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Capstone Presentation 2

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

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Capstone Presentation 2

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  1. Capstone Presentation 2 Team 4 October 25th, 2006

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

  3. Project Proposal – IR Sensor System for Aquatic Neurobehavioral Research • Project is designed to test the effects of positive reinforcement in a controlled habitat for fish. • Advantages of Project for Team #4: • Previous research and experience in optics • Prior microprocessor design and buildup • Knowledge of control devices

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

  5. Risks and Problem Areas • Infrared beams’ transmission through water and potential damage to specimen’s (fish) tissue (i.e. eyes). • Potential long lead time for IR transmitters (laser diodes), IR receivers, display, and stepper motors. • Possible need for placement of IR sensing block inside the fish tank • Possible prototyping issue with the fish tank and water • Potential need for LabVIEW (expensive)

  6. System Level Requirements • Standard Requirements • Power: • One AC Energy Source • Min Oper. Voltage Range:100-264V • Frequency Range: 47 – 63Hz • Max Total Power (AC): 100W • Environmental: • Min. Oper. Temp. Range: 10 - 40°C • Min. Storage Temp. Range: −10 - 60°C • Min. Oper. Humidity Range: 0 - 80%Rh • Min. Storage Humidity Range: 0 – 100%Rh • Min. Oper. Altitude Range: 0 – 2000m • Min. Storage/Shipping Altitude Range: 0 – 15000m • Max Storage Duration: 10 yrs

  7. Standard Requirements: Mechanical: Max Volume: 94390 cm3 Max Mass: 3 kg Max # of PCBs: 4 Max Total PCB Area: 645 cm2 Max Shock Force: 0.1 G Safety: Safety Standards: UL1018; CISPR11 EMC Standards: IEC-60825-1; IEC-61000-4-2; IEC-61000-4-3; IEC-61000-4-4; IEC-61000-4-5; IEC-61000-4-6; IEC-61000-4-11; IEC-61000-3-3 System Level Requirements

  8. Standard Requirements: Manufacturing: Max Total Parts Count: 250 Max Unique Parts Count: 100 Max Parts and Material Cost: $600 Max Mfg Cost: $240 Life Cycle: Estimated Production Life: 8 years Estimated Product Life / MTBF: 5 years Full Warranty Period: 0.5 yrs System Level Requirements

  9. System Level Requirements • Performance Requirements • External On/Off Switch • Operation Modes: • Power Modes: On, Off • Functional Modes: Test1, Test2 • Two Feeder Mechanisms: • Food Volume: to be determined • Optical Indicator: • One White LED • Brightness: 6000 mcds • Viewing angle: 20 degrees • RS232 Port for PC interface: • Speed: 9600 bauds • Rate: 3.68 MHz Clock

  10. System Level Requirements • Performance Requirements • User display interface: • Input: • Type: Keypad – Numeric; Min 3x3 • Controls: Start; Reset; Test Duration; Test Selection; Iteration Duration • Output: • Type: Display – LCD, Alpha-Numeric • Indicates: Test Selected, Total Time, Tot. # of Iterations • Display Reqs: Min 11 Char/Line; Min 2 Lines; Min 33 Pixels of X Res.; Min 10 Pixels of Y Res. • Product Sensitivity/Accuracy: • Min. Detectable Specimen Height: 2 cm • Time between breaking IR beams and throwing food into water ≤ 1ms • Detection Width: 6 in • IR Beams: • IR Wavelength Range: 700 – 950 nm

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

  12. Block Diagram Description

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

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

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

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

  17. High Level Project Plan

  18. Block Level Prototyping Plan

  19. Power Supply Team 4 Jon Reisner

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

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

  22. Block Requirements - Standard • AC Input: • 120V/240V • Voltage Range: 102V – 264V • Frequency Range: 47Hz – 63Hz • ±12VDC • Voltage Range: 11.88V – 12.12V • Max Current: 4.103A • 3.3VDC • Voltage Range: 3.135V – 3.465V • Max Current: 0.365mA

  23. Block Requirements - Standard • Max Parts and Materials Cost: $60 • Max Mfg Assembly/Test Cost: $36 • Max Total Parts Count: 62 • Max Total Unique Parts Count: 8 • Mechanical Reqs: • Max Volume: 18878 cm3 • Max Mass: 0.6 kg • Max Total PCB Area: 96.75 cm2 • Max Shipping Container Volume: 44245 cm3 • Max Storage Duration: 10 yrs • Environmental Reqs: • Min Oper Temp: 10 - 40 °C • Min Storage Temp: -10 – 60 °C • Min Oper Humidity: 0 – 80%Rh • Min Operating Altitude Range: 0 – 2000 m • Min Storage Altitude Range: 0 – 15000 m • Max Total Power Consumption: 40W

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

  25. Block Requirements - Performance • Operation Modes: On/Off • AC Power Input: 120V/240V • DC Power Outputs: ±12 VDC; 3.3 VDC • AC Power Frequency Tolerances: 47Hz-63Hz • Input Connector: NEMA 5-15 (15A/125V Grounded) • Safety Features: • Input Surge Protection Fuse • Over-temperature Shut Down Circuit • Reverse Voltage Protection

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

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

  28. Block Breakdown Diagram Current Protection 120V/240V AC Input Transformer Rectifier Regulator Regulator Regulator 12V 4.2A -12V 4.2A 3.3V 0.4mA

  29. Block Prototype Schematic Va

  30. Block Prototype BOM

  31. Block Prototype Netlist NetInterconnections −12Vout U2-P3, C8-P1 +12Vout U1-P3, C7-P1 +3.3Vout U3-P3, C9-P1 Va D1-P1, C2-P1, C3-P1, C4-P1, C5-P1, C6-P1, D2-P1, D3-P1, U2-P1, U1-P1 U3-P1 VAC F-P1

  32. Block Prototype Layout

  33. Block Reliability Estimation • Total λ = 2500.3 • MTBF = 45.625 yrs • Warranty of 0.5 yrs • Electrolytic Capacitors most likely to fail • λ = 120 (Base) • Could be replaced with filter package

  34. MPU w/ RS232 Port Team 4 Chad Due

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

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

  37. Block Requirements - Standard • Max Parts & Material Cost: $30 • Max Mfg Cost: $24 • Max Total Parts Count: 13 • Max Unique Parts Count: 8 • Mechanical: • Max Volume: 4719.5 cm3 • Max Mass: 0.15 kg • Max PCB Area: 193.5 cm2

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

  39. Block Requirements - Performance • Operational Modes: Start, Reset, P1,P2 • Speed: 9600 Baud • Rate: 3.68 Mhz Clock • Optical Indicators: • One White LED • 6000 mcd • 20 degree • Mechanical Interfaces: DB9 Connector

  40. Power Signals Inputs: Block Signal I/O Summary Vcc 12VDC Range: 11.88V – 12.12V Vripple = 0.01V Imax = 300mA Vcc 3.3VDC Range: 3.135V – 3.465V Vripple = 0.1V Imax = 0.2mA

  41. Block Signal I/O Summary • Digital Input Interface 1,2,4: VIH = 2v(min), VIL = 0.5v(max) (User Controls, IR sensors, IIH = 5uA(max), IIL = -5uA(max) RS232) • Digital Output Interface 6: VOH = 2.4v(min), VOL = 0.8v(max) (Feeders) IOH = -50uA(max), IOL = 50uA(max) • Digital Output Interface 5: VOH = 2.4v(min), VOL = 0.8v(max) (Display) IOH = -.1mA(max), IOL = .1mA(max) • Digital Output Interface 2: VOH = 2.4v(min), VOL = 0.8v(max) (IR On/Off) IOH = -25uA(max), IOL = 25uA(max) • Digital Output Interface 7: VOH = 2.4v(min), VOL = 0.8v(max) (LED Indicator) IOH = -100uA(max), IOL = 100uA(max)

  42. Block Breakdown Diagram LED Indicator DISPLAY/CTRLS 7 1 FEEDER CONTROL 1 4 MAX232 DB9 MPU 6 FEEDER CONTROL 2 2 2 IR TRANSMITTER IR RECIEVER

  43. Block Prototype Schematic

  44. Block Prototype BOM

  45. Block Prototype Netlist NetInterconnections +3.3 V D1-P1 U2-P12 U2-P35 U1-P16 GND U2-P13 U2-P34 C1-P1 C2-P1 C6-P2 U1-P15 J1-P5

  46. Block Prototype Layout

  47. Block Reliability Estimation • Total λ : 223.361 • MTBF: 510.730 yrs. • Warranty of 0.5 yrs • Failure @ 1 period: 0.1 percent • Failure @ 10 yrs.: 1.9 percent

  48. IR Sensors Team 4 Aleks Plavsic

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

  50. Block Description and Purpose • Description: • 2 columns of IR LEDs matched with 2 columns of IR Photosensors – 2 IR beam curtains • Purpose: • Need to detect when a fish specimen crosses from one side of a fish tank to the other – when beam is broken • Need to sense the direction of specimen’s motion

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