Transcript Presentation Slides

Poolside Alarm

Jay Bombien – BSEE


Darren Pallesen- BSEE


Lead Presentation Manager
Peter Brunner- BSEE


Lead Project Integrator
Louis Chatfield- BSEE


Lead Report Manager
Lead System Designer
Milja Cumbo- BSEE

Lead Manufacturing Mgr
1
Major Functions and Features

Functions:



Monitor a pool for potential hazardous situations
Loud audible alarms when a child falls in unnoticeably
Features:



Outdoor unit will display water temp, air temp, and low
battery indicator
Solar cells on poolside unit to keep outdoor battery
charged
User Control On/Off
2
Poolside Alarm
 The
device will monitor a pool for potential
hazardous situations. (i.e. child falling in)
 Indoor unit will display water temp, air
temp, and low battery indicator.
 Wireless home receiver and display unit
with loud audible signal.
 Solar cells on poolside unit to keep
outdoor battery charged.
3
Poolside Alarm
Similar Existing Product
4
Poolside Alarm
Block Assignment
Outdoor
Peter
Darren
Jay
Milja
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Louis
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
5
Standard Requirements
System Standard Requirements:
Market:
 Est. Total Market Size
 Est. Annual Vol.
 Min. List Price
$1,000,000
3,000
$250
Manufacturing:
 Min. Total Parts Count
 Max. Unique Parts Count
 Max. Parts & Materials Cost
 Max. MFG Assembly / Test Cost
160
50
$175
$50
Life Cycle:
 Est. Max. Production Lifetime
 Product Life Reliability in MTBF
 Full Warranty Period
10 years
1.99 years
30 days
6
Standard Requirements
Power Sources
Indoor:
 Source(1): 120Vac
108V to 138V
Frequency Range:
57-63Hz
AC Power Dissipation:
400 mW
Plugs: Type B (Flat blades with round grounding pin)
2.1 mm male-to-female DC Plug
 Source(2): 3AA
3.9V to 4.8V
 Battery Power:
2000 mAh
Outdoor:
 Source(1): Solar Cell
 Source(2): 8AA
 Battery Power
13.3V to 16.2V
10.8V to 12.6V
2000 mAh
Max. Total Power
20W
7
Performance Requirements
Mechanical:
 Max. Product Vol.
 Max. Shipping Container Vol.
 Max. Product Mass
 Max. # of boards
 Max. Total PCB Area
 Max. Shock Force

Indoor

Outdoor
 Max. Shock Repetitions / Year
Environmental:
 Operating Ambient Temp. Range
 Operating Ambient Humidity Range
 Operating Altitude Range
 Storage Ambient Temp. Range
 Storage Ambient Humidity Range
 Storage / Shipping Altitude Range
 Max Storage Duration
11,000
8,000
5 kg
3
425 cm2
50 G’s
10 G’s
15
5°C to 50°
0%Rh to 100%Rh
0.5 to 1.5 ATM
-20°C to 80°C
0%Rh to 100%Rh
-100m to 3000m
3 years
8
Safety Standards

UL 464 - Audible Signal Appliances


UL 1703 - Flat-Plate Photovoltaic Modules and Panels


Flat-plate photovoltaic modules used as either freestanding or attached
to buildings
PS 128-01, Provisional Specification for Pool Alarms



Electrically and electronically operated bells, buzzers, horns, and similar
audible signal appliances intended for indoor or outdoor locations.
Alarms sound at poolside and in adjacent buildings when a minimum
weight of 18 lbs hits the water.
Alarms sound at poolside and in adjacent buildings that a minimum
sound of 80dB at 100ft is possible
IEC 61558-1

Safety of power transformers, power supply units and similar devices
9
Key Risk Areas







Developing and implementing a wave sensor could
be very complicated
Not much market on workable child safety poolside
devices
Difficulty to present prototype.
Sensor Interfacing
Power Supply interfacing with step-down
transformer
Outdoor product requiring waterproofing
Needs to be near foolproof, should not go off with
falling branches, excessive wind, etc.
10
EMC Standard Summary Table
EMC Standards Summary PS/Outdoor PS/Indoor User Interface Sensors RFTrans. Alarms
IEC61000-3-3 EMC Part3
xx
xx
xx
xx
xx
xx
IEC61000-4-2 EMC Part4
xx
xx
xx
xx
xx
IEC61000-4-3 EMC Part4
xx
IEC61000-4-11 EMC Part4
xx
xx
xx
xx
IEC61000-4-6 EMC Part4
xx
US/FCC47 CFR 15
xx
US/FCC47 CFR 18
xx
CISPR 11
xx
CISPR 16
xx
CISPR 22
xx
US/FCC: 47 CFR 15 - Radio Frequency Devices
47 CFR 18 - Industrial Scientific and Medical Equipment
61000-3-3 EMC Part 3: Limits - Section 3: low-voltage supplies <16A
61000-4-2 EMC Part 4: Test/measurement techniques - Section 2: ESD immunity tests
61000-4-3 EMC Part 4: Test/measurement techniques - Section 3: Radiated radiofrequency immunity
61000-4-6 EMC Part 4: Test/measurement techniques - Section 6: Conducted radiofrequency immunity
61000-4-11 EMC Part 4: Test/measurement techniques - Section 11: Voltage dips, short interruptions
and variations
CISPR:
11 Limits and methods of measurement for Industrial, Scientific and Medical Equipment
16 Specifications for Radio Interference Measuring Apparatus and Measurement Methods
11
22 Limits and Methods of Measurements of Radio Interference of Information
Equipment
Design Plan Summary
Total Manpower
Estimated: 1750 hrs
Available: 975 hrs
Total Material Cost
Estimated: $337
Available: $350
Percentage of total manpower
System Design Tasks: 15%
Detailed Design Tasks: 35%
Verification Tasks: 15%
Documentation Tasks: 35%
12
Prototype Summary Slide
•
Total # of bds
• 8 bds – 1 for Each Block
•
Total PCB area (cm2)
• B1(40), B2(65), B3(40), B4(50), B5(50),
B6(40), B7(50), B8(90)
• Total = 425
•
Technology:
• Perfboard, PCB, Breadboard
• Soldering & Wirewrap
13
Gantt Chart
14
Outdoor Power Supply
Peter Brunner
15
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Peter
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
16
Functional Purpose

To receive Infra red rays from the sun
to charge the solar panels

To recharge the battery through a regulator
when it loses 10% of its power.

To output the required regulated voltage for
the other block power inputs
17
Performance Requirements
Electrical Interfaces:
 Signal Type: Power.
 Power Consumption: 2W
 Signal Direction: Input / Output.
 Battery Type: 8AA
 Output Voltage:
• Nominal: 3.3
Range: 3-3.6
• Nominal: 12
Range: 10.8-13.2
• Nominal: 9
Range: 8.1-9.9
 Output Current max. : 1 A

Input Voltage:
• Nominal: 15.4
 Input Current max: 120 mA
Range: 13.3 – 16.4
Safety Standard:
 UL 1703 - Flat-Plate Photovoltaic Modules and Panels
EMC Standard:
 EMC 61000-3-3: Limitation of voltage fluctuations and flicker in low-voltage
supplies <16A
18
Standard Requirements
Mechanical




Block cost
Parts count
Unique parts count
PCB Area
<$65
<15
<6
40 cm2
Environment:



Operating temperature range
Storage temperature range
Operating humidity
5 to 55 C
-20C to 65C
0 to 100%
Life Cycle



Reliability MTBF
R(1 warranty)
Disposal
Percent Allocations
237.3 years
99.7%
Throw away
26% of cost
10% of parts
9% of PCB area
19
Block Assignment
Sun
15.4V
Charging Circuit
Battery
12V
Switching Regulator
3.3V
9V
Other Blocks
20
Electrical Interfaces
Power Signals
Power1 VCC +3.3V
Power2 VCC +9V
Source1 VCC +12V
Source2 VCC +15.4V
Type
DC Power
DC Power
DC Power
DC Power
Direction
Output
Output
Output
Input
Voltage
Nominal
3.3
9
12
15.4
Voltage Range
Freq
Freq Range
Min
Max Nominal Min Max
3
8.1
10.8
13.3
3.6
9.9
12.6
16.2
DC
DC
DC
DC
0
0
0
0
N/A
N/A
N/A
N/A
% V-Reg V-Ripple Current
Max
Max
Max
10.00%
10.00%
-10%/+5%
-15%/+5%
0.1V
0.1V
0.1V
0.1V
0.5A
0.5A
0.5A
.12A
21
Parts Count Reliability
Component Description
Flexible Solar Panel
Resistors (carbon)
Caps (ceramic)
NPN Transistor
PNP Transistor
Voltage Switching Supply
NiMh Battery
Diodes
Zener Diode
Total
Qty
1
3
2
1
1
3
1
2
1
Base l
FITs
31
2.6
1.2
4
4
31
22
2.4
70
M ax R ated
T e m p C o ( T r)
90
125
125
150
150
100
125
125
200
M a x O pe r
T emp C o (T a)
43.33
40
40
40
40
40
50
40
40
M ax R ated
V o lt a ge ( V r)
M a x O pe r
V o lt a ge ( V a )
15.6 n/a
250
100
50
50
40
30
20
20
9.6
9.6
20
20
12
9.6
9.6
9.6
pT
pV
pE
pQ
2.131
1.201
1.201
1.039
1.039
1.548
1.548
1.201
0.884
1.000
0.141
0.150
0.264
0.264
0.208
0.217
0.341
0.341
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
15
l
247.6756
4.947656
1.626646
0.152
0.152
112.1367
27.66529
7.363605
79.04826
T o tal
480.77
- Total Fits = 480.77, Total MTBF (yrs) = 237.3
- R(30 day warranty) = e^(-0.8/237.3) * 100% = 99.7%
- Dominant Failure part is the Flexible Solar Panel. Not
much can be done to improve this part for higher reliability.
22
Prototype Plan
Block
Name
Outdoor
Power
Supply
Block Area
(cm2)
Total PCB
Area (cm2)
200
40
PCB
Substrate
Type
Perfboard
Comp
Attachment
Type
Solder
Socketed
Components
Switching
regulators
Types of
Connectors
6 AA
Battery Clip
23
Indoor Power Supply
Jay Bombien
24
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Jay
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
25
Indoor Power Supply
Block Description and Purpose:
 Electrical
device that will transform the
standard wall electricity (AC) to lower
voltages (DC).
 The DC voltage will power the indoor
control panel, RF transceiver, and the
alarm.
 Will charge the battery unit used as the
backup power system.
26
Indoor Power Supply
Standard Requirements

Block cost
Parts count
Unique parts count
PCB Area
Power consumption
Operating temperature range
Storage temperature range
Reliability MTBF
Operating humidity
Disposal

Percent Allocation:












Cost:
Parts:
PCB:
<$25
<18
<8
65 cm2
3W
5 to 55 C
-20C to 65C
7.8 years
0 to 100%
Throw away
10.0%
11.25%
15.29%
27
Indoor Power Supply
Performance Requirements
* Electrical Interfaces:







Signal Type:
Power
Signal Direction:
Input / Output.
Output Voltage:
Nominal: 3.3 VDC (Range: 3.0 – 3.6 VDC)
V-Ripple max. :
100 mV
Output Current max. : 1 A
Input Voltage:
Nominal: 120 VAC (Range:108 - 138 VAC)
Input Current max:
1.038 A
Safety Standard:
 IEC 61558-1: Safety of power transformers, power supply units and
similar devices EMC Standard:
EMC Standard:
 EMC 61000-3-3: Limitation of voltage fluctuations and flicker in lowvoltage supplies <16A
28
Indoor Power Supply
AC/DC
Converter Block
Battery
Charger Circuit
DC Regulator
Circuit
Converter/Charger
Switch
Alarm
Battery
DC Regulator
Circuit
Indoor MPU and Display
29
Indoor Power Supply
Signal Input/Output Summary
PowerSig
Type
Dir
Voltage
V Range
Freq Freq Range % V-Reg V-Ripple Current
Nominal Min Max Nominal Min Max
Max
Max
Max
AC Input
AC Power Input
120
108 138
60 Hz
57
63 -10%/+15%
NA
37.5mA
DC source DC Power Output
3.3V
3.0V 3.6V
DC
0
N/A
+/- 9%
100 mV
1A
DC battery DC Power Input
4.5V
3.9 V 4.8 V
DC
0
N/A
+/- 6.7%
150 mV
1A
30
Indoor Power Supply
Prototyping Plan
Block
Name
Block Area
(cm2)
Total PCB
Area
(cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Indoor
Power
Supply
90
65
Perfboard
Solder
None
2.1mm
male/female
31
Indoor Power Supply
Block Parts Count Reliability
Component
Description
NmH Battery
Capacitor
MOS Dig IC(<1000 gates)
Transformer (> 1 VA)
Diode Bridge
Total



l
Qty Base
FITs
4
6
3
1
1
22
1.2
13.3
5
2.4
Max Rated Max Oper Max Rated
Max Oper
Voltage
Temp Co
Temp Co
Voltage (Va)
(Vr)
(Tr)
(Ta)
125
125
85
125
125
65
65
70
100
100
30
100
4.8
250
250
15
5
5
3.6
132
132
pT
pV
pE
pQ
2.555
2.555
105.943
54.198
54.198
0.165
0.143
2.718
0.414
0.414
1.0
1.0
1.0
1.0
1.0
1.25
1.25
1.25
1.25
1.25
Total
l
46.45
3.28
14363.10
140.31
67.35
14620
Total FITs: 14620 Total MTBF (years): 7.8
The MOS Digital ICs are most unreliable
R = 90.25%
32
Indoor MPU and Display
Darren Pallesen
33
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Darren
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
34
Indoor MPU and Display
Block Description

Allows user to turn the unit on/off. Also allows
user to deactivate both alarms from inside.
 Receives signals from the transceiver (alarm
activated, alarm deactivated from outside,
outdoor unit power off, and low battery).
 Transfers signals to alarm (activate/deactivate).
 Sends signals to the indoor display unit for user
visibility (power on, low battery, alarm activated).
35
Indoor MPU and Display
Performance Requirements
User Indicators and Displays:
 Indicator Parameters: Power On, Outdoor Unit Power Off, Low Battery, Alarm
Activated.
 Indicator Color and Type: Amber LED, Green LED, Green LED, Red LEDs.
 Indicator Viewing Environment: Indoor Lighting, Complete Darkness.
Electrical Interfaces:
 Power Consumption: 1 W
 Signal Types: DC Power, Digital.
 Signal Directions: Input, Bi-Directional, Output.
 Input Nominal Voltage: 3.3 VDC
 Input Current Max: 24 mA
 Output Nominal Voltage: 3.3 VDC
 Output Current Max: 24 mA
Range: 3.0 VDC – 3.3 VDC
Range: 3.0 VDC – 3.3 VDC
EMC Standard:
 61000-4-2 EMC Part 4: Test/measurement techniques - Section 2: ESD immunity
tests
36
Indoor MPU and Display
Standard Requirements
Mechanical:
 Block Cost
 Parts Count
 Unique Parts Count
 PCB Area
Environmental:
 Operating temperature range
 Storage temperature range
 Operating humidity
Life Cycle:
 MTBF(years)
 R(warranty)
 Disposal
Percent Allocation:
 Block Cost
 Parts Count
 PCB Area
< $25
< 16
<5
40 cm2
5 to 55 C
-20C to 65C
0 to 100%
183.53 years
99.57%
Throw away
10% of Total
10% of Total
9% of Total
37
Indoor MPU and Display
Block Detail
Alarm Turn-Off
User
Power Supply
Power On / Off
Control
3.3V
Alarm Activated
Alarm Turn-Off
RF
Transceiver
Alarm On / Off
Low Battery
Alarm
MPU
Outdoor Unit Power Off
Alarm Turn-Off
Outdoor
Power On
Unit
Low
Alarm
Battery
Activated
Off
Digital Signals
Analog Signals
Display (LED Indicators)
38
Indoor MPU and Display
Electrical Interfaces
Power Signals
Outdoor Supply
Digital
Signals
Type
Type
Direction
DC Power
Dir
Input
Output
Input
Str.
Str.
Std
Voltage
Voltage Range
Freq
Freq Range
% V-Reg
V-Ripple
Current
Nominal
Min
Max
Nominal
Min
Max
Max
Max
Max
3.3V
3.0V
3.6V
DC
0
N/A
+/-9%
0.1V
260mA
Tech
Freq
Logic
Input Characteristics
Output Characteristics
Nom.
Voltage
Vih
Min
Iih
Max
ViL
Max
IiL
Max
Voh
Min
Ioh Max
VoL
Max
IoL Max
CMOS
2.0Mhz
3V
2.0V
5uA
0.8V
-5uA
2.4V
-24mA
0.5V
24.0mA
Sensors
from RF
Digital
Bidir
Tri
MPU to
Display
Digital
Output
Tri
CMOS
2.0Mhz
3V
N/A
N/A
N/A
N/A
2.4V
-24mA
3.0V
24.0mA
MPU to
Siren
Digital
Output
Tri
CMOS
2.0Mhz
3V
N/A
N/A
N/A
N/A
2.4V
-24mA
0.5V
24.0mA
User
Input
Digital
Input
CMOS
2.0Mhz
3V
2.0V
5uA
0.8V
-5uA
N/A
N/A
N/A
N/A
Std
39
Indoor MPU and Display
Parts Count Reliability Estimation
Component
Description
Max
Rated
Temp
Co (Tr)
Max
Oper
Temp Co
(Ta)
Max
Rated
Voltage
(Vr)
Qty
Base
l FITs
M4A3 64/32-10 JC CPLD
1
31
150
70
4.5
TTL Clock
1
13.3
70
40
Capacitor
2
1.2
125
LED
6
1
Resistor
6
10
Total
16
Max
Oper
Voltage
(Va)
pT
pV
pE
pQ
Total l
3.6
1.999
7.389
1.000
1.250
572.3298
15
3.6
3.394
0.186
1.000
1.250
10.47099
40
100
3.6
1.201
0.140
1.000
1.250
0.50614
125
25
4
2.1
0.884
0.409
1.000
1.250
2.709859
125
40
200
3.6
1.201
0.138
1.000
1.250
35.55706
Total
621.57
• MTBF(years) = 183.53
• R(30 day warranty) = e^-(0.8 / 183.53) = 0.9957 = 99.57%
• The dominant part for unreliability is the CPLD chip. Not much can be done to
improve the reliability of this part because of the amount of gates in the IC.
40
Indoor MPU and Display
Block Prototyping Plan Template
Block
Name
Block Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Component
Attachment
Type
Socketed
Components
Types of
Connectors
Indoor
MPU and
Display
75
40
PCB,
Perfboard
Solder
ICs, Lattice
Chip
2.1mm
male/female
connector
41
Wave Sensor
Jay Bombien
42
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Jay
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
43
Wave Sensor
Block Description and Purpose:
 Sensing
unit that will detect the presence
of wave motion in the pool.
 This signal will be passed through an A/D
converter and then on to the RF
transceiver.
44
Wave Sensor
Standard Requirements

Block cost
Parts count
Unique parts count
PCB Area
Power consumption
Operating temperature range
Storage temperature range
Reliability MTBF
Operating humidity
Disposal

Percent Allocation:












Cost:
Parts:
PCB:
<$20
<12
<2
30 cm2
<2.25 W
5 to 55 C
-20C to 65C
9.9 years
0 to 100%
Throw away
8.0%
7.5%
7.05%
45
Wave Sensor
Performance Requirements
* Electrical Interface:

Signal Type: Power.

Signal Direction: Input

Input Nominal Voltage: 9 VDC (Range: 8.1 – 9.9 VDC)

Input Current max: 0.5 A
* Data Interface:

Signal Type: Digital

Signal Direction: Output

Input Nominal Voltage: 1.4 VDC (Range: 0.8 – 2.0 VDC)

Input Current max: 5 uA
EMC Standard:
 61000-3-3 EMC Part 3: Limits - Section 3: Limitation of voltage
fluctuations and flicker in low-voltage supplies
<16A
 61000-4-11 EMC Part 4: Test/measurement techniques - Section 11:
Voltage dips, short interruptions and
variations
46
Wave Sensor
Outdoor
Power Supply
Oscillator Circuit
Voltage Comparator
RF
Transceiver
Wave Sensing Unit
Data Lines
Power Lines
47
Wave Sensor
Signal Input/Output Summary
Power Signals
Type
Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current
Nominal Min Max Nominal Min Max Max
Max
Max
Power2 VCC +9V DC Power Output
9
8.1
9.9
DC
0 N/A 10.00%
0.1V
0.5A
Digital Signals Type
Dir
Dir
Output
Input Tech Freq
Logic
Output Characteristics
Structure Structure
Nominal Voltage Voh Min Ioh Max VoL Max IoL Max
Wave Sensor Digital Output N/A
Standard CMOS 2.0Mhz 3.3V
2.0 V
5 uA
0.8V
5 uA
48
Wave Sensor
Prototyping Plan
Block
Name
Block Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Components
Types of
Connectors
Water
Sensor
50
30
Perfboard
Solder
None
None
49
Wave Sensor
Block Parts Count Reliability
Component
Description
Resistor
Sensor
Capacitor
MOS Dig IC(<1000 gates)
Total



Qty Base l
FITs
8
1
2
1
0.2
30
1.2
13.3
Max
Max
Rated
Oper
Temp Co Temp Co
(Tr)
(Ta)
125
125
85
85
50
65
65
70
Max
Rated
Voltage
(Vr)
250
25
220
4.8
12
Max
Oper
Voltage
(Va)
10
10
5
3.6
pT
1.548
2.555
25.390
105.943
pV
0.141
0.264
0.139
2.718
pE pQ Total l
3.0
3.0
3.0
3.0
1.0
1.0482
1.0 60.60257
1.0 25.32281
1.0 11490.48
11577
Total FITs: 11577 Total MTBF (years): 9.9
The MOS Digital ICs are most unreliable
R = 92.24%
50
Air & Water Temp Sensor
Peter Brunner
51
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Peter
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
52
Function

To measure the current pool water and outdoor
air temperature

To convert the temperature into a positive digital
voltage to be sent to the MPU with an accuracy of
±3C (max) over a range of 5C to 55C
53
Performance Requirements

Voltage

Power Consumption: <5 W

Supply = 3.3V ± 10%

Output = 3.3 V high, 0V low
• A/D converter: 8-bit.

Input = 0 – 2.048 Vac

Current

Output < 25 mA

Accuracy

±3C over full range

.195C / bit

EMC Standard:
61000-4-2 EMC Part 4: Test/measurement techniques for ESD
immunity tests
54
Standard Requirements
Mechanical

Block cost

Parts count

Unique parts count

PCB Area
Environment:



Operating temperature range
Water
Air
Storage temperature range
Operating humidity
Life Cycle

Reliability MTBF

R(1 Warranty)

Disposal
Percent Allocations
<$35
<25
<8
50 cm2
5 to 55 C
5 to 55C
-20C to 65C
0 to 100%
403.5 years
99.8%
Throw away
14% of cost
16% of parts
12% of PCB area
55
Block Assignment
3.3 V
Power Supply
Temp
Sensors
Low-Pass Filter
(Passive)
Amplifier
A/D converter
8-Bit
Data Lines
RF Transceiver
Power Lines
56
Electrical Interfaces
Power Signals
Type
Power1 VCC +3.3
Power1 VCC +5
Digital Signals
Digital Water Temp
Digital Air Temp
Analog Signals
Air Temperature
Water Temperature
Direction
DC Power Input
DC Power Input
Type
Digital
Digital
Voltage
Nominal
3.3
5
Dir
Output
Structure
Output N/A
Output N/A
Type
Analog
Analog
Input
Tech
Structure
Standard CMOS
Standard CMOS
Direction
Input
Input
Voltage Range
Min
Max
2.7
3.6
4.5
5.5
Coupling
Direct
Direct
Freq
Freq Range
Nominal
Min
Max
DC
0
N/A
DC
0
N/A
% V-Reg V-Ripple Current
Max
Max
Max
10.00% 0.1V
0.1
10.00% 0.1V
0.1
Freq
Logic
Output Characteristics
Nominal Voltage Voh Min Ioh Max VoL Max IoL Max
2.0Mhz
3.3V
2.4V
-3.2 mA
0.5V
24 mA
2.0Mhz
3.3V
2.4V
-3.2 mA
0.5V
24 mA
Voltage Max
Impedance
Amplitude
Min
Max
2.048
10
1M
2.048
10
1M
Freq Range
Min
Max
5
20
5
20
Leakage
Max
1uA
1uA
57
Parts Count Reliability
Component Description
Resistors (carbon)
Caps (ceramic)
CMOS A/D converter
Op-Amp
Diodes
Type J thermocouple
Total
Qty
5
5
2
1
1
1
Base l
FITs
2.6
1.2
113.3
13.3
2.4
0.1
M ax R ated
T e m p C o ( T r)
125
125
125
125
125
1200
M a x O pe r
T emp C o (T a)
40
50
50
65
40
150
M ax R ated
V o lt a ge ( V r)
250
50
15
22
20
24
M a x O pe r
V o lt a ge ( V a )
5.1
5.1
3.6
5
5.1
5
pT
pV
pE
pQ
1.201
1.548
1.548
2.555
1.201
0.754
0.138
0.152
0.186
0.182
0.191
0.176
3.000
3.000
3.000
3.000
3.000
3.000
1.250
1.250
1.250
1.250
1.250
1.250
15
l
8.090018
5.279825
244.0867
23.13851
2.059797
0.049757
T o tal
282.7
- Total Fits = 282.7, Total MTBF (yrs) = 403.5
-R(30 day warranty) = e^(-0.8/403.5) * 100% = 99.8%
- Dominant Failure part are the CMOS A/D converters. Not
much can be done to improve these.
58
Prototype Plan
Block
Name
Air / Water
Temp
Sensor
Block Area
(cm2)
Total PCB
Area (cm2)
100
50
PCB
Substrate
Type
Perfboard
Comp
Attachment
Type
Solder
Wire wrap
Socketed
Components
None
Types of
Connectors
None
59
Motion Sensor
Louis Chatfield
60
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Louis
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
61
Function
 This
block utilizes a passive motion IR
motions signal which is when tripped by a
person near a pool.

IR sensor detects body heat from a human
sends a signal
 The
motion sensor sends a digital signal to
the Outdoor MPU.
 Once the Outdoor MPU receives this
signal, it triggers the indoor and outdoor
alarms.
62
Performance Requirements

Power Inputs

DC Power 10 – 13 VDC

Current Draw <= 17 mA

Coverage Wide Angle

40 ft x 40 ft (12m x 12m)

Actual Beam Coverage: 40 ft x 20 ft (12m x 6m)

Electrical Interfaces

Digital input from motion sensor

Digital signal is conveyed the outdoor MPU

Safety Standards:
UL 508C – Power Conversion Equipment
UL 2017 – General Purpose Signaling Devices and Systems
IEC 61000-4-2 – Electro Static Discharge
63
Standard Requirements
Mechanical





Block cost
% Cost Allocation
Parts count
Unique parts count
PCB Area
Environment:



Operating temperature range
Storage temperature range
Operating humidity
<$30
20%
<25
<5
60 cm2
5 to 55 C
-20C to 65C
0 to 100%
Life Cycle


Reliability MTBF
Disposal
28.3 years
Throw away
64
Block Diagram
OUTDOOR
POWER
SUPPLY
REGULATOR
POWER
POWER
12 VDC
PASSIVE IR
SENSOR
9V – 16V
9V
POWER
OUTDOOR
MPU
REGULATOR
SIGNAL
RF
TRANSCEIVER
3V
SIGNAL
FILTER/
SMOOTHING
CIRCUIT
SMOOTHING: KEEPS DC VARYING TO ONLY A SMALL RIPPLE
REGULATORS: ELIMINATES RIPPLE BY SETTING DC OUTPUT TO FIXED VOLTAGE
65
Signal Input/Output Summary
PWR
Signal
Type
Direction
Nom
Vol.
Voltage Range
Min
Max
Nom
Freq
Freq Range
Min
Max
%Vreg
Max
Vripple
Max
Max
Curr.
Motion
Sensor
DC /
DIG
Output
3.3
3
DC
N/A
.05
.1 V
17
mA
3.6
N/A
66
Parts Count Reliability Estimation
Component
Description
Base l
FITs
Qt y
Resistor 10 k
1
Resistor 2 k
1
Resistor 22 k
1
220 ohm
1
Resistor Var 100 k
1
Resistor Var 50 k
2
Cap .0047 micro
2
cap .01 micro
1
cap .1 micro
1
inductor 10 micro
1
diode
1
photodiode
1
NPN Phototransistor
1
LM 555 IC
1
LM 1458 IC
1
Infrared Reflector
1
Prototype Ckt Breadboard 1
cap .01 micro (bypass of Ics)
2
Total
M ax R at ed
T emp C o
( T r)
2.6
2.6
2.6
2.6
2.6
2.6
1.2
1.2
1.2
1.2
2.4
2.4
150
10
10
2
2
1.2
125
125
125
155
125
125
100
100
100
125
150
150
150
125
150
70
90
100
M ax Oper
T emp C o
( T a)
65
65
65
100
70
70
85
85
85
65
70
70
70
70
70
50
45
85
M ax R at ed
Vo lt age
( Vr)
250
250
250
500
250
250
50
50
50
15
15
15
15
7
7
20
50
50
M ax Oper
Vo lt age
( Va)
125
125
125
250
125
125
25
25
25
5
5
5
5
4.5
4.5
16
20
25
pT
2.555
2.555
2.555
5.761
3.171
3.171
288.669
288.669
288.669
2.555
1.999
1.999
1.999
3.171
1.999
11.782
2.318
288.669
pV
0.368
0.368
0.368
0.368
0.368
0.368
0.368
0.368
0.368
0.223
0.223
0.223
0.223
0.819
0.819
7.389
0.264
0.368
pE
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
3.000
pQ
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
1.250
21
MTBF = 28.3 YEARS.
l
9.162585
9.162585
9.162585
20.66243
11.3723
22.74461
955.7597
477.8799
477.8799
2.564949
4.014084
4.014084
250.8803
97.34434
61.37028
652.9613
4.583193
955.7597
T o t al
4027.3
RELIABILITY = 97 %
MOST DOMINANT PART RELATED TO UNREALIABILITY IS THE
CAPACITORS
67
Prototyping Plan
Block
Name
Block Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Component
Attachment
Type
Socketed
Components
Types of
Connectors
Motion
Sensor (IR)
Block 6
155
60
Breadboard
/ Perfboard
Spring
Loaded
Connection/
Solder
IC socket
N/A
68
RF Transceiver
Milja Cumbo
69
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Milja
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
70
RF Transceiver
Block Purpose and Description

Block Purpose
To process and control data from sensors, power supplies, and switches
To transmit and receive data between outdoor and indoor units

Block Description
Read input digital signals from sensors into the Outside Controler
Send processed data to the Outdoor Transceiver
Control push button switch with debounce component and ESD
protection
Send processed digital signal to the Transceiver
Send/Receive wireless signal to/from the Transceiver
Send/Receive the data signal to/from the Indoor Controler
71
RF Transceiver
Product Performance
Requirements





Electrical Interfaces:
Different Signal types: Digital, DC Power Supply.
Different Signal Directions: Input, Output, Bi Directional
Input Current max: 24 mA
Output Nominal Voltage: 3.3 VDC
Output Current max: 24 mA
72
RF Transceiver
Product Safety Requirements

UL 464 - Audible Signal Appliances
 Electrically and electronically operated bells, buzzers,
horns, and similar audible signal appliances intended
for indoor or outdoor locations.
73
RF Transceiver
Product Standard Requirements










Block cost
Parts count
Unique parts count
PCB Area
Power consumption
Operating temperature range
Storage temperature range
Reliability MTBF
Operating humidity
Disposal
<$40
<20
<5
50 cm2
<5W
5 0C to 55 0C
-20 0C to 65 0C
31.36 yrs.
0 to 100 %
Discard
74
EMC Standards Summary
US/FCC:
47 CFR 15 - Radio Frequency Devices
47 CFR 18 - Industrial Scientific and Medical Equipment
61000-3-3 EMC Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker
in low-voltage supplies <16A
61000-4-2 EMC Part 4: Test/measurement techniques - Section 2: ESD immunity tests
61000-4-3 EMC Part 4: Test/measurement techniques - Section 3: Radiated
radiofrequency immunity tests
61000-4-6 EMC Part 4: Test/measurement techniques - Section 6: Conducted
Radiofrequency immunity tests
CISPR: 11 Limits and methods of measurement for Industrial, Scientific and Medical Equipment
16 Specifications for Radio Interference Measuring Apparatus and Measurement
Methods
22 Limits and Methods of Measurements of Radio Interference of Information
Technology Equipment
75
RF Transceiver Block Diagram
digital
signals Alarm Activated
digital
signals
Water Sensor
Motion Sensor
AirTemp.Sensor
Alarm
Deactivated
Outside
Controller
Low Battery
Power ON/OFF
WaterTemp Sensor
Power ON/OFF
Low Battery
Alarm
Deactivated
From Inside
Outdoor
Transceiver
Indoor
Transceiver
Outdoor
Antenna
Indoor
Antenna
76
RF Transceiver Input/Output
Digital Signals
Type
Direction
In
Water Sensor
Digital
Input
Motion Sensor
Digital
Air Temp.
Out
Tech
Freq.Nom
Logic V
Std
CMOS
2.0 MHz
3V
Input
Std
CMOS
2.0 MHz
3V
Digital
Input
Std
CMOS
2.0 MHz
3V
Water Temp.
Digital
Input
Std
CMOS
2.0 MHz
3V
Power ON/OFF
Digital
BiDir
Std
CMOS
2.0 MHz
3V
Low Battery
Digital
Input
Std
CMOS
2.0 MHz
3V
Sensors to Indoor MPU
Digital
Output
Std
CMOS
2.0 MHz
3V
Alarm Activated
Digital
Output
Std
CMOS
2.0 MHz
3V
Alarm Deactivated
Digital
Output
Std
CMOS
2.0 MHz
3V
Std
77
RF Transceiver
Input/Output contd.
Digital
Signals
Water
Sensor
Motion
Sensor
Air Temp.
Water
Temp.
Power
ON/OFF
Low
Battery
Input Characteristics
VIH
IIH
VIL
IIL
min
max
max
max
Output Characteristics
VOH
IOH
VOL
IOL
min
max
max
max
2V
5 uA
0.8 V
-5uA
2.4 V
-3.2 mA
0.5 V
24 mA
2V
5 uA
0.8 V
-5uA
2.4 V
-3.2 mA
0.5 V
24 mA
2V
5 uA
0.8 V
-5uA
2.4 V
-3.2 mA
0.5 V
24 mA
2V
5 uA
0.8 V
-5uA
2.4 V
-3.2 mA
0.5 V
24 mA
2V
5 uA
0.8 V
-5uA
2.4 V
-3.2 mA
0.5 V
24 mA
2V
5 uA
0.8 V
-5uA
2.4 V
-3.2mA
0.5 V
24 mA
78
RF Transceiver
Input/Output contd.
Voltage
Range
Frequency
Range
%VReg
VRipple
Current
Type
Dir
VNom
DC Power
Indoor
Input
3.3V
3.0 V
3.6 V
0
N/A
+/-9V
100 mV
100 mA
DC Power
Outdoor
Input
3.3V
3.0 V
3.6 V
0
N/A
+/-9V
100 mV
100mA
min
max
min
max
max
max
max
79
RF Transceiver
Parts Count Reliability
Qt
y
Bas
el
FIT
s
Max
Rated
Temp
Co (Tr)
Max
Oper
Temp
Co
(Ta)
Max
Rated
Voltag
e (Vr)
Max
Oper
Volta
ge
(Va)
Metal Film Resistor Indoor
1
0.2
105
65
250
Metal Film Resistor
Outdoor
3
0.2
105
65
10
1.2
105
M4A3 64/32-10JC CPLD
1
31
Inductor
3
MOS Dig IC < 1000 gates
Indoor
pT
pV
pE
pQ
10
4.678
0.141
1.000
1.250
0.16502349
250
10
2.555
0.223
5.000
1.250
2.13661875
65
150
10
2.555
0.223
1.000
1.250
8.546475
150
70
4.5
3.6
1.999
7.389
1.000
1.250
572.3298152
10
125
65
100
15
2.555
0.161
5.000
1.250
77.33220218
1
13.3
125
85
4.5
3.6
2.555
0.223
1.000
1.250
9.472343125
MOS Dig IC < 1000 gates
Outdoor
1
13.3
125
85
4.5
3.6
7.973
7.389
3.000
1.250
2938.245317
Switch
1
20
125
65
150
12
2.555
0.148
3.000
1.250
28.28426541
Component Description
Electrolytic Capacitor
Total
21
Total l
3636.51206
The most unreliable part is Mos Dig IC <1000 gates(2938.24). The number
of the gates cannot change.
80
RF Transceiver
Block Prototyping Plan
Block
Name
RF
transceiver
Block Area
(cm2)
80
Total PCB
Area (cm2)
50
PCB
Substrate
Type
PCB,
Perfboard
Comp
Attachment
Type
Solder
Socketed
components
ICs, Lattice
Chip
Types of
connectors
PCB
mount,
male/
female
connector
81
Alarms
Louis Chatfield
82
Poolside Alarm
Block Assignment
Outdoor
Indoor
Power Supply
Power Supply
Air / Water
Sensor
Wave
Sensor
Louis
Alarm
RF
Transceiver
Indoor MPU and Display
Motion
Sensor
Data Lines
Alarm
Power Lines
83
Functionality
 Purpose:
To sound an alarm.
 Description:


Siren/horn produces a high decibel audible
sound (at least 100 dB)
Siren/horn needs to notify the surrounding
area there is a possibility of a child jumping
into an unsupervised pool.
84
Performance Requirements

Power Inputs

DC Power 2.55 – 3.3 VDC

Current Draw <= 0.7 A

Output

Max 101 dB at 10 feet

Electrical Interfaces

Digital output is sent from Indoor MPU

Digital signal is amplified via audio amplifier, which is sent to the
siren/horn
Safety Standard:
 UL 464 - Audible Signal Appliances
 UL 1492 – Audio-Video Products and Accessories
 IEC 61000-4-2 Electro Static Discharge Immunity
85
Standard Requirements
Mechanical

Block cost

% Cost Allocation

Parts count

Unique parts count

PCB Area
<$10
~7%
<10
<3
40 cm2
Environment:

Operating temperature range

Storage temperature range

Operating humidity
5 to 55 C
-20C to 65C
0 to 100%
Life Cycle

Reliability MTBF

Disposal
75.2 years
Throw away
86
Motion Sensor Diagram
INDOOR
MPU
3.3 V DIGITAL
SIGNAL
AUDIO
AMPLIFIER
AMPLIFIED
SIGNAL
SIREN/HORN
87
Signal Input/Output Summary
PWR
Signal
Type
Direction
Nom
Vol.
Voltage Range
Min
Max
Nom
Freq
Freq Range
Min
Max
%Vreg
Max
Vripple
Max
Max
Current
Alarm
DC
Input
9
8.2
DC
N/A
.05
.25
0.5A
9.8
N/A
88
Count Reliability Estimation
Component
Description
Base l
FITs
Qty
Resistor 100 k
1
Resistor 47 ohm
1
Cap 470 micro
1
Cap .15 micro
1
Speaker 8 ohm
1
LM3909 IC
1
cap .01 micro (bypass for Ics)
1
Total
2.6
2.6
1.2
1.2
1
6.7
1.2
M ax R ated
T emp C o
( T r)
125
125
100
100
125
125
100
M a x O pe r
T emp C o
(T a)
65
65
85
85
65
70
85
M ax R ated
V o lt a ge
( V r)
250
250
50
50
5
7
50
M a x O pe r
V o lt a ge
(Va)
125
125
25
25
6
4.5
25
pT
2.555
2.555
288.669
288.669
2.555
3.171
288.669
pV
0.368
0.368
0.368
0.368
0.000
0.819
0.368
pE
3.000
3.000
3.000
3.000
3.000
3.000
3.000
7
MTBF = 75.2 YEARS.
pQ
1.250
1.250
1.250
1.250
1.250
1.250
1.250
l
9.162585
9.162585
477.8799
477.8799
0.003214
65.22071
477.8799
T o tal
1517.2
RELIABILITY = 99 %
MOST DOMINANT PART RELATED TO UNREALIABILITY IS THE
CAPACITORS
89
Prototyping Plan
Block
Name
Block Area
(cm2)
Total PCB
Area (cm2)
PCB
Substrate
Type
Comp
Attachment
Type
Socketed
Component
s
Types of
Connector
s
Alarm
165
40
Breadboard
/Perfboard
Spring Loaded
Connection/
Solder
IC Socket
N/A
90
Project Reliability Rollup
Block
Number
Block
Block
Block
Block
Block
Block
Block
Block
Block
Block
1
2
3
4
5
6
7
8
9
10
Total FITs
Block Name
Power Supply - Outdoor
Power Supply - Indoor
Indoor MPU and Display
Wave Sensor
Air & Temp Sensor
Motion Sensor
RF Transceiver
Indoor Alarm
Outdoor Alarm
l Total
Block l
Totals in
FITs
480.767
14620.495
621.574
14084.416
282.705
4027.279
3634.540
4833.421
14500.263
0.000
57085.459
MTBF (Yrs)
1.998
MTBF (Hrs)
w
F(w)
Warranty (w) Period in Years =
Failures at 1 Warranty Period =
17517.596
0.08
0.039
Failures at 1 Year =
0.394
Failures at 10 Years =
Time in Years for 1% failures =
Time in Days for 1% failures =
0.993
0.020
7.336
F (1 Yr)
F (10 Yr)
F(t) = 1%
F(t) = 1%
91
Reliability Assessment

F(w) = 0.04 = 4% failures within the warranty
period of 30 days.
 R(w) = 0.96 = 96% reliability within the warranty
period.
 To get a reliability of R(w) = 99%, we found that
we had to reduce our warranty to t = 0.02 or 7
days.
 Our group decided to stick with the 30 day
warranty so that consumers would have more
confidence in our product.
92
Reliability Summary

Most Unreliable Parts
•
•
•
•
•
•
•
•

CPLD
NPN Phototransistor
LM 555 IC
Relay
LM 3909 IC
Electrolytic Outdoor Capacitor
Mos Dig IC < 1000 Gates – Outdoor
Photovoltaic Cells
Improvements



Can research and maybe choose better qualified parts for
low reliability components
Could buy higher efficient components, but would be much
more costly.
Protect against voltage and current swings so parts do not
get close to their max ratings.
93
Reliability Growth Plan - Outside
Stress
24 Hour
Model
10 Year
Model
9.6V
9.6
0.1
100
20C – 45C
20C-45C
Number of
Thermal
Cycle
1
720
Max Shock
Grms
10
10
1
150
Max Input
Voltage
Number of
Power Cycles
Thermal
Range
Number of
Shock Cycles
Accelerated
Stress Model
Accelerated
1 Cycle Time
Acceleration
Factor
N/A
N/A
N/A
N/A
N/A
N/A
- We are probably not going to test these prototypes for these types of tests except
the input voltage cycles. We will probably test all prototypes for this. The other
requires an environmental chamber and the G-force one could be destructive. 94
Reliability Growth Plan - Outside
Stress
24 Hour
Model
10 Year
Model
Max Input
Voltage
4.8
4.8
Number of
Power
Cycles
0.1
100
15C – 30C
15C –30C
Number of
Thermal
Cycle
0.2
350
Max Shock
Grms
50
50
Number of
Shock
Cycles
0.2
300
Thermal
Range
Accelerated
Stress
Model
Accelerated
1 Cycle
Time
Acceleration
Factor
N/A
N/A
N/A
N/A
N/A
N/A
- We are probably not going to test these prototypes examples for these types of tests
except the input voltage cycles. We will probably test all prototypes for this. The other
95
requires an environmental chamber and the G-force one could be destructive.