EE595 Capstone Design: Team 6

1. EE595 Capstone Design: Team 6 Team Members: • Mike Loften • Shane Ehster • Chad Ehnert • Kevin Kuhl Degree Sought: • BSEE • BSEE • BSEE • BSEE • BS Physics

2. Team 6: Expertise & Experience • Mike Loften • Chad Ehnert • Kevin Kuhl • Shane Ehster • Expertise: Electrical circuits Experience: Hands on controls experience • Expertise: PIC/ATMEL controllers, USB, Digital Logic, Troubleshooting, Mechanical Aptitude Experience: Co-Op with Alliance Laundry and Andis • Expertise: PCB layout, Microprocessors, Experience: 3 Co-Op terms: Kohler Power Systems • Expertise: Power, Motors Experience: 4 Co-Op terms with ATC

3. Team 6: Total Resources • 32 hrs/week Manhours • $400 • Chad: Prototype USB board, breadboards, components, soldering iron • Shane: Various tools, soldering iron • Mike: Components, breadboard • Kevin: Board layout program

4. Team 6: Decision Making • Majority vote will be implemented unless there is a strong disposition to an idea. In which case further suggestion will be used and a re-vote.

5. Roles to Define & Assign • Lead Project Integrator (LPI): Chad • 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

6. Roles to Define & Assign • Lead System Designer (LSD): Chad • 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

7. Roles to Define & Assign • Lead Presentation Manager (LPM): Shane • 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

8. Roles to Define & Assign • Lead Report Manager (LPM): Kevin • 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

9. Roles to Define & Assign • Lead Manufacturing Mgr (LMM): Mike • 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 gluing.

10. Project 1 • A device to sense when a parking checker marks the tires of your car. The device will send a signal to an external communication device to notify the user that the car has been marked. • Power sources: Battery • User interface will be a small key chain. • There is no other known product like this on the market • Project fits team interests well and could be potentially marketable.

11. Block Diagram for Parking Checker Device Processor to determine good/bad data Input from motion sensor Communication Device (Sending signal) External Interface to notify user

12. Project 2 • Alarm clock that has an internal MP3 player built into the device. The alarm clock would have a removable flash memory for music storage. • There would be a display for choosing the music like similar MP3 players. • AC cord from 120volt/ 60 Hz outlet with battery back up. • There is currently no product like this on the market. • Highly attractive project to the group and personal interests.

13. Alarm Clock with MP3 Player

14. Project 3: Automated Pigment Dispenser Custom-Paint • Automated pigment dispenser for custom paint mixing • Receives paint recipe from off-the-shelf hardware store color scanner • Output data to a automated rotating pigment dispenser to get exact color match • Fits group interest by incorporating motor control and PIC programming.

15. Project 3: Automated Pigment Dispenser Custom-Paint Pigment selection Paint recipe (from color scanning computer) Controller Selected pigment dispensing User instructions, interface Base paint can sensor

16. WEEK 2: Project Refinements All 3 initial projects were scrapped and 2 new, more specific proposals were created. The following slides will detail these projects as well as a recommended project.

17. Additional Project 1Sewer Pipe Inspection Vehicle • A device that fits inside of a residential sewer pipe with a camera that could be used to inspect the inside of a pipe. • The vehicle will likely carry some sort of umbilical cord to interface with the user controls. • The user controls will have forward and reverse ability as well as some sort of display.

18. Residential Sewer Inspection Vehicle (Non-recommended project) VEHICLE Frame Drive System Camera Microprocessor Roll Stabilizer Lights Vehicle Power Supply Tether Video Display User Controls User Interface Power Supply USER INTERFACE Enclosure

19. Selection Matrix

20. Project Selection • This project was selected based on team members personal interests and abilities. There was a strong interest in doing a project with motor control and the RC Jeep project should be a great exercise in this. • The other projects were rejected due to high cost and extreme amounts of ancillary engineering design that may not be able to be completed in 1 semester. • The project was eventually unanimously selected by the team. There were some regrets letting go of the other project but they were resolve relatively easily through discussion. • Project Risks: • Being dependent on the timeframes of other groups working on the jeep. • Not being to interface with the existing technology

21. Proposed Product Summary • CEAS RC Jeep with larger DC motors, drive protection, and motor speed sensing control (Traction Control). • User requirements: Ability to operate a hand held transmitter with forward and reverse controls. • The primary benefit is a product that get the attention of the audience the school is trying to reach. • The product can be used for promotion of the school of engineering at grade/high schools or other university sponsored events. • The UWM Police have a similar vehicle they use as a promotional tool. We do not believe that the product has a commercial market at this time. • The vehicle fits into the consumer products industry.

22. RC Jeep Project Block Diagram • MOSFET Bridge & Drivers Block • Four MOSFETs and Two BJTs • Misc. Resistors & Capacitors • Inputs: PWM and Batt. Voltage • Outputs: Voltage to motor • Current Limiting Block (protect Mosfets) • Sense current going to MOSFETs • Shutdown drivers if excessive current • Roughly 15 comp • Two Opamps • Two BJTs • A diode and misc. resistors and Capacitors • Feedback speed Control • Used when two motors are used • Components or parts: • 2 optical encoders--Inputs • Phase comparator • Integrator • Microprocessor • Inputs: PWM from Receiver • Outputs: PWM to MOSFET Drivers • Inputs: Feedback from speed control

23. Block Diagram Description

24. Current Patents • Patent # 7,151,394 • Phase shifting and PWM driving circuits and methods • December 19, 2006 • Patent # 7,173,350 • Load drive control apparatus having minimized power consumption when functioning in waiting status. • June 27, 2003 • Patent # 7,173,393 • Phase current detection method, inverter control method, motor control method, and apparatus used in these methods. • April 10, 2003

25. Ethics and Societal Issues • Product failure could cause fire, bodily injury due to a collision. • User hazards: Collisions and fire. • Harm can be avoided by inserting current limiting on the driver circuit, possibly a speed governor, making the vehicle more controllable with feedback control. • Faulty/Flawed engineering would lead to the protection devices not working properly or injury to user/damage to property. • The driver circuitry and remote controlled aspects need to be 100% robust.

26. Standard Requirements • Max Oper Temp. Range: 0C to 55C • Max Oper Humidity Range: 0 – 95% Non condensing • Max Oper Altitude Range: -300ft to 15,000ft above sea level • Max Storage Temp. Range: -20 to 65C • Max Storage Humidity Range: 0 - 95% Non condensing • Max Storage Pressure Range: 0.5 to 1.5 atm

27. System Standard Requirements (Power Inputs) • 12-48VDC Battery Supply • Temporary Connection to Source (Charging) • Min. Operating range: 5 - 7VDC • Max Power Consumption: 20A (2 motors at 10A each) at 12V = 240W • 12V at 9.5A/hr = 120W/hr

28. Max Volume: Max Ship Container Size Max Mass Elec I/F Connector(s) Max # of PC Bds Max PCB Circuit Area Max Shock .25 cubic meters .75 cubic meters 45 Pounds Solder, Harnesses 3 150 cm^2 8 G’s System Standard Requirements (Mechanical Inputs)

29. Max Parts Count Max Unique Parts Count Parts/Mat $ Allocation Asm/Test $ Allocation Product Life, Reliability Full Warranty Period Product Disposition Production Life Support Service Strategy TBD TBD TBD TBD TBD TBD TBD TBD TBD System Standard Requirements (Mfg and Life Cycle)

30. Competitors Market Size Average List Price Market Geography Market Demography Intended Application N/A 426 WI Districts * 5 Schools per district = 2130 units $599.00 Mainly the U.S. Ages 12 and up due to safety requirements Promotional tool for schools, businesses. Market and Business Case

31. Material Cost Annual Volume $495.00/unit 1200 units Market and Business Case Con’t