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IR Sensor System for Aquatic Neurobehavioral Research – Presentation 2

IR Sensor System for Aquatic Neurobehavioral Research – Presentation 2. Team 4 October 25 th , 2006. Team 4: Members. Jeff Mueller: LPI – BSEE Chad Due: LMM – BSEE Jon Reisner: LPM – BSEE Aleks Plavsic: LSD – BSEE John Schwittay: LRN – BSEE. Project Proposal.

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IR Sensor System for Aquatic Neurobehavioral Research – Presentation 2

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  1. IR Sensor System for Aquatic Neurobehavioral Research – Presentation 2 Team 4 October 25th, 2006

  2. Team 4: Members • Jeff Mueller: LPI – BSEE • Chad Due: LMM – BSEE • Jon Reisner: LPM – BSEE • Aleks Plavsic: LSD – BSEE • John Schwittay: LRN – BSEE

  3. Project Proposal • This product will be designed to test the effects of positive reinforcement in a controlled habitat for fish • Automated experiments and data collection • Test different health concerns in fish • Project will be the first attempt to collect data for aquatic neurobehavioral studies • No known products are currently on the market • Device will be used at Great Lakes Institute, Milwaukee, WI • Product could be modified to assist similar water & marine studies

  4. Risks and Problem Areas • Infrared beams’ transmission through water and potential damage to specimen’s (fish) tissue (i.e. eyes). • Potential long lead time for IR transmitters (laser diodes), IR receivers, display, and stepper motors. • Possible need for placement of IR sensing block inside the fish tank • Possible prototyping issue with the fish tank and water • Potential need for LabVIEW (expensive) • Advantages of Project for Team #4: • Previous research and experience in optics • Prior microprocessor design and buildup • Knowledge of control devices

  5. US Patents • US 6,627,892 - Infrared detector packaged with improved antireflection element; September 30, 2003 • US 6,082,299 - Automatic fish feeder; July 4, 2000 • US 6,433,684 - Device for detecting and signaling or indicating status as regards contents in a container, and in particular a letterbox; August 13, 2002

  6. Estimation-Reconciliation Summary • Total Manpower Estimated: 762 hours • Total Manpower Anticipated: 1100 hours • Total Material $ Estimated: $535 • Total Material $ Anticipated: $1000 • Manpower Allocation: • System Design Tasks 25% • Detailed Design Tasks 35% • Verification Tasks 10% • Documentation Tasks 30 %

  7. System Level Requirements • Standard Requirements • Power • One AC Energy Source • Min Oper. Voltage Range: 100-264V • Frequency Range: 47-63Hz • Max Total Power (AC): 84W • Environmental • Min. Oper. Temp. Range: 10 – 40°C • Min. Storage Temp. Range: -10 – 60°C • Min. Oper. Humidity Range: 0 – 80%Rh • Min. Storage Humidity Range: 0 – 100%Rh • Min. Oper. Altitude Range: 0 – 2000 m • Min. Storage/Shipping Altitude Range: 0 -1500 m • Max Storage Duration: 10 yrs.

  8. System Level Requirements • Standard Requirements • Mechanical: • Max Volume: 94390 cm3 • Max Mass: 3 kg • Max # of PCB’s: 4 • Max Total PCB Area: 645 cm2 • Max Shock Force: 0.1 G • Std. AC plug connector • Manufacturing: • Max Total Parts Count: 500 • Max Unique Parts Count: 100 • Max Parts and Material Costs: $600 • Max Mfg Cost: $240 • Life Cycle: • Estimated Production Life: 8 years • Estimated Product Life/MTBF: 5 years • Full Warranty Period: 0.5 years

  9. System Level Requirements • Standard Requirements • Safety • Safety Standards • Electric Aquarium Equipment (UL1018) • RF Emissions (CLSPR11) • EMC Standards • Guidance on Laser Products (IEC-60825) • ESD Immunity (IEC-61000-4-2) • E Field Immunity (IEC-61000-4-3) • EFT (IEC-61000-4-4) • Power Input Surge Immunity (IEC-61000-4-5) • RF Conducted Immunity (IEC-61000-4-6) • Voltage Dip (IEC-61000-4-11) • Voltage Fluctuate (IEC-61000-3-3)

  10. System Level Requirements • Performance Requirements • External on/off switch • Operation Modes: • Power Modes: On, Off • Function Modes: Test 1, Test 2 • Two Feeder Mechanisms: • Food volume: to be determined • Optical Indicator: • One White LED • Brightness:6000 mcds • Viewing angle: 20 degrees • RS232 Port for PC interface: • Speed: 9600 Bauds • Rate: 3.68 MHz Clock • 9 pin Serial Connector

  11. System Level Requirements • Performance Requirements • User display interface: • Inputs: • Type: Keypad – Numeric; Min 3X3 • Controls: Start, Reset, Test Duration, Test Selection, Iteration Duration • Output: • Type: Display – LCD, Alpha-Numeric • Indicates: Test Selected, Total Time, Tot # of Iterations • Display Req’s: Min 11 Char/Line, Min 2 Lines, Min 33 Pixels of X res., Min 10 Pixels of Y res. • Product Sensitivity/Accuracy: • Min. Detectable Specimen Height: 2 cm • Time Between Breaking IR beams and throwing food into water <= 1 ms • Detection width: 6 in. • IR Beams: IR Wavelength Range: 700 – 1000 nm

  12. AC Line Input Fuses Description: 2 fuses on AC input lines 1 and 2 Purpose: to protect input line from overheating, preventing tripping of circuit breaker, and prevent fire hazards inside PSU Power Supply Over-Temp Shut-Down Circuit Description: IC that monitors temperature inside the PSU casing Purpose: to disable PSU in the event of overheating of internal components In-Line GFIC Cable Description: GFCI placed in line with power supply Purpose: GFCI will automatically cut off the flow of electricity in the event of a short. Safety Devices

  13. Standard Limits and Guidelines Summary • CISPR 11: RF Emissions • Power Supply Conducted Radiated • IEC61000-4-2: ESD • Power Supply, MPU w/ RS232, User Inputs/Display ESD Air: 15 kV ESD Contact: 8 kV ESD Coupling Planes: 8 kV • IEC61000-4-3: E Field Immunity • Power Supply, MPU w/ RS232, User Inputs/Display, IR Sensors, Feeders 6 V/m @ 26-1000 MHz AM 80% 1 kHZ • IEC61000-4-4: EFT • Power Supply, User Inputs/Display, Feeders To plug connection supply: 4 kV

  14. Standards Limits and Guidelines Summary • IED61000-4-5: Power Input Surge Immunity • Power Supply Common Mode: 3 kV Differential Mode: 5 kV • IEC 61000-3-3: Voltage Fluctuate • Power Supply • IEC 61000-4-6: RF Conducted Immunity • Power Supply, MPU w/ RS232, User Inputs/Display, IR Sensors, Feeders 3 V/m @ 0.15-80 Mhz AM 1 kHz • IEC 61000-4-11: Voltage Dip • Power Supply 0.5 cycle @ 0% Vnom 5.0 cycles @ 10% Vnom 25 cycles @ 70% Vnom 5 seconds @ 0% Vnom

  15. User Interface MPU w/ RS232 Port Feeders Indicator Light Block Allocation Aleks P. Jeff M. Chad D. Jon R. John S. IR Sensors PC IR Sensor System for Aquatic Neurobehavioral Research User Ctrls Display Data 8 bit IR Rx Feeder Ctrl 2 bit IR Tx On/Off 2 bit Power Supply

  16. Block Diagram Description

  17. High Level Project Plan

  18. Block Level Prototyping Plan

  19. Power Supply Team 4 Jon Reisner

  20. PC Power Supply User Interface User Ctrls Display Data IR Rx MPU w/ RS232 Port Feeders Feeder Ctrl IR Sensors IR Tx On/Off Indicator Light Block Allocation Aleks P. Jeff M. Chad D. Jon R. John S. Power Supply

  21. Block Description and Purpose • Description: • Takes in AC voltage and outputs regulated DC voltages • Purpose: • Delivers voltage and current as needed by other blocks • Protects other blocks by preventing surges

  22. Block Requirements - Standard • AC Input: • 120V/240V • Voltage Range: 102V – 264V • Frequency Range: 47Hz – 63Hz • ±12VDC • Voltage Range: 11.88V – 12.12V • Max Current: 4.2A • 3.3VDC • Voltage Range: 3.135V – 3.465V • Max Current: 0.4mA • Max Total Power Consumption: 40W

  23. Block Requirements - Standard • Max Parts and Materials Cost: $60 (10%) • Max Mfg Assembly/Test Cost: $36 (15%) • Max Total Parts Count: 125 (25%) • Max Total Unique Parts Count: 15 (15%) • Mechanical Reqs: • Max Volume: 18878 cm3 (20%) • Max Mass: 0.6 kg (20%) • Max Total PCB Area: 96.75 cm2 (15%) • Max Shipping Container Volume: 44245 cm3 (20%) • Max Storage Duration: 10 yrs • Environmental Reqs: • Min Oper Temp: 10 - 40 °C • Min Storage Temp: -10 – 60 °C • Min Oper Humidity: 0 – 80%Rh • Min Operating Altitude Range: 0 – 2000 m • Min Storage Altitude Range: 0 – 15000 m

  24. Block Requirements - Standard • Safety Standards: • UL 1018: Electric Aquarium Equipment • CISPR 11: RF Emissions • EMC Standards: • IEC 61000-4-2: ESD • IEC 61000-4-3: E Field Immunity • IEC 61000-4-4: EFT • IED 61000-4-5: Power Input Surge Immunity • IEC 61000-3-3: Voltage Fluctuate • IEC 61000-4-6: RF Conducted Immunity • IEC 61000-4-11: Voltage Dip

  25. Block Requirements - Performance • Operation Modes: On/Off • Safety Features: • Input Surge Protection Fuse • Over-temperature Shut Down Circuit • Reverse Voltage Protection

  26. Power Signals Inputs: Block Signal I/O Summary 120/240VAC Range: 102V – 264V Frequency = 47 – 63 Hz Imax = 0.7A/0.35 V-RegMAx = -15%/10% Connector - NEMA 5-15

  27. Power Signals Outputs: Block Signal I/O Summary Vcc ±12VDC Range: 11.88V – 12.12V (± 1%) Vripple = 0.01V Imax = 4.2A Connector - Cable Vcc 3.3VDC Range: 3.135V – 3.465V (± 5%) Vripple = 0.1V Imax = 0.4mA Connector - Cable

  28. Block Breakdown Diagram Current Protection 120V/240V AC Input Transformer Rectifier Regulator Regulator Regulator 12V -12V 3.3V

  29. Block Prototype Schematic

  30. Block Theory of Operation • Takes in AC Voltage Via Power Cord • Fuse: • Acts as Over Current Protection • Transformer: • Steps Down Input Voltage to a more Manageable Voltage • Bridge Rectifier: • Changes the Voltage from Ac to DC for use by Voltage regulators • Capacitors C-C4: • Reduce Voltage Ripple Left by rectifier • Capacitors C5-C8: • Protect circuit from high frequency response brought on by the AC to DC Rectification • Voltage Regulators: • Each regulator is chosen to match the required voltage needed by the product. (±12V,3.3V) • Diode D2: • Reverse Voltage Protection

  31. Detailed Design • Selected Transformer: • 115V/230V at 50/60Hz • Series Connection 48V @ 0.75mA • Selected Fuse: • 125V, 1.5A • Over Current Protection • Selected Diode: • Fast SWT, 75V • Reverse Voltage Protection

  32. Detailed Design • Voltage Regulator Output Voltage: +12VDC+3.3VDC Vout(max) = 12.24VVout(max) = 3.432V Vout(min) = 11.76VVout(min) = 3.168V −12VDC Vout(max) = -11.64V Vout(min) = -12.36V

  33. Detailed Design • Capacitance Calculations: Vripple≤ 2V IL = 0.75A f = 60 Hz Vripple = IL / 2fC → C = 0.75 / (2)(60)(2) C = 3125uF By choosing 4700uF at ±20% we achieve the needed capacitance.

  34. Block Prototype BOM

  35. Block Production BOM

  36. Block Prototype Netlist NetInterconnections −12Vout U4-P3, C8-P1, D2-P2 +12Vout(1) U2-P3, C6-P1 +12Vout(2) U3-P3, C7-P1 +3.3Vout U1-P3, C5-P1 Va D1-P1, C-P1, C1-P1, C2-P1, C3-P1, C6-P1, U2-P1, U1-P1, U3-P1 Vb D1-P3, C-P2, C4-P1, D2-P1, U4-P1 VAC F-P1

  37. Block Prototype Layout 2.525” 1.6”

  38. Block Reliability Estimation

  39. Block Reliability Estimation • Total λ = 1394.1 • MTBF = 81.829 yrs • Warranty of 0.5 yrs • Electrolytic Capacitors most likely to fail • λ = 120 (Base) • Could be replaced with filter package

  40. Block Verification Plan • Using Detailed Design: • Simulate and verify results in Spice • Construct Prototype • Verify results in the lab • Modify if needed

  41. MPU w/ RS232 Port Team 4 Chad Due

  42. PC MPU w/ RS 232 User Interface 3 bits 8 bit data line 2 bit high/low 2 bit Feeder selection MPU w/ RS232 Port Feeders IR Sensors interrupt Bidirectional data line Indicator Light Block Allocation Aleks P. Jeff M. Chad D. Jon R. John S. Power Supply

  43. Block Description and Purpose • Description: • To control the operation of all the devices in the system • Also to execute two different program sequences • Purpose: • Read Digital output of IR Sensors • Provide LCD with proper data • Read Digital output of user controls • Enable feeder 1 or 2 • Send data to PC though serial connection

  44. Block Requirements - Standard • Max Parts & Material Cost: $30 • Max Mfg Cost: $24 • Max Total Parts Count: 25 • Max Unique Parts Count: 15 • Mechanical: • Max Volume: 4719.5 cm3 • Max Mass: 0.15 kg • Max PCB Area: 193.5 cm2

  45. Block Requirements - Standard • Environmental: • Min Oper Temp Range: 10 - 40 C • Min Oper Humidity Range: 0 - 80%Rh • Min Oper Altitude Range: 0 – 2000 m • Min Storage Temp Range: −10-60 C • Min Storage Humidity Range: 0-100% Rh • Min Storage Altitude Range: 0 - 15000 m • Safety and EMC Standards: • Electric Aquarium Equipment (UL1018) • ESD Immunity (IEC-61004-2) • Life Cycle • Minimum MTBF: 0.5 yrs

  46. Block Requirements - Performance • Operational Modes: Start, Reset, P1,P2 • Speed: • 9600 Baud • Rate: • 8 MHz Clock • Optical Indicators: • One White LED • 6000 mcd • 20 degree • Mechanical Interfaces: DB9 Connector

  47. Power Signals Inputs: Block Signal I/O Summary Vcc 12VDCVcc 3.3VDC Range: 11.88V – 12.12V Range: 3.135V – 3.465V Vripple = 0.01V Vripple = 0.1V Imax = 300mA Imax = 0.2mA • Digital Inputs: VIH = 2v(min), VIL = 0.5v(max) IIH = 5uA(max), IIL = -5uA(max) • Digital Outputs: VOH = 2.4v(min), VOL = 0.8v(max) IOH = -.1mA(max), IOL = .1mA(max)

  48. Block Breakdown Diagram 1 – 8 Bit Data Line (Display) 2 - 3 bits to receive/send data to user CTRLs 3 – 2 bit Bi-directional Pc Interface data line 4 – 2 bit signal denoting both direction and IR Sensor break 5 – Interrupt on/off for IR Sensors 6 – Enable signal to Feeder 1 or Feeder 2 7 – Enable LED LED Indicator DISPLAY/CTRLS 7 1 2 FEEDER CONTROL 1 MAX232 DB9 MPU 3 6 FEEDER CONTROL 2 5 4 IR TRANSMITTER IR RECIEVER

  49. Block Prototype Schematic

  50. Block Theory of Operation • 1 – PIC will enable IR Sensors, Get info from User Ctlrs telling program info, display all indicated info, start experiment • 2 – When time delay timer gets to zero turn on LED, enable proper feeder, monitor IR senor pins, send data to PC when needed • 3 – reset timer and continue experiment, monitor IR sensors, turn off LED, wait for next delay timer zeroing, repeat steps until program sequence ends

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