Transcript Presentation Slides

318-595 Capstone Project
Team #2
Automotive Advanced Warning
Power On / Off
Forward
Left
Right
Reverse
Audio On / Off
Garage 1
BLIND SPOT!!
Garage 2
Parallel Parking
Driving
text
Power On
System On
1
318-595 Capstone Project
Team #2: Staff
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Andy Panos
Brian Truttmann
Kevin Ristow
Bob Alexander
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Lead Project Integrator
Lead System Designer
Lead Manufacturing Manager
Lead Presentation Manager
Lead Report Manager
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318-595 Capstone Project
Team #2: Expertise & Experience
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Andy Panos
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Brian Truttmann
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Bob Alexander
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Kevin Ristow
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Expertise: Digital: VHDL, Microprocessors
Analog: Filtering, Power Supplies
Experience: 2 Years full-time/part-time @ GE
Healthcare
Expertise: Analog: Filters/PSPICE
Experience: Currently enrolled in training classes at
FVTC for PLC’s
Expertise: Digital/ Analog design
Experience: 8 years as an Avionics technician,
aircraft system trouble shooting, component level
repair, aircraft wiring
Expertise: Digital design, VHDL, Microprocessors
Experience: Automotive wiring and aftermarket
electronics.
3
318-595 Capstone Project
Estimation Summary
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Estimated Manpower: 661.6
Allowed Manpower: 800
Estimated Material Cost: $590
Allowed Material Cost: $500
System Design Tasks: 8.65%
Detailed Design Tasks: 68.68%
Verification Tasks: 5.06%
Documentation Tasks: 17.61%
4
318-595 Capstone Project
Automotive Sensing Design
Features
• This product will detect objects present in the vehicle’s
blind spot.
• Our project will also provide additional features:
– Precision garage parking
– Parallel parking assistance
• Vehicle display will alert the user of the presence of
objects and identify their distance to the vehicle.
• Audible alerts will be present so the driver does not need
to constantly look at the display.
5
318-595 Capstone Project
Benefits to User
• Improves driver awareness of other vehicles
on the road
• Reduces collisions while driving and
parking
• Allows for precision garage parking
6
318-595 Capstone Project
Intended Market
• Automotive market
• This design would compete with existing products
providing parallel parking assistance and garage
parking assistance
• This product would incorporate garage parking
assistance, street parking, and blind spot detection.
• Very few, if any, products that all these features in
a single package.
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318-595 Capstone Project
Technical Risks & Problem Areas
• Implementing Sensors that will allow
distance detection of objects.
• Prototype demonstration of design
• Operation in special environmental
conditions; external components need to be
waterproof.
8
318-595 Capstone Project
Automotive Sensing Block Diagram
12V_Reg
Power Supply
Vehicle Power
12V_Reg
1
4
3.3V_Reg
AC Sensor
Power
Controls and
Sensing
3
3.3V_Reg
User Alerts
PWM Signal
Transformer Enable Bus
Audio
Enable
Display Data Bus
Microcontroller
and Interface
2
Sensor Data Bus
Andy Panos
Kevin Ristow
Robert Alexander
Brian Truttmann
9
318-595 Capstone Project
System Std Reqs:Market and Business Case
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Requirement
Competitors
Model No.
Market Size
Average List Price
Market Geography
Market Demography
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Intended Application
Material Cost
Manufacturing Cost
Annual Volume
Definition
Leadway Technology, Valeo
LY868-6 (Leadway Technology)
1.5 Million
$250.00
World wide
males/females who are of legal driving
age
Automotive
$100.00
$100.00
12,000
( Competitor Product –Valeo)
10
318-595 Capstone Project
System – Std Reqs: Env & Safety
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Requirement
Units to Specify
Min Oper Temp Range
Min Oper Humidity Range Non-condensing
Min Oper Alt or Press Range
Min Storage Temp Range
Min Storage Humidity Range
Min Storage Alt or Press Range
Max Storage Duration
-20 ºC  70 ºC
0%  100%
-50  3000 Meters
-30 oC  90 oC
0%  100%
-100 3500 Meters
2 Years
11
318-595 Capstone Project
Primary EMC Standards
• IEC: 61000-3-2
– Limitation of harmonics in low-voltage supplies < 16A
• IEC: 61000-3-3
– Limitation of voltage fluctuations and flicker in low-voltage
supplies < 16A
• IEC: 61000-4-2
– ESD Immunity Test
• IEC: 61000-4-5
– Surge Immunity Tests
• IEC: 61000-4-11
– Voltage dips, short interruptions and variations
12
318-595 Capstone Project
System – Std Reqs: Power Interfaces
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•
Requirement
Units to Specify
Energy Source List
Source Connection List
Min Oper Voltage Range
Max Power Consumption
Automotive Battery
Permanent
10 - 16 VDC
6W
13
318-595 Capstone Project
System – Std Reqs: Mechanical
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Requirement
Max Volume
Shipping Container Size
Max Mass
Elec I/F Connectors
Max # of PC Bds
Max PCB Circuit Area
Max Shock
Units to Specify
785 cm3
25 x 20 x 15 cm
2.5Kg
Ribbon, Mate-N-Lok
2
185 cm2
50g
14
318-595 Capstone Project
System – Std Reqs: Mfg & Life Cycle
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Requirement
Units to Specify
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
300 parts
75 parts
$100
$100
2.8 Years
30 Days
Recycle
10 Years
Factory Repair
15
318-595 Capstone Project
System – Perf Reqs: Modes of Operation
Requirement
• Power Modes
• Calibration Mode
• Operating Modes
Definition
ON/OFF
Programs distances for garage
parking mode
Driving Mode
Parallel Parking Mode
Garage Parking Mode
16
318-595 Capstone Project
System –Perf Reqs: Operator I/F
Inputs/Outputs
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Requirement
Definition
Optical Indicators, Lights
Display Type
Display Char Matrix
Display Size
Display Illumination
Switch
Green and Red LEDs
Graphical LCD
TBD
16cm x 11cm
LED
Momentary push
17
318-595 Capstone Project
System –Perf Reqs: Mech Interfaces
Requirement
• Mounting
• Sensory
• Connectors
Definition
Sensor: snap in place
LCD: bracket
Processor: Feet
Distance: 0.2m  1.5m
Precision: 0.02m
Ribbon, mate n lock
18
318-595 Capstone Project
Block Diagram Description
Block
#
Block Name
Owner
Brief Description
Of Block Function
Power
Interfaces
Digital
Interfa
ces
Analog
Interface
s
1
Power Supply
Andy Panos
Converts Vehicle Power to
DC power. Generates
PWM signals for sensors.
In: 11-16V DC
Out: 3.3VDC,
5VDC, 120V pk
to pk
None
None
2
Microcontroller
And Interface
Kevin Ristow
Performs computations for
distance, Interfaces with
controls, user interface,
display, creates PWM
signal. Allows the user to
turn the unit on and off,
program garage mode1
and 2, switch modes
In: Vdd
In: PWM,
data bus
Out:
PWM,
data bus,
Pulse
signal
None
3
Controls and
Distance
Sensors
Robert
Alexander
Takes in PWM and creates
the input for the sensors.
Takes the output of the
sensors and amplifies and
filters before sending to the
processor.
Send and receive
ultrasonic signal at 40kHz
in order to detect objects
In: Vdd,120Vpp
In: PWM
Out:
PWM
Out:
None
Informs the user of how
close they are to an object,
or if an object is present by
audio alerts.
Visually show the user
what is going on, alerts,
warnings, mode.
In: Vdd
In: Enable
signal,
Data bus
Out: Audio
Tones
4
User Alerts
Brian
Truttmann
Out: PWM,
1 20Vpp
19
318-595 Capstone Project
Project Plan
20
318-595 Capstone Project
Safety Standards
• Standard: 61508-1 Copyright IEC: 1998
- Description: Electrical and Programmable
• Standard: 60065 Copyright IEC:
2001+A1:2005
- Description: Common Electrical Hazards
• Standard: 180E P.59 NESC 1993
Description: Control Switchboards
21
318-595 Capstone Project
Safety Requirements
• Standard: Federal Motor Vehicle Safety Standards
and Regulations – Standard No. 101
- Description: Controls and Displays
• Essential controllers must be located within reach of the driver
when the driver is restrained by the seatbelt. Certain controls
mounted on the instrument panel must be identified.
• Requirements based on standard:
– Display must be visible from 762mm away from the
edge of the operator’s seat
– Controls must be mounted within 610mm from the
edge of the operator’s seat
22
318-595 Capstone Project
Safety Requirements Continued
• Standard: 173A P.56 NESC 1993
Description: Switches & Disconnecting Devices
• Switches shall be of suitable voltage and ampere
rating for the circuit in which they are installed.
Switches used to break load current shall be marked
with the current that they are rated to interrupt.
• Requirements based on Standard
• Switches will produce a logic hi or low no greater
than 5V
23
318-595 Capstone Project
Power Supply
By: Andy Panos
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318-595 Capstone Project
Automotive Sensing Block Diagram
12V_Reg
Power Supply
Vehicle Power
12V_Reg
1
4
3.3V_Reg
AC Sensor
Power
Controls and
Sensing
3
3.3V_Reg
User Alerts
PWM Signal
Transformer Enable Bus
Audio
Enable
Display Data Bus
Microcontroller
and Interface
2
Sensor Data Bus
Andy Panos
Kevin Ristow
Robert Alexander
Brian Truttmann
25
318-595 Capstone Project
Power Supply Block Diagram
Input
Vehicle Power
12V
Circuit
Protection
Voltage
Regulation
12V_Reg
3.3V_Reg
5V_Reg
12V
3.3V PWM
PWM Amplifier
12V PWM
Voltage Range
Conversion
+/-12V
Step-Up
Transformers
AC Sensor Power
Transformer Enable Bus
26
318-595 Capstone Project
Description and Purpose
• Power supply will regulate incoming power
to provide a constant 12V. Power will also
be generated at 3.3V
• Power supply will provide circuit protection
from automotive sensing to rest of vehicle
power
• Power supply will generate high voltage
square wave to power distance sensors
27
318-595 Capstone Project
Performance Requirements
Power and Protection
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LED: Indicate Power ON
Fuse: Automatic Resetting Fuse for Over Current Protection
Diode: Reverse Bias Diode Protection
Operational Modes
•
ON/OFF
Electrical Interfaces
• Inputs:
– 12V Car Battery Power 10V to 16V
– 3.3V PWM Signal From Microprocessor
– 3.3V Transformer Enable 3 Bit Bus From Microprocessor
• Outputs:
– Processor Power, Controls Reference Voltage: 3.3V +/- 5%
– Speaker Power, Display Power: 12V +/- 5%
– Distance Sensor Power: 60V @ 40KHz +/- 15%
28
318-595 Capstone Project
Standard Requirements
Operating Conditions
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Min Oper Temp Range
Min Oper Humidity Range Non-condensing
Min Oper Alt or Press Range
Min Storage Temp Range
Min Storage Humidity Range
Min Storage Alt or Press Range
-20 ºC  70 ºC
0%  100%
-50M  3000M
-30 oC  90 oC
0%  100%
-100M 3500M
Life Cycle
• Product Life, Reliability
• Max Storage Duration
• Disposal
8.4 Years
2 Years
Recycle
29
318-595 Capstone Project
Standard Requirements
Safety
• EMC Standards
– 61000-3-2: Limitations of Harmonics in low voltage supplies < 16A
– 61000-3-3: Limitation of voltage fluctuations and flicker in low-voltage
supplies < 16A
– 61000-4-5: Surge Immunity Tests
– 61000-4-11: Voltage dips, short interruptions and variations
• Safety Standards
– Standard: 173A P.56 NESC 1993: Switches and Disconnecting
Devices
– 60065 Copyright IEC: 2001+A1:2005: Common Electrical Hazards
30
318-595 Capstone Project
Standard Requirements
Mechanical
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Power Supply Volume
Shipping Container Volume
Power Supply Mass
Max PCB Area
Max Shock
196.25 cm3
1875 cm3
0.9Kg
45.5 cm2
50g
Manufacturing
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Max Unique Parts
Max Part Count
Max Parts Cost
Max Assembly Cost
18 Parts
95 Parts
$15
$15
31
318-595 Capstone Project
Power Block Signal Definitions
Power Signals
Power Signals
Vehicle Power
12V_Reg
AC Sensor Power
3.3V_Reg
Type
DC Power
DC Power
AC Power
DC Power
Direction
Input
Output
Output
Output
Voltage
Nominal
12.0V
12.0V
120V
3.3V
Voltage Range
Min
Max
9.0V
11.4V
102V
3.14V
16.0V
12.6V
138V
3.46V
Freq
Nominal
DC
DC
40KHz
DC
Freq Range
Min
Max
0
0
34KHz
0
N/A
N/A
46KHz
N/A
% V-Reg V-Ripple Current
Max
Max
Max
25.00%
5.00%
15.00%
5.00%
0.1V
0.25V
N/A
0.01V
4.0A
4.0A
1.0A
1.3A
Digital Signals
Digital Signals
PWM signal
Transformer Enable Bus
Type
Digital
Digital
Dir
Input
Input
Output
Input
Structure Structure
Tech
Tristate+Schmitt
Standard CMOS
Tristate+Schmitt
Standard CMOS
Freq
Logic
Nominal Voltage
40Khz
N/A
3.3V
3.3V
Input Characteristics
Vih Min Iih Max ViL Max IiL Max
2.0V
2.0V
25uA
25uA
0.8V
0.8V
-24uA
-24uA
32
318-595 Capstone Project
Reliability Summary
Component Description
Resistor
Ceramic Capacitor
Electrolytic Capacitor
Diode
Zener Diode
Optocouplers
Transformers < 1VA
Mosfets
MOS Linear IC < 1000 (Regulator)
Plastic Shell Connector, Plug Jack
LED
Mos Dig IC < 1000 Gates (Inverter)
Mos Dig IC < 1000 Gates (Flip Flop)
Total
Qty
Base l
FITs
18
22
1
6
1
9
8
4
1
12
1
1
1
0.2
1.2
120
2.4
3.2
12
50
4
13.3
105
1
13.3
13.3
M ax R ated
T emp C o
( T r)
125
125
125
175
175
100
125
175
125
125
100
125
125
M a x O pe r
T emp C o
(T a)
70
70
70
70
70
70
70
70
70
70
70
70
70
M ax R ated
V o lt a ge
( V r)
250
100
70
100
100
35
15
20
30
50
80
18
18
M a x O pe r
V o lt a ge
(Va)
13
13
16
16
16
13
5
13
13
13
13
13
13
pT
3.171
3.171
3.171
1.548
1.548
9.912
3.171
1.548
3.171
3.171
9.912
3.171
3.171
pV
0.143
0.157
0.182
0.164
0.164
0.244
0.223
0.867
0.291
0.192
0.164
1.822
1.822
pE
7.000
7.000
7.000
7.000
7.000
7.000
7.000
7.000
7.000
7.000
7.000
7.000
7.000
pQ
1.250
1.250
1.250
1.250
1.250
1.250
3.000
1.250
1.250
1.250
1.250
1.250
1.250
85
l
14.27848
115.0949
605.9245
31.93013
7.095584
2288.991
5942.592
187.8375
107.2795
6722.301
14.25141
672.318
672.318
T o tal
17382
•Power Supply: R = .991
•MTBF: 8.47 Years
•Reliability Improvements: Reduce # of Connectors, Use Electrolytic Capacitor
with Higher Voltage Rating, Use Transformer With Higher Voltage Rating
33
318-595 Capstone Project
Prototype Plan
Block
Name
Block Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Power
Supply
80
58
Perfboard
Soldering
Opto,
MOSFET,
Inverter,
Flip Flop
Mate-NLok
34
318-595 Capstone Project
Microprocessor and Interface
By: Kevin Ristow
35
318-595 Capstone Project
Automotive Sensing Block Diagram
12V_Reg
Power Supply
Vehicle Power
12V_Reg
1
4
3.3V_Reg
AC Sensor
Power
Controls and
Sensing
3
3.3V_Reg
User Alerts
PWM Signal
Transformer Enable Bus
Audio
Enable
Display Data Bus
Microcontroller
and Interface
2
Sensor Data Bus
Andy Panos
Kevin Ristow
Robert Alexander
Brian Truttmann
36
318-595 Capstone Project
Block Description
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•
Generates PWM signal
Calculates distance to objects
Interprets signals from user interface
Controls LCD screen
Controls Operational Modes
Takes in 6 inputs from user
Displays which mode/state via LED
Retains User set data from Garage Parking
37
318-595 Capstone Project
Block 2 Performance Requirements
User Inputs/Outputs
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•
Momentary Push Button
LED
Debounce Time < 5ms
Green LED to display Mode
Red LED to display completed Calibration
Operation Modes
•
Power Mode
ON/OFF
•
Calibration Mode
Programs distances for garage
parking mode
•
Functional Modes
Driving Mode
Parallel Parking Mode
Garage Parking Mode
Electrical Interface
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•
PWM
Processor
40kHz, PW .8ms, Interval 60ms
> 20 I/O, Flash Memory, Oscillator
Safety
•
Controls
•
Switches
Must be mounted within 610mm from the
edge of the operator’s seat
Produce a logic hi or low no greater than 5V
38
318-595 Capstone Project
Block 2 Standard Requirements
Environmental
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•
•
•
•
•
•
Min Oper Temp Range
Min Oper Humidity Range Non-condensing
Min Oper Alt or Press Range
Min Storage Temp Range
Min Storage Humidity Range
Min Storage Alt or Press Range
Max Storage Duration
-20 ºC  70 ºC
0%  100%
-50  3000 Meters
-30 oC  90 oC
0%  100%
-100 3500 Meters
2 Years
Safety
•
EMC standards
–
–
–
•
61000-4-2: ESD Immunity Tests
61000-4-5: Surge Immunity Tests
61000-4-11: Voltage dips, short interruptions and variations
Safety Standards
–
–
–
NESC 173A P.56: Switches & Disconnecting Devices
Federal Motor Vehicle Safety Standards and Regulations – Standard No. 101: Controls and Displays
IEC 61508-1: Electrical and Programmable
39
318-595 Capstone Project
Block 2 Standard Requirements
Mechanical
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•
•
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•
Block Volume
Mass
Electrical I/F Connectors
Number of PC Boards
Max PCB Circuit Area
Max Shock
< 200 cm3
< .5Kg
Ribbon, Mate-N-Lok
2
< 50 cm2
50g
Manufacturing
•
•
•
•
•
•
•
•
•
Max Parts Count
Max Unique Parts Count
Parts/Mat $ Allocation
Asm/Test $ Allocation
Block Life, Reliability
Full Warranty Period
Product Disposition
Production Life Support
Service Strategy
< 40
< 20
< $10
< $30
34.2 Years
30 Days
Recycle
10 Years
Factory Repair
40
318-595 Capstone Project
Block Breakdown
BLOCK 2 MICROCONTROLLER AND INTERFACE
On/Off
3.3 V Reg
PWM SIGNAL
Sensor Data Bus
Block 3
Controls and
Sensing
MICROPROCESSOR
PIC18LF8490
80 pin TQFP
Garage Mode 1
8 BIT
DEBOUNCE
CIRCUIT
Garage Mode 2
Parallel Parking
Mode
Driving Mode
Display Data Bus
Transformer Enable
Bus
Audio Enable
Block 1
Power Supply
Audio On/Off
Block 4
User Alerts
41
318-595 Capstone Project
Block 2 Signal Definitions
POWER SIGNALS
Direction Voltage
Voltage Range
Nominal
Min
Max
Input
3.3V
3.14V
3.47V
Freq
Freq Range
Nominal
Min
Max
DC
0
N/A
% V-Reg V-Ripple Current
Max
Max
Max
5.00%
0.1V
0.3A
DIGITAL SIGNALS
Input
Digital Signals
Sensor Data Bus
Type
Digital
Dir
Input
Output
Input
Tech
Freq
Logic
Input Characteristics
Structure Structure
Nominal Voltage Vih Min Iih Max ViL Max IiL Max Vth Min
N/A
Schmitt
CMOS 40kHz
3.3V
2.0V
5uA
0.8V
8uA
N/A
Output
PWM Signal
Display Data Bus
Transformer Enable Bus
Audio Enable
Digital
Digital
Digital
Digital
Output
Output
Output
Output
Structure Structure
Tristate+Schmitt
Tristate
Tristate
Tristate
CMOS
CMOS
CMOS
CMOS
Nominal
40kHz
1kHz
1kHz
1kHz
Voltage
3.3V
3.3V
3.3V
3.3V
Voh Min
2.4V
2.4V
2.4V
2.4V
Ioh Max
10uA
10uA
10uA
10uA
VoL Max
.5V
.5V
.5V
.5V
42
IoL Max
30uA
30uA
30uA
30uA
318-595 Capstone Project
Block 2 Reliability
Component
Description
Carbon Resistor
Ceramic Capacitor
Led
Schmitt Trigger
Switch
PIC18F8490
Plastic Shell Connector
Total
Base l
FITs
Qty
10
6
6
6
6
1
4
2.6
1.2
1
13.3
20
31
105
M ax R ated
T emp C o
( T r)
125
125
100
125
125
130
125
M a x O pe r
T emp C o
(T a)
M ax R ated
V o lt a ge
( V r)
70
70
70
70
70
70
70
250
150
5
18
28
7.5
50
M a x O pe r
V o lt a ge
(Va)
3.25
3.25
3.25
3.25
3.25
3.25
3.25
pT
3.171
3.171
9.912
3.171
3.171
2.811
3.171
pV
0.137
0.138
0.867
0.169
0.154
0.291
0.145
pE
7.000
7.000
7.000
7.000
7.000
7.000
7.000
pQ
l
98.91245
27.63809
451.1177
373.4671
513.7682
177.3703
1690.434
T o tal
1.250
1.250
1.250
1.250
1.250
1.000
1.250
39
3332.7
Reliability Summary
The Plastic Shell Connector is most unreliable component in my block. The overall
reliability of the block could be improved by reducing the number of connectors.
•MTBF (Yrs) = 34.2
•Microcontroller and Interface R = .99
43
318-595 Capstone Project
Block 2 Prototyping Plan
Block
Part
Part
Area
(cm2)
Total PCB
Area
(cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Microprocessor
Demo Board
250
190
N/A
Soldered
None
Pins
User Interface
50
40
Perfboard
Soldering
Schmidt
Trigger
Plastic Shell
44
318-595 Capstone Project
Controls and Sensing
By: Robert Alexander
45
318-595 Capstone Project
Automotive Sensing Block Diagram
12V_Reg
Power Supply
Vehicle Power
12V_Reg
1
4
3.3V_Reg
AC Sensor
Power
Controls and
Sensing
3
3.3V_Reg
User Alerts
PWM Signal
Transformer Enable Bus
Audio
Enable
Display Data Bus
Microcontroller
and Interface
2
Sensor Data Bus
Andy Panos
Kevin Ristow
Robert Alexander
Brian Truttmann
46
318-595 Capstone Project
Block 3 Breakdown
60V @ 40kHz
Ultrasonic
Sensors
12 VDC
Amplifier
12 VDC
40kHz
Filter
3.3 VDC
8-BIT
OUTPUT
Comparator
47
318-595 Capstone Project
Block 3 Description and Purpose
• Purpose of sensing and control block is to detect objects in
range of the ultrasonic sensor, and also to send a
conditioned signal to the microprocessor.
• The signal from the ultrasonic sensor will initially be
amplified and sent through a 40kHz band pass filter.
• The comparator will take the output of the amplified and
filtered signal and check if the output is above the 400mV
reference voltage.
• If the voltage is above 400mV it will send a 3.3V signal to
the microprocessor to stop the microprocessors count cycle
and perform the distance calculation.
48
318-595 Capstone Project
Performance Requirements
Power Signals
Type
Direction
Power1 VCC +12
Power2 VDD+3
Power3 AC sensor power
DC Power
DC Power
AC Power
Input
Input
Input
Digital Signals
Type
Direction
Digital1 Data 7-Data 0
Digital
Output
Voltage
Nominal
12.0V
3.3V
120V peak-peak
Output
Structure
Tristate+Schmitt
Electrical Interfaces
•
Band Pass filter
Bandwidth:
Center frequency:
Attenuation @ 40kHz:
•
Ultrasonic Sensors
Operating frequency:
Sensing Range:
Sensing Precision:
Output Voltage:
Voltage Range
Min
Max
11.4
12.6
3.14
3.46
136
184
Input
Structure
Standard
Tech
CMOS
Freq
Nominal
DC
DC
40 kHz
Freq Range
Min
Max
0
N/A
0
N/A
34 kHz
46 kHz
Freq
Nominal
2.0Mhz
Logic
Voltage
3V
Voh Min
2.4V
% V-Reg
Max
5.00%
5.00%
15.00%
V-Ripple
Max
0.1V
0.25V
N/A
Current
Max
2.0A
1.0A
1.0A
Output Characteristics
Ioh Max VoL Max
-1.0mA
0.5V
IoL Max
1.0mA
8kHz
40kHz
40dB
40kHz
0.2  1.5m
0.02m
5  100mV
49
318-595 Capstone Project
Standard Requirements
Operating Conditions
•
•
•
•
•
•
Min Oper Temp Range
Min Oper Humidity Range Non-condensing
Min Oper Alt or Press Range
Min Storage Temp Range
Min Storage Humidity Range
Min Storage Alt or Press Range
-20 ºC  70 ºC
0%  100%
-50M  3000M
-30 oC  90 oC
0%  100%
-100M 3500M
Life Cycle
• Product Life, Reliability
• Max Storage Duration
• Disposal
1.32 Years
2 Years
Recycle
50
318-595 Capstone Project
Standard Requirements
Safety
• EMC Standards
– 61000-4-2: ESD Immunity Tests
– 61000-4-5: Surge Immunity Tests
– 61000-4-11: Voltage dips, short interruptions and
variations
• Safety Standards
– 60065 Copyright IEC: 2001+A1:2005: Common
Electrical Hazards
51
318-595 Capstone Project
Standard Requirements
Mechanical
•
•
•
•
•
•
Block Volume
Mass
Electrical I/F Connectors
Number of PC Boards
Max PCB Circuit Area
Max Shock
< 175 cm3
< .5Kg
Mate-N-Lok
1
< 29 cm2
50g
Manufacturing
•
•
•
•
Max Parts Count
Max Unique Parts Count
Max Parts Cost
Max Assembly Cost
< 130
< 20
< $150
< $30
52
318-595 Capstone Project
Reliability Analysis
Sensing & Control
Component Description
Resistor
Capacitor
Opamp (MOS Dig IC < 1000 gates)
Plastic Shell Connector: Plug, Jack
Ultrasonic Sensors
Total
Base l
Qty FITs (Tr) (Ta) (Vr) (Va) pT
64
32
6
11
8
121
•
•
•
•
•
2.6
1.2
13.3
105
40
100
125
155
125
85
70
70
70
70
50
250
25
22
50
80
13
13
13
13
60
9.912
3.171
1.879
3.171
3.773
pV pE pQ
0.143
0.400
0.574
0.192
2.718
7.000
7.000
7.000
7.000
7.000
1.000
1.000
1.000
3.000
3.000
Total l
1650.657912
340.7723319
602.0655559
14789.06116
68915.97861
86298.53557
Most unreliable component is the ultrasonic sensors.
Overall component reliability can be increased by reducing the operation
voltage of ultrasonic sensors to 40V.
Eliminating the use of plastic shell connectors will also cause an increase in
the products overall reliability.
MTBF (years) = 1.32
Sensing and Control block R = .903
53
318-595 Capstone Project
Block 3 Prototyping Plan
Block
Name
Block
Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Sensing and Control
39
29
Perfboard
Soldering
Op-Amp
Comparator
Mate-N-Lok
54
318-595 Capstone Project
Sensing & Controls Design
Equations (Amplifier Stage)
Gain Equation:
Av  
R2 50k

 10
R1
5k
55
318-595 Capstone Project
Sensing & Controls
Design (40kHz Band Pass Filter)
• Utilized the Delyiannis-Friend Band pass
filter model.
• Equations to determine component values:
Q
fo
B
R3 
Q
pf o C
R2 
R3
4Q 2  2 H o
R1 
R3
2H o
56
318-595 Capstone Project
Sensing & Controls Design
Determining Component Values
•
•
•
•
•
Center frequency (fo = 40kHz)
Minimum frequency = 36kHz
Maximum frequency = 44kHz
Frequency Bandwidth (B = 8kHz)
Determine the Q factor or roll off rate of our filter:
Q
•
f o 40kHz

5
B
8kHz
Determine the Value of R3 by picking the capacitance value of 100pF
Q
5
R3 

 400k
pf oC p (40kHz)(100 pF )
57
318-595 Capstone Project
Sensing & Controls
Design (40kHz Band Pass Filter)
• Determine the remaining component values:
R2 
R3
400k

 5k
4Q 2  2 H o 4(5) 2  2(10)
R1 
R3
400k

 20k
2 H o 2(10)
58
318-595 Capstone Project
Sensing & Controls
Design (40kHz Band Pass Filter)
59
318-595 Capstone Project
Completed Design
Sensing & Control Circuit
60
318-595 Capstone Project
Transient Output of Amplifier Stage
61
318-595 Capstone Project
Transient Output of Filter Stage
62
318-595 Capstone Project
AC Analysis
Filter Stage
63
318-595 Capstone Project
AC Analysis
64
318-595 Capstone Project
Introduction: User Alerts
• Owner: Brian Truttmann
Display Power
Power Supply
Vehicle Power
1
4
Processor Power
Sensor
Power (DC)
Controls and
Sensing
3
Control Power
User Alerts
PWM Signal
Sensors Enable
Audio
Enable
Microcontroller
and Interface
2
Sensor Data
Andy Panos
Kevin Ristow
Robert Alexander
Brian Truttmann
65
318-595 Capstone Project
User Alerts
• Description: Show user what is going on, i.e. alerts,
warnings, mode.
• Allows user to turn unit on and off.
• There will be an LCD. It will display letters as well as
numbers, but letters are what is primarily needed.
• When there is a vehicle in the blind spot the LCD should
display “Caution”, and the buzzer should sound.
• When you are going to hit something while parking the
LCD should display “Stop”, and the buzzer should sound.
66
318-595 Capstone Project
Performance Requirements
• IR write as internal operation (display, clear, etc.).
RS (Register Selector Signal) = 0 and R/W
(Read/Write) = 0.
• Read busy flag (DB7) and address counter (DB0 –
DB7). RS = 0 and R/W = 1
• Write data to (Display Data) DDRAM or
(Character Generator) CGRAM (DR to DDRAM
or CGRAM). RS = 1 and R/W = 0
• Read data from DDRAM or CGRAM(DDRAM or
CGRAM or DR). Both RS and R/W = 1.
67
318-595 Capstone Project
Standard Requirements
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
16 Characters by 2 lines
Parallel interfacing
Module Dimension: 84.0*44.0*13.5 (mm) (MAX)
View Area: 66.0*16.0 (mm).
Active Area: 56.20*11.5 (mm).
Dot Size: 0.55*0.65 (mm).
Dot Pitch: .60*.70 (mm).
Character Size: 2.95*5.55 (mm).
Character Pitch: 3.55*5.95 (mm).
Operating Temp: -10º C to +50º C
Storage Temp: -20º C to + 70º C
Supply Voltage: ~ 5V dc
Power of amp for speakers is 1W and for LCD should be 3mW.
Supply Current:~ .6mA
There is a frame frequency of 64 Hz.
Gain of the speaker amplifier can be adjusted between 20 and 200.
68
318-595 Capstone Project
Block Diagram
RS = 0 or 1
COM1 ~ 16
R/W = 0 or 1
MPU
E
DB0 – DB7
Controller/Com
Driver
16 by 2 LCD
Vss = 0V (ground)
Vdd = 5V dc
Vss (variable)
Bias and
Power Circuit
SEG1 ~ 40
D
M
12V dc
Speaker
Amplifier
Seg Driver
CL1
CL2
Vdd, Vss, V1~V5
69
318-595 Capstone Project
Signal Table
Power Signals
12V_Reg
5V_Reg
Digital Signals
Display Data Bus
Audio Enable
Type
Direction
DC Power Input
DC Power Input
Type
Digital
Digital
Voltage
Nominal
12.0V
5.0V
Dir
Input
Output
Output
Structure
Voltage Range
Min
Max
11.4V
4.75V
Input
Structure
Schmitt
Tristate
12.6V
5.25V
Tech
CMOS
CMOS
Freq
Nominal
Freq Range
Min
Max
DC
DC
Freq
Nominal
1kHz
1kHz
N/A
N/A
Logic
Voltage
3.3V
3V
Vih Min
2
2.4V
% V-Reg
Max
0.05
0.05
Iih Max
25uA
10uA
V-Ripple
Max
0.25
0.05V
Current
Max
4A
1mA
Input Characteristics
ViL Max
IiL Max
0.8V
.5V
-24uA
30uA
70
Vth Min
N/A
N/A
318-595 Capstone Project
Reliability Analysis
M ax R ated
Component
Description
Base l
FITs
Qty
T emp C
o
M a x O pe r
T emp C
( T r)
o
(T a)
M ax R ated
M a x O pe r
V o lt a ge
V o lt a ge
( V r)
pT
(Va)
pV
pE
pQ
T o tal
l
Resistor
2
2.6
250
70
18
13
1.075
1.822
7.000
1.250
72.14025
Capacitor
6
1.2
100
70
18
13
9.912
1.822
7.000
1.250
33.2955
Potentiometer (10k)
1
0.2
250
70
18
13
1.075
1.822
7.000
1.250
5.5493
IC LM386N
1
6.7
150
70
18
13
1.999
1.822
7.000
1.250
185.9
LED 3mm Red LED
1
1
125
70
18
13
3.171
1.822
7.000
1.250
27.74625
8 pin IC socket
1
2.4
85
70
18
13
105.943
1.822
7.000
1.250
66.591
PCB mount SPDT switch
1
20
125
70
18
13
3.171
1.822
7.000
1.250
554.925
2 pin header and jumper
1
35
125
70
18
13
3.171
1.822
7.000
1.250
971.1188
Printed Circuit Board
1
2.4
125
70
18
13
3.171
1.822
7.000
1.250
66.591
71
318-595 Capstone Project
Reliability Assessment
• Total FITs are 8,449.9, and the total MTBF is 13.5
years.
• The two most dominant parts for unreliability are
the switch and 2 pin header and jumper, with Base
λ FITs of 20 and 35 respectively.
• The best way for me to improve my reliability
would be to see if I could use any other parts from
the standard failure rates table in place of the one I
am using for my 2 pin header and jumper.
72
318-595 Capstone Project
Prototyping
Block
Name
Block Area
(cm2)
Total PCB
Area
(cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
User Alerts
39
29
PCB
Soldering
Op-Amp
Male/Female
73
318-595 Capstone Project
Project Reliability
Block Number
Block
Block
Block
Block
1
2
3
4
Total FITs
MTBF (Yrs)
MTBF (Hrs)
w
F(w)
F (1 Yr)
F (10 Yr)
F(t) = 1%
F(t) = 1%
Block Name
Power Supply
Microcontroller and User Interface
Controls and Sensing
User Alerts
l Total
Warranty (w) Period in Years =
Failures at 1 Warranty Period =
Failures at 1 Year =
Failures at 10 Years =
Time in Years for 1% failures =
Time in Days for 1% failures =
Block l Totals in FITs
17382.211
3332.700
19236.182
8449.944
48401.037
2.357
20660.714
0.08
0.033
0.346
0.986
0.024
8.652
74
318-595 Capstone Project
Prototype Plan
Block
Name
Block Area
(cm2)
Total PCB PCB
Area
Substrate
(cm2)
Type
Comp
Socketed
Attachment Components
Type
Types of
Connectors
Power
Supply
80
58
Perfboard Soldering
Opto,
MOSFET,
Inverter, Flip
Flop
Mate-N-Lok
Sensing and 39
Control
29
Perfboard Soldering
Op-Amp
Mate-N-Lok
Microproce
ssor and
User
Interface
300
230
Perfboard Soldering
Schmidt
Trigger
Mate-NLok/Pins
User Alerts
39
29
Perfboard Soldering
Op-Amp
Male/Female
75
318-595 Capstone Project
Prototype Summary
•
•
•
•
# of Boards: 6
Total PCB Area: 346 cm2
Total Prototype Area: 458 cm2
Prototype Packing:
– PCB Packaging: Perfboards and Demoboard
enclosed by plastic housing
– LCD, User Interface, Speakers enclosed by
plastic housing
76
318-595 Capstone Project
Reliability Summary
• MTBF: 2.81 Yrs
• Power Supply, Controls and Sensing Blocks
have the lowest reliability
• Connector Shells, Transformers, Sensors,
and Optocouplers have the highest
reliability issue
77
318-595 Capstone Project
Reliability Test Plan
Stress
24 Hour
Model
10 Year
Model
Max Input
Voltage
16
16
Number of
Power
Cycles
4
14602
Thermal
Range
15oC
35oC
Number of
Thermal
Cycle
4
80
Max Shock
Grms
3
50
Number of
Shock
Cycles
20
73002
Accelerated
Stress
Model
Accelerated
1 Cycle
Time
Acceleratio
n Factor
N/A
N/A
N/A
N/A
N/A
N/A
78