TEAM 2 Remote Control Car.

TEAM 2 Remote Control Car

Team #2: Total Resources
500 Man hours $500 or key part availability for material and prototyping LPI-Sean (BSEE) LSD-Russ (BSEE) LPM-Adam (BSEE) LRM-Brad (BSEE) LMM-Barry (BSEE)

Team #2 Project Our project is a remote control car, that can display battery life speed and direction, and can turn on the lights at the flip of a switch or if it gets dark. The benefit to the user would be a better remote control car There are similar types of products, however we are the only one that has all of these features. Our product would fall under the consumer industry Picture from

Project Features The remote control car has a two-way antenna that can transmit to and receive data from the car. Control of the car will come from the controller. The car can turn its lights on and off manually, and automatically if it gets dark enough. The display will tell us the speed and direction of the car, and the battery life remaining.

Team #2: Project 1 Block Assignment
Digital RF Trans / Rec Sean [4] RF Trans / Rec Sean [4] Digital Digital Digital Power Supply Brad [2] Ctrlr Processor Brad [3] Car Processor Russ [6] On Car Sensing Adam [8] Digital Analog Analog Electromechanical Control Russ[7] Digital Signal Input & Display Barry [1] Power Source Sean [5] PCB 1, power supply will be connected to all blocks PCB 2, power supply will be connected to all blocks

Requirement Units to Specify
Competitor’s Slide Requirement Units to Specify Competitors Market Size Average List Price Market Geography Market Demography Intended Application Material Cost Manufacturing Cost Annual Volume Traxxus, Tra5510 $600 million, website $200 World-Wide 6 yr. old to adult, boys Home, toy $80 / unit $20 / unit 6 million / yr

System - Std Reqs: Production Requirement Units to Specify
Max Volume Shipping Container Size Max Mass Max # of PC Bds Max PCB Circuit Area Max Shock 12,000 cm3 18,000 cm3 2 Kilograms 5 200 cm2 Total 50 G force

System - Std Reqs: Mfg & Life Cycle Requirement Units to Specify
Max Parts Count Max Unique Parts Count Parts/Mat $ Allocation Asm/Test $ Allocation Product Life, Reliability Full Warranty Period Service Strategy 200 Total Parts 100 Unique Parts $80 (Parts+Mfg=Product Cost) $20 (Parts+Mfg=Product Cost) 3 yrs 6 months Repair

System - Std Reqs: Enviroment Requirement Units to Specify
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 10-60 Co 10-90% non-condensing Meters 0-80Co 10-90% non-condensing 1 year

System - Std Reqs: Power Interfaces Requirement Units to Specify
Min Oper Voltage Range Max Power Consumption Max Energy Consumption Car Battery Chemistry Car Battery Capacity Controller Battery Pack Controller Display Segments Controller Accuracy Modes of Operation 5-9.0 V and V 18.0 Watts Total 6000 mAH Total Nimh 6000 mA-Hrs i.e. AA 1.5V 10 bars ⅛ battery life On/Off

System – Perf Reqs: Display
LCD Display: Display size: Max. Display Distance: Viewing Environment: Display Char Matrix: Display Size: Display Illumination: Mono Color 150mm x 70mm 1 meter Any 20 Total Char/Row, 4 Total Rows 20cm x 10cm LED

System – Perf Reqs: Operator I/F Inputs Requirement Definition
40 dB 1% 80 .25V .005s 300m Min SNR Max THD Min Power Gain Max Error Voltage Max Delay Min EM Transmission Distance

System – Perf Reqs: Lights & Speed Requirement Definition
Power Saving Modes Accuracy Updates Speed Range Response Time Input/Output ON/OFF/AUTO None ± 3 mph 200 ms 0-40 mph 8 Directional Units 0-5V logic levels

System – Perf Reqs: Safety Standards
We will be using the standards UL , UL , UL 1977, Cispr , EMC , EMC , and EMC in order to make sure that our product is safe. These standards insure that there is no risk to the user from the product and vice versa. The EMC standards protect our product from ESD and power surges.

Estimation Slide From Lab 1 Manhours-500 Material $500 ~2% for design
~86% for detailed design ~2% for verification ~10% for documentation From Lab 3 Manhours-1702 Material $1031 These values may be off due to overlapping of projects.

Block Prototyping Plan Template Overall
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Overall 1550 650 Perfboard, breadboard Pins/ wires/solder None

Gantt Chart

Product Assembly We will try to use as many SMT components as we can.
We will use a Perfboard to connect all components.

Designed by: Barry Gentz
Signal Input Designed by: Barry Gentz

Block 1 Signal input consists of 2 potentiometers, a switch, ESD protection, filtering, and logic gates.

Block 1 - Std Reqs: Env & Safety Requirement Units to Specify

Block 1 - Std Reqs: Power Interfaces Requirement Units to Specify
Energy Source List Source Connection List Operating Voltage Range Max Power Consumption Max Energy Consumption Max Potential Power Supply Permanent/Temp V 18.0 Watts 1000 mAH 9 V

Block 1 - Std Reqs: Mechanical Requirement Units to Specify
Elec I/F Connector(s) Max # of PC Bds Max PCB Circuit Area Max Shock Tyco 1 100 cm2 Total 50 G force

Block 1- Std Reqs: Mfg & Life Cycle Requirement Units to Specify
Max Parts Count Max Unique Parts Count Parts/Mat $ Allocation Asm/Test $ Allocation Product Life, Reliability Full Warranty Period Product Disposition Service Strategy 25 Total Parts 12 Unique Parts $125 $50 3 yrs 6 months Dispose Dispose or Repair

Block 1 – Perf Reqs: Operator I/F Inputs Requirement Definition
60 dB 1% 80 .25V Min SNR Max THD Min Power Gain Max Error Voltage

Block 1– Perf Reqs: Mech Interfaces / Safety
Connectors Signal 1 Max Current Limit Signal 1 Max Trip Time Signal 2 Max Current Limit Signal 2 Max Trip Time Signal 3 Max Current Limit Signal 3 Max Trip Time Male pin .005 Amps .004 s

Signal Input Speed Analog Direction Processor Analog Lights Digital
Power ( 5V )

Sub-Block Design Analysis Plan
5K Pot ESD LP Filter Processor 5K Pot ESD LP Filter Switch ESD De-Bounce Digital Signal Analog Signal Power Signal Power

Detailed Design: Speed & Direction

Detailed Design: Light Switch

Signal Input : Signal Type
Digital Analog

Task-Resource Estimate Summary
Resources (after 10/11) Time 200 hours Money $125 max

Applicable Worst Case Analysis Plan
Sub Circuit Type Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 LP Filter R, L & C Tolerances RLC Specs Cutoff Freq Output Impedance Small Signal IC Amp Max Offset Voltage DC Gain vs Component Variations Gain vs Freq vs Comp Var Phase vs Freq vs Comp Var Slewrate Power Bandwidth Pulse Response & Delay Analog Switch Input Impedance Over Current Protect Upper-Lower TP, Hysteresis Noise and/or Ripple Passive Filter V or I Transfer Function Task 7 Task 8 Task 9 Task 10 Task 11 Task 12 Task 13 Open Loop Gain Margin Open Loop Phase Margin Semicond Power & Junct Temps Semicond Package & Heatsink Pole Zero Locations or Fosc Applicable Worst Case Analysis Plan

Digital Block DFM - DC Drive Analysis Table DC Drive Device Parameters
Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked Switch Std TTL 4.9 5.1 .1A 2.8A .6 4.3 8.5mA 3mA NA Vxx in Volts, Ixx in mA Source Currents Listed as Negative Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Passive Specifications

BOM QTY Generic Name Mfg 1 Mfg 1 Part # Mfg 2 TH/SMT Package Tol%
$Cost/One $Cost Total 1 150KΩ resistor Ohmite OD154JE TH Bulk 5 $0.42 4 130KΩ resistor Yageo CFR-25JR-130K Panasonic TR/CT $0.10 $0.40 .1uF Fixed Capacitor Kemet C0603C104K8RACTU CT 10 $0.08 1.5uF Fixed Capacitor C0805C155K8PACTU $0.47 $1.88 DPDT switch E-Switch 100DP3T2B4VS2RE PCB $6.77 2 Potentiometer 5kΩ Bourns Inc. TC86P-1-502 6mm Rnd 20% $0.23 $0.46 OP Amp T.I. LM124DR $0.30 $0.60 ESD Device(Varistors) EZJZRV120JA Tyco SMT 805 4 array $1.50 $3.00 Total $9.87 $13.61

Testing Functional tests are needed after assembly which include :
Turning on the controller/car and running through dir/speed operations, turning on/off lights, running in dark environment.

Designed by: Brad LaCount
Power Supply Designed by: Brad LaCount

Power Supply Block Consists of 10 AA style batteries and a low-dropout voltage reference supplying 5V to the controller components.

Block 2 - Std Reqs: Env & Safety Requirement Units to Specify

Block 2 - Std Reqs: Power Interfaces Requirement Units to Specify
Energy Source List Source Connection List Operating Voltage Range Max Power Consumption Max Energy Consumption Battery Temporary V 18.0 Watts 2800 mAH

Block 2 - Std Reqs: Mechanical Requirement Units to Specify
Elec I/F Connector(s) Max # of PC Bds Max PCB Circuit Area Max Shock Tyco 1 20 cm2 Total 50 G force

Block 2- Std Reqs: Mfg & Life Cycle Requirement Units to Specify
Max Parts Count Max Unique Parts Count Parts/Mat $ Allocation Asm/Test $ Allocation Product Life, Reliability Full Warranty Period Product Disposition Service Strategy 30 Total Parts 5 Unique Parts $10 (Parts+Mfg=Product Cost) $50 (Parts+Mfg=Product Cost) 3 yrs 6 months Dispose Dispose or Repair

Block 2 – Perf Reqs: Power Input(s)
Controller Battery Pack 10 AA 1.5V

Block 2 – Perf Reqs: Electrical Interfaces
Electrical Signal Req Direction Power Signal Output

Block 2 – Perf Reqs: Operator I/F Inputs Requirement Definition
60 dB 1% 80 .25V Min SNR Max THD Min Power Gain Max Error Voltage

Requirement Definition
Block 2– Perf Reqs: Mech Interfaces / Safety Requirement Definition Connectors Max Potential Male pin, Battery tray 9V

Requirement Definition
Block 2 – Perf Reqs: Modes of Operation Requirement Definition Power Modes Power Saving Modes ON/OFF None

Controller Power Supply Block Diagram
Battery Pack Lights Voltage Regulator 5V LDO CPU Speed Direction

Block Prototyping Plan Template Power Supply
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Power Supply 250 20 Perfboard Pins/ wires/solder DIP and SMT Conversion Sockets None

Designed by: Brad LaCount
Controller Processor Designed by: Brad LaCount

Block 3 :CPU and Display Description Four line display
It is mounted on the controller to relay information to the user Able to view in dim/dark environment – backlight The Processor is used to coordinate and executed the function of the Controller Display mounted on the controller to relay information to the user Chip on glass (COG) technology

Block 4 Standard Requirements
Min Oper Temp Range: Min Oper Humidity Range: Min Oper Alt or Press Range: Min Oper Range (Distance): Min Storage Temp Range: Min Storage Humidity Range: Min Storage Alt or Press Range: Max Storage Duration: Value 0-60 Co 10-90% non-condensing Meters Line of Sight 0-80Co 10-90% non-condensing 1 year

Controller Processor Block Diagram

Block 3 Analog Digital Power

Block Prototyping Plan Template Controller Processor
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Controller Processor 250 50 Perfboard Pins/ wires/solder DIP and SMT Conversion Sockets None

Designed by: Sean Murphy
RF Transceivers Designed by: Sean Murphy

Block 4 - RF Two way real time digital communication between controller and car processors Feeds information to car such as speed, direction, and light control Feedback information to controller on battery life, speed, and direction Peer to peer configuration

Block 4 - RF Standard Requirements
Value Co 10-90% non-condensing Line of Sight 0-80 Co 10-90% non-condensing 1 year Co Requirement Min Oper Temp Range: Min Oper Humidity Range: Min Oper Range Min: Storage Temp Range: Min Storage Humidity Range: Max Storage Duration: Max Storage Temp Range:

Block 4 Performance Requirements
Modes: Input Power: Current Consumption: Regulations: Standards: Connectors: Packet Size: Value On/Off &Tx/Rx 5V DC ±2%, 50mVpp ripple 115mA FCC Parts 15 and 27 CISPR IEC 20 Pin Mini Connector Min 15 bits

Car Processor Power RF Transceiver Supply Power RF Transceiver Supply
Block 4 Signals RF Car Processor Digital Power Supply 5V DC Transmitted Bit Package Car To Controller: Speed Indicator Direction Indicator Battery Life RF Transceiver Digital Transmitted Bit Package Controller To Car: Speed From User Dir From User Lights On/Off/Ambient Power Supply RF Transceiver 5V DC Digital Ctrlr Processor

Block 4: Transceiver, Processor, and PS Interface

RF Transceiver : Digital
RF Transceiver : Power RF Transceiver : Digital

Block 4 - Timing Analysis

Block 4 - RF

Block 4 Prototyping Plan Template
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors RF 250 200 (2 – 10x10) Glass fiber Standoffs N/A Multi-pin

Designed by: Sean Murphy
Power Source Designed by: Sean Murphy

Block 5: Car Power Source
Provides power to all on car devices and functions Indicates battery life remaining to processor Will require voltage regulation

Standard Requirements:
PS Type: Source Type & mAh: Oper Temp Range: Vo Regulator: Vp-p Ripple Max: Io(Max): Connection: Safety: Nimh Battery Pack DC, 6000mAh max 10 – 60 Co 5V ±2% 50mV 350mA Temporary UL 2054 (Batteries)

Performance Requirements:
Voltage Regulator VR Type: LDO High Discharge Vin Min/Max: 5.5V/9.6V Vo Nominal: 5V Vo Max Tol: 2% Vp-p Ripple Max: 50mV Io Max: mA Battery Fuel Indicator Type: Gas Gauge Vin Battery Min/Max: 5.5V/9.6V Vin Supply: 5V Accuracy: 15%

Block 5: Car Power Source
Block Diagram Nimh Battery Pack 0-9.6V Battery Life Voltage Regulator (5V Nominal) Car Processor V Direction Sensor Speed Sensor Lights RF Trans / Rec 0-9.6V For Motor Electromechanical Control

Block 5: Voltage Regulator Detailed Design
Want Cout large due to large changes in current.

Block 5: Fuel Gauge Detailed Design
PFC = BatCap*Rsense

Power Source: Power Fuel Gauge : Digital

Block 5 – Car Power Supply

Block Prototyping Plan Template Power Source
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Car Power 250 50 Perfboard Pins/ wires/solder DIP and SMT Conversion Sockets None

Designed by: Russ Diamond
Car CPU Designed by: Russ Diamond

Block 6: Car Processor Inputs Outputs 5V from Power Supply CPU for Car
DO to steering servo Analog Input from Battery Sense circuit DI Speed Indicator 3 DO for Lights DI data from Transceiver Transceiver Data Request DI from Compass 4 DO for Motor Control DI from Photocell Clock signal from Crystal DO to Transceiver

Block 6: Car Processor Interprets signals from the transceiver and outputs control signals to the rest of the board. It also passes back data sensed on the car to the transceiver.

Performance Requirements
- Input to Output Requirements (Freq Response, SNR, Gain, etc) - Applicable Operational Modes (ON, Standby, Calibrate, Fast, Slow, etc)

Car Processor

Block 6: Car Processor Inputs Outputs

Applicable Worst Case Analysis Plan (See DFM Analysis Guide)
Block 6 DFM Plan Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Crystal oscillator Voltage vs Freq Phase vs Freq Slewrae BW Step Resp Input Impedance Output DC Offset V Total Noise Input Capacitor C Tol C spec Slewrate

Block 6 - DC Drive Analysis Table DC Drive Device Parameters
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked Micro TS .75 2.0 -1u 1.0u .6 4.3 8.5m -.3m 1.25 Vxx in Volts, Ixx in mA Source Currents Listed as Negative Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Block 6 DFM - Timing Analysis Table
Dig Signal Output Type Input Type Timing Parameters Other Tsu Setup Th Thold Margin Fmax F Tpulse Min Checked Micro signals TS 200n 400n .1 20M 5M .01 Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Block Prototyping Plan Template Car Processor
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Car CPU 25 40 Perfboard Pins/ wires/solder DIP and SMT Conversion Sockets 20 pin mini

Electromechanical Control
Designed by: Russ Diamond

Block 7 – Motor Control Motor Control Circuit 4 Digital inputs
2 Analog outputs To Motor 1 Digital Input Traxxas Servo Position Control is achieved by sending a pulse to the servo every 20ms. The length of the pulse determines the positioning of the servo.

Block 6: Motor Control Generates an analog voltage across the voltage terminals for the motor Controls the steering of the car

Block 7: Car Processor Min Oper Temp Range 10-60 Co
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 10-60 Co 10-90% non-condensing Meters 0-80Co 10-90% non-condensing 1 year

Performance Requirements

Electromechanical Control

Motor Control Circuit

Block 7 DFM Plan Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Mosfet Drivers R, L & C Tol RLC Specs Gain vs Freq Phase vs Freq Slewrate BW Step Resp Input Impedance Output DC Offset V Total Noise Current Diodes Resistor Max Offset Error Max Gain Max DNL Max INL Worst Case Total Error Bits, Volts Sample/Hold Required? Conversion Speed Fn(s)

Block 7 - DC Drive Analysis Table DC Drive Device Parameters
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked Traxxas 2015 servo Mec Std. .80 3.5 -.1m .1m n/a 2.7 Vxx in Volts, Ixx in mA Source Currents Listed as Negative Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Block 7 DFM - Timing Analysis Table
Dig Signal Output Type Input Type Timing Parameters Other Tsu Setup Th Thold Margin Fmax F Tpulse Min Checked Q1 Std. n/a 15KHz Q2 Q3 DC Q4 Servo 1m 2m 500 Hz Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Block Prototyping Plan Template Motor Control
Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Motor Control 30 15 Perfboard Pins/ wires/solder None Three position connector

Designed by: Adam Wozniak
Car Signals Designed by: Adam Wozniak

Block 6: Car Sensing Signals if the lights are on or off Uses light detection to determine if lights should turn on or off Signals how fast the car is going Signals in which direction the car is moving

Standard Reqs: Car Sensor Requirement Definition
3 30 cm2 20 3 yrs 10-60 C 0-80 C Max # of PC Boards Max PCB area Max Parts Count Product Life Operating Temp Storage Temp

Performance Reqs: Car Sensor Requirement Definition
8 Directional Units 200 ms + 3 mph 0-40 mph Direction Sensor Accuracy Response Time Speed Sensor Updates Speed Range Light Sensor Sensitivity

Car Sensor: Power Car Sensor: Digital

Block 8: Car Sensing Direction Sensor Car Processor
Digital Car Processor Controller Processor Transmit to/from Processor Speed Sensor Speed digital Lights digital Comparator Light Sensor Lights digital Power Lights Lights digital

Direction Sensor Diagram

Light Sensor Diagram

Speed Sensor Diagram

Analog Block DFM Plan Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Speed Sensor R, L & C Tol RLC Specs Input Impedance Output DC Offset V Speed Limits Magnetic noise Accuracy Conversion Speed OpAmp Gain vs Freq Phase vs Freq Slewrate BW Step Resp Total Noise Photodiode Sensitivity RLC total Output Impedance Input Impedance

Digital Block DFM - DC Drive Analysis Table DC Drive Device Parameters
Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked HM55B Std NA TTL 5.2V 4.8V 7mA 3mA Std = Standard, OC = Open Collector/Drain, TS = Tristate, ST – Schmitt Trigger

Digital Block DFM - Timing Analysis Table
Dig Signal Output Type Input Type Timing Parameters Other Tsu Setup Th Thold Margin Fmax F Tpulse Min Checked HM55B Std 30ns 100ns 5MHz 1MHz 30mS 40mS

Passive Component Specifications

Analog Circuit DFM Analysis

Bill Of Materials

Special Mfg and Testing
The Photocell will need to be mounted such that it is able to sense outside light. The speed sensor will need to be mounted within a ¼ inch of the wheel gear

Reliability Slide

Assembly Level/Steps

Boards Subassembly

Reliability Conclusions
The total FIT’s are 28.2, thus the MTBF is 4045 hours The most unreliable parts are the resistors The reliability could be better if we could get more reliable resistors

Reliability Conclusions
The total FIT’s are 28.2, thus the MTBF is 4045 hours % of products will fail in the warranty period The most unreliable parts are the resistors The reliability could be better if we could get more reliable resistors

Life Stress Model

Reliability Growth Plan

TEAM 2 Remote Control Car.

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TEAM 2 Remote Control Car.

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