1. Team 1: Staff Dan Piessens Henrik Gustavsson David Luu Brent Wellner
BSEE / BSCS
BSEE

2. Team 1: Expertise & Experience
Dan Piessens
Henrik Gustavsson
David Luu
Brent Wellner
Expertise: PLD/FPGA, Microprocessors, Software
Experience: 5 yrs software development
Expertise: Microprocessors, AutoCAD, Software
Experience: 6 semesters TetraPak
Expertise: AC/DC Conversion, MathCAD, Matlab
Experience: N/A
Expertise: PLD/FPGA, VHDL
Experience: 1.5 yrs Modine Manufacturing

3. Team 1: Contact Info
Dan Piessens
Henrik Gustavsson
David Luu
Brent Wellner
Phone: (414)
Phone: (262)
Phone: (414)
Phone: (920)

4. Team 1: Weekly Availability Worksheet
Dan Piessens
Henrik Gusatvsson
David Luu
Brent Wellner
Time 1: M/W 12:30 - …. Time 2: F/S/Su
Time 3: T 1:00 - 3:30 Time 4:
Time 1: M/W 12:30 - 3:30 Time 2: T/Th - 3:30
Time 3: M/W 6:30 - …. Time 4: F/S/Su
Time 1: M/W 1:00 - 3:00 Time 2: F/S/Su
Time 3: T …. - 6:30 Time 4:
Time 1: M/W …. - 5:00 Time 2: Su
Time 3: T/Th …. - 6:30 Time 4:

5. Team 1: Weekly Project Meeting Plan
Weekly Meeting 1: IEEE Office, Thursday 01/27/05 8: :30 PM
Henrik, All attendees & Purpose: Discuss Project Objectives
Weekly Meeting 2: IEEE Office, Tuesday 02/01/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Expand on Project Ideas
Weekly Meeting 3: IEEE Office, Tuesday 02/08/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Finalize Project Selection
Weekly Meeting 4: IEEE Office, Tuesday 02/15/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Constructed Project Overall Design
Weekly Meeting 5: IEEE Office, Tuesday 02/22/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Individual Blocks & Requirements
Weekly Meeting 6: IEEE Office, Tuesday 03/01/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Finalized Requirements Spreadsheet
Weekly Meeting 6: IEEE Office, Tuesday 03/08/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Finalized Task lists
Weekly Meeting 6: IEEE Office, Tuesday 03/11/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Correct Presentation 2 Slides
Weekly Meeting 6: IEEE Office, Tuesday 03/1505 1:00 - 3:00 PM
Henrik, All attendees & Purpose: Preparation for Lab 5
Weekly Meeting 6: IEEE Office, Tuesday 03/29/05 1:00 - 3:00 PM
Henrik, All attendees & Purpose:
Note: Meeting Owners Send Weekly Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

6. Team 1: Total Resources
1000 Man-hours (Including: lab, weekly meetings, individual commitments )
$400 or key part availability for material and prototyping

7. Team 1: Decision Making
Decisions will be made through a consensus, based upon: resources, time consumption and cost.
Majority vote applies in the event of an irresolvable conflict.

8. Roles to Define & Assign
Project Integrator: Dan Piessens - Owns weekly progress reports to TA. Logistics and communication of team meetings. Develops and Tracks overall project plan. Integrates Block design plans. Tracks expenditures. Owns project level verification and validation plan, capture and documentation of results.
Presentation Mgr: Henrik Gustavsson - Owns master MS Powerpoint slide set for team including formats, logos, fonts, colors, header/footer, backgrounds, rev control, submission of master floppy or CD for P1-P4 and Final Presentation.
Report Mgr: Brent Wellner - Owns master MS Word document for team including revision control, formats, logos, fonts, colors, header/footer, table of contents, submission of master floppy or CD for Final report.
Archive Web Mgr: Dan Piessens - Owns weekly backup of all electronic material generated that week. Backup for Presentation Mgr and Report Mgr. Management of any team Web site resources.
Assembly & Proto Mgr: Brent Wellner - Owns overall assembly level definitions, basic assembly drawings, master prototype & product parts lists, collection of block parts lists, procurement of proto components. Overall prototype mechanical and electrical assembly
PCB Layout Mgr: David Luu - Owns overall PCB layout, Block to PCB mapping, PCB tools, PCB design drawings, PCB procurement, PCB assembly including special tools, soldering, wire-wrapping, drilling, and gluing.

9. Catch-a-Buzz Buzzer system: Why is this a good project?
This system is designed for users to participate in games like a quiz bowl. Users would be able to hit a button on a remote unit that would transmit the response wirelessly to a center console that indicates who responded and keeps track of a scores. Alternately user can respond to a multiple choice question, the console would then indicate the correct answer and score.
Buzzer system:
Allows for 1 to N remote units
Master console that indicates responses and team scores
Two operation modes:
First unit to respond
Correct answer multiple choice
Display team scores either on LCD or TV out
Why is this a good project?
Large target market: schools, organizations, weddings
Easy to use for people, simple remote interface
Utilizes the skill of each team member fully

10. Catch-a-Buzz - Block Diagram
Console Unit
Remote Unit
Power
120V Transformer
RF Transceiver
Power
Battery
RF Transceiver
Microprocessor
CPLD
LCD Display / LED
Keypad Input
LED / 7 Segment Display
Button Input

11. RF controlled Belaying Machine
The RF controlled belaying machine is a device intended for use by rock climbers in an indoor rock climbing facility. The primary objective of this device is to substitute the use of a human belayer through the safe use of a belaying machine.
The key performance aspect of this device is that it eliminates the use of a belayer when indoor rock climbing. It delivers all control to the climber through a simple RF module which controls the various modes in which the machine can be used.
The base/motor drive is powered by a typical 120V power outlet. The remote unit is Li-polymer powered and is recharged through a unit positioned on the base/motor drive. The user interface consists of a pushbutton type user interface with confirmation LED’s for each command. The user interface controls the different modes of operation: belay, slack adjustment, stop and rappel.
This project is a good fit for the team due to it’s interesting and practical nature. An RF controlled belaying machine does not exist, it would be the first of it’s kind. It’s marketability is very plausible for all indoor rock climbing centers.

12. Belaying Machine - Block Diagram
Base / Motor Drive
Remote Transceiver
Remote Charger
Transceiver
Transceiver
Input / LED’s
CPU
CPLD
Power Supply
Motor / Drive
Power Supply

13. Enroute - Overview Transit Notification System:
This system consists of units at each bus stop that communicate with a remote on every running bus. This allows a bus to only stop at a bus stop if notified by the unit at the station. The users notify the bus via push buttons on the station transceiver. Both Transceivers are programmable via a keypad on their respective units. The station transceiver also contains a taxi call card swipe that sends a request to a server via a network interface.

14. Enroute - Features Station Transceiver Unit: Bus Transceiver Unit:
Ability to request different busses via push buttons
Programmable via keypad
Network interface for taxi notification and confirmation
Powered by 120V AC Source
Bus pickup notification
Bus Transceiver Unit:
LCD & LED display for stop notification
Communicates with stations via RF transceiver
Powered by 12V DC Source
Post-pickup cancellation

15. Enroute - Block Diagram
Bus Transceiver Unit
Station Transceiver Unit
U.I. 1
Transceiver
Transceiver
NIC
Henrik
U.I. 2
CPU1
CPU2
Dan
Brent
PSU 1
Setup Controls
PSU 2
Setup Controls
David

16. Enroute - Justification
Why is this a good project?
Large target market: useful in any city with a public transit system.
No competitive products exist: Unique to the transportation market
Easy to use for people, simple interfaces on both ends
Reduces ride time and mechanical wear
Convenience of notifying taxies
Fully utilizes the skill of each team member

17. Enroute - Product Selection Process
Major Risks:
Too many blocks - overly complicate design
Why were other projects rejected?
Other projects were not as closely related to our individual expertise
Mechanical challenges with the Belaying machine
Lack of marketability for the Catch-A-Buzz product
Product Selection:
Project selection was unanimous

18. Standard System Level Requirements
Standard Requirements
Environmental:
Operating Temperature Range: -40 to 70 °C
Operating Humidity Range: 2 to 98 %
Storage Temperature Range: -30 to 80 °C
Storage Humidity Range: 2 to 98 %
Storage Duration: 2 Years
Energy Sources:
120 VAC ( V, Hz)
12 VDC (10-15 V)
Over Voltage Protection Circuitry

19. Standard System Level Requirements
Standard Requirements
Mechanical:
Max Product Volume = 9,000 cm2
Max Product Mass = 5 Kg
Max Total PCB Area = 600 cm2
Life Cycle:
Production Lifetime = 5 Years
Reliability in MTBF = 5 Years
Full Warranty Period = 1 Year
Service Strategy: Distributor Repair, Return to Mfg.

20. Performance System Level Requirements
Performance Requirements
Electrical Functions:
Power Modes:
On, Off
Function Modes:
Normal
Configure
Functional Features:
Bus Call
Taxi Request
Electrical Interfaces:
Analog, Digital and Power Signals
Bi-Directional RF Transceivers
RS232 Network Interface

21. Performance System Level Requirements
Performance Requirements
Operator I/F Outputs:
LED (1)
Momentary Pushbutton (4)
16 Digit Matrix Numeric Keypad (2)
16 x 2 LCD Display (2)
Magnetic Card Swipe (1)
Mechanical Interfaces:
Mounting Brackets
RS232 Connectors
RJ-45
DIN-5

22. Performance System Level Requirements
Performance Requirements
Safety
Power Signal Current Limit Max = 1.5 Amps
Power Signal Current Limit Max Trip Time = 2 Sec
Power Signal Ground Fault Max = 500 mAmps
Power Signal Ground Fault Max Trip Time = 8.3 mSec
Maximum Potential of User Surfaces = 5 Volts
Ground Fault Protection

23. Performance System Level Requirements
Safety Codes
IEC 61204
IEC 61204 specifies the safety requirements for power supply units (PSUs) providing DC output(s) with or without auxiliary AC output(s) operating from AC or DC source voltages up to 600 V AC or 1 000 V DC.
IEC
Applies to electrical and electronic apparatus intended for use in the industrial environment for which no dedicated product or product-family emission standard exists. Apparatus designed to radiate electromagnetic energy for radio communication purposes is excluded from this standard. Disturbances in the frequency range 0Hz to 400 GHz are covered. Fault conditioning of apparatus are not taken into account. Also applies to apparatus intended to operate in industrial locations or in proximity to industrial power installations.
IEC
Applies to electrical and electronic apparatus intended for use in the residential, commercial and light-industrial environment for which no dedicated product or product-family emission standard exists designed to radiate. Disturbances in the frequency range O Hz to 400 GHz are covered.
EN (level 1)
No degradation of performance or loss of function is allowed below a performance level specified by the Mfg when the apparatus is used as intended.

24. Basic Business Case
Estimate the Average Product Selling Price (ASP$): $200 (Base) / $100 (Bus)
Estimate the Product Annual Sales Volume: 2,000,000 (Base) / 1,000,000 (Bus)
Estimate the Per Unit Cost of all Parts and Materials using the above annual volume assumption: $130 (Base) / $50 (Bus)
Estimate the Per Unit Cost of all the Assembly, Test and Mfg using the above annual volume assumption: $20 (Base) / $20 (Bus)
Estimate the Total Development Cost in $ incl. Labor & Material: $500,000
Calculate the Annual Sales $ = 500 M
Calculate the Per Unit CM$ = $150 (Base) / $70 (Bus)
Calculate the CM% = (Base) / 0.70 (Bus)
Calculate the Annual CM$ = $362.5 M
Calculate the ROI Time in Years = 0.01 Years

25. Setup Block Specifications
Description:
Using a 4x4 keypad, a PIC 16F84 micro detects the manual input producing a digital ascii character output to a 1-wire rs232 interface which is sent to the corresponding CPU.
Performance Requirements:
Power Inputs:
5 VDC input (nominal)
Electrical Interfaces:
4x4 Input Keypad
rs232 Network Interface
Operator Outputs:
Digital ascii character output on a 1-wire rs232 interface to CPU

26. Setup Block Specifications
Standard Requirements:
Environment:
Operating Temperature Range: -40 to 70 °C
Operating Humidity Range: 2 to 98 %
Storage Temperature Range: -30 to 80 °C
Storage Humidity Range: 2 to 98 %
Life Cycle:
Production Life 5 Years
Full Warranty Period: 1 Year
Service Strategy: Distributor Repair
Mechanical:
Block Mass: .5 Kg
Block PCB area: 60 cm2

27. Setup Block Specifications
Internal Block Diagram
CPU 1 / 2
6 Data Lines
PIC Processor
8 Data Lines
4 x 4 Keypad
Power Supply
5V DC

28. Setup Block: Signal Table
Power
Digital

29. Setup Block Specifications
Prototyping Plan:
Purchase components
construct circuit layout
build prototype
Costs:
$12 - Keypad
$2 - PIC
$2 - Resistors / Capacitors
Total for Setup Block ≈ $16
Maximum per Block Cost = $25.20
Maximum Mfg Assembly / Test Cost per Block = $5.60

30. Setup Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate Type
Comp
Attachment Type
Socketed
Components
Types of
Connectors
Setup 60
None
Plastic pads, no busses
Prototype board
0.25 headers

31. CPU1 Block Specifications
Description:
Primary processing core for bus
Handles processing of RF data
Receives Inputs from UI and Setup blocks and responds appropriately
Performance Requirements:
Power Inputs:
3.3 VDC Input
Electrical Interfaces:
10 bit Digital Line Interface to RF Block
6 bit Digital input from Setup Block
8 bit Digital I/O with User Interface 1
Operator Outputs:
Digital signal to LCD display

32. CPU1 Block Specifications
Standard Requirements:
Environment:
Operating Temperature Range: -40 to 70 °C
Operating Humidity Range: 2 to 98 %
Storage Temperature Range: -30 to 80 °C
Storage Humidity Range: 2 to 98 %
Life Cycle:
Production Life: 5 Years
Full Warranty Period: 1 Year
Service Strategy: Distributor Repair
Mechanical:
Block Mass: .5 Kg
Block PCB area: 60 cm2

33. CPU1 Block Specifications
Internal Block Diagram
UI I/O 8 Data Lines
U.I.1 Block
Setup Block
6 Data Lines
Atmel Processor
RF I/O 10 Data Lines
RF Block
Power Supply
5V DC

34. CPU1 Block: Signal Table
Power
Digital

35. CPU1 Block Specifications
Prototyping Plan:
Use Atmel ATMega chip as a microprocessor
Use the development board to prototype block
Program system incrementally, testing modular interfaces such as I/O based on temporary mock-ups on a breadboard before item is complete
Costs:
Atmel Board = $38
Maximum Block Cost = $18
Maximum Mfg Assembly / Test Cost per Block = $4

36. CPU1 Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate Type
Comp
Attachment Type
Socketed
Components
Types of
Connectors
CPU 1
121
Plastic pads, no busses
Prototype board
None
0.25 headers

37. RF Block Specifications
Description:
Receives serial signal with governing clock from CPU for transmission
Transmits serial data from RF receiver with internal clocking signal
Chip is a Freescale part and handles all transmit/receive functions internally eliminating the need for external amplification / recovery
Performance Requirements:
Power Inputs:
5 VDC input
Electrical Interfaces:
Analog Antenna Receive / Transmit
10 bit Digital line Interface
Operator Outputs:
None

38. RF Block Specifications
Standard Requirements
Environment:
Operating Temperature Range: -40 to 70 °C
Operating Humidity Range: 2 to 98 %
Storage Temperature Range: -30 to 80 °C
Storage Humidity Range: 2 to 98 %
Life Cycle:
Production Life: 5 Years
Full Warranty Period: 1 Year
Service Strategy: Distributor Repair

39. RF Block: Signal Table
Power
Digital
Analog

40. RF Block Specifications
Internal Block Diagram
2 Analog Lines
Freescale Transceiver
RF I/O 10 Data Lines
CPU2 Block
Power Supply
3.3V DC

41. RF Block Specifications
Prototyping Plan:
Layout circuit from Freescale in a PCB layout program
Purchase circuit board, transceiver, discrete components and antennas
Test signals by hooking up fixed voltage sources to try transmission / link
Interface with CPU block
Costs:
$20 PCB Boards
$2 - Resistors / Capacitors
Maximum Block Cost = $25
Maximum Mfg Assembly / Test Cost per Block = $10

42. RF Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate Type
Comp
Attachment Type
Socketed
Components
Types of
Connectors RF 20
Plastic pads, no busses
PCB Board
None
0.25 headers

43. CPU2 Block Specifications
Description:
Primary processing core for station
Handles processing of RF data
Receives Inputs from UI and Setup blocks and responds appropriately
Uses NIC block to communicate over TCP/IP to server for Taxi system
Performance Requirements:
Power Inputs:
3.3 VDC input
1.5 VDC input
Electrical Interfaces:
10 bit Digital line Interface to RF
32 bit Digital line Interface to NIC
10 bit Digital input from Setup
10 but Digital I/O with U.I. 2

44. CPU2 Block Specifications
Standard Requirements:
Environment:
Operating Temperature Range: -40 to 70 °C
Operating Humidity Range: 2 to 98 %
Storage Temperature Range: -30 to 80 °C
Storage Humidity Range: 2 to 98 %
Life Cycle:
Production Life: 5 Years
Full Warranty Period: 1 Year
Service Strategy: Distributor Repair

45. CPU2 Block: Signal Table
Power
Digital

46. CPU2 Block Specifications
Internal Block Diagram
NIC Block
NIC I/O 32 Data Lines
UI I/O 8 Data Lines
U.I.2 Block
Setup Block
6 Data Lines
Altera CPLD
RF I/O 10 Data Lines
RF Block
Internal Bus
1.5V DC
Power Supply
16 MB SDRAM
4 MB Flash
3.3V DC

47. CPU2 Block Specifications
Prototyping Plan:
Use Altera Stratix CPLD as a soft processor system
Use the development board I own to prototype CPU and NIC blocks
Program system incrementally, testing modular interfaces such as car swipe and I/O based on temporary mock – ups on a breadboard before item is complete.
Connect final components and program final TCP/IP server code
Costs:
Maximum Block Cost = $22
Maximum Mfg Assembly / Test Cost per Block = $5

48. CPU2 Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate Type
Comp
Attachment Type
Socketed
Components
Types of
Connectors
CPU 2
121
Plastic pads, no busses
Prototype board
None
0.25 headers

49. UI Block Specifications
Performance Requirements
Operator I/F Outputs:
LED
Momentary Pushbutton
16 x 2 LCD Display
Power Modes of Operation:
ON/DC LCD Display
On/Mom DC Pushbutton
***Optic Sensor (for backlight of LCD)***

50. Standard System Level Requirements
Standard Requirements
Environment:
Operating Temperature Range: -40 to 70 °C
Operating Humidity Range: 2 to 98 %
Storage Temperature Range: -30 to 80 °C
Storage Humidity Range: 2 to 98 %
Storage Duration: 2 Years
Energy Sources: DC
LCD digital max power range 4.75V – 5.0V

51. Block Signal Table: Power
Most Blocks will consume or deliver power
All Power Distribution must be accounted for

52. Block Signal Table: Digital

53. U.I. 1 Block Specifications
Internal Block Diagram
LCD Display
UI I/O 8 data lines

54. U.I. 2 Block Specifications
Internal Block Diagram
Push Buttons
LCD Display
Card Swipe
UI I/O 10 data lines

55. U.I. Block Specifications
Prototyping Plan:
Purchase components (LCD Display, Push-Button)
construct circuit layout
build prototype
Costs:
$6.00 * 4 push buttons
$12.00 * 2 LCD Displays

56. Power1 Block Diagram Power1 at the bus +5V +5.25V 12 V +3.3V +5V
TRANSC.1
+5.25V
U I.1
12 V
PS1
CPU1
+3.3V
+5V
SC.1

57. Power2 Block Diagram Power2 at the station +5 V +5.25V 120 V AC +3.3V
TRANSC.2
+5.25V
U I.2
CONVERTER
TRANSFORMER
PS2
120 V AC
CPU2
+3.3V
+5 V
SC.2

58. Power Block Introduction Description
• Using 120VAC, permanent supply to the Set-up Control, CPU, U.I
and Transceiver at the Station Using 12 V DC supply to the Set up
Control , CPU, IU and Transceiver at the Bus

59. Power Block Performance Requirements
Power Inputs:
120 V AC power input ranging from Hz (Station Unit)
12V DC input (Bus Unit)
Over Voltage Protection
Electrical Functions:
Power supply to the CPU, Set up Control, UI and Transceiver
Electrical Interfaces:
Analog, Digital and Power Signals
Bi-Directional RF Transceivers
RS232 Network Interface

60. Power Block Performance Requirements
Electrical Functions:
Power Modes:
On, Off
Function Modes:
Normal
Configure
Functional Features:
Bus Call
Taxi Request
Electrical Interfaces:
Analog, Digital and Power Signals
Bi-Directional RF Transceivers
RS232 Network Interface

61. Power Block Performance Requirements Electrical Functions:
Power Modes:
On, Off
Function Modes:
Normal
Configure
Functional Features:
Bus Call
Taxi Request
Electrical Interfaces:
Analog, Digital and Power Signals
Bi-Directional RF Transceivers
RS232 Network Interface

62. Power Block Standard Requirements Energy Source:
• VAC ( 108 to 132 VAC % )
• VAC transformer secondary: 10 V , 20VA

63. Power Block Standard Requirements
Modes:
On ( Primary, 120 VAC)
Frequency Range:
• Hertz ( 57 to 63 Hz range)
Safety:
• A max current limit protection
• V maximum potential of user surface
• V over-voltage surge protection

64. Power Block Standard Requirements Mechanical: Life Cycle:
Maximum area of the power supply board is 400 cm²
Life Cycle:
Production Life 5 Years
Full Warranty Period: 1 Year
Service Strategy: Distributor Repair

65. Power Electrical Interface signal

66. Power Block Implementation
Power1 at the bus
TRANSC. 1
U I.1
12VDC
CPU. 1
SC .1

67. Power Block Implementation
Power2 at the station
TRANSC. 2
U I.2
120VAC
Transformer.2
Converter.2
Power Isolation2
CPU. 2
SC .2

68. Power1 Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
Components
components
Costs
Power 1
200
12 V DC
AC/DC converter
Diodes, R, C
$30

69. Power2 Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
Components
components
Costs
Power 2
200
120V AC
AC/DC converter
Diodes, R, C
$30

70. Block Prototyping Plan
Name
Block Area (cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Socketed
Components
Types of
Connectors
CPU 1
121
Plastic pads, no busses
Prototype board
None
0.25 headers
CPU 2
UI Modules
Soldering
Power 1,2
2,622
AC Adapt
Setup 60
RF Module
72.6

71. EnRoute Timeline Summary
Hours Total
Total Manpower
Estimated: 1085
Available 1000
Total Material
Estimated: $247
Available $500
Time Percentages
Overall Project Design : 10%
Block Design: 90%
Recommendations
Time will be less for RF and NIC blocks since they require no prototypes.

72. EnRoute Gantt Chart