EE595 Senior Design Team 2 Spring 2007

1. EE595 Senior Design Team 2Spring 2007

2. Team 2: Staff • Dan Lauber • Ibrar Ahmad • Josh Sutinen • Tim Thierfelder • Bill Burton • BSEE, BACS • BSEE, CS Minor • BSEE • BSEE • BSEE, Physics

3. Team 2: Expertise & Experience • Expertise: Software, General Design • Experience: 3yr Internships, Design & project ownership • Expertise: Access to parts, contacts, IEEE measurer Experience: 2yr Internship, 1yr Co-op • Expertise: Microprocessors, motor control Experience: 1yr Internship • Expertise: Digital Logic, Powerpoint Experience: Internship@American Transmission Co • Expertise: Digital Logic, IC’s Experience: Software, assembly • Dan Lauber • Ibrar Ahmad • Josh Sutinen • Tim Thierfelder • Bill Burton

4. Team 2: Contact Info • Dan Lauber • Ibrar Ahmad • Josh Sutinen • Tim Thierfelder • Bill Burton • Phone 1: 414-975-4190 Email: djlauber@uwm.edu • Phone 1: 414-403-6026 Email: iahmad@uwm.edu • Phone 1: 262-573-4929 Email: jsutinen@gmail.com • Phone 1: 414-226-0243 Email: thierfe2@uwm.edu • Phone 1: 920-359-0063 Email: wmburton@uwm.edu

5. Team 2: Weekly Availability Worksheet • Dan Lauber • Ibrar Ahmad • Josh Sutinen • Tim Thierfelder • Bill Burton • Time 1: Mon 2-5 Time 2: Tues/Th 3-6 • Time 1: Mon/Th 5- Time 2: Wed 3- Time 3: Fri Any • Time 1: Mon/Wed 7- Time 2: Tues/Th 1- Time 3: Fri 5- • Time 1: Mon/Wed 6-8 Time 2: Tues/Th 4-6 Time 3: Fri 4-8 • Time 1: Wed Any except 3-5 Time 2: 4-

6. Team 2: Weekly Project Meeting Plan • Weekly Meeting 1: W270 (IEEE), Tuesday 4:30-6:30 PM Chair: Ibrar Ahmad Attendees: All Purpose: General • Weekly Meeting 2: W270 (IEEE), Thursday 4:30-6:30 PM Chair: Ibrar Ahmad Attendees: All Purpose: General Note: Meeting Owners Send Weekly Email Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

7. Team 2: Total Resources • 1200 Manhours • $1000 Overall investment • Cash outlay • PCB Prototyping • Enclosure • Components

8. Team 2: Decision Making • Primary decisions will be decided by a consensus with a democratic vote in the event there is no consensus.

9. Roles to Define & Assign • Lead Project Integrator (LPI): Bill Burton • Owns the MS Excel Project Plan documents • Tracks and reports progress to project plan • Owns weekly progress reports to TA • Owns Logistics and communication of ALL team meetings • Keeps Team Attendance at all meetings • Owns the Block Diagram Assignments and oversees Design Partitioning • Integrates Block design plans • Tracks expenditures to budget • Helps LMM procure prototype components • Keeps a secondary backup of ALL major project deliverable files • Identifies contingencies for problems incl team members MIA

10. Roles to Define & Assign • Lead System Designer (LSD): Dan Lauber • Owns the overall product requirements and data sheet • Owns the MS Excel Product Requirements document including negotiating and documenting the flowdown of requirements to design block level • Owns the Block Diagram Implementation and Design Partitioning • Reviews for Completeness ALL Block-Block Interface Requirements • Helps integrate and populate Detailed Block design plans including DFM • Has primary responsibility for the Safety & Compliance Features in the product • Owns project level verification and validation plan • Owns capture and documentation of all verification results • Owns the MS Word Product User Manual document

11. Roles to Define & Assign • Lead Presentation Manager (LPM):Ibrar Ahmad • Owns the master MS PPT Presentation slide set for team • Keeps backup copy of master slide set and integrates weekly progress submissions from ALL team members • Defines and sets ALL slide formats in template form including • Logos • Font sizes & font styles, • Colors • Header/footers • Slide backgrounds • Rev controls • Responsible for good visibility of slide presentation • Integrates pictures incl schematics, digital photos, animations and other non-PPT file types • Checks presentation content against master checklist and communicates gaps • Responsible for time allocations and controls during final presentation • Submits CD and paper copies for all Preliminary Presentations P1-P4 and Final Presentation

12. Roles to Define & Assign • Lead Report Manager (LPM):Josh Sutinen • Owns the master MS Word Project Report file for team • Keeps backup copy of master report and integrates weekly progress submissions from ALL team members • Defines within guidelines, report flow including chapter numbering, subchapter numbering, sub-sub chapter numbering, etc. • Defines and sets ALL report formats in template form including • Logos • Font sizes & font styles • Colors • Header/footers and chaptering • Rev controls • Responsible for good visibility and proper spelling in report • Responsible for integrating data sheets as needed • Integrates pictures incl schematics, digital photos, block diagrams and other non-WORD file types • Checks report content against master checklist and communicates gaps • Submits final file on CD and printed paper copy of Final Project Report

13. Roles to Define & Assign • Lead Manufacturing Mgr (LMM):Tim Thierfelder • Owns and documents the product overall assembly and test levels • Owns master prototype & product parts lists including integration of design block parts lists • Owns procurement of prototype components including identification of long lead components • Defines the product and prototyping technologies • Owns any required assembly drawings • Owns the overall prototype mechanical and electrical assembly • Owns the overall PCB layout strategy including Block to PCB mapping, PCB tools, PCB design drawings, and PCB procurement • Owns the PCB assembly including any special tools, soldering, wire-wrapping, drilling, and glueing.

14. Project Ideas • RC Car • Attendance Counter • Living Environment Controller • Absolute position based "virtual" limiting system • Fully automated test bench

15. RC Car • Create plugin interface for additional modules and future expansion • Features: Odometer, Sensors, RF Communications, Charge Controller, Motor Controller

16. Attendance Counter • Sensors Count the Number of People on the Bus • The Count is Displayed • Visual Alerts are Given for Capacity and Deboarding • Audio Warnings are Given for Capacity and Deboarding • Power is drawn from the bus battery

17. Attendance Counter Bus Tender – Block Diagram Sensors User Interface signal signal power Visual Displays signal power Microcontroller Power Supply signal signal Audio Signals power

18. Living Environment Controller • Curtain/Blind controller adjusts based on room conditions/sunlight availability • Power: 120VAC/Battery backup • Thermostat interface • Temp display • Occupancy sensor, thermostat • Schedulable, web server

19. Absolute Position based Virtual Limit Switch • Accessory for Linear Actuators • Programmable limit of travel • Integrated service life counter • Reduces mechanical parts count of existing accessories

20. Absolute Position based Virtual Limit Switch – Block Diagram Encoder Data signal power Motor Control signal power Power Supply Microcontroller Position Output signal Battery Backup power

21. Fully Automated Actuator Test Bench • Operator inputs specifications • Bench automatically conducts tests and displays and records results • Measured data: Speed, stroke, current, force

22. Feasibility Decisions

23. The WinnerRC Car • We chose this project because: • The project is funded up to $750 • We are able to get support from Dave M. • Many blocks to choose from • Blocks are a good match for team technical skills • Car is on campus, so it is convenient • We have a previous group’s mistakes and successes • Appealing to leave the car behind for reference in later senior design classes/development

24. RC Car • Major Risks in Project • Radio Frequency interference • Overheating of motors and battery • Working with Lead Acid batteries can be hazardous • Mechanical senior design may work on the car at the same time, so it may interfere with our work • Interfacing with the existing microcontroller may be a challenge

25. Why were other projects rejected? • Not enough blocks • No funding • Long lead time • Not enough required skills • Did not seem as practical • Did not seem as fun to work on • Not enough on-campus support/help on developing the product • Unanimously Supported • YES

26. System - Standard Requirements: Environment and Safety • Market • Operation Temperature Range: 5°C to 35°C • Operation Humidity Range: 30 to 80% • Non-condensing • Operation Altitude Range: 0 to 1000 Meters • Storage Temperature Range: 0°C to 40°C • Max Storage Duration: 2 years • Small Competitors in Field • Size of Market: $250,000 • List Price of: $2,000 • Market Geography: Europe, North America • Market Demography: Males • ages 18+ • Market Industry: Recreation, Promotional • Material Cost: $500 • Manufacturing Cost: $200 • Annual Volume: 100 units

27. System - Standard Requirements: • Energy Source 1 (48 VDC): Four Lead Acid Batteries • Operating Voltage: +/-12VDC,+5VDC,+48VDC • Power Consumption: 13 Ah Power Mechanical • Max Product Volume: 700000 cm3 • Shipping Container Size: 800000 cm3 • Maximum Product Mass: 30 kgs • Maximum Number of PCB: 6 • Maximum PCB Area: 600 cm2 • Maximum Shock Force: 5 G’s • Moisture Resistance: Sealed

28. System - Standard Requirements: • Manufacturing • Maximum total parts count: 300 parts • Maximum unique parts count: 20 parts • Maximum parts and material cost: $500 • Maximum mfg. assembly/test cost: $200 • Max production lifetime: 5 years • Warranty Period: 1 year

29. RC Car

30. Block Diagram

31. Applicable Patents • Patent Name • Central speed control mechanism for remote control cars • Method and system for multiple servo motor control • Toy system Patent Number 6979246 7038421 6322416 Patent Date January 20, 2005 December 23, 2004 December 12, 2002

32. Ethical and Societal Issues • A visiting user could run into someone at high speed without intending to. • Speed regulator into the control system. • Sensor that would apply the brakes. • Foam bumpers (mechanical?) • A visitor might shock themselves while inspecting the car. • Case over the cable attachments. • Voltage warning stickers.

33. Steps to Prevent Flawed Engineering • Test a speed regulator • Test the product with a user trying to doing erratic maneuvers • Test the effects of a collision on performance • Test the predicted behavior of a novice inspector to ensure they can have no contact with live voltage