Transcript Presentation Slides

Team #5: Staff
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Sean Kuter
Kurt Stonger
Andrew LaPointe
Eric Fritz
Shawn Bostwick
(LPI)
(LRM)
(LSD)
(LPM)
(LMM)
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BSEE
BSEE
BSEE
BSEE
BSEE
1
Project Plan Summary
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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
2
Selected Project
Key Features
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Reptile Environmental Control Unit:
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Monitor Environment
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Ambient Temperature
Surface Temperature
Humidity
Monitor Ambient Temperature
Control Surface Temperature
Control Humidity
Security System to Prevent Escape
Cable Management System
3
Product Applications
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Exclusive environmental control to support:
 Snakes (primarily)
 Turtles, lizards, and other rare reptiles
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Typical market:
 Professional/Amateur Breeders and Herpetologists
 Pet Stores
4
Hoffer’s Tropical Pet Store
5
Potential Competitors
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www.habitatcontrolsystems.com
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Targeted market
Don’t meet all of the key objectives
Room for product growth
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4 Zone Programmable
Controller
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Made for multiple units
Monitors and controls
temperature only
No security control
$249.00 USD
6
Refined Block Diagram
Inputs and Signal
Conditioning:
Inputs and Signal
Conditioning:
Andrew LaPointe
ANALOG
Ambient
Temperature
Sensors
ANALOG
Signal
Conditioning
DIGITAL
Relay
Switches
29 VAC
DIGITAL
Relay
Switches
120 VAC
Signal
Conditioning
Controller
Humidity Sensors
ANALOG
Keypad
DIGITAL
DIGITAL
Eric Fritz
Signal
Conditioning
Door Sensors
Kurt Stonger
Shawn Bostwick
Sean Kuter
Surface
Temperature
Sensors
Outputs:
Power Distribution:
DIGITAL
LCD Display
Foggers
Heat Mats
4 State
Controllers
Lights
5VDC
Alarm Horn
7
Block Assignments
Power
interfaces
Digital
Interfaces
Analog
Interface
s
Block #
Block Name
Owner
Description
1
Power
conversion &
distribution
Shawn
Bostwick
Standard AC input to
5/24VDC and 115
VAC output
In:115 VAC
Out: 115VAC
5VDC, 24VDC
none
none
2
A/D conv &
Signal
conditioner
Sean
Kuter
Convert 0-10 VDC
analog signals to
digital data
In: 5VDC
Power
Out: Sensor
data to Micro
Controller
In: Analog
sensor data
3
Micro
Controller
Eric
Fritz
Take in Digital data,
perform calculations,
output digital On/Off
signal
In: 5VDC
Power
Out: On/Off
signal to
outputs
none
Inputs
Andy
LaPointe
ambient/mat temp,
humidity, door
sensor, keypad
In: 5 VDC
Out: 0-5VDC
none
Out: 0-5VDC
analog
Outputs
Kurt
Stonger
Fogger, heat pad,
heat lamp, LCD,
alarms
In: 115Vac,
24Vdc, 5Vdc
In: Data Bus
On/Off signal
none
4
5
8
Performance Requirements
Requirement
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Display type
Units to Specify
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LCD
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Temperature Sensors
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Humidity Sensors
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Keypad type
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Key definitions
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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
9
Standard Requirements
Requirement
Units to Specify
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Min Oper. Temp Range
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5 - 45° C
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Min Oper. Humidity Range
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0 – 99% relative humidity
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Max Dimensions
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12” x 12” x 6”
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Source Connection List
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Temporary, with ability to move
unit
10
Standard Requirements
Requirement
Units to Specify
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Min Oper. Voltage Range
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102 – 132 VAC
120 VAC nom.
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AC power freq range
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57 – 63 Hz
60 Hz nom.
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Max Power. Consumption
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850 W
7A
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Parts/Material $ Allocation
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$500 (total, $100/member)
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Connector Type
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Type B Plug
11
Safety Standards
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IEC 6100-4-2:
ESD Immunity
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IEC 61140 Edition 3.0:
Electric Shock Protection
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IEC 730:
Auto. Elec. Controls for Household
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UL 60730-1A
Auto. Elec. Controls for Household
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UL 60730-2-9
Auto. Elec. Controls for Household
Part 2: Particular for Temperature
Sensing Controls
12
Specific Safety Requirements
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IEC 60335-2-71 Edition 2.0
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UL 873
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Household and similar electrical appliances – Safety – Part 271: Particular requirements for electric heating appliances for
breeding and rearing animals
Temperature-Indicating and Regulating Equipment
UL 60730-2-13A
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Automatic Electric Control for Household and Similar Use;
Part 2: Particular Requirements for Humidity Sensing
Controls
13
EMC Standards
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61000-4-2: ESD Immunity Tests
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61000-4-5: Surge Immunity Tests
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IC’s
Lightning discharges & switching disturbances
61000-4-11: Voltage dips, short interruptions,
and variations
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Line voltage variances
14
ECU Technical Risk & Problem
Areas
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Sensors/Sensing Issues
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Programming
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Analog sensor output > Digital Processor
Pic/Microcontroller selection
Programming Hardware
Programming Software
Power Supply
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Design
Build
Safety (explosion, fire, shock)
15
Individual Reliability Report:
Andrew La Pointe
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Maximum FIT’s:
832.31
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MTBF:
137.06 years
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Most Unreliable Part:
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Humidity Sensor
Suggested Improvement:
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Find a part with a lower lambda
16
Individual Reliability Report:
Eric Fritz
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Maximum FIT’s:
6928.5
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MTBF:
16.46 years
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Most Unreliable Part:
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D-flip flops
Suggested Improvement:
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Use a different part
Use fewer parts
17
Individual Reliability Report:
Shawn Bostwick
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Maximum FIT’s:
1919.00
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MTBF:
59.45 years
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Most Unreliable Part:
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Zener Diodes
Suggested Improvement:
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Use heatsinks for temperature
18
Individual Reliability Report:
Kurt Stonger
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Maximum FIT’s:
454.09
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MTBF:
251.22 years
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Most Unreliable Part:
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Electromagnetic coil relay
Suggested Improvement:
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Use transistorized switch, or SCR
19
Individual Reliability Report:
Sean Kuter
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Maximum FIT’s:
41.595
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MTBF:
2742.57 years
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Most Unreliable Part
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Resistors
Suggested Improvement
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None needed
20
Ambient / Surface Temp Sensing
Sean Kuter
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To provide a controlled temperature scaled
inputs to the microcontroller block:
Ambient Temperature
 Surface Temperature
 Impedance matching
 Amplified Signals
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21
Sean Kuter
Ambient and Surface Temperature Inputs Per
Reptile Environmental Unit
5 Vdc
From
Power Dist.
Block
5 Vdc
+/- 12 Vdc
Ambient
Temperature
Sensor
+/- 12 Vdc
5 – 45 mVdc
OpAmp
Impedance
Matching
5 – 45 mVdc
OpAmp
(AV = 100)
To Reptile Unit
Ambient Temperature
Multiplexer
0.5 – 4.5 Vdc
(AV = 100)
Surface
Temperature
Sensor
5 – 45 mVdc
Microcontroller Block
Impedance
Matching
0.5 – 4.5 Vdc
5 – 45 mVdc
To Reptile Unit
Surface Temperature
Multiplexer
Microcontroller Block
22
Ambient and Surface Temperature
Sensors Per Reptile Unit
Sean Kuter
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Standard Requirements
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IEC 6100-4-2 Electrostatic
Discharge Immunity
Operating Temperature Range
5 – 45 oC
Oper. Humidity Range
0 – 99% RH
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Performance Requirements
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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
23
Ambient And Surface Temperature
Block Summary
Analog Signals
Type
Direction
Coupling
Voltage Max
Amplitude
Impedance
Min
Max
Freq Range
Min
Max
Leakage
Max
Surface Temp. Sensor
Analog
Output
Direct
5.0V
0.09
ohm
0.11ohm
n/a
n/a
60uA
Ambient Temp. Sensor
Analog
Output
Direct
5.0V
0.09
ohm
0.11ohm
n/a
n/a
60uA
uA741 Opamps
Analog
Output
Direct
5.0V
300K
2M
n/a
n/a
60uA
Power Signals
Type
Direction
Voltage
Voltage Range
Nominal
Min
Max
Freq
% VReg
VRipple
Current
Nomina
l
Max
Max
Max
Surface Temperature Sensor
DC
Power
Input
5.0V
4.5V
5.5V
DC
10.00%
n/a
10mA
Ambient Temperature
Sensor
DC
Power
Input
5.0V
4.5V
5.5V
DC
10.00%
n/a
10mA
uA741 Opamps
DC
Power
Input
5.0V
4.5V
5.5V
DC
10.00%
n/a
3.3mA
24
Humidity Sensor/Alarm
Andrew LaPointe
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Humidity Sensing
Senses humidity
 Gives proper signal to microcontroller
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Alarm
Senses Door position (open or closed)
 Gives audible alarm for open door
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25
Andy LaPointe
Humidity sensor input and Alarm Circuit
Per Reptile Environmental Unit
Magnetic Door Switch Ckt 1
Alarm
Horn
Magnetic Door Switch Ckt 2
+5VDC
0.05 - 5VDC
Humidity Multiplexer
Microcontroller Block
Owned by:
Eric Fritz
+5VDC
+5VDC
+5VDC
Humidity
Sensor
.01-1VDC
+5VDC
Impedance
Matching
Network
.01-1VDC
Op-Amp
Av = 5
5VDC
+5VDC
Power Block
Owned by:
Shawn Bostwick
26
Humidity Sensor/Alarm Block
Standard/Safety Requirements
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Standard
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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 Block
Performance Requirements
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Performance
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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
Analog Signals
Type
Direction
Voltage
Max
Coupling
Impedance
Amplitude
Min
Max
Freq Range
Min
Leakage
Max
Max
uA741 Opamps X4
Analog
Output
Direct
5.0V
300K
2M
N/A
N/A
N/A
Analog1 Door Switch X8
Analog
Output
Direct
6V
0.1 ohm
open
N/A
N/A
N/A
Analog2 Humidity Sensor X4
Analog
Output
Direct
1.0V
200ohm
200ohm
N/A
N/A
60uA
Freq
Power Signals
Type
Direction
Voltage
Voltage Range
Nominal
Min
% V-Reg
V-Ripple
Current
Max
Max
Max
Nominal
Max
Humidity Sensor X4
DC
Power
Input
5.0V
4.5V
5.5V
DC
10.00%
n/a
10mA
Alarm Horn
DC
Power
Input
5.0V
3.0V
6.0V
DC
20.00%
n/a
60mA
uA741 Opamps X4
DC
Power
Input
5.0V
4.5V
5.5V
DC
10.00%
n/a
3.3mA
29
Outputs
Kurt Stonger

Control output signals to Fogger, Heat Mat and
Light

Relay switches
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Bang Bang control

3 light settings
30
Outputs
Kurt Stonger
Relay Coil Voltage;
Microcontroller
Component Voltage;
Power Block
24 VAC
5 VDC
24 VAC
Relay
120 VAC
5 VDC
Fogger
Relay
120 VAC
Heat Mat
5 VDC
12 VDC
Relay
Driver
Relay
6 VDC
5 VDC
12 VDC
V-Division
Relay
V-Division
Light
9 VDC
5 VDC
12 VDC
Relay
12 VDC
31
Outputs
Kurt Stonger

Standards
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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

Performance

Fogger



Heat Mat



Relay Controlled power
0 – 90% Relative Humidity
Relay Controlled power
0 – 30C Range
LEDs
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Relay Controlled power
4 stages Low 816 Lumens,
Medium 1224 Lumens, High 1632
Lumens and Off
EM Relays
 5 Vdc & 75mA @ coil
32
Output
Block Summary
Power
Signals
Type
Direction
Voltage
Nominal
Voltage Range
Min
Max
Freq
Nominal
Freq Range
Min
Max
% V-Reg
V-Ripple
Current
Max
Max
Max
Power1
Fogger
AC
Power
Input
24V
21.6V
26.4V
60Hz
57Hz
63Hz
15.00%
N/A
1A
Power2
Heat Mat
AC
Power
Input
120V
102V
132V
60Hz
57Hz
63Hz
15.00%
N/A
.111A
Power3
LED
DC
Power
Input
12V
6V
14V
0Hz
N/A
N/A
15.00%
N/A
.3A
33
Power Supply
Shawn Bostwick

Power Supply Block

Supply AC Power To:
Heating Pads
 Foggers


Supply Rectified DC Power To:
Microcontroller
 Sensors
 Alarm
 Lights

34
Shawn Bostwick
Power Supply
Power in
120Vac
Overvoltage/
Overcurrent
Protection
120Vac
Transformer
120Vac
120Vac
24Vac
Fogger Control
Circuit
Heating Pad
Control Circuit
5Vdc/7Vdc/12Vdc
Transformer
Lighting Control
Circuit
Voltage
Regulator
Circuit
Rectifiers
5Vdc
Microcontroller
Block
Alarm
Circuit
Humidity
Sensor
Ambient
Temp. Sensor
Surface
Temp. Sensor
35
Block Summary: Power
Power Signals
Type
Direction
Voltage
Freq
Current
Nominal
Nominal
Max
Power1 AC Input
AC Power
Input
120V
60Hz
7.0A
Power2 Temp. Sensor
DC Power
Output
5.0V
DC
10mA
Power3 Humdity Sensor
DC Power
Output
5.0V
DC
10mA
Power4 Processor
DC Power
Output
3.3V
DC
30mA
Power5 Fogger
AC Power
Output
29V
60Hz
1.0A
Power6 Heat Mat
AC Power
Output
120V
60Hz
0.3A
Power7 Light
DC Power
Output
12V
DC
0.3A
Power8 Alarm
DC Power
Output
5.0V
DC
10mA
Power9 LCD
DC Power
Output
24V
DC
1.0A
Power10 Door Sensor
DC Power
Output
5.0V
DC
10mA
Power11 Ambient Temp. Sensor
DC Power
Output
5.0V
DC
10mA
36
Micro Controller Block
Eric 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
37
Microcontroller
Ambient
Temperature
Sensors
Eric Fritz
4x1
MUX
Analog Input
Control
MicroController
Signal
Surface
Temperature
Sensors
Light
Logic
8-Bit
Latch
Light
Logic
D0
Signal
D0 Lights
4x1
MUX
3x8
Decoder
Control Signal
5VDC
Power
8
Control
Signal
Humidity
Sensors
Terrarium #1 12V Relay
4x1
MUX
Control
Terrarium #1 7V Relay
8
3
4x1
MUX
Terrarium #1 5V Relay
Light
Logic
D1 Heaters/Humidifiers
D2 LCD Display
3
8
8-Bit
Latch
Light
Logic
D3 Keypad Input
Terrarium #1 Heater Relay
D2 Sensor Input
Terrarium #2 Heater Relay
D5 Not used
Terrarium #3 Heater Relay
8
D6 Not used
8-Bit
Latch
Terrarium #4 Heater Relay
D7 Not Used
D4
Terrarium #1 Fogger Relay
D1
Terrarium #2 Fogger Relay
Terrarium #3 Fogger Relay
Terrarium #4 Fogger Relay
8
8-Bit
Latch
6 Button
User
Interface
8
8-Bit
Latch
8
4 x 20 LCD
Display
D3
D2
38
Micro Controller
Eric 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
39
Micro-Controller
Block Summary
Power Signals
Microcontroller +5.0VDC
Digital Signals
Type
Direction
DC Power
Input
Type
Voltage
Voltage Range
Nominal
Min
5.0V
Max
2.2V
Dir
Freq
Nominal
5.5V
DC
Output
Input
Tech
Structure
Structure
Light
Digital
Output
N/A
Standard
TTL
Keypad
Digital
Input
N/A
Standard
TTL
Fogger
Digital
Output
Open Col/Drain
Standard
TTL
LCD Display
Digital
Output
Open Col/Drain
Standard
TTL
Heat Mat
Digital
Output
Open Col/Drain
Standard
TTL
Analog Signals
Type
Direction
Coupling
Voltage Max
Amplitude
Ambient Temp Sensor
Analog
Input
Direct
1.0V
Heat Mat Temp Sensor
Analog
Input
Direct
1.0V
Humidity Sensor
Analog
Input
Direct
1.0V
40
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
41
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
42
Block Prototype Plan
Block
Name
Block
Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Eric Fritz
270
260
Perf-Board
with pads
Direct solder
or IC socket
ICs, Microcontroller
Ribbon cable, Headers,
Solid Wire Solder Conn.
Shawn
Bostwick
120
100
Perf-Board
with pads
Direct solder
or IC socket
Relays, ICs,
rectifiers
Ribbon cable, Headers,
NEC/IEC power
connectors,
Solid Wire Solder Conn
Andy
LaPointe
24
24
Perf-Board
with pads
Direct solder
or IC socket
ICs
Ribbon cable, Headers
Solid Wire Solder Conn
Kurt Stonger
24
24
Perf-Board
with pads
Direct solder
or IC socket
ICs
Ribbon cable, Headers
Solid Wire Solder Conn
Sean Kuter
24
24
Perf-Board
with pads
Direct solder
or IC socket
ICs
Ribbon cable, Headers
Solid Wire Solder Conn
43
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
44
Reliability Test Plan
Stress
24 Hour
Model
10 Year
Model
Max Input
Voltage
132 VAC
132 VAC
Number of
Power
Cycles
0
20
Thermal
Range
23-26 c
20-30 c
Number of
Thermal
Cycle
0
5
Max Shock
Grms
5
20
Number of
Shock
Cycles
0
10
Accelerated
Stress
Model
Accelerated
1 Cycle
Time
Acceleratio
n Factor
N/A
N/A
N/A
N/A
N/A
N/A
45