ECE 477 Final Presentation Group 11  Fall 2004 Jeff Killen Brandon Ade Drew Whipple Matt Compton

Outline Project overviewProject overview Block diagramBlock diagram Professional componentsProfessional components Design componentsDesign components Success criteria demonstrationsSuccess criteria demonstrations Individual contributionsIndividual contributions Project summaryProject summary Questions / discussionQuestions / discussion

Project Overview “Cold as Ice” Refrigerator“Cold as Ice” Refrigerator Intelligent applianceIntelligent appliance –RFID scanning for real-time inventory –Digital temperature control –Remote user interface through Ethernet –Local user interface with LCD and keypad RFID is an emerging technologyRFID is an emerging technology –Current products –Many future applications

Block Diagram 9V DC wall-wart Texas Instruments Housed S6350 Midrange RFID Reader RabbitCore RCM2200 C- Programmable Module 12V DC wall-wart National Semiconductor LM2676S – 5.0 3A step-down voltage regulator Maxim +/- 15kV ESD-Protected, Signle/Dual/Octal, CMOS Switch Debouncers Storm 3K button keypad Microchip TC72 Digital Temperature Sensor with SPI Interface Potter & Brumfield T77S1D10-05 Sealed Power Relay Compressor Ethernet Port 120V AC wall outlet DB9 Connector 9 2 ~ Reset Switch Crystalfontz America, Inc. Mod. CFAH2004A-NYA-JP 4x20 LCD RFID Button

Professional Components Constraint analysis and component selection rationaleConstraint analysis and component selection rationale Patent liability analysisPatent liability analysis Reliability and safety analysisReliability and safety analysis Ethical and environmental impact analysisEthical and environmental impact analysis

Constraint Analysis MicrocontrollerMicrocontroller –Ethernet Interface –Simplicity RFID KitRFID Kit –Range - Ideally –Problems –Alternatives

Patent Liability Analysis Possible Literal InfringementsPossible Literal Infringements –6,327,576: System and method for managing expiration-dated products utilizing an electronic receipt Recommend to pay licensing fees to FujitsuRecommend to pay licensing fees to Fujitsu Possible Doctrine of Equivalents InfringementPossible Doctrine of Equivalents Infringement –6,793,127: Internet enabled resource constrained terminal for processing RFID tags Recommend to continue with developmentRecommend to continue with development –6,802,186: Refrigerator system and software architecture for 2 refrigerated compartments with user specified temperature Recommend to pay licensing fees to GERecommend to pay licensing fees to GE

Reliability/Safety Analysis 5 critical components analyzed5 critical components analyzed –LM2676 Step-down Regulator – MTTF 9.8 years –T77 Power Relay – MTTF 19 years –TC72 Temperature Sensor – 51 years –Rabbit 2000 Microcontroller – MTTF 52 years –TIP122 NPN Transistor – 575 years High criticality failuresHigh criticality failures –Voltage regulator power supply –Compressor control involving temperature sensor

Ethical/Environmental Analysis Ethical IssuesEthical Issues –Protect electrical components from food spills / condensation –Warning label on main board enclosure –Compressor blowout prevention module –Cold environment component ratings –High temperature/food spoilage prevention module Environmental IssuesEnvironmental Issues –PCB fabrication (high material consumption) & disposal (lead, hazardous waste) Dry plasma metal depositionDry plasma metal deposition –Refrigerator coolant Substitute for Freon and other CFC/HCFCSubstitute for Freon and other CFC/HCFCrefrigerants

Design Components Packaging design considerationsPackaging design considerations Schematic design considerationsSchematic design considerations PCB layout design considerationsPCB layout design considerations Software design considerationsSoftware design considerations

Packaging Design Packaging ComponentsPackaging Components –Mini-fridge, LCD, keypad, RFID, scan- request pushbutton Weight: 58 lbsWeight: 58 lbs Cost: $854.30Cost: $854.30

Schematic Design

PCB Layout Design

6.706” x 3.030”6.706” x 3.030” 12 mil / 40 mil tracings12 mil / 40 mil tracings Decoupling caps for all ICsDecoupling caps for all ICs Single point ground/powerSingle point ground/power 3 segments (power supply, relay driver, micro/all else)3 segments (power supply, relay driver, micro/all else) Off-board relayOff-board relay Result: no burnt traces or EMI problemsResult: no burnt traces or EMI problems

Software Design Interrupt Driven/PollingInterrupt Driven/Polling ModulesModules –Keypad Control Module –RFID Control Module –Temperature Control Module –Web Server

Success Criteria Demonstrations 1. Ability to sense and decode RFID tags affixed to ‘food’ items 2. Ability to query ‘food inventory’ via web Demonstration of 1 & 2 Demonstration of 1 & 2 Demonstration of 1 & 2 3. Ability to update/maintain a food inventory Demonstration of 3 Demonstration of 3 4. Ability to display status information on an LCD display – Demonstration of 4 Demonstration of 4Demonstration of 4 5. Ability to control cabinet temperature via keypad and web via keypad and web Demonstration of 5 Demonstration of 5

Individual Contributions Team Leader – Drew WhippleTeam Leader – Drew Whipple Team Member 2 – Matt ComptonTeam Member 2 – Matt Compton Team Member 3 – Brandon AdeTeam Member 3 – Brandon Ade Team Member 4 – Jeff KillenTeam Member 4 – Jeff Killen

Team Leader – Drew Whipple Packaging DesignPackaging Design Patent Liability AnalysisPatent Liability Analysis Software implementationSoftware implementation Software/hardware interactionSoftware/hardware interaction

Member 2 – Matt Compton Component Selection RationaleComponent Selection Rationale SoftwareSoftware –Design of Software Structure –Software Implementation Hardware/Software InteractionHardware/Software Interaction Hardware DebugHardware Debug

Member 3 – Brandon Ade Reliability/Safety AnalysisReliability/Safety Analysis SchematicSchematic Hardware components selectionHardware components selection PCB solderingPCB soldering Hardware testing and modificationsHardware testing and modifications

Member 4 – Jeff Killen PCB Layout and DesignPCB Layout and Design Ethical and Environmental Impact AnalysisEthical and Environmental Impact Analysis Refrigerator selection/preparation/modificationRefrigerator selection/preparation/modification Hardware testing/debuggingHardware testing/debugging Adapt to separate temperature compartmentsAdapt to separate temperature compartments

Project Summary Important lessons learnedImportant lessons learned –Division of labor and individual accountability –Get parts as early in the project as possible –Peer reviews of other team members’ work –Plan in-depth early –Understand components’ soldering temperature limits

Project Summary Second iteration enhancementsSecond iteration enhancements –Better optimized product packaging –More robust/secure web server and LCD –Online recipe database –More powerful RFID scanner

Questions / Discussion