1. EE595 Senior Design Team 2 Spring 2007

2. Team 2: Staff Dan Lauber Ibrar Ahmad Josh Sutinen Tim Thierfelder
Bill Burton
BSEE, BACS
BSEE, CS Minor
BSEE
BSEE, Physics

3. Team 2: Expertise & Experience
Dan Lauber
Ibrar Ahmad
Josh Sutinen
Tim Thierfelder
Bill Burton
Expertise: Software, General Design
Experience: 3yr Internships, Design & project ownership
Expertise: Access to parts, contacts, IEEE measurer
Experience: 2yr Internship, 1yr Co-op
Expertise: Microprocessors, motor control
Experience: 1yr Internship
Expertise: Digital Logic, Powerpoint
Experience: Transmission Co
Expertise: Digital Logic, IC’s
Experience: Software, assembly

4. Team 2: Contact Info
Dan Lauber
Ibrar Ahmad
Josh Sutinen
Tim Thierfelder
Bill Burton
Phone 1:
Phone 1:
Phone 1:
Phone 1:
Phone 1:

5. Team 2: Weekly Availability Worksheet
Dan Lauber
Ibrar Ahmad
Josh Sutinen
Tim Thierfelder
Bill Burton
Time 1: Mon 2-5 Time 2: Tues/Th 3-6
Time 1: Mon/Th 5- Time 2: Wed 3-
Time 3: Fri Any
Time 1: Mon/Wed 7- Time 2: Tues/Th 1-
Time 3: Fri 5-
Time 1: Mon/Wed 6-8 Time 2: Tues/Th 4-6
Time 3: Fri 4-8
Time 1: Wed Any except 3-5 Time 2: 4-

6. Team 2: Weekly Project Meeting Plan
Weekly Meeting 1: W270 (IEEE), Tuesday 4:30-6:30 PM
Chair: Ibrar Ahmad
Attendees: All
Purpose: General
Weekly Meeting 2: W270 (IEEE), Thursday 4:30-6:30 PM
Note: Meeting Owners Send Weekly Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

7. Team 2: Total Resources 1200 Manhours $1000 Overall investment
Cash outlay
PCB Prototyping
Enclosure
Components

8. Team 2: Decision Making
Primary decisions will be decided by a consensus with a democratic vote in the event there is no consensus.

9. Roles to Define & Assign
Lead Project Integrator (LPI): Bill Burton
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

10. Roles to Define & Assign
Lead System Designer (LSD): Dan Lauber
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

11. Roles to Define & Assign
Lead Presentation Manager (LPM): Ibrar Ahmad
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

12. Roles to Define & Assign
Lead Report Manager (LPM): Josh Sutinen
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

13. Roles to Define & Assign
Lead Manufacturing Mgr (LMM): Tim Thierfelder
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 glueing.

14. Project Ideas RC Car Attendance Counter Living Environment Controller
Absolute position based "virtual" limiting system
Fully automated test bench

15. RC Car
Create plugin interface for additional modules and future expansion
Features: Odometer, Sensors, RF Communications, Charge Controller, Motor Controller

16. Attendance Counter Sensors Count the Number of People on the Bus
The Count is Displayed
Visual Alerts are Given for Capacity and Deboarding
Audio Warnings are Given for Capacity and Deboarding
Power is drawn from the bus battery

17. Bus Tender – Block Diagram
Attendance Counter
Bus Tender – Block Diagram
Sensors
User Interface
signal
signal
power
Visual Displays
signal
power
Microcontroller
Power Supply
signal
signal
Audio Signals
power

18. Living Environment Controller
Curtain/Blind controller adjusts based on room conditions/sunlight availability
Power: 120VAC/Battery backup
Thermostat interface
Temp display
Occupancy sensor, thermostat
Schedulable, web server

19. Absolute Position based Virtual Limit Switch
Accessory for Linear Actuators
Programmable limit of travel
Integrated service life counter
Reduces mechanical parts count of existing accessories

20. Absolute Position based Virtual Limit Switch – Block Diagram
Encoder Data
signal
power
Motor Control
signal
power
Power Supply
Microcontroller
Position Output
signal
Battery Backup
power

21. Fully Automated Actuator Test Bench
Operator inputs specifications
Bench automatically conducts tests and displays and records results
Measured data: Speed, stroke, current, force

22. Feasibility Decisions

23. The Winner RC Car We chose this project because:
The project is funded up to $750
We are able to get support from Dave M.
Many blocks to choose from
Blocks are a good match for team technical skills
Car is on campus, so it is convenient
We have a previous group’s mistakes and successes
Appealing to leave the car behind for reference in later senior design classes/development

24. RC Car Major Risks in Project Radio Frequency interference
Overheating of motors and battery
Working with Lead Acid batteries can be hazardous
Mechanical senior design may work on the car at the same time, so it may interfere with our work
Interfacing with the existing microcontroller may be a challenge

25. Why were other projects rejected?
Not enough blocks
No funding
Long lead time
Not enough required skills
Did not seem as practical
Did not seem as fun to work on
Not enough on-campus support/help on developing the product
Unanimously Supported
YES

26. System - Standard Requirements:
Environment and Safety
Market
Operation Temperature Range: 5°C to 35°C
Operation Humidity Range: to 80%
Non-condensing
Operation Altitude Range: to 1000 Meters
Storage Temperature Range: °C to 40°C
Max Storage Duration: years
Small Competitors in Field
Size of Market: $250,000
List Price of: $2,000
Market Geography: Europe, North America
Market Demography: Males
ages 18+
Market Industry: Recreation, Promotional
Material Cost: $500
Manufacturing Cost: $200
Annual Volume: 100 units

27. System - Standard Requirements:
Power
Energy Source 1 (48 VDC): Four Lead Acid Batteries
Operating Voltage: +/-12VDC,+5VDC,+48VDC
Power Consumption: 13 Ah
Mechanical
Max Product Volume: cm3
Shipping Container Size: cm3
Maximum Product Mass: 30 kgs
Maximum Number of PCB: 6
Maximum PCB Area: cm2
Maximum Shock Force: 5 G’s
Moisture Resistance: Sealed

28. System - Standard Requirements:
Manufacturing
Maximum total parts count: 300 parts
Maximum unique parts count: 20 parts
Maximum parts and material cost: $500
Maximum mfg. assembly/test cost: $200
Max production lifetime: 5 years
Warranty Period: 1 year

29. RC Car Block # Block Name Owner Brief Description Of Block Function
Power
Interfaces
Digital
Analog 1
Power Supply
Ibrar
Ahmad
Converts 48 VDC Power to +5VDC and +/-12VDC
In: VDC
Out: +5VDC,
+/-12VDC
None
Out: Vbat 2
CPU
Dan
Lauber
Interfaces between digital and hardware devices
In: +5VDC
Out: Data Bus, Aux. outputs
In: Data Bus, Aux. inputs
In: Vbat 3
User Interface
Tim
Thierfelder
Magnetic Sensed Revolution
Counter and relayed to the CPU
In: +5VDC
In: cable from sensor
Out: Port A 4
H-Bridge (drive) Motor Controller
Josh
Sutinen
Takes power from battery to the two motors and drives the motors at variable speeds.
In: VDC
In: CPU
Out: Output is to motor power 5
Headlights
Bill
Burton
Interfaces w/ power supply and CPU
In: +5 VDC
In: CPU 6
Charging Unit for 48V Battery
Takes household voltage to charge four lead acid batteries in series. Charged battery indicator.
In: 120 VAC
Out: 48 VDC
Out: Four Batteries (Vbat)

30. Block Diagram

31. Applicable Patents Patent Name
Central speed control mechanism for remote control cars
Method and system for multiple servo motor control
Toy system
Patent Number
Patent Date
January 20, 2005
December 23, 2004
December 12, 2002

32. Ethical and Societal Issues
A visiting user could run into someone at high speed without intending to.
Speed regulator into the control system.
Sensor that would apply the brakes.
Foam bumpers (mechanical?)
A visitor might shock themselves while inspecting the car.
Case over the cable attachments.
Voltage warning stickers.

33. Steps to Prevent Flawed Engineering
Test a speed regulator
Test the product with a user trying to doing erratic maneuvers
Test the effects of a collision on performance
Test the predicted behavior of a novice inspector to ensure they can have no contact with live voltage