Capstone Design Project

Capstone Design Project
EE Capstone Design Project Spring 2005 Team #3 1

Team #3: Staff Nole Martin Paul Simons Eric Ritzke Tom Reuter
Steven Krol Murtadha B. Tunis BSEE

Team #3: Total Resources
1200 Man hours $1000 for material and prototyping Based on our individual experiences and knowledge our team will strive to exceed all project expectations.

Selected Product Wireless Weather Buoy
Primary Benefit: Real-time Local Weather Information Intended for use by private water-front property owners. Product will report air and water temperature, barometric pressure and wind speed via RF communications. Similar weather stations exist, but not for private use. Maritime Consumer Market

Similar Existing Product
Features Wind speed Wind direction Barometer Safety lights GPS Solar power Humidity sensor Water quality analyzer Advantages of our product: Cost effective Only essential sensors will be implemented

Block Diagram Eric – Green Paul - Yellow
Solar Recharging Battery Pressure Sensor 4 6 5 1 Microprocessor 2 3 10 LED w/ Controls 7 9 8 11 Outdoor Unit (Buoy) Indoor Unit (Display) Eric – Green Paul - Yellow Murtadha – Orange Steve – Light Blue Nole – Red Tom – Dark Blue Data Lines Wireless Link Power Lines

System Level Requirements
System Performance Requirements: Max Display Viewing Distance 3m Max Buoy Lighting Perception Distance 1,000m Number of Numeric Displays 10 Number of Lines of Displays 4 Buoy Functional Modes Active, Sleep Display Functional Modes Active Min SNR 35dB Max Noise 5nV/rtHz Min Transmission Distance 100m Max Buoy Power Current 1A

System Standard Requirements: Market: Est. Total Market Size $700,000 Est. Annual Vol. 1,000 Min. List Price $700 Max. Product Materials Cost $300 Max. Product MFG Cost $50 Power: Buoy Power 8V to 18V Solar Panel AC/DC Adapter 3.3V to 8.7V Max. Total Power 50W

System Standard Requirements: Mechanical: Max. Product Vol. 1,000,000 cm^3 Max. Shipping Container Vol. 1,100,000 1,000,000 Max. Shipping Container Vol. Max. Product Mass 40kg Max. # of PCB’s 4 Max. Total PCB Area 500 cm^2 Max. Shock Force 12.0 G’s Max. Shock Repetitions 6 Environmental: Operating Ambient Temp. Range -5°C to 70°C Operating Ambient Humidity Range -1000m to 20000m 0%Rh to 100%Rh Operating Altitude Range Storage Ambient Temp. Range -20°C to 80°C Storage Ambient Humidity Range 0%RH to 100%RH Storage / Shipping Altitude Range -1500m to 30000m

System Standard Requirements: Manufacturing: Min. Total Parts Count 150 Max. Unique Parts Count 65 Max. Parts & Materials Cost $300 Max. MFG Assembly / Test Cost $50 Life Cycle: Est. Max. Production Lifetime 5 years Product Life Reliability in MTBF Full Warranty Period 1 years

Safety Standards UL Power Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles and Marine Crafts UL Standard for Safety for Floating Water Lights Electrical Equipment For Measurement, Control, and Laboratory Use ISO 14000 ISO 9001

Basic Business Case Estimated Average Product Selling Price: $700
Estimated Product Annual Sales Volume: Units Estimated Per Unit Cost of Parts and Materials: $300 Estimated Per Unit Cost of Assembly, Testing and Mfg: $50 Estimated Total Development Cost (Labor + Material): $494,000 Calculated Annual Sales (ASP$ x Annual Volume): $700,000

Basic Business Case Calculated Per Unit Cost Margin (ASP$ - [Parts + Materials + Mfg] x Costs$): $350 Calculated Cost Margin (Per Unit CM$ / ASP$): 50% Calculated Annual Cost Margin (CM% x Annual Sales$): $350,000 Calculated Return On Investment (Est. Dev. Cost$ / Annual CM$): Years.

Block #1: Power Block

Block Diagram Data Lines Power Lines Solar Recharging Battery Water
Temperature Sensor Pressure Sensor Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Functional Purpose To receive Infra red rays from the sun
to charge the solar panels To regulate the solar voltage for the charging circuit To recharge the available power for the battery through an intelligent regulator To output the required regulated voltage for the power conversion circuit

Standard Requirements
Block cost <$120 Parts count <30 Unique parts count <20 PCB Area <350mm2 Operating temperature range -5 to 70 C Storage temperature range -20 to 80 C Reliability MTBF years Operating Humidity – 100% Percent Allocations % of cost 45% of mass 33% of parts 17% of total area

Performance Requirements
Battery Life years Battery Type V Deep cycle battery Rated Capacity < 7AH Supply voltage Vdc ± 3% Supply current <50mA Solar Panel <17V

Electrical Interface signals
Signal or Grouped Signal Name Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current Nominal Min Max Battery DC Power Output 12.0V 10.5V 13.7V DC N/A 14.00% 1.13A Power4 VCC +12V Input 14.0V 13.0V 17.0V 20.00%

Detail Design of Charging Circuit
Block Interface SUN Infra-Red Rays Intelligent Voltage Regulator Solar Panels Detail Design of Charging Circuit Voltage Regulator Power Conversion Circuit Deep Cycle Marine Battery

Prototype Plan 3.5mm Male CUI Inc. MP-3501 0.33649 Part QTY
Description Manufacturer/ Distributor Part # Cost ($) Solar Panels 2 Kyocera photovoltaic module Kyocera Kc60 $75/unit Battery 1 12 volt Deep Cycle At 8AH U.S.Battery/ Northern battery 24TM $49.95 Regulator Adjustable micropower National Semiconductor LP2951 $1.48 Plug 3.5mm Male CUI Inc. MP-3501

Power Regulation and Switching
Nole Martin

Functional Purpose To convert battery voltage from 12V to 5V
To distribute power to sensors, LED display, transmitter, and MPU. To include a switch so that the processor can power down the sensors. To include a push-button reset switch with de-bounce components and ESD protection.

Power Regulation and Switching
12V Battery 1 5V DC Switching Regulator 2 LED, Transmitter Switching Circuit MPU 2 Sensors Power Line Control Line

Power Regulation and Switching Standard Requirements
Block Cost <$10 Parts Count <20 Voltage Provided 5V +/- 4% Operating Temperature -5°C to 70°C Storage Temperature °C to 80°C Reliability Range years Operating Humidity %

Power Regulation and Switching Performance Requirements
Output Voltage 5V +/- 4% Supply Current >800 mA Regulator Efficiency >75%

Power Conversion and Switching Electrical Interfaces

Regulator and Switching Detailed Design Schematic

Regulator and Switching Detailed Design DFM Analysis Plan
Sub Circuit Type Applicable Worst Case Analysis Plan Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 5VDC Regulator R, L & C Tol Max Offset Voltage Pulse Response Over Current Protect Ripple V vs. I Regulation Power Semi J Temp Power Semi Package 5V Switching Regulator 5%,20% +/- 1% 93%<D<98% Thermal Shutdown <1.5% <85 C/W 16 Dip

Regulator and Switching Detailed Design Calculation Max Load Current vs. Max Regulator Output Current Load Max Current Draw Transmitter mA CPU mA Wind Speed Sensor <1mA Air Temperature Sensor <1mA Water Temperature Sensor <1mA Pressure Sensor mA LED Display mA Total mA (<<1A)

*all simulations done using National Semiconductor Websim Software
Regulator and Switching Detailed Design Calculation WC Analysis Regulator Components Vin=10.5,L1+10%,C2+20% Vin=10.5,L1+10%,C2-20% Vin=10.5,L1-10%,C2+20% *all simulations done using National Semiconductor Websim Software

Regulator and Switching Detailed Design Calculation WC Analysis Regulator Components Vin=13.7,L1+10%,C2+20% Vin=13.7,L1+10%,C2-20% Vin=13.7,L1-10%,C2+20% *all simulations done using National Semiconductor Websim Software

Regulator and Switching Detailed Design Calculation WC Analysis Regulator Components Results: No significant change in ripple or offset based on WC component tolerances or WC Input Voltage. *all simulations done using National Semiconductor Websim Software

Regulator and Switching Component Specifications

Regulator and Switching Prototype Bill of Material

Regulator and Switching Product Bill of Materials

Regulator and Switching Reliability Table

Regulator and Switching Summary of Reliability Table
The dominant parts for unreliability are the electrolytic capacitors. This is due to the method of approximation used as well as the voltage rating selected. For the capacitors higher voltage rated components could be introduced to improve reliability.

Regulator and Switching Obsolescence Table

Regulator and Switching Obsolescence Table
The worst parts for obsolescence is the SMT-voltage regulator. The results do not warrant replacement. The worst obsolescence window found was 6.5 years. This is above the product life requirement of 5 years.

Regulator and Switching Verification
Parameter Required Actual Verification DC Voltage (V) Regulator Min 4.8 Datasheet Max 5.2 Reference 4.95 4.995 5.05 5.005 Operating Temperature (C) -5 -40 70 125 Efficiency (%) 75 76 99 78 Output Current (A) 1 Regulator Ripple .2V .13V Simulation Reference Ripple 100uV 35uV Button De-bounce Time (ms) 5 8.375 Calculation Production Cost <$10 $9.95 Parts Count <20 15

Regulator and Switching Assembly Specifications
All components for this block reside on PCB Board #1 Testing will be performed on the regulator to ensure a clean +5V output.

Microprocessor Nole Martin

Functional Purpose Read analog outputs of the sensors and convert them to digital. Process the results to obtain meaningful data. Send meaningful data to the transmitter. Control power to sensors.

MPU-Block Diagram 5V DC Microprocessor 5V DC Ref+ Wind Sensor
Push Button Switch Microprocessor Wind Sensor Transmitter Pressure Sensor Switching Circuit Air Temperature Sensor Power Line Water Temperature Sensor Control Signal 5V DC Ref+ Data Signal

MPU Standard Requirements
Block Cost <$7 Parts Count <10 Operating Voltage 5V+/- 4% Operating Temperature -5°C to 70°C Operating Storage Temperature -20°C to 80°C Reliability years Operating Humidity % Disposal Throw Away

MPU Performance Requirements
Operating modes off/sleep/active A/D Converters 4 -With accuracy bit+ Transmission capability UART Timer for sleep/wake-up >10min DC power (VDD) 5V+/-4% Reference (VREF+) 5V+/-1% De-bounce Circuit Time >5ms

MPU Electrical Interfaces

MPU Detailed Design Schematic

Applicable Worst Case Analysis Plan (See DFM Analysis Guide)
MPU DFM Analysis 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 10 Bit A-D Converter R, L & C Tol RLC Specs Max Offset Error Max Gain Max DNL Max INL Input Impedance Worst Case Total Error Bits, Volts Sample/Hold Required? Conversion Speed Wind Speed NA +/-2 LSB +/-1 LSB 2.5kOhm +/- 5 LSB Sample 40 us Pressure Air Temp Water Temp Analog Switch Max Offset Voltage Input Impedance Hysteresis Ripple Package Sensor Power 5% +/- 20mv 1k Ohm < 5 mv Surface Mount Crystal Oscillator Fosc Processor Clock 4 MHz

DC Drive Device Parameters
MPU DFM Analysis Plan 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 MPU-Tx Pin Std NA ST .2Vdd .8Vdd +/-1uA 25mA .6V Vdd-.7 -3.0mA I/O Pin Sensor Power TTL Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 5VDC Reference R, L & C Tol Max Offset Voltage Dynamic Impedance Output Noise Power Semi Package 5V Reference Diode 5% +/- .1% .5 35uV SOT-23

MPU Detailed Design Calculation Voltage Reference RS Selection
RS = 1.0 k Selected

MPU Detailed Design Calculation WC Analysis for De-bounce Circuit
RC circuit used to prevent PIC from seeing multiple button presses Propagation Time = RC Button Press < 5ms Need RC > 5ms -R = 20k +/- 1% -C=.47uF +/- 10% RC = 9.4ms WC at minimum levels R = 19.8k, C = .423u RC = 8.375ms > 5ms +5V

MPU Timing Analysis for A/D Converter

MPU Timing Analysis for Transmitter

MPU Transmission Message Format
10 packages each containing 3 bytes sent one millisecond apart from each other Each package containing first an 8-bit product ID code followed by an 8-bit data byte followed by an 8-bit all ones message. 8 bit data product ID will protect product from errant data receptions 8 bit product ID code = 8 bit data code = 4 bit address of register in display processor corresponding to a specific 7-segment display AND a 4-bit BCD number to be stored in that address 8 bits of all 1’s is necessary to inform receiving processor that 2 bytes of data were received and are ready to be read.

MPU Compatibility of Signals with Transmitter/ Receiver
Regulator 4.9<VDD<5.1 RF Max VIL=0.3VDD=1.47V Min VIH=0.7VDD=3.57 IIL=-1 to 1uA IIH=-1 to 1uA Max VOL=0.4V Min VOH=VDD-0.4=4.5V IOL=2mA IOH=-2mA MPU Max VIL=0.2VDD=.98V Min VIH=0.8VDD=4.08 IIL=-1 to 1 uA IIH=25mA Max VOL=0.6V Min VOH=VDD-0.7=4.2V IOL=25mA IOH=-3mA .4V Max .98V Max RF MPU 2mA Low <25mA 4.5V Min 4.08V Min RF MPU 2mA High <25mA 1.47V Max 0.6V Max RF MPU <25mA Low 3mA 3.57V Min 4.2V Min RF MPU <25mA High 3mA All signals are within acceptable levels.

MPU Flowchart Power on sensors Convert analog sensor
signals to digital Initialization Steps Port A as inputs Port B as outputs Select XT Oscillator Watchdog On Configure Watchdog Watchdog Wake-up Process results into meaningful values Serially send data to transmitter Power off sensors Sleep (10minutes)

MPU Component Specifications

MPU Prototype Bill of Materials

MPU Product Bill of Materials

MPU Reliability Table

MPU Summary of Reliability Table
The crystal, inverter gate, and ESD diodes could be considered as the worst parts for reliability. This could be solved by finding components with higher voltage ratings. A different method could be selected as well for better results.

MPU Obsolescence Table

MPU Summary of Obsolescence Table
The worst parts are the reference diode and the crystal. These results do not warrant replacement however. The worst obsolescence window found was 6.5 years. This is above the product life requirement of 5 years.

MPU Verification of Requirements
Parameter Required Actual Verification Operating DC Voltage (V) Min 4.8 4 Datasheet Max 5.2 5.5 Reference 4.95 4.995 5.05 5.005 Operating Temperature (C) -5 -40 70 85 Operating Modes Sleep Active Off A/D Converters 6 Transmission Capability UART USART Timer 10min >10min Production Cost <$7 $5.47 Calculation Parts Count <10

MPU Assembly and Testing
All components will reside on PCB #1. Testing should be done to observe proper A/D conversion and UART transmission.

Temperature Sensors Steven Krol

Block Diagram Data Lines Power Lines Outdoor Unit (Buoy)
Pressure Sensor Solar Recharging Battery Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Functional Purpose To measure the current water temperature
To measure the current air temperature To convert the temperatures into the positive voltage that is needed for the MPU to manipulate the voltage The reading manipulated by the MPU will have an accuracy of ±2.5C (max) over our operating range of -5C to 70C for the air temp sensor The reading manipulated by the MPU will have an accuracy of ±3.5C (max) over our operating range of -5C to 70C for the water temp sensor

Block cost <$46 Parts count <10 Unique parts count <10 PCB Area mm2 Power consumption <5 mW Operating temperature range -5 to 70 C Storage temperature range -20 to 80 C Operating Altitude Range m to 20000m Reliability MTBF 5 years Operating humidity 0 to 100% Disposal Throw away % allocations Cost 14.3% Parts 10% Unique parts 14% PCB Area 10% Power <3%

Input Voltage Supply = 5 V ±5% Output Current < 1mA Voltage = 0 to 5 V Temperature Measurement -5 to 70C Accuracy ±2.5C over full range for air temperature ±3.5C over full range for water temperature

Temperature Sensor Block Interface
Analog1carrier output signal +5V Power signal 5V DC Power Supply Air Temperature Sensor MPU Analog1carrier output signal Amplified analog1 carrier output signal +5V Power signal 5V DC Power Supply Water Temperature Sensor Amplifier Circuit MPU

Characteristic output
Detailed Design Characteristic output

Detailed Design Passive Components Tolerance Power Rating Max Working
Voltage % Min 0.1uF capacitor 10 .101uF .099uF 50V 100Ω resistor 5 105Ω 95Ω .25W 200V 10kΩ resistor 10.5kΩ 9.5kΩ

Detailed Design for the Air Temp Sensor
4 3 Vout MPU LM20BIM7 +5V Sent from Regulator 0.1uF 2 0.1uF NC 1 5

Detailed Design Vmpu = (Vthermocouple) * Av
Characteristic output using a J Type Thermocouple Vmpu = (Vthermocouple) * Av where Av is the inverted gain provided from the Op Amp Vthermocouple = (.0289mV) * T mV Vtotal = Vref - Vmpu/G Vref = (.0289mV) * Tair mV Twater = (Vtotal mV)/(.0289mV) = Tair - Vmpu/28.9mV

for the Water Temp Sensor
Detailed Design for the Water Temp Sensor

Temperature Sensors Analog 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 Small Signal IC Amp for Water Temp Sensor R, L & C Tol RLC Specs Input Impedance DC Offset V Total Noise Air Temp IC Sensor circuit Output

Reliability Analysis Generic Name Asm PPM Reli FITS Max Tr Max Vr πT
πQ λB MTBF (years) Temp sensor 398.27 130C 6.5V 2.800 3.793 3 1.25 10 286 .1uF Capacitor 37.763 4.31 125C 50V 3.170 0.151 1.2 26480 100Ω resistor 1.183 0.13 200C 400V 1.313 0.137 0.2 845575 100kΩ resistor Op Amp 21.52 22V 0.181 5302 Type J Thermocouple 0.384 0.04 1200C 24V 0.663 0.176 0.1 Totals 424.40 269

Reliability Analysis The air temperature sensor IC is the main component contributing to unreliability We could find another component with a higher max voltage to improve reliability The only other component having a significant effect is the op amp

Sustainability Generic Name μ σ μ+2.5σ μ+3.5σ Temp sensor 2008 6 2023
Temp sensor 2008 6 2023 2029 .1uF Capacitor 1980 14.0 2015 100Ω resistor 1990 12.0 2020 2032 100kΩ resistor Op Amp 1987 7.8 2007 2014 Type J Thermocouple 2004 6.0 2019 2025

Sustainability The op amp is the component closest to becoming obsolete at 2.5σ and 3.5σ Switch the technology level or package for longer component lifetime The ceramic capacitors were the next predicted obsolete component at 2.5σ and third most at 3.5σ Switch to electrolytic capacitors would extend the lifetime The J type thermocouple was third at 2.5σ and second most obsolete at 3.5σ

Power Signals Type Direction Voltage Range Freq % V-Reg V-Ripple Current Nominal Min Max Power1 VCC +5 DC Input 5V 4.75V 5.25V 5.00% 0.1V 1mA Analog Signals Type Direction Coupling Voltage Max Amplitude Impedance Freq Range Leakage Min Analog1 Carrier Output Analog Capacitive 5V 1pF 5µF 25μA

Temperature Sensors Prototyping Plan
Block Area (cm2) Total PCB Area (mm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors 20 200 Perf board Solder NA

Verification of Requirements
Parameter Required Actual Covered DC Voltage (VDC) min 4.75 2.4 datasheet max 5.25 5.5 Output Voltage (VDC) 5 2.48 Power Consumption (mW) 0.05 Operating Temperature (C) -5 -55 70 130 Storage Temperature (C) -20 -65 80 150 Production Cost ($) 46.00 22.14 distributor PCB Area (mm2) 400 124 Parts Count 10 7 verified Unique Parts Count 6

Manufacturing Aspects
EMC Standard Tests Test Reason ESD Immunity Chance of human contact during installation or part replacement Radiated E-Field Immunity Electric fields could have the ability to affect the output voltage

Bill of Materials QTY Generic Name Mfg 1 Mfg 1 Part # TH/SMT P A C K G
Area Mm2 PCB Function or Description Attributes Tol % $COST/ ONE $Cost Total 1 Temp sensor National Semiconductor LM20BIM7 SMT SC70 50 Find Air Temp 2.5˚C accuracy NA 1.24 2 .1uF Capacitor Kemet ND TH Axial 3 Bypass Capacitors 50V max, Ceramic 10 0.20 0.40 100Ω resistor Panasonic P100CACT-ND use for opamp gain .25W, Metal Film 0.17 100kΩ resistor P100KCACT-ND Op Amp Maxim-IC MAX400EPA-ND DIP 60 Amplify signal f/ water sensor Input & output protection 13.52 Type J Thermocouple J & W Instruments JAA Find Water Temp Iron vs Constantan 19.50 7 Totals 121 $35.00

Wind Sensor Steven Krol

Block Diagram Data Lines Power Lines Outdoor Unit (Buoy)
Pressure Sensor Solar Recharging Battery Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Functional Purpose Wind is used to force an object to rotate
The wind speed sensor measures the horizontal speed of the wind converting the rate of rotation to a frequency

Block cost <$40 Parts count <10 Unique parts count <10 PCB Area mm2 Power consumption <5 mW Operating temperature range -5 to 70 C Storage temperature range -20 to 80 C Operating Altitude Range m to 20000m Reliability MTBF 5 years Operating humidity 0 to 100% Disposal Throw away % allocations Cost 11.4% Parts 10% Unique parts 14% PCB Area 10% Power <3%

Input Voltage Supply = 5 V ±5% Output Current < 3mA Voltage = 0 to 5 V Wind Measurement 0 to 110 mph Accuracy ±4.5mph over full range

Wind Sensor Block Interface
Analog1 output carrier signal Converted analog1 Output carrier signal +5V Power signal Frequency to Voltage Converter 5V DC Power Supply Wind Sensor MPU

Detailed Design ACCURACY: a few tenths of a mph from 0 to 10 mph /-4% from 10 to 50 mph and above Worst Case at low wind speeds Measured/Actual*100 = %Accuracy 3.7mph / 4mph * 100 = 92.5% accuracy or within 0.3mph Worst Case at high wind speeds [(Actual – Measured)/Actual]*100 = % Accuracy [( * 0.04) / 110] * 100 = 96% accuracy or within 4.4mph

Detailed Design Passive Components Tolerance Power Rating Max Working
Voltage % Min 0.02uF capacitor 10 .101uF .099uF 50V 1uF capacitor 1.1F .9uF 470Ω resistor 5 493.5Ω 446.5Ω .25W 200V 3.3kΩ resistor 3.465kΩ 3.135kΩ 4.7kΩ resistor 4.935kΩ 4.465kΩ 100kΩ resistor 105kΩ 95kΩ 10kΩ resistor 10.5kΩ 9.5kΩ

Detailed Design

Wind Sensor Analog 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 Small Signal IC Amp for 12VDC Regulation R, L & C Tol RLC Specs Total Noise Input Impedance DC Offset V Over Current Protect Input Voltage Range Frequency to Voltage Conversion Circuit

Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current Nominal Min Max Power1 VCC +5 DC Input 5V 4.75V 5.25V 1GHz 5.00% 0.1V 3mA Analog Signals Type Direction Coupling Voltage Max Impedance Freq Range Leakage Amplitude Min Analog1 Carrier Output Analog Capacitive 5.25V 1pF 100µF 0Hz 1GHz 200μA

Wind Sensor Prototyping Plan
Block Area (cm2) Total PCB Area (mm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors 20 400 Solder NA

Reliability Analysis Generic Name Asm PPM Reli FITS Max Tr Max Vr πT
πQ λB MTBF (years) 10kΩ resistor 1.183 0.13 200C 400V 1.313 0.137 3 1.25 0.2 845575 100kΩ resistor 470Ω resistor 1uF Capacitor 18.882 2.15 125C 50V 3.170 0.151 1.2 52960 .02uF Capacitor Freq to voltage conv. 85C 28V 0.286 10 100 anemometer 39.181 4.47 20V 0.188 2 25522 Totals

Reliability Analysis The IC used for the frequency to voltage conversion has the highest failure rate We could look for a new component with a higher max temperature to improve reliability

Sustainability Generic Name μ σ μ+2.5σ μ+3.5σ 10kΩ resistor 1990 12.0
10kΩ resistor 1990 12.0 2020 2032 100kΩ resistor 470Ω resistor 1uF Capacitor 1980 14.0 2015 2029 .02uF Capacitor Freq to voltage conv. 1987 7.8 2007 2014 anemometer 2008 6.0 2023

Sustainability The frequency to voltage IC is the component nearest to obsolescence at 2.5σ and 3.5σ Switch the technology level or package for longer component lifetime The ceramic capacitors were the next predicted obsolete components at 2.5σ and at 3.5σ Switch to electrolytic capacitors would extend the lifetime

Parameter Required Actual Covered Output Voltage (VDC) min .013 datasheet max 5 .490 Power Consumption (mW) .05 Speed Range (mph) 3 110 125 Accuracy (mph) 4.5 4.4 0.3 .3 Production Cost ($) 40.00 31.31 distributor PCB Area (mm2) 150 143 Parts Count 10 verified Unique Parts Count

Manufacturing Aspects
EMC Standard Tests Test Reason ESD Immunity Chance of human contact during installation or part replacement Radiated E-Field Immunity Electric fields could have the ability to affect the output voltage

Bill of Materials QTY Generic Name Mfg 1 Mfg 1 Part # TH/SMT P A C K G
Area mm2 PCB Function or Description Attributes Tol% $Cost/ One $Cost Total 1 10kΩ resistor BC components BC10KW-2CT-ND TH axial 3 assist freq to voltage conversion 2W, Metal Film 5 0.32 100kΩ resistor Panasonic P100KCACT-ND .25W, 0.17 470Ω resistor P470CACT-ND 1uF Capacitor Kemet ND 50V max, Ceramic 10 0.84 .02uF Capacitor ND 20 0.19 Freq to voltage conv. National Semiconductor LM2907N-8-ND SMT 60 freq to voltage NA 1.80 anemometer Inspeed Vortex pro 1200 plus 2 Measure wind speed 125mph max 30.00 7 Totals 77 $33.49

RF Transmitter Tom Reuter

Key Component Selection
Micrel MICRF103BM ISM Band ASK Transmitter Advantages: Fully integrated IC transmitter for low BOM design. Direct loop antenna drive and automatic antenna tuning. Meets most design requirements. Disadvantages: Data encoding must be done externally. ASK modulation has wider bandwidth than desired.

Requirement MICRF103BM Spec Supply Voltage 4.9 to 5.1 VDC 4.75 to 5.5 VDC Supply Current 20mA max 18.5mA max Transmission Distance 100 meters ~100 meters 9600bps) Transmission Frequency 862MHz to 928MHz 800MHz to 1GHz selected w/ crystal Modulation Type Frequency Shift Keying ASK

MICRF103BM Schematic

Bill of Materials

Analog DFM

Analog DFM Analog Worst-Case Analyses:
Voltage or Current Transfer Function Maximum Offset Voltage Phase vs. Frequency vs. Component Variations Output Impedance Open Loop Phase Margin Pole & Zero Locations (Fosc) Noise and/or Ripple Semiconductor Package & Heatsink

Digital DFM DC Drive Analysis Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Checked MICRF103BM Std 0.49V 4.08V -10uA 10uA N/A PIC MPU 0.98V -1uA 25mA 0.6V 4.2V -3mA

Pressure Sensor Eric Ritzke

Functional Purpose The pressure sensor sends a voltage to the CPU to accurately measure pressure in kilopascals (kPa). Allows for the prediction of weather with change in pressure.

Pressure Sensor Standard Requirements
Block Cost < $25 Parts Count < 5 Mass < 20g Power Consumption < .01A Voltage Required V +/- 5% Operating Temperature C to +70C Storage Temperature C to +80C Reliability Range years Operating Humidity % Disposal Throw away

Pressure Sensor Performance Requirements
Output Voltage V – 4.8V Supply Current < 10 mA Pressure Range – 115 kPa +/- 1.5% (2.2 – 16.7 psi) User Interface None Minimum Life years

Block Diagram Water Temperature Sensor Pressure Sensor Solar
Recharging Battery Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Pressure Sensor Electrical Interfaces

Pressure Sensor Schematic

Detailed Design DFM Analysis Plan Pressure Sensor

Detailed Design Component Specifications Pressure Sensor
Passive Discrete Specifications

Detailed Design Bill of Materials Pressure Sensor

Detailed Design Calculation Pressure Sensor
Nominal Transfer Value: Vout = Vs * (0.009 * P – 0.095) +/- (Pressure Error * Temp. Factor * * Vs) Vs = 5.1 +/ Vdc

Reliability Table

Pressure Sensor Prototyping Plan
Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socket Components Types of Connectors 20 Surface Mount Solder 4 Long Lead

Pressure Sensor Task Estimate
Cost of components: $25 Estimated Man Hours: 25 Hours

Light Controller Circuit Eric Ritzke

Functional Purpose Multiple ultra-bright blue LEDs will act as a light beacon to achieve maximum brightness. LEDs will flash sequentially. The LEDs turn on at dusk and off at dawn.

Light Controller Circuit and LEDs Standard Requirements
Block Cost < $30 Parts Count < 30 Mass < 50g Power Consumption < .05A Voltage Required V +/- 5% Operating Temperature C to +70C Storage Temperature C to +80C Reliability Range years Operating Humidity % Disposal Throw away

Light Controller Circuit and LEDs Performance Requirements
Brightness – 4000 mcd (luminous intensity) Visibility Range > 100 m Viewing angle /- 20º User Interface None Minimum Life years

Block Diagram Water Temperature Sensor Pressure Sensor Solar
Recharging Battery Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Light Controller Circuit and LEDs Electrical Interfaces

Detailed Design Schematic Light Controller Circuit

Detailed Design DFM Analysis Plan Pressure Sensor

Detailed Design Component Specifications Light Controller Circuit
Passive Discrete Specifications

Detailed Design Bill of Materials Light Controller Circuit

Reliability Table

Light Controller Circuit and LEDs Prototyping Plan
Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors 100 Surface Mount Solder 27 Leads

Light Controller Circuit and LEDs Task Estimate
Cost of components: $30 Estimated Man Hours: 75 Hours

RF Receiver Tom Reuter

Micrel MICRF005MB ISM Band ASK Receiver Advantages: Fully integrated IC transmitter for low BOM design. Single antenna input and single data output. Meets most design requirements. Disadvantages: Data decoding must be done externally. ASK modulation has wider bandwidth than desired.

Requirement MICRF103BM Spec Supply Voltage 4.9 to 5.1 VDC 4.75 to 5.5 VDC Supply Current 20mA max 18.5mA max Transmission Distance 100 meters ~100 meters 9600bps) Transmission Frequency 862MHz to 928MHz 800MHz to 1GHz selected w/ crystal Modulation Type Frequency Shift Keying ASK

MICRF103BM Schematic

Bill of Materials

Analog DFM

Analog DFM Analog Worst-Case Analyses:
Voltage or Current Transfer Function Maximum Offset Voltage Phase vs. Frequency vs. Component Variations Output Impedance Open Loop Phase Margin Pole & Zero Locations (Fosc) Noise and/or Ripple Semiconductor Package & Heatsink

Digital DFM DC Drive Analysis Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Checked MICRF005BM Std N/A 0.49V 4.59V 5uA -5uA PIC MPU 0.98V 4.08V -1uA 25mA 0.6V 4.2V -3mA

Indoor Microprocessor and Display
Paul Simons

Temperature Sensor Air Temperature Sensor Pressure Sensor Wind Speed Sensor 7 6 4 5 1 Power Conversion Circuits Microprocessor Microprocessor And Display 2 3 11 LED w/ Controls RF Transmitter RF Receiver 8 10 9 Power Conversion Circuits 12 Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Functional Purpose Read digital data out of RF Receiver
Process the results and send digital signal to proper location Display a visual readout of data

MPU and Display 5V DC Microprocessor RF Receiver 7- Segment Displays
Power Line Data Signals

Standard Requirements For MPU and Display
<$40 <30 <4 W 0 to +40 C -20 to +80 C 5 years 0-100% (just stay dry!) Throw away Block cost Parts count Power consumption Operating temperature range Storage temperature range Reliability Operating humidity Disposal

MPU Performance Requirements
Operating Modes Active Supply Voltage 5VDC Receiving capability UART

Performance Requirements For Display Unit
Digital VIL(max) 1 V VIH(min) 3 V Power Voltage 5 V ± 5% Current 400 mA User interface for entire product Visual Display Size 0.39” x 0.13”

MPU Electrical Interfaces

Detailed Design Schematic MPU

Detailed Design DFM Analysis Plan for MPU
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 Fosc 4 MHz R, L & C Tol RLC Specs Max Offset Error Max Gain Max DNL Max INL Input Impedance Worst Case Total Error Bits, Volts Sample/Hold Required Conversion Speed RX Pin NA +/-2 LSB +/-1 LSB 2.5kOhm +/- 5 LSB Sample 40 us

Detailed Design DFM Analysis Plan MPU
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 MPU-Rx Pin Std NA ST .2V .8V +/-1uA 25mA .6V Vdd-.7 -3.0mA I/O Pin TTL LS244 0.8V 2V -0.2mA 20uA 0.5V 24mA -15mA 0.2V

Detailed Design Component Specifications for MPU and Buffers

Display MPU-Detailed Design Flowchart
Data at Bus Enable Display Initialization Steps Port A as inputs Port B and D as outputs Select XT Oscillator Disable Display Check for new data New Data No New Data Serially attain data from RF Receiver Store data in appropriate registers

MPU-Detailed Design Compatibility of Signals with Transmitter/ Receiver
Regulator 4.9<VDD<5.1 RF Max VIL=0.3VDD=1.47V Min VIH=0.7VDD=3.57 IIL=-1 to 1 uA IIH=-1 to 1 uA Max VOL=0.4V Min VOH=VDD-0.4=4.5V IOL=2mA IOH=-2mA MPU Max VIL=0.2VDD=.98V Min VIH=0.8VDD=4.08 IIH=25mA Max VOL=0.6V Min VOH=VDD-0.7=4.2V IOL=25mA IOH=-3mA .4V Max .98V Max RF MPU 2mA Low <25mA 4.5V Min 4.08V Min RF MPU 2mA High <25mA 1.47V Max 0.6V Max RF MPU <25mA Low 3mA 3.57V Min 4.2V Min RF MPU <25mA High 3mA All signals are within acceptable levels.

Detailed Design Bill of Materials MPU and Display

Reliability Table

MPU and Display Summary of Reliability Table
The dominant part for unreliability are the crystal. This is due to the method of approximation used. To improve this characteristic, a different method of approximation should be used.

Obsolescence Table

Obsolescence Summary The worse obsolescence case is 6.5 years, which is the crystal. However, this exceeds our speculated reliability period of 5 years.

Actual Cost for Entire Block <$47 $11.95 Total Parts Count <50 42 Operating Voltage 5V +/- 5% 5V +/-4% Power Consumption <4W Reliability 5 years 10 years Operating Temp -5C to 40C -15C to 60C Storage Temp -40C to 80C Operating Humidity 0-100% Disposal Throw Away

MPU and Display Manufacturing and Testing Requirements
All components reside on PCB #3. Must test all 7-segment displays to ensure functionality. Processor must be programmed before soldering onto PCB. Test entire display unit with RF receiver, MPU, buffers, and displays.

Display Power Regulation
Paul Simons Team 3

Temperature Sensor Air Temperature Sensor Pressure Sensor Wind Speed Sensor 7 6 4 5 1 Power Conversion Circuits Microprocessor Microprocessor 2 3 11 LED w/ Controls RF Transmitter RF Receiver 8 10 9 Power Conversion 12 Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines

Functional Purpose To convert 120VAC to 5VDC
To distribute power to the RF Receiver, the MPU and the LED displays.

Power Regulation 120VAC To 5VDC Wall Adapter Display Unit RF Receiver
MPU Power Line Control Line

Display Power Standard Requirements
Block cost Parts count Unique parts count Mass (power supply) PCB Area Operating Voltage Operating temperature range Storage temperature range Reliability Operating humidity Disposal % allocations <$10 <10 <5 1 kg 1000 mm2 120 VAC +/- 5%, 60 Hz -5 to +40 C -20 to +60 C 5 years 0 to 100% Throw Away Cost 5% Parts 10% Mass 10%

Output Voltage 5 V +/- 10% Output Current : 478 mA 7 Segment Displays : 40mA/Display *12 Displays = 424 mA MPU : 4 mA Receiver : 50 mA Power Connection AC/DC Plug Adapter Mechanical Interfaces 5V DC power supply will need to be connected to a jack on the indoor unit Jack will be connected directly to the PCB

Display Power Electrical Interface

Detailed Design Calculation Regulator and Switching
Max Load Current vs. Max Regulator Output Current Load Max Current Draw Receiver mA CPU mA LED Displays mA Total mA (<< 1A)

Detailed Design DFM Analysis Plan Regulator
Sub Circuit Type Applicable Worst Case Analysis Plan Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 5VDC Regulator R, L & C Tol R, L & C Specs Over Current Protect V vs I Regulation Power Semi J Temp Power Semi Package Input Voltage Range 5V Switching Regulator 5%,20% Thermal Shutdown <1.5% <85 C/W 16 Dip 8V-40V

Obsolescence Table

Obsolescence Summary The worse obsolescence case is 7.8 years for the wall transformer. However, this exceeds our speculated reliability period of 5 years.

Actual Block Cost <$10 $5.94 Parts Count <20 5 Total Output Current <460mA 254mA Operating Temp -5C to 40C -15C to 60C Storage Temp -40C to 80C Operating Humidity 0-100% Disposal Throw Away Reliability 5 years 10 years

Display Power Assembly and Testing
Test to ensure 5V output. Solder leads from wall transformer to PCB.

Assembly Level Level 1: Program PIC Microcontrollers
Test PIC functionality Level 2: Assemble components on PCB 1 (Buoy) and solder Assemble components on PCB 2 (Buoy) and solder Assemble components on PCB 3 (Display) and solder

Assembly Level Level 3: Construct buoy Mount battery in the buoy
Mount PCB in the buoy Mount sensors on buoy externally Mount antenna on buoy externally Mount Solar Panel and connect to battery

Assembly Level Level 4: Level 5: Level 6: Mount PCB in display casing
Perform all necessary functionality tests Seal buoy and display cases Level 6: Place buoy and display module in packaging with user manual.

Buoy PCB Board

Display PCB Board

Sensor PCB Board

Assembly-Flow Diagram
Obtain Components PCB Manufacture Clean/Bake PCB Organize Components Operations Through hole SMT Auto-Component Insertion Screen Solder Paste Vision System Inspection Wave Solder Auto Component Placement Lead Trim Re-flow Solder (Oven) Vision System Inspection Stresses and Test Processes

Capstone Design Project

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