1. Team #5: Staff Sean Kuter (LPI) Kurt Stonger (LRM)
Andrew LaPointe (LSD)
Eric Fritz (LPM)
Shawn Bostwick (LMM)
BSEE

2. Project Plan Summary
Total Manpower Estimated vs. Available
Meetings man-hours
Labs man-hours
Individual man-hours
To date 219 man-hours out of 900 total man-hours available
Total Material Cost to date
$ out of $ total available budget
% of Total Manpower
System design 14.84%
Detailed design 36.30%
Verification 10.73%
Documentation 38.13%
To date there is an overestimate of 61% of man-hours
To date there is 64% of material not procured

3. Selected Project Key Features
Reptile Environmental Control Unit:
Monitor Environment
Ambient Temperature
Surface Temperature
Humidity
Monitor Ambient Temperature
Control Surface Temperature
Control Humidity
Security System to Prevent Escape
Cable Management System

4. Product Applications Exclusive environmental control to support:
Snakes (primarily)
Turtles, lizards, and other rare reptiles
Typical market:
Professional/Amateur Breeders and Herpetologists
Pet Stores

5. Hoffer’s Tropical Pet Store

6. Potential Competitors
Targeted market
Don’t meet all of the key objectives
Room for product growth
4 Zone Programmable Controller
Made for multiple units
Monitors and controls temperature only
No security control
$ USD

7. Refined Block Diagram Sean Kuter Shawn Bostwick Kurt Stonger
Inputs and Signal Conditioning: Andrew LaPointe
Inputs and Signal Conditioning:
Sean Kuter
Power Distribution:
Shawn Bostwick
Outputs:
Kurt Stonger
Surface Temperature Sensors
ANALOG
Relay Switches
Signal Conditioning
DIGITAL
29 VAC
Foggers
Relay Switches
DIGITAL
120 VAC
Heat Mats
Ambient Temperature Sensors
ANALOG
Signal Conditioning
Controller
Eric Fritz
4 State Controllers
DIGITAL
Humidity Sensors
ANALOG
Signal Conditioning
Keypad
DIGITAL
DIGITAL
LCD Display
Lights
5VDC
Door Sensors
Alarm Horn

8. Out: On/Off signal to outputs
Block Assignments
Block #
Block Name
Owner
Description
Power interfaces
Digital Interfaces
Analog Interfaces 1
Power
conversion &
distribution
Shawn
Bostwick
Standard AC input to
5/24VDC and 115
VAC output
In:115 VAC
Out: 115VAC
5VDC, 24VDC
none 2
A/D conv &
Signal
conditioner
Sean
Kuter
Convert 0-10 VDC
analog signals to
digital data
In: 5VDC
Out: Sensor
data to Micro
Controller
In: Analog
sensor data 3
Micro
Eric
Fritz
Take in Digital data,
perform calculations,
output digital On/Off
signal
Out: On/Off signal to outputs 4
Inputs
Andy
LaPointe
ambient/mat temp,
humidity, door
sensor, keypad
In: 5 VDC
Out: 0-5VDC
analog 5
Outputs
Kurt
Stonger
Fogger, heat pad,
heat lamp, LCD,
alarms
In: 115Vac,
24Vdc, 5Vdc
In: Data Bus
On/Off signal

9. Performance Requirements
Display type
Temperature Sensors
Humidity Sensors
Keypad type
Key definitions
Units to Specify
LCD
4 Lines by 20 Characters/Line
Accuracy: +/- 1oC
Range: oC
Accuracy: +/- 5% RH
Range: 10 – 90% RH
Matrix arrangement
up/down/left/right arrows, enter, numbers

10. Standard Requirements
Min Oper. Temp Range
Min Oper. Humidity Range
Max Dimensions
Source Connection List
Units to Specify
5 - 45° C
0 – 99% relative humidity
12” x 12” x 6”
Temporary, with ability to move unit

11. Standard Requirements
Min Oper. Voltage Range
AC power freq range
Max Power. Consumption
Parts/Material $ Allocation
Connector Type
Units to Specify
102 – 132 VAC 120 VAC nom.
57 – 63 Hz 60 Hz nom.
850 W 7A
$500 (total, $100/member)
Type B Plug

12. Safety Standards IEC 6100-4-2: ESD Immunity
IEC Edition 3.0: Electric Shock Protection
IEC 730: Auto. Elec. Controls for Household
UL A Auto. Elec. Controls for Household
UL Auto. Elec. Controls for Household
Part 2: Particular for Temperature Sensing Controls

13. Specific Safety Requirements
IEC Edition 2.0
Household and similar electrical appliances – Safety – Part 2-71: Particular requirements for electric heating appliances for breeding and rearing animals
UL 873
Temperature-Indicating and Regulating Equipment
UL A
Automatic Electric Control for Household and Similar Use; Part 2: Particular Requirements for Humidity Sensing Controls

14. EMC Standards 61000-4-2: ESD Immunity Tests
IC’s
: Surge Immunity Tests
Lightning discharges & switching disturbances
: Voltage dips, short interruptions, and variations
Line voltage variances

15. ECU Technical Risk & Problem Areas
Sensors/Sensing Issues
Analog sensor output > Digital Processor
Programming
Pic/Microcontroller selection
Programming Hardware
Programming Software
Power Supply
Design
Build
Safety (explosion, fire, shock)

16. Individual Reliability Report: Andrew La Pointe
Maximum FIT’s:
MTBF: years
Most Unreliable Part:
Humidity Sensor
Suggested Improvement:
Find a part with a lower lambda

17. Individual Reliability Report: Eric Fritz
Maximum FIT’s:
MTBF: years
Most Unreliable Part:
D-flip flops
Suggested Improvement:
Use a different part
Use fewer parts

18. Individual Reliability Report: Shawn Bostwick
Maximum FIT’s:
MTBF: years
Most Unreliable Part:
Zener Diodes
Suggested Improvement:
Use heatsinks for temperature

19. Individual Reliability Report: Kurt Stonger
Maximum FIT’s:
MTBF: years
Most Unreliable Part:
Electromagnetic coil relay
Suggested Improvement:
Use transistorized switch, or SCR

20. Individual Reliability Report: Sean Kuter
Maximum FIT’s:
MTBF: years
Most Unreliable Part
Resistors
Suggested Improvement
None needed

21. Ambient / Surface Temp Sensing Sean Kuter
To provide a controlled temperature scaled inputs to the microcontroller block:
Ambient Temperature
Surface Temperature
Impedance matching
Amplified Signals

22. Sean Kuter Ambient and Surface Temperature Inputs Per Reptile Environmental Unit
From Power Dist. Block

23. Ambient and Surface Temperature Sensors Per Reptile Unit Sean Kuter
Standard Requirements
IEC Electrostatic Discharge Immunity
Operating Temperature Range
5 – 45 oC
Oper. Humidity Range
0 – 99% RH
Performance Requirements
Monitor a Temperature Range 5 – 45 oC ( 41 – 113 oF )
Provide a sensor accuracy of +/- 1 oC
Provide an Output Voltage Range 0.5 – 4.5 Vdc

25. Humidity Sensor/Alarm Andrew LaPointe
Humidity Sensing
Senses humidity
Gives proper signal to microcontroller
Alarm
Senses Door position (open or closed)
Gives audible alarm for open door

26. Andy LaPointe Humidity sensor input and Alarm Circuit Per Reptile Environmental Unit
Humidity Multiplexer
Microcontroller Block
Owned by:
Eric Fritz
Magnetic Door Switch Ckt 1
Alarm
Horn
+5VDC
VDC
Magnetic Door Switch Ckt 2
+5VDC
+5VDC
+5VDC
+5VDC
+5VDC
Power Block
Owned by:
Shawn Bostwick
Humidity
Sensor
Impedance
Matching
Network
Op-Amp
Av = 5
5VDC
.01-1VDC
.01-1VDC

27. Humidity Sensor/Alarm Block Standard/Safety Requirements
Min Oper. Temp Range
5 - 45° C
Min Oper. Humidity Range
0-99 % RH
Operating Voltage Range
4.5 – 5.5 VDC
Source Connections
temporary (hi-density plugs)
IEC Electrostatic Discharge Immunity

28. Humidity Sensor/Alarm Block Performance Requirements
Humidity sensor has accuracy of +/- 5 % R.H. and range of 0-99% R.H.
Humidity sensor outputs
VDC
Door switches open to a max of 1” before horn sounds
Horn provides
dB 2 ft

29. Humidity Sensors and Alarm Circuit Block Summary
Analog Signals
Type
Direction
Coupling
Voltage
Max
Impedance
Freq Range
Leakage
Amplitude
Min
uA741 Opamps X4
Analog
Output
Direct
5.0V
300K 2M
N/A
Analog1 Door Switch X8 6V
0.1 ohm
open
Analog2 Humidity Sensor X4
1.0V
200ohm
60uA
Power Signals
Type
Direction
Voltage
Voltage Range
Freq
% V-Reg
V-Ripple
Current
Nominal
Min
Max
Humidity Sensor X4
DC Power
Input
5.0V
4.5V
5.5V DC
10.00%
n/a
10mA
Alarm Horn
3.0V
6.0V
20.00%
60mA
uA741 Opamps X4
3.3mA

30. Outputs Kurt Stonger
Control output signals to Fogger, Heat Mat and Light
Relay switches
Bang Bang control
3 light settings

31. Outputs Kurt Stonger Component Voltage; Relay Coil Voltage;
Microcontroller
Component Voltage;
Power Block
Fogger
24 VAC
24 VAC
Relay
5 VDC
Heat Mat
120 VAC
Relay
120 VAC
5 VDC
5 VDC
Relay
V-Division
Relay
Driver
12 VDC
6 VDC
5 VDC
Light
Relay
V-Division
12 VDC
9 VDC
5 VDC
Relay
12 VDC
12 VDC

32. Outputs Kurt Stonger Standards Performance Fogger Heat Mat LEDs
Power Surge IEC
Fogger
24 Vac
Heat Mat
132 – 102 Vac
LEDs
Vdc & 20 mA Max
Solid State Relay
6-4 Vdc
Relay Drivers
5 Vcc
4.5 – 16 Vdc Vout & 1.8 A max
EM Relays
5 Vdc & coil
Performance
Fogger
Relay Controlled power
0 – 90% Relative Humidity
Heat Mat
0 – 30C Range
LEDs
4 stages Low 816 Lumens, Medium 1224 Lumens, High 1632 Lumens and Off

33. Output Block Summary Power Signals Type Direction Voltage
Voltage Range
Freq
Freq Range
% V-Reg
V-Ripple
Current
Nominal
Min
Max
Power1
Fogger AC
Input
24V
21.6V
26.4V
60Hz
57Hz
63Hz
15.00%
N/A 1A
Power2
Heat Mat
120V
102V
132V
.111A
Power3
LED DC
12V 6V
14V
0Hz
.3A

34. Power Supply Shawn Bostwick
Power Supply Block
Supply AC Power To:
Heating Pads
Foggers
Supply Rectified DC Power To:
Microcontroller
Sensors
Alarm
Lights

35. Shawn Bostwick Power Supply
Power in
120Vac
Microcontroller
Block
Overvoltage/
Overcurrent
Protection
Transformer
120Vac
Rectifiers
5Vdc
120Vac
120Vac
Alarm
Circuit
5Vdc
Voltage
Regulator
Circuit
Transformer
5Vdc/7Vdc/12Vdc
Humidity
Sensor
5Vdc & +/-12Vdc
24Vac
Fogger Control
Circuit
Ambient
Temp. Sensor
Heating Pad
Control Circuit
Lighting Control
Circuit
Surface
Temp. Sensor
5Vdc & +/-12Vdc

37. Micro Controller Block Eric Fritz
Takes Inputs from sensors
Performs Calculation
Sends Outputs to relays
LCD Display
Displays data
Key Pad Input
Allows user to change set points

38. Microcontroller Eric Fritz
Light Logic
Terrarium #1 5V Relay
Ambient Temperature Sensors
4 x 1 MUX
Terrarium #1 7V Relay
Analog Input 8
Micro-Controller
Terrarium #1 12V Relay
Control
Signal
Light Logic 3 8
8-Bit Latch
Surface Temperature Sensors
4 x 1 MUX
4 x 1 MUX
Light Logic
Control
Signal
Control
Signal D0
D0 Lights
Humidity Sensors
4 x 1 MUX
3 x 8 Decoder
Light Logic
D1 Heaters/Humidifiers
Control Signal 3
D2 LCD Display
D3 Keypad Input
Terrarium #1 Heater Relay
D2 Sensor Input
Terrarium #2 Heater Relay
5VDC Power
8-Bit Latch 8
D5 Not used
Terrarium #3 Heater Relay 8
8-Bit Latch
D6 Not used
Terrarium #4 Heater Relay
D7 Not Used D4
Terrarium #1 Fogger Relay D1
Terrarium #2 Fogger Relay
Terrarium #3 Fogger Relay
Terrarium #4 Fogger Relay
6 Button User Interface 8
8-Bit Latch 8
8-Bit Latch 8
4 x 20 LCD Display D3 D2

39. Micro Controller Eric Fritz
Standard
VDC
0-45oC
0-90% RH
IEC
ESD guideline
UL A
Automatic Electrical Controls for Household and Similar Use; Part 1: General Requirements
Performance
40MHz Clock Speed
4 x 20 line LCD
0-5VDC analog input
6 button Keypad interface
8-bit data bus
5 VDC I/O

41. Individual Reliability Report: Eric Fritz
Maximum FIT’s:
MTBF: years
Most Unreliable Part:
D-flip flops
Suggested Improvement:
Use a different part
Use fewer parts

42. Overall Prototype Plan
Total Block Area: 462 cm2
Total PCB Area: 432cm2
Substrate Type: Perf-Board w/Pads
Comp. Attach. Type: Direct Solder or IC Socket
Socketed Components: IC’s, Relays, Rectifiers, and Microcontroller
Connector Types: Ribbon cable, Solder, NEC/IEC, and Headers

43. Block Prototype Plan Block Name Block Area (cm2) Total PCB Area (cm2)
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
Eric Fritz
270
260
Perf-Board with pads
Direct solder or IC socket
ICs, Micro-controller
Ribbon cable, Headers, Solid Wire Solder Conn.
Shawn Bostwick
120
100
Relays, ICs, rectifiers
Ribbon cable, Headers, NEC/IEC power connectors,
Solid Wire Solder Conn
Andy LaPointe 24
ICs
Ribbon cable, Headers
Kurt Stonger
Sean Kuter

44. Total Reliability Report
Maximum FIT’s:
MTBF: years
Most Unreliable Part
D-flip flop
Suggested Improvement
Reduce number of D-flip flops
Change components

45. Accelerated Stress Model Accelerated 1 Cycle Time
Reliability Test Plan
Stress
24 Hour
Model
10 Year Model
Accelerated Stress Model
Accelerated 1 Cycle Time
Acceleration Factor
Max Input Voltage
132 VAC
N/A
Number of Power Cycles 20
Thermal Range
23-26 c
20-30 c
Number of Thermal Cycle 5
Max Shock Grms
Number of Shock Cycles 10