1. EE595 Spring 2007 Group III
Project Proposal

2. Team III: Staff Don Murray Brett Sheleski Ike Butler Mike Baerenwald
EE Major
CS Minor
Ike Butler
Brett Sheleski
EE Major
CS Major
Mike Baerenwald

3. Team III: Expertise & Experience
Don Murray
Expertise:
Embedded Systems
Motor Control
Experience:
ROV Team Electronics Design
Microcontroller Programming
Ike Butler
Analog Systems
Linear/Digital Sensors
Johnson Controls
McNair Scholar
Brett Sheleski
Expertise:
Software development
Experience:
CAD Drafting
IT Intern
Mike Baerenwald
Power Systems
Stora Enso Paper Mill
Kohler Co. Co-op

4. Team III: Contact Info
Phone: (414)
Phone: (920)
Phone: (262)
Phone: (414)
Brett Sheleski
Mike Baerenwald
Don Murray
Ike Butler

5. Team III: Weekly Availability Worksheet
Time 1: MW after 5:00 Time 2:
Time 3: R 8:30 – 10:00 Time 4:
Time 1: MW before 3:00 Time 2:
Time 3: R 8:30 – 10:00 Time 4:
Time 1: MW before 3:00 Time 2: TR 11:00-5:30
Time 3: Time 4:
Time 1: FSa before 6:00 Time 2:
Brett Sheleski
Mike Baerenwald
Don Murray
Ike Butler

6. Team III: Weekly Project Meeting Plan
Weekly Meeting 1: E225, Thursday 2/1/07 8:30-9:00 PM
This meeting was to discuss options for the design project. All members were present.
Weekly Meeting 2: E225, Monday 2/5/07 9:00 PM
This meeting discuss P1. Mike & Don were present, Brett was ill, and Ike was a no show.
Note: Meeting Owners Send Weekly Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

7. Team III: Total Resources
10 Man-hours per week, per person
$100+ per person for material (if needed)
Design and build a solar power supply that adjusts the direction of the solar panels towards the brightest light source to maximize the amount of power generated.

8. Team III: Decision Making
Decisions by consensus
If no consensus, consult TA or instructor.

9. Roles to Define & Assign
Lead Project Integrator (LPI):
Don Murray (01/23/07 – Present)
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):
Brett Sheleski (01/23/2007 – Present)
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):
All (01/23/07 – Present)
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):
Ike Butler (01/23/2007 – Present)
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):
Mike Baerenwald (01/23/2007 – Present)
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. Random Number Generator
Take readings from various sensors producing a random number
Produces random number with testing from Chi Square algorithm.
USB/Serial connector getting power either independently or from data cable.
Heavy computer science background among group as well as common interest

15. ROV Sensor Package
Distance sensor for ROV-Team’s underwater robot to determine surroundings.
Use ROV’s power source (car battery) for powering the device.
Don is a member of the ROV team and the project is interesting and challenging.

16. Traffic Controller A wireless traffic controller to replace
manually operated
stop signs on
UWM campus

17. Solar Sun Follower
Solar panels that automatically adjust so they are always facing the brightest light source so they generate the maximum amount of power possible.

18. Standard Requirements-Market
Estimated Market Size: $100,000,000
Estimated Annual Volume: $1,000,000
Minimum List Price: $50
Max Product Material Cost: $20
Max Product Manufacturing Cost: $10
Estimated Annual Contribution: $600,000

19. Market Cont. Market Geography: Worldwide
Market Demography: Robotics Hobbyists
Market Competitors: Power supply manufacturers
Market Industry: For Residential Use

20. Power
Energy Sources:
9 Solar Panels
1 Battery

21. Mechanical
2 Servo Motors
Enclosure

22. Environmental Temperature Range: -40°C to +120°C
Humidity Range: 0% to 80%
Altitude Range: Unlimited

23. Safety Primary Safety Standards: “Intelligent” Battery Charger
Primary EMC Standards: TBD

24. Manufacturing Maximum total parts count: 100
Maximum unique parts count: 20
Maximum Parts & Material Cost: $20
Maximum Mfg Assembly/Test Cost: $10

25. Life Cycle Estimated Max Production Lifetime: 20 yrs
Service Strategy: In Home
Product Life, Reliability in MTBF: TBD
Full Warranty Period: 1 Year
Product Disposal: Recyclable

26. Performance Requirements- User Inputs
Enable / Disable solar power
Enable / Disable battery
Select manual motor control
Manual motor controls
Display selection

27. User Indicators & Displays
Battery charge meter
Status LEDs
Voltage meter
Current meter

28. Operation Modes Automatic Manual
Automatically tracks light source for maximum power generation
Solar panel array is positioned automatically
Manual
Solar panel array is positioned manually

29. Safety Battery must not be overcharged
Clear safety notifications must be present to prevent use of incorrect batteries

30. Basic Business Case for the Solar Sun Follower (Inputs)
Estimated Average Product Selling Price (ASP$):
$50
Estimated Annual Product Sales Volume in Units:
20000
Estimated Per Unit Cost of All Parts & Materials:
$20
Estimated Per Unit Cost of All Assembly, Test, and Mfg:
$10
Estimated Total Development Cost including Labor and Material:
Engineering $ per hour: 600
Material: $400
Total: $90400

31. Basic Business Case for the Solar Sun Follower (Outputs)
Annual Sales Revenue $ = ASP$ * Annual Volume:
$1,000,000
Annual Var Costs $ = (Unit Material $ + Mfg $) * Annual Volume:
$400,000
Per Unit CM$ = ASP$ – (Unit Material $ + Mfg $):
$30
CM% = Per Unit CM$/ASP$:
60%
Annual CM$ = Unit CM $ * Volume = Annual Sales $ - Annual Var Costs $:
$600000
ROI (Return on Investment) Time in Years = Est Dev Cost $/Annual CM$:
0.15

32. Overall Block Diagram

33. Block Diagram Description
Block Name
Owner
Brief Description
Of Block Function
Power
Interfaces
Digital
Analog 1
Power Distribution
Don
Receives power from battery and solar panels and delivers to additional blocks.
In: TBD
Out: XX VDC
None
Out: Vbat 2
Solar Panels
Mike
Nine solar panels that supply power to the power distribution block as well as supplies analog signal to the Solar Logic block.
Out: TBD
Out: VS1-5 3
User Interface
Brett
Give user voltage and current readings as well as provide manual override of motors.
In: TBD
Out: Motor control signal (x2)
Out: Power Switches, Voltage/Current readings. 4
Solar Logic
Read Voltage readings from 5 panels and convert to digital signal.
Out: Binary values of voltage (x5)
In: Voltage readings (x5) 5
Motor Control
Ike
Compare digital signal from the Solar Logic to adjust motors accordingly.
Out: Motor Control Signal (x2)
In: Off-setting for manual override 6
Motors
Motors for adjusting solar panels (x2)
In: Motor Control Signal (x2) 7

34. Three Related Patents
Patent number
Two Axis Tracking Solar Collector Mechanism
January 1, 2001
Patent number
Sun Tracker System for a Solar Assembly
February 4, 1997
Patent number
Solar Tracking System
May 27, 1997

35. Ethical and Societal Issues
Charging of the battery presents the greatest potential danger to the user, as overcharging a battery can cause an explosion
The battery must be properly chosen for this application, and the type required must be communicated clearly to the end user of the product
Any other failures of the product would present a nuisance to the end user, but no specific danger. This product is not intended for use in devices where an exceptionally high level of reliability is required, such as medical devices or industrial controls. This must be communicated to the end user