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EE595 Spring 2007 Group III

EE595 Spring 2007 Group III. Project Proposal. Team III: Staff. Brett Sheleski EE Major CS Major Mike Baerenwald EE Major. Don Murray EE Major CS Minor Ike Butler EE Major CS Minor. Team III: Expertise & Experience. Don Murray Expertise: Embedded Systems Motor Control

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EE595 Spring 2007 Group III

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  1. EE595 Spring 2007 Group III Project Proposal

  2. Team III: Staff • Brett Sheleski • EE Major • CS Major • Mike Baerenwald • EE Major • Don Murray • EE Major • CS Minor • Ike Butler • EE Major • CS Minor

  3. Team III: Expertise & Experience • Don Murray • Expertise: • Embedded Systems • Motor Control • Experience: • ROV Team Electronics Design • Microcontroller Programming • Ike Butler • Expertise: • Analog Systems • Linear/Digital Sensors • Experience: • Johnson Controls • McNair Scholar • Brett Sheleski • Expertise: • Software development • Experience: • CAD Drafting • IT Intern • Mike Baerenwald • Expertise: • Power Systems • Experience: • Stora Enso Paper Mill • Kohler Co. Co-op

  4. Team III: Contact Info • Brett Sheleski • Mike Baerenwald • Don Murray • Ike Butler • Phone: (414) 305 - 4784 Email: brettjs2@uwm.edu • Phone: (920) 213 - 0725 Email: baerenw2@uwm.edu • Phone: (262) 689 - 5029 Email: dtmurray@uwm.edu • Phone: (414) 248 - 5160 Email: ilbutler@uwm.edu

  5. Team III: Weekly Availability Worksheet • Brett Sheleski • Mike Baerenwald • Don Murray • Ike Butler • Time 1: MW after 5:00 Time 2: Time 3: R 8:30 – 10:00 Time 4: • Time 1: MW before 3:00 Time 2: Time 3: R 8:30 – 10:00 Time 4: • Time 1: MW before 3:00 Time 2: TR 11:00-5:30 Time 3: Time 4: • Time 1: FSa before 6:00 Time 2: Time 3: R 8:30 – 10:00 Time 4:

  6. Team III: Weekly Project Meeting Plan • Weekly Meeting 1: E225, Thursday 2/1/07 8:30-9:00 PM This meeting was to discuss options for the design project. All members were present. • Weekly Meeting 2: E225, Monday 2/5/07 9:00 PM This meeting discuss P1. Mike & Don were present, Brett was ill, and Ike was a no show. Note: Meeting Owners Send Weekly Email Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records

  7. Team III: Total Resources • 10 Man-hours per week, per person • $100+ per person for material (if needed) • Design and build a solar power supply that adjusts the direction of the solar panels towards the brightest light source to maximize the amount of power generated.

  8. Team III: Decision Making • Decisions by consensus • If no consensus, consult TA or instructor.

  9. Roles to Define & Assign • Lead Project Integrator (LPI): • Don Murray (01/23/07 – Present) • 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): • Brett Sheleski (01/23/2007 – Present) • 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): • All (01/23/07 – Present) • 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): • Ike Butler (01/23/2007 – Present) • 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): • Mike Baerenwald (01/23/2007 – Present) • 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. Random Number Generator • Take readings from various sensors producing a random number • Produces random number with testing from Chi Square algorithm. • USB/Serial connector getting power either independently or from data cable. • Heavy computer science background among group as well as common interest

  15. ROV Sensor Package • Distance sensor for ROV-Team’s underwater robot to determine surroundings. • Use ROV’s power source (car battery) for powering the device. • Don is a member of the ROV team and the project is interesting and challenging.

  16. Traffic Controller • A wireless traffic controller to replace manually operated stop signs on UWM campus

  17. Solar Sun Follower • Solar panels that automatically adjust so they are always facing the brightest light source so they generate the maximum amount of power possible.

  18. Standard Requirements-Market • Estimated Market Size: $100,000,000 • Estimated Annual Volume: $1,000,000 • Minimum List Price: $50 • Max Product Material Cost: $20 • Max Product Manufacturing Cost: $10 • Estimated Annual Contribution: $600,000

  19. Market Cont. • Market Geography: Worldwide • Market Demography: Robotics Hobbyists • Market Competitors: Power supply manufacturers • Market Industry: For Residential Use

  20. Power • Energy Sources: • 9 Solar Panels • 1 Battery

  21. Mechanical • 2 Servo Motors • Enclosure

  22. Environmental • Temperature Range: -40°C to +120°C • Humidity Range: 0% to 80% • Altitude Range: Unlimited

  23. Safety • Primary Safety Standards: “Intelligent” Battery Charger • Primary EMC Standards: TBD

  24. Manufacturing • Maximum total parts count: 100 • Maximum unique parts count: 20 • Maximum Parts & Material Cost: $20 • Maximum Mfg Assembly/Test Cost: $10

  25. Life Cycle • Estimated Max Production Lifetime: 20 yrs • Service Strategy: In Home • Product Life, Reliability in MTBF: TBD • Full Warranty Period: 1 Year • Product Disposal: Recyclable

  26. Performance Requirements- User Inputs • Enable / Disable solar power • Enable / Disable battery • Select manual motor control • Manual motor controls • Display selection

  27. User Indicators & Displays • Battery charge meter • Status LEDs • Voltage meter • Current meter

  28. Operation Modes • Automatic • Automatically tracks light source for maximum power generation • Solar panel array is positioned automatically • Manual • Solar panel array is positioned manually

  29. Safety • Battery must not be overcharged • Clear safety notifications must be present to prevent use of incorrect batteries

  30. Basic Business Case for the Solar Sun Follower(Inputs) • Estimated Average Product Selling Price (ASP$): $50 • Estimated Annual Product Sales Volume in Units: 20000 • Estimated Per Unit Cost of All Parts & Materials: $20 • Estimated Per Unit Cost of All Assembly, Test, and Mfg: $10 • Estimated Total Development Cost including Labor and Material: Engineering hours @ $150.00 per hour: 600 Material: $400 Total: $90400

  31. Basic Business Case for the Solar Sun Follower(Outputs) • Annual Sales Revenue $ = ASP$ * Annual Volume: $1,000,000 • Annual Var Costs $ = (Unit Material $ + Mfg $) * Annual Volume: $400,000 • Per Unit CM$ = ASP$ – (Unit Material $ + Mfg $): $30 • CM% = Per Unit CM$/ASP$: 60% • Annual CM$ = Unit CM $ * Volume = Annual Sales $ - Annual Var Costs $: $600000 • ROI (Return on Investment) Time in Years = Est Dev Cost $/Annual CM$: 0.15

  32. Overall Block Diagram

  33. Block Diagram Description

  34. ThreeRelated Patents • Patent number 5169456 Two Axis Tracking Solar Collector Mechanism January 1, 2001 • Patent number 5600124 Sun Tracker System for a Solar Assembly February 4, 1997 • Patent number 5632823 Solar Tracking System May 27, 1997

  35. Ethical and Societal Issues • Charging of the battery presents the greatest potential danger to the user, as overcharging a battery can cause an explosion • The battery must be properly chosen for this application, and the type required must be communicated clearly to the end user of the product • Any other failures of the product would present a nuisance to the end user, but no specific danger. This product is not intended for use in devices where an exceptionally high level of reliability is required, such as medical devices or industrial controls. This must be communicated to the end user

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