1. Remote Controlled Car

2. Team #: 4 BSEE Jordan Acevedo Phosay Bouapha Corey Preuss Ben Reider
Lee Strauss

3. Team #4: Expertise & Experience
Jordan Acevedo
Phosay Bouapha
Corey Preuss
Ben Reider
Lee Strauss
Expertise: Digital: PLD/FPGA VHDL, Soldering, Troubleshooting
Experience: 2 Year Internship at Rockwell Automation
Expertise: Analog: Amplifier, Filter Design
Experience: None
Expertise: Hardware, Software Validation, Mathematics Minor
Experience: 3 Internship Terms at GE Healthcare
Expertise: Power Supplies & Systems, Soldering, Business Minor
Experience: 2 Co-Ops at Kohler Corp.
Expertise: Power Supplies & Amplifiers

4. Team #4: Total Resources
10 Manhours/week
$200 budget

5. Proposed Product Summary
Selected Product
Remote Controlled Car
Entertainment
Details
Miniature toy replica of a car, controlled remotely.
Primary use of product is for entertainment and educational purposes.
With proximity sensors, user is less likely to break product by running it into a wall.
Yes there are similar products, but not identical due to fact of added damage protection and intended future use.
Major industry family the product belongs to is consumer toys.

6. Project Selection Overall Selection Process
The remote controlled car project provided more challenges and involved more complex aspects than the other projects.
Major risks involve making sure all of our components work together well. Because our product contains moving parts, it is important that they work according to our specifications because safety concerns.
Our other projects were rejected because they did not have enough blocks in the diagrams to satisfy our electronic requirements.
This project was unanimously supported by all five members of our group.

7. System Level Performance Requirements
Remote controlled (frequency band)
Forward and Reverse, left and right steering, power
Proximity sensors
Detection of distance from nearby objects and emergency power shut off if car gets too close
Headlights
Headlights attached to front of car for illumination purposes. Can be turned on or off by the user from the remote control. Lights will also have dimming capability.
Blinkers
Array of 10 LEDs will click on or off based on user input to represent turn direction.

8. System Level Standard Requirements
100 Total Parts
30 Unique Parts
$150 (Parts+Mfg=Product Cost)
$50 (Parts+Mfg=Product Cost)
4 yrs
6 months
Repair
Max Parts Count
Max Unique Parts Count
Parts/Mat $ Allocation
Asm/Test $ Allocation
Product Life, Reliability
Full Warranty Period
Service Strategy

9. System Level Standard Requirements
Min Oper Temp Range
Min Oper Humidity Range
Min Oper Alt or Press Range
Min Storage Temp Range
Min Storage Humidity Range
Min Storage Alt or Press Range
Max Storage Duration
0-60 Co
20-95% non-condensing
Meters
10-65Co
0-90% non-condensing
1 year

10. System Level Standard Requirements
Estimated Annual Income
Min List Price
Max Product Material Cost
Max Product Mfg Cost
Estimated Annual Contribution
Operating Voltage Range
$100000
300
$80
$30
$50000
12V to 48V

11. Team Block Diagram DC-DC Converters Battery Motor PWM Microprocessor
Proximity Sensor
Dimming HeadLights
Blinkers
RF Signal

12. Block Diagram Description
Block Name
Owner
Brief Description
Of Block Function
Power
Interfaces
Digital
Analog 1
Power Supply
Lee
Converts Battery 12-48VDC Power to 5, 12, -12 VDC
In: DC12-48V
Out: 5 VDC
Out: 12 VDC
Out: -12VDC
None 2
PWM Controller/
Micro-Processor
Jordan
Receives the RF signal controls the PWM signal to relate to the speed and direction desired by the user.
In: 5VDC
Out: 5VDC
PWM Signal 3
Blinkers
Ben
Receives the RF signal and controls the cars blinkers.
In:5VDC
Out:5VDC
On/Off pulse 4
Proximity Sensor
Corey P.
Senses distance from nearby objects and stops the car through the main PWM signal.
On/Off 5
Dimming Headlights
Phosay
Brightness of the headlights controlled external environment.
Photo Sensor

13. Ethics Considerations
Since this is an entertainment product, the group did not see much room for conflicts of interest, bribery, and kickbacks.
Safety can be an issue though; since children could play with the car, we’d have to make sure that the moveable parts are safe.
While driving the car, someone could be hit, which could cause potential injury.
To mitigate this, we need to make sure our proximity sensor switch works effectively.
Legally, our remote controlled car could have problems if it is not differentiated enough from other cars in the market.
Since remote controlled cars have been being manufactured for years, the idea is probably in the public domain.
To stray from this, we will be using a remote controlled car of a larger size.
Environmentally, the group doesn’t see any major considerations that must be made.
We could try to find a more efficient power source, since batteries must be thrown away or recharged.
Also, we could use more environmentally friendly solder and materials to minimize the effects of lead and other hazardous materials found in many components.

14. Applicable Patents Title: Radio control car
Document Type and Number: United States Patent
There is no work around with this patent, royalties will be determined.
Title: Recreational electric vehicle
Document Type and Number: United States Patent :
This patent involves an indoor or outdoor vehicle for one or two people with a space for personal goods.. REV is driven using a joystick and is able to turn on the spot. Our design will not use a joystick that can control the vehicle in a 360 degree manner, but only in forward and reverse. Also our vehicle will not be primarily used for people to ride
Title: Children's ride-on vehicle
Document Type and Number: United States Patent: D393888
This is the actual patent for a power wheels vehicle that we will be using, therefore we must pay royalties.

15. Team Gantt Chart

16. Block 1: Power Supplies Owner: Lee Strauss
Power the system that runs and controls the car.
Looking for +5 volts for operation
Input of 12 volts from battery
Buck Regulator used to achieve 5 volt output

17. Block Diagram

18. Buck Regulator LM5005 Current: 250mA – 2.5A
Operating Frequency: 50kHz to 500kHz
Integrated 75V, 2.5A N-Channel Buck Switch
Ultra-wide input voltage range from 7V to 75V
Internal high voltage bias regulator
Current mode control with emulated inductor current ramp
Wide bandwidth error amplifier

19. 5V Buck Regulator

20. Bill of Materials High Voltage Buck Regulator – LM5005
Capacitor 0.022uF – Part#: C223JAT2A
Capacitor 1uF – Part#: D105KAT2A
Capacitor 0.027uF – Part#: D105KAT2A
Capacitor 6.8 uF, 1.8ohms – Part#: EEV-FC1V6R8R
Capacitor 10uF, 2ohms – Part#: EEV-FC1H100P
Capacitor 0.003uF – Part#: GRM2165C1H302JA01D
Capacitor uF – Part#: C822KAT2A
Diode 0.5v – Part#: B130B-13
Inductor 330uH, 0.574ohms – Part#: DR R
Resistor 1.43K ohms – Part#: ERJ-6ENF1431V
Resistor 1K ohms – Part#: ERJ-8ENF1001V
Resistor 2.26K ohms – Part#: ERJ-6ENF2261V
Resistor 21K ohms – Part#: ERJ-6ENF2102V

21. Block 2: PWM Controller/ Micro-Processor Owner: Jordan Acevedo

22. Block 2: PWM Controller/Micro-Processor Description and Purpose
The PWM Controller will receive a digital pulse transmitted from remote control and the width of the pulse will determine the desired speed of the car and the width of another pulse will determine the driving direction of the car (forward/reverse).
Purpose:
Control the speed and direction of the car.

23. Block 2: PWM Controller/Micro-Processor Block Diagram
In From Proximity Sensors
Output to Motor Controller
Pulse Width Modulation (PWM) Chip
Input RF Signals
Micro Processor
In From Power Supply (+5V)
In From Power Supply (+5V)

24. Block 2: PWM Controller/Micro-Processor Block Signal Definitions
Block Name:
PWM Controller/Micro-Processor
Block Number: 4
Power Signals
To - From
Type
Direction
Block-Block
Voltage
Voltage Range
Block #'s
Interconnect
Nominal
Min
Max
Power2 5VDC 2
DC Power
Input
Connector-Cable 5V
4.5V
5.5V
Freq
Freq Range
% V-Reg
V-Ripple
Current
60Hz
55Hz
65Hz
<10%
200mA
Digital Signals
Dir
Output
Tech
Logic
Structure
Digital 1 RF Signal Processor
Receiver
Digital
PCB Trace
N/A
Standard
TTL
Variable
Digital 2 PWM Signal Controller
Mot. Contr.
Digital 3 Proximity Sensors 5
Cable
Input Characteristics
Output Characteristics
Vih Min
Iih Max
ViL Max
IiL Max
Vth Min
Vth Max
Voh Min
Ioh Max
VoL Max
IoL Max
0-1.8V
0-0.7A V A

25. Block 2: PWM Controller/Micro-Processor Theory of Operation
As the user presses forward on the remote control, the remote transmits pulses to the receiver.
The width of two of these pulses will determine the speed and driving direction of the car.
As the control stick on the remote is pressed further, the width of the pulses increases and the car will move faster in the desired direction.
If the IR Proximity Sensors are tripped “ON”, the car will no longer be able to drive forward, when the sensors are “OFF” and then full operation will be restored.

26. Block 3: Blinkers Owner: Ben Reider
Description - To receive and interpret a RF signal from controller and output a pulse that blinks either the right or left side blinkers on the car.
Purpose – An accessory used to indicate which direction the car turn.

27. Block 3: Block Level Requirements
Must work off of a 5 Vdc power supplied
Must be able to handle a max current input of 150mA if needed to meet power supplies min current output.
Needs to operate within system temp. requirements of 0-60°C
Must read and interpret RF signal
Needs to relay power from battery in order to ensure brightness of lights
Needs to blink lights once every other second
Robustly build to protect against driving collisions
Low power dissipation
Low cost

28. Block #3 Blinkers Block Diagram#2
12V Battery #1
5 VDC Power Supply #3
Microprocessor
PIC12F509
8 Pin, DIP #6
MOSFET #4
MOSFET
#7 Front
Light Array
12V
#7 Rear
Light Array
12V
#5 Front
Light Array
12V
#5 Rear
Light Array
12V
RF Signal

29. Block #3 Blinkers Block Specifications

30. Block #3 Microprocessor Program Flow Diagram
Start
Check for pulse Signal
Read in 5th pulse
Measure width of
5th pulse
Compare width to
nominal value
Check zero flag
Z=0
LeftBlink=1
Z=1
RightBlink=1
Output
Output
1 Sec Delay
1 Sec Delay
Output
LeftBlink=0
RightBlink=0
Output
Interrupt
1 Sec Delay
1 Sec Delay
Interrupt

31. Block #3 Component Selection
LEDs
Selected because in a series connection they could meet the change in source voltage(12-48V)
Low cost and Long Lifetime
Robustly built
Low Power (144mW each)
Transistors
60V Source to drain Voltage which meets the max source voltage of 48V
Low power dissipation at 350mW Max
Microprocessor
Least expensive yet meet programming requirements
6 output/input
Can handle the max current input of 150mA
Lower Power (800mW Max)

32. Block #3 Component Specifications

33. Block #3 Preliminary Schematic

34. Block #3 Bill of Materials

35. Block 4: Proximity Sensor Owner: Corey Preuss
Part #: GP2Y3A003K0F
(from Digikey)
Wide Angle Distance Measuring sensor unit (40 – 300cm)

36. Block 4: Proximity Sensor Preliminary Bill of Materials
Part Mfg Part # Description Qty. Package
Dimensions
1 GP2Y3A003K0F Wide Angle Distance x20x18mm
Measuring Sensor Unit
Capacitor 10uF

37. Block 4: Proximity Sensor Calculations and Specifications Absolute Maximum Values/Limits
Measuring Distance Range: cm
# of Outputs/Type: 5 Analog Outputs
Detection Angle: 25 Degrees
Supply Voltage Range (Vcc): -0.3 to +7V
Output Terminal Voltage(Vot): -0.3 to Vcc(+0.3V)
Input Voltage(Vin H/L and LED H/L): -0.3 to +Vcc(0.3V)
Operating Temperature(Topr): -10 to +60 Degrees Celcius
Storage Temperature: -40 to +70 Degrees Celsius

38. Block 4: Proximity Sensor Calculations and Specifications Electro-optical Characteristics
Average Supply Current(Icc Ave./Max.): 30/50mA
Ideal Supply Voltage(Vcc): 4.5 to 5.5V
Output Voltage(Vo): Min: 2.0 Ave: 2.3 Max: 2.6V
Output Voltage Differential(ΔVo):
Min: 0.9 Ave: 1.2 Max: 1.5V (between 40cm and 100cm)
Input Voltage: VinH: 4.5V(min.) VinL: 0.3V(max.)
LED H: 4.5V(min.) LED L: 0.5V(max.)

39. Block 4: Proximity Sensor Theory of Operation
Proximity switch receives input voltage and current from power supply via the microprocessor
Sensor measures distance to nearby object
If object is close enough to trigger the sensor “ON”, an interrupt will be sent through the microprocessor to the motor disabling the car’s forward position movement
Vehicle will be allowed to move in reverse direction until proximity sensor is switched “OFF”, and the car will then be allowed to move forward

40. Block 4: Proximity Sensor Description and Purpose
Sensor used for measuring distance from the car to nearby objects and sending a signal to the motor via the microprocessor to shut off if it gets too close to the object. Car will then only be allowed to move in reverse until it is a safe distance away from the object and will then be allowed to move forward.
Operation is used for safety concerns

41. Block 4: Proximity Sensor Block Diagram Breakdown/Schematic

42. Block 5: Dimming Headlights Owner: Phosay

43. Block 5: Dimming Headlights
Description – Circuit to dim the headlights when the car is in a bright environment, while operating in a bright environment, the head lights will be at max brightness.
Purpose – An accessory used to allow the car to automatically control the headlights by it self.

44. Block 5: Dimming Headlights Block Diagram
P722-5R
Block 5: Dimming Headlights Block Diagram
+12V Battery
+5V Power Supply
-12V Power Supply
Photo-resister
2 x Inverting op-amps
Left Head light
Right Head Light

45. Block #5 Detailed Design Calculations and Component Selection
Lights
Selected because of price and efficiency.
Long Lifetime
Low Power (144mW each)
Photo-Resistor
Type(P722-5R)
Resistance range of 15KOhms at 1 lux to 1.1KOhms at 100 lux
Has desired performance range
Power dissipated (70mW)
Op-amp
Inexpensive and meets performance requirements

46. Block 5: Proximity Sensor Preliminary Bill of Materials
Part #
(Radio Shack)
LM741CN
1.0KQBK-ND
SSL-LX3044YD-12V
Description
Photo-resistor
Op-amp
Resistor
Lights(LED)
Qty.1 2 4 60
Price(each)
$0.40
$0.22
$0.054
$0.23
Total cost = $14.86

47. Bright environment (100lux) max photocell resistance(Rp)
Block 5
Bright environment (100lux) max photocell resistance(Rp)

48. Output Voltage in bright environment (100lux) max photocell resistance
Block 5
Output Voltage in bright environment (100lux) max photocell resistance

49. Dark environment (1lux) min photocell resistance(Rp)
Block 5
Dark environment (1lux) min photocell resistance(Rp)

50. Output Voltage in dark environment (1lux) min photocell resistance
Block 5
Output Voltage in dark environment (1lux) min photocell resistance

51. Output Voltage in medium environment, 7KOhms photocell resistance
Block 5
Output Voltage in medium environment, 7KOhms photocell resistance