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Team #5: Staff

Team #5: Staff. Sean Kuter (LPI) Kurt Stonger (LRM) Andrew LaPointe (LSD) Eric Fritz (LPM) Shawn Bostwick (LMM). BSEE BSEE BSEE BSEE BSEE. Project Plan Summary. Total Manpower Estimated vs. Available Meetings 93.0 man-hours Labs 101.5 man-hours

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Team #5: Staff

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  1. Team #5: Staff • Sean Kuter (LPI) • Kurt Stonger (LRM) • Andrew LaPointe (LSD) • Eric Fritz (LPM) • Shawn Bostwick (LMM) • BSEE • BSEE • BSEE • BSEE • BSEE

  2. Project Plan Summary • Total Manpower Estimated vs. Available • Meetings 93.0 man-hours • Labs 101.5 man-hours • Individual 23.5 man-hours To date 219 man-hours out of 900 total man-hours available • Total Material Cost to date • $179.98 out of $500.00 total available budget • % of Total Manpower • System design 14.84% • Detailed design 36.30% • Verification 10.73% • Documentation 38.13% • To date there is an overestimate of 61% of man-hours • To date there is 64% of material not procured

  3. Selected ProjectKey Features • Reptile Environmental Control Unit: • Monitor Environment • Ambient Temperature • Surface Temperature • Humidity • Monitor Ambient Temperature • Control Surface Temperature • Control Humidity • Security System to Prevent Escape • Cable Management System

  4. Product Applications • Exclusive environmental control to support: • Snakes (primarily) • Turtles, lizards, and other rare reptiles • Typical market: • Professional/Amateur Breeders and Herpetologists • Pet Stores

  5. Hoffer’s Tropical Pet Store

  6. Potential Competitors • www.habitatcontrolsystems.com • Targeted market • Don’t meet all of the key objectives • Room for product growth • 4 Zone Programmable Controller • Made for multiple units • Monitors and controls temperature only • No security control • $249.00 USD

  7. Refined Block Diagram Inputs and Signal Conditioning:Andrew LaPointe Inputs and Signal Conditioning: Sean Kuter Power Distribution: Shawn Bostwick Outputs: Kurt Stonger Surface Temperature Sensors ANALOG Relay Switches Signal Conditioning DIGITAL 29 VAC Foggers Relay Switches DIGITAL 120 VAC Heat Mats Ambient Temperature Sensors ANALOG Signal Conditioning Controller Eric Fritz 4 State Controllers DIGITAL Humidity Sensors ANALOG Signal Conditioning Keypad DIGITAL DIGITAL LCD Display Lights 5VDC Door Sensors Alarm Horn

  8. Block Assignments

  9. Requirement Display type Temperature Sensors Humidity Sensors Keypad type Key definitions Units to Specify LCD 4 Lines by 20 Characters/Line Accuracy: +/- 1oC Range: 5 - 95oC Accuracy: +/- 5% RH Range: 10 – 90% RH Matrix arrangement up/down/left/right arrows, enter, numbers Performance Requirements

  10. Requirement Min Oper. Temp Range Min Oper. Humidity Range Max Dimensions Source Connection List Units to Specify 5 - 45° C 0 – 99% relative humidity 12” x 12” x 6” Temporary, with ability to move unit Standard Requirements

  11. Requirement Min Oper. Voltage Range AC power freq range Max Power. Consumption Parts/Material $ Allocation Connector Type Units to Specify 102 – 132 VAC 120 VAC nom. 57 – 63 Hz 60 Hz nom. 850 W 7A $500 (total, $100/member) Type B Plug Standard Requirements

  12. Safety Standards • IEC 6100-4-2: ESD Immunity • IEC 61140 Edition 3.0: Electric Shock Protection • IEC 730: Auto. Elec. Controls for Household • UL 60730-1A Auto. Elec. Controls for Household • UL 60730-2-9 Auto. Elec. Controls for Household Part 2: Particular for Temperature Sensing Controls

  13. Specific Safety Requirements • IEC 60335-2-71 Edition 2.0 • Household and similar electrical appliances – Safety – Part 2-71: Particular requirements for electric heating appliances for breeding and rearing animals • UL 873 • Temperature-Indicating and Regulating Equipment • UL 60730-2-13A • Automatic Electric Control for Household and Similar Use; Part 2: Particular Requirements for Humidity Sensing Controls

  14. EMC Standards • 61000-4-2: ESD Immunity Tests • IC’s • 61000-4-5: Surge Immunity Tests • Lightning discharges & switching disturbances • 61000-4-11: Voltage dips, short interruptions, and variations • Line voltage variances

  15. ECU Technical Risk & Problem Areas • Sensors/Sensing Issues • Analog sensor output > Digital Processor • Programming • Pic/Microcontroller selection • Programming Hardware • Programming Software • Power Supply • Design • Build • Safety (explosion, fire, shock)

  16. Individual Reliability Report:Andrew La Pointe • Maximum FIT’s: 832.31 • MTBF: 137.06 years • Most Unreliable Part: • Humidity Sensor • Suggested Improvement: • Find a part with a lower lambda

  17. Individual Reliability Report:Eric Fritz • Maximum FIT’s: 6928.5 • MTBF: 16.46 years • Most Unreliable Part: • D-flip flops • Suggested Improvement: • Use a different part • Use fewer parts

  18. Individual Reliability Report:Shawn Bostwick • Maximum FIT’s: 1919.00 • MTBF: 59.45 years • Most Unreliable Part: • Zener Diodes • Suggested Improvement: • Use heatsinks for temperature

  19. Individual Reliability Report:Kurt Stonger • Maximum FIT’s: 454.09 • MTBF: 251.22 years • Most Unreliable Part: • Electromagnetic coil relay • Suggested Improvement: • Use transistorized switch, or SCR

  20. Individual Reliability Report:Sean Kuter • Maximum FIT’s: 41.595 • MTBF: 2742.57 years • Most Unreliable Part • Resistors • Suggested Improvement • None needed

  21. Ambient / Surface Temp SensingSean Kuter • To provide a controlled temperature scaled inputs to the microcontroller block: • Ambient Temperature • Surface Temperature • Impedance matching • Amplified Signals

  22. Sean KuterAmbient and Surface Temperature Inputs Per Reptile Environmental Unit From Power Dist. Block

  23. Standard Requirements IEC 6100-4-2 Electrostatic Discharge Immunity Operating Temperature Range 5 – 45 oC Oper. Humidity Range 0 – 99% RH Performance Requirements Monitor a Temperature Range 5 – 45 oC ( 41 – 113 oF ) Provide a sensor accuracy of +/- 1 oC Provide an Output Voltage Range 0.5 – 4.5 Vdc Ambient and Surface TemperatureSensors Per Reptile UnitSean Kuter

  24. Humidity Sensor/AlarmAndrew LaPointe • Humidity Sensing • Senses humidity • Gives proper signal to microcontroller • Alarm • Senses Door position (open or closed) • Gives audible alarm for open door

  25. Andy LaPointeHumidity sensor input and Alarm Circuit Per Reptile Environmental Unit Humidity Multiplexer Microcontroller Block Owned by: Eric Fritz Magnetic Door Switch Ckt 1 Alarm Horn +5VDC 0.05 - 5VDC Magnetic Door Switch Ckt 2 +5VDC +5VDC +5VDC +5VDC +5VDC Power Block Owned by: Shawn Bostwick Humidity Sensor Impedance Matching Network Op-Amp Av = 5 5VDC .01-1VDC .01-1VDC

  26. Humidity Sensor/Alarm BlockStandard/Safety Requirements • Standard • Min Oper. Temp Range 5 - 45° C • Min Oper. Humidity Range 0-99 % RH • Operating Voltage Range 4.5 – 5.5 VDC • Source Connections temporary (hi-density plugs) • IEC 6100-4-2 Electrostatic Discharge Immunity

  27. Humidity Sensor/Alarm BlockPerformance Requirements • Performance • Humidity sensor has accuracy of +/- 5 % R.H. and range of 0-99% R.H. • Humidity sensor outputs 0.5 -4.5 VDC • Door switches open to a max of 1” before horn sounds • Horn provides 90-100 dB sound @ 2 ft

  28. Humidity Sensors and Alarm Circuit Block Summary

  29. Outputs Kurt Stonger • Control output signals to Fogger, Heat Mat and Light • Relay switches • Bang Bang control • 3 light settings

  30. Outputs Kurt Stonger Relay Coil Voltage; Microcontroller Component Voltage; Power Block Fogger 24 VAC 24 VAC Relay 5 VDC Heat Mat 120 VAC Relay 120 VAC 5 VDC 5 VDC Relay V-Division Relay Driver 12 VDC 6 VDC 5 VDC Light Relay V-Division 12 VDC 9 VDC 5 VDC Relay 12 VDC 12 VDC

  31. Standards Power Surge IEC 6100-4-6 Fogger 24 Vac Heat Mat 132 – 102 Vac LEDs 14 - 6 Vdc & 20 mA Max Solid State Relay 6-4 Vdc Relay Drivers 5 Vdc @ Vcc 4.5 – 16 Vdc Vout & 1.8 A max EM Relays 5 Vdc & 75mA @ coil Performance Fogger Relay Controlled power 0 – 90% Relative Humidity Heat Mat Relay Controlled power 0 – 30C Range LEDs Relay Controlled power 4 stages Low 816 Lumens, Medium 1224 Lumens, High 1632 Lumens and Off Outputs Kurt Stonger

  32. Output Block Summary

  33. Power SupplyShawn Bostwick • Power Supply Block • Supply AC Power To: • Heating Pads • Foggers • Supply Rectified DC Power To: • Microcontroller • Sensors • Alarm • Lights

  34. Shawn BostwickPower Supply Power in 120Vac Microcontroller Block Overvoltage/ Overcurrent Protection Transformer 120Vac Rectifiers 5Vdc 120Vac 120Vac Alarm Circuit 5Vdc Voltage Regulator Circuit Transformer 5Vdc/7Vdc/12Vdc Humidity Sensor 5Vdc & +/-12Vdc 24Vac Fogger Control Circuit Ambient Temp. Sensor Heating Pad Control Circuit Lighting Control Circuit Surface Temp. Sensor 5Vdc & +/-12Vdc

  35. Micro Controller BlockEric Fritz • Microcontroller • Takes Inputs from sensors • Performs Calculation • Sends Outputs to relays • LCD Display • Displays data • Key Pad Input • Allows user to change set points

  36. Microcontroller Eric Fritz Terrarium #1 5V Relay Light Logic AmbientTemperatureSensors 4 x 1 MUX Terrarium #1 7V Relay 8 Analog Input Terrarium #1 12V Relay Micro-Controller Control Signal Light Logic 3 8 8-Bit Latch SurfaceTemperatureSensors 4 x 1 MUX 4 x 1 MUX Light Logic Control Signal Control Signal D0 D0 Lights Light Logic 4 x 1 MUX 3 x 8 Decoder Humidity Sensors D1 Heaters/Humidifiers D2 LCD Display Control Signal 3 Terrarium #1 Heater Relay D3 Keypad Input D2 Sensor Input Terrarium #2 Heater Relay 5VDC Power 8 D5 Not used Terrarium #3 Heater Relay 8-Bit Latch 8 8-Bit Latch D6 Not used Terrarium #4 Heater Relay D7 Not Used Terrarium #1 Fogger Relay D4 D1 Terrarium #2 Fogger Relay Terrarium #3 Fogger Relay Terrarium #4 Fogger Relay 6 Button User Interface 8 8-Bit Latch 8 8 8-Bit Latch 4 x 20 LCD Display D3 D2

  37. Micro ControllerEric Fritz • Standard • 4.5-5.5 VDC • 0-45oC • 0-90% RH • IEC 61000-4-2 • ESD guideline • UL 60730-1A • Automatic Electrical Controls for Household and Similar Use; Part 1: General Requirements • Performance • 40MHz Clock Speed • 4 x 20 line LCD • 0-5VDC analog input • 6 button Keypad interface • 8-bit data bus • 5 VDC I/O

  38. Individual Reliability Report:Eric Fritz • Maximum FIT’s: 6928.5 • MTBF: 16.46 years • Most Unreliable Part: • D-flip flops • Suggested Improvement: • Use a different part • Use fewer parts

  39. Overall Prototype Plan • Total Block Area: 462 cm2 • Total PCB Area: 432cm2 • Substrate Type: Perf-Board w/Pads • Comp. Attach. Type: Direct Solder or IC Socket • Socketed Components: IC’s, Relays, Rectifiers, and Microcontroller • Connector Types: Ribbon cable, Solder, NEC/IEC, and Headers

  40. Block Prototype Plan

  41. Total Reliability Report • Maximum FIT’s: 10246.75 • MTBF: 11.13 years • Most Unreliable Part • D-flip flop • Suggested Improvement • Reduce number of D-flip flops • Change components

  42. Reliability Test Plan

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