1. EE595 Capstone Design: Team 6
Team Members:
Mike Loften
Shane Ehster
Chad Ehnert
Kevin Kuhl
Degree Sought:
BSEE
BS Physics

2. Team 6: Expertise & Experience
Mike Loften
Chad Ehnert
Kevin Kuhl
Shane Ehster
Expertise: Electrical circuits
Experience: Hands on controls experience
Expertise: PIC/ATMEL controllers, USB, Digital Logic, Troubleshooting, Mechanical Aptitude
Experience: Co-Op with Alliance Laundry and Andis
Expertise: PCB layout, Microprocessors,
Experience: 3 Co-Op terms: Kohler Power Systems
Expertise: Power, Motors
Experience: 4 Co-Op terms with ATC

3. Team 6: Total Resources 32 hrs/week Manhours $400
Chad: Prototype USB board, breadboards, components, soldering iron
Shane: Various tools, soldering iron
Mike: Components, breadboard
Kevin: Board layout program

4. Team 6: Decision Making
Majority vote will be implemented unless there is a strong disposition to an idea. In which case further suggestion will be used and a re-vote.

5. Roles to Define & Assign
Lead Project Integrator (LPI): Chad
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
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

6. Roles to Define & Assign
Lead System Designer (LSD): Chad
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

7. Roles to Define & Assign
Lead Presentation Manager (LPM): Shane
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
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 CD and paper copies for all Preliminary Presentations P1-P4 and Final Presentation

8. Roles to Define & Assign
Lead Report Manager (LPM): Kevin
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
Logos
Font sizes & font styles
Colors
Header/footers and chaptering
Rev 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 final file on CD and printed paper copy of Final Project Report

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

10. Project 1
A device to sense when a parking checker marks the tires of your car. The device will send a signal to an external communication device to notify the user that the car has been marked.
Power sources: Battery
User interface will be a small key chain.
There is no other known product like this on the market
Project fits team interests well and could be potentially marketable.

11. Block Diagram for Parking Checker Device
Processor to determine good/bad data
Input from motion sensor
Communication Device (Sending signal)
External Interface to notify user

12. Project 2
Alarm clock that has an internal MP3 player built into the device. The alarm clock would have a removable flash memory for music storage.
There would be a display for choosing the music like similar MP3 players.
AC cord from 120volt/ 60 Hz outlet with battery back up.
There is currently no product like this on the market.
Highly attractive project to the group and personal interests.

13. Alarm Clock with MP3 Player

14. Project 3: Automated Pigment Dispenser Custom-Paint
Automated pigment dispenser for custom paint mixing
Receives paint recipe from off-the-shelf hardware store color scanner
Output data to a automated rotating pigment dispenser to get exact color match
Fits group interest by incorporating motor control and PIC programming.

15. Project 3: Automated Pigment Dispenser Custom-Paint
Pigment selection
Paint recipe
(from color
scanning
computer)
Controller
Selected pigment dispensing
User instructions,
interface
Base paint can sensor

16. WEEK 2: Project Refinements
All 3 initial projects were scrapped and 2 new, more specific proposals were created. The following slides will detail these projects as well as a recommended project.

17. Additional Project 1 Sewer Pipe Inspection Vehicle
A device that fits inside of a residential sewer pipe with a camera that could be used to inspect the inside of a pipe.
The vehicle will likely carry some sort of umbilical cord to interface with the user controls.
The user controls will have forward and reverse ability as well as some sort of display.

18. Residential Sewer Inspection Vehicle (Non-recommended project)
Frame
Drive System
Camera
Microprocessor
Roll Stabilizer
Lights
Vehicle Power Supply
Tether
Video Display
User Controls
User Interface
Power Supply
USER INTERFACE
Enclosure

19. Selection Matrix Totals Weighting Team's Average 15% 10% 20% 100%
Totals
Team's Average
Weighting
15%
10%
20%
100%
Project 1 - RC Jeep
98.75
77.50
2.50
82.50
100.00
67.50
14.81
11.63
0.38
12.38
15.00
10.13
79.13
Project 2 - Sewer Vehicle
75.00
12.50
72.50
11.25
1.88
10.88
78.56
Project 3 - Parking Checker
83.75
78.75
37.50
55.00
0.00
48.75
12.56
11.81
5.63
8.25
7.31
60.56
Project 4 - alarm clock MP3
125.00
116.67
133.33
70.00
59.33
86.67
18.75
11.67
13.33
14.00
11.87
13.00
82.62

20. Project Selection
This project was selected based on team members personal interests and abilities. There was a strong interest in doing a project with motor control and the RC Jeep project should be a great exercise in this.
The other projects were rejected due to high cost and extreme amounts of ancillary engineering design that may not be able to be completed in 1 semester.
The project was eventually unanimously selected by the team. There were some regrets letting go of the other project but they were resolve relatively easily through discussion.
Project Risks:
Being dependent on the timeframes of other groups working on the jeep.
Not being to interface with the existing technology

21. Proposed Product Summary
CEAS RC Jeep with larger DC motors, drive protection, and motor speed sensing control (Traction Control).
User requirements: Ability to operate a hand held transmitter with forward and reverse controls.
The primary benefit is a product that get the attention of the audience the school is trying to reach.
The product can be used for promotion of the school of engineering at grade/high schools or other university sponsored events.
The UWM Police have a similar vehicle they use as a promotional tool. We do not believe that the product has a commercial market at this time.
The vehicle fits into the consumer products industry.

22. RC Jeep Project Block Diagram
MOSFET Bridge & Drivers Block
Four MOSFETs and Two BJTs
Misc. Resistors & Capacitors
Inputs: PWM and Batt. Voltage
Outputs: Voltage to motor
Current Limiting Block (protect Mosfets)
Sense current going to MOSFETs
Shutdown drivers if excessive current
Roughly 15 comp
Two Opamps
Two BJTs
A diode and misc. resistors and Capacitors
Feedback speed Control
Used when two motors are used
Components or parts:
2 optical encoders--Inputs
Phase comparator
Integrator
Microprocessor
Inputs: PWM from Receiver
Outputs: PWM to MOSFET Drivers
Inputs: Feedback from speed control

23. Block Diagram Description
Block Name
Owner
Brief Description
Of Block Function
Power
Interfaces
Digital
Analog 1
Micro-Controller
Chad Ehnert
Receives signal from receiver box and convert it to a PWM signal. The PWM signal will then be fed to the drive circuitry.
In: 5 VDC Out: DC Signal (PWM)
In: Variable duty cycle signal from receiver.
In: Feedback
Out: PWM 2
Motor Drive Circuitry
Kevin Kuhl
Receives PWM signal from Micro-Controller and uses MOSFETS or IGBT’s to control the duty cycle of the motor.
In: +12 VDC
None
In: PWM
Out: DC Current 3
Motor Shaft Speed Feedback Control
Mike Loften
Monitors the shaft speed of each motor (each wheel is driven independently) to ensure that one wheel is not turning faster than the other. If one of them is, it will adjust the duty cycle of that motor.
In: +12VDC
In: Signal from Opto sensor
Out: Digital Signal to Micro 4
Drive Over-Current Protection Circuitry
Shane Ehster
Monitors the current in the drive circuit to ensure that the circuitry is not damaged.
Out: DC signal to drive circuit.

24. Current Patents Patent # 7,151,394 Patent # 7,173,350
Phase shifting and PWM driving circuits and methods
December 19, 2006
Patent # 7,173,350
Load drive control apparatus having minimized power consumption when functioning in waiting status.
June 27, 2003
Patent # 7,173,393
Phase current detection method, inverter control method, motor control method, and apparatus used in these methods.
April 10, 2003

25. Ethics and Societal Issues
Product failure could cause fire, bodily injury due to a collision.
User hazards: Collisions and fire.
Harm can be avoided by inserting current limiting on the driver circuit, possibly a speed governor, making the vehicle more controllable with feedback control.
Faulty/Flawed engineering would lead to the protection devices not working properly or injury to user/damage to property.
The driver circuitry and remote controlled aspects need to be 100% robust.

26. Standard Requirements
Max Oper Temp. Range: 0C to 55C
Max Oper Humidity Range: 0 – 95% Non condensing
Max Oper Altitude Range: -300ft to 15,000ft above sea level
Max Storage Temp. Range: -20 to 65C
Max Storage Humidity Range: % Non condensing
Max Storage Pressure Range: 0.5 to 1.5 atm

27. System Standard Requirements (Power Inputs)
12-48VDC Battery Supply
Temporary Connection to Source (Charging)
Min. Operating range: 5 - 7VDC
Max Power Consumption: 20A (2 motors at 10A each) at 12V = 240W
12V at 9.5A/hr = 120W/hr

28. System Standard Requirements (Mechanical Inputs)
Max Volume:
Max Ship Container Size
Max Mass
Elec I/F Connector(s)
Max # of PC Bds
Max PCB Circuit Area
Max Shock
.25 cubic meters
.75 cubic meters
45 Pounds
Solder, Harnesses 3
150 cm^2
8 G’s

29. System Standard Requirements (Mfg and Life Cycle)
Max Parts Count
Max Unique Parts Count
Parts/Mat $ Allocation
Asm/Test $ Allocation
Product Life, Reliability
Full Warranty Period
Product Disposition
Production Life Support
Service Strategy
TBD

30. Market and Business Case
Competitors
Market Size
Average List Price
Market Geography
Market Demography
Intended Application
N/A
426 WI Districts * 5 Schools per district = 2130 units
$599.00
Mainly the U.S.
Ages 12 and up due to safety requirements
Promotional tool for schools, businesses.

31. Market and Business Case Con’t
Material Cost
Annual Volume
$495.00/unit
1200 units