RF I/O 10 Data Lines RF Block Power Supply 5V DC

CPU1 Block: Signal Table Power Digital

CPU1 Block Specifications Prototyping Plan: Use Atmel ATMega chip as a microprocessor Use the development board to prototype block Program system incrementally, testing modular interfaces such as I/O based on temporary mock-ups on a breadboard before item is complete Costs: Atmel Board = $38 Maximum Block Cost = $18 Maximum Mfg Assembly / Test Cost per Block = $4

CPU1 Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Type Socketed Components Types of Connectors CPU 1 121 Plastic pads, no busses Prototype board None 0.25 headers

RF Block Specifications Description: Receives serial signal with governing clock from CPU for transmission Transmits serial data from RF receiver with internal clocking signal Chip is a Freescale part and handles all transmit/receive functions internally eliminating the need for external amplification / recovery Performance Requirements: Power Inputs: 5 VDC input Electrical Interfaces: Analog Antenna Receive / Transmit 10 bit Digital line Interface Operator Outputs: None

RF Block Specifications Standard Requirements Environment: Operating Temperature Range: -40 to 70 °C Operating Humidity Range: 2 to 98 % Storage Temperature Range: -30 to 80 °C Storage Humidity Range: 2 to 98 % Life Cycle: Production Life: 5 Years Full Warranty Period: 1 Year Service Strategy: Distributor Repair

RF Block: Signal Table Power Digital Analog

RF Block Specifications Internal Block Diagram 2 Analog Lines Freescale Transceiver RF I/O 10 Data Lines CPU2 Block Power Supply 3.3V DC

RF Block Specifications Prototyping Plan: Layout circuit from Freescale in a PCB layout program Purchase circuit board, transceiver, discrete components and antennas Test signals by hooking up fixed voltage sources to try transmission / link Interface with CPU block Costs: $20 PCB Boards $2 - Resistors / Capacitors Maximum Block Cost = $25 Maximum Mfg Assembly / Test Cost per Block = $10

RF Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Type Socketed Components Types of Connectors RF 20 Plastic pads, no busses PCB Board None 0.25 headers

CPU2 Block Specifications Description: Primary processing core for station Handles processing of RF data Receives Inputs from UI and Setup blocks and responds appropriately Uses NIC block to communicate over TCP/IP to server for Taxi system Performance Requirements: Power Inputs: 3.3 VDC input 1.5 VDC input Electrical Interfaces: 10 bit Digital line Interface to RF 32 bit Digital line Interface to NIC 10 bit Digital input from Setup 10 but Digital I/O with U.I. 2

CPU2 Block Specifications Standard Requirements: Environment: Operating Temperature Range: -40 to 70 °C Operating Humidity Range: 2 to 98 % Storage Temperature Range: -30 to 80 °C Storage Humidity Range: 2 to 98 % Life Cycle: Production Life: 5 Years Full Warranty Period: 1 Year Service Strategy: Distributor Repair

CPU2 Block: Signal Table Power Digital

CPU2 Block Specifications Internal Block Diagram NIC Block NIC I/O 32 Data Lines UI I/O 8 Data Lines U.I.2 Block Setup Block 6 Data Lines Altera CPLD RF I/O 10 Data Lines RF Block Internal Bus 1.5V DC Power Supply 16 MB SDRAM 4 MB Flash 3.3V DC

CPU2 Block Specifications Prototyping Plan: Use Altera Stratix CPLD as a soft processor system Use the development board I own to prototype CPU and NIC blocks Program system incrementally, testing modular interfaces such as car swipe and I/O based on temporary mock – ups on a breadboard before item is complete. Connect final components and program final TCP/IP server code Costs: Maximum Block Cost = $22 Maximum Mfg Assembly / Test Cost per Block = $5

CPU2 Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Type Socketed Components Types of Connectors CPU 2 121 Plastic pads, no busses Prototype board None 0.25 headers

UI Block Specifications Performance Requirements Operator I/F Outputs: LED Momentary Pushbutton 16 x 2 LCD Display Power Modes of Operation: ON/DC LCD Display On/Mom DC Pushbutton ***Optic Sensor (for backlight of LCD)***

Standard System Level Requirements Standard Requirements Environment: Operating Temperature Range: -40 to 70 °C Operating Humidity Range: 2 to 98 % Storage Temperature Range: -30 to 80 °C Storage Humidity Range: 2 to 98 % Storage Duration: 2 Years Energy Sources: 4.75-5.25 DC LCD digital max power range 4.75V – 5.0V

Block Signal Table: Power Most Blocks will consume or deliver power All Power Distribution must be accounted for

Block Signal Table: Digital

U.I. 1 Block Specifications Internal Block Diagram LCD Display UI I/O 8 data lines

U.I. 2 Block Specifications Internal Block Diagram Push Buttons LCD Display Card Swipe UI I/O 10 data lines

U.I. Block Specifications Prototyping Plan: Purchase components (LCD Display, Push-Button) construct circuit layout build prototype Costs: $6.00 * 4 push buttons $12.00 * 2 LCD Displays

Power1 Block Diagram Power1 at the bus +5V +5.25V 12 V +3.3V +5V TRANSC.1 +5.25V U I.1 12 V PS1 CPU1 +3.3V +5V SC.1

Power2 Block Diagram Power2 at the station +5 V +5.25V 120 V AC +3.3V TRANSC.2 +5.25V U I.2 CONVERTER TRANSFORMER PS2 120 V AC CPU2 +3.3V +5 V SC.2

Power Block Introduction Description • Using 120VAC, permanent supply to the Set-up Control, CPU, U.I and Transceiver at the Station Using 12 V DC supply to the Set up Control , CPU, IU and Transceiver at the Bus

Power Block Performance Requirements Power Inputs: 120 V AC power input ranging from 57 - 63 Hz (Station Unit) 12V DC input (Bus Unit) Over Voltage Protection Electrical Functions: Power supply to the CPU, Set up Control, UI and Transceiver Electrical Interfaces: Analog, Digital and Power Signals Bi-Directional RF Transceivers RS232 Network Interface

Power Block Performance Requirements Electrical Functions: Power Modes: On, Off Function Modes: Normal Configure Functional Features: Bus Call Taxi Request Electrical Interfaces: Analog, Digital and Power Signals Bi-Directional RF Transceivers RS232 Network Interface

Power Block Performance Requirements Electrical Functions: Power Modes: On, Off Function Modes: Normal Configure Functional Features: Bus Call Taxi Request Electrical Interfaces: Analog, Digital and Power Signals Bi-Directional RF Transceivers RS232 Network Interface

Power Block Standard Requirements Energy Source: • 120 VAC ( 108 to 132 VAC +- 10% ) • 120 VAC transformer secondary: 10 V , 20VA

Power Block Standard Requirements Modes: On ( Primary, 120 VAC) Frequency Range: • 60 Hertz ( 57 to 63 Hz range) Safety: • 1.5 A max current limit protection • 12 V maximum potential of user surface • 132 V over-voltage surge protection

Power Block Standard Requirements Mechanical: Life Cycle: Maximum area of the power supply board is 400 cm² Life Cycle: Production Life 5 Years Full Warranty Period: 1 Year Service Strategy: Distributor Repair

Power Electrical Interface signal

Power Block Implementation Power1 at the bus TRANSC. 1 U I.1 12VDC CPU. 1 SC .1

Power Block Implementation Power2 at the station TRANSC. 2 U I.2 120VAC Transformer.2 Converter.2 Power Isolation2 CPU. 2 SC .2

Power1 Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) Components components Costs Power 1 200 12 V DC AC/DC converter Diodes, R, C $30

Power2 Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) Components components Costs Power 2 200 120V AC AC/DC converter Diodes, R, C $30

Block Prototyping Plan Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors CPU 1 121 Plastic pads, no busses Prototype board None 0.25 headers CPU 2 UI Modules Soldering Power 1,2 2,622 AC Adapt Setup 60 RF Module 72.6

EnRoute Timeline Summary Hours Total Total Manpower Estimated: 1085 Available 1000 Total Material Estimated: $247 Available $500 Time Percentages Overall Project Design : 10% Block Design: 90% Recommendations Time will be less for RF and NIC blocks since they require no prototypes.

EnRoute Gantt Chart