Senior Design Project P06201: Modified Home Entry

1. Senior Design Project P06201: Modified Home Entry Project Sponsor: National Science Foundation Team Members: Robert Karpowicz (ME) Team Leader Brian Long (ME) Chief Engineer Jeff Webb (ME) Josh Ribbeck (ME) Team Coordinator: Dr. Alan Nye Team Mentors: Dr. Margaret Bailey Dr. Elizabeth DeBartolo

2. Introduction • Client: Arc of Monroe County • Sponsor: National Science Foundations (NSF) • This material is based upon work supported by the National Science Foundation under Award No. BES-0527358 • Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation. • Goal: To create a system to open and close main doors automatically for residents with disabilities at assisted living locations. • Locations – Arc of Monroe County Assisted Living Locations • Rush, NY (priority) • Penfield, NY (if resources allow)

3. Rush Location – View from outside

4. Penfield Location – View from outside

5. Business Analysis • Primary Stakeholders – Members of the Arc of Monroe County • Complete goals of project while staying within the limits of grant ($1500) • Primary Business Goal • Design a working prototype for the Arc residents to use in their assisted living locations.

6. Background Research • Costs of current commercial systems • Price Quote from www.privatedoor.com • Costs start at $600 (door only) • Additional $600 for actuating lock system • Michigan State performed similar project • 2 doors for $10,000 • RIT cost approximately $3000 per door

9. Design Objectives • Design with off-the-shelf components • Makes assembly and integration simplistic • Minimize costs • Modularize design - “Plug and Play” • Only connections • AC power • Door mechanism • Locking mechanism • Sensors

10. Design Process for Senior Design I • Determine end-user needs with Needs Assessment • Quantify needs with specific goals • Brainstorm concepts to meet goals • Perform feasibility assessments (Pugh Chart) • Select best concept • Perform engineering analysis • Select components

11. Needs Assessment Objectives • Door open/close with only single input from user • Remote activation by specified users only • User input ignored during system operation • Preserve regular door function • Door remains open until closed or close on its own • Door stopped when object in path detected • High reliability • Easy maintenance

12. Major Design Requirements

13. 4 Concepts for Door Opening • Linear Actuator • Motor / Gear • Hydraulic Ram • Pulley System

14. Linear Actuator Design Concept Sketch • Pros: • Complete electrical control • Low resistance to manual operation • Simple integration • Low maintenance • Cons: • Long travel • Cost

15. Motor / Gear System • Pros: • Off-the-shelf components • Ease of integration • Low cost • Quiet operation • Low maintenance • Cons: • High resistance

16. Hydraulic System • Pros: • Off-the-shelf components • Simple design • Cons: • Noise • High power consumption • Cost • High maintenance

17. Pulley System • Pros: • Cost • Cons: • Integration • Complicated • Fragile operation • Complicates manual operation • Aesthetics

19. 3 Concepts for Lock Actuation • Electromagnetic actuation • Rack and pinion with motor • Electric solenoid 1 Concept for System Activation • Wireless transmitter and receiver

20. Existing Door Frame (Rush Location)

21. Lock Bypass Mechanism The door frame will be modified to allow the door to open without moving the latch. A movable piece (shown in red) will be installed to allow normal operation of the door.

22. Electromagnetic Unlocking • Pros: • Ease of maintenance • 1 Moving part • Quiet • Cheap • Cons: • Questionable effectiveness

23. Rack and Pinion with Motor Unlocking • Cons: • Moving parts • Bulky assembly • Pros: • Off-the-shelf components • Reliability

24. Solenoid Unlocking • Pros • Easy set up, and maintenance • Only 1 moving part. • Quiet • Cheap • Cons • Reliability (continuous duty)

26. Engineering Analysis and Synthesis • Motor selection • Design of door lock bypass • Use of sensors • Logic controller • Logic and wiring diagrams • Transmitter / receiver • Electrical accessories

27. Box Containing: -Motor -Receiver -Stamp -Electrical Components Electromagnets Locking Mechanism IR Sensors Electromagnetic Clutch Clutch

28. Actuation and Unlocking Systems • Parallax Logic Stamp for programming • Rolling code transmitter / receiver • Similar to garage door • Security • About 1 trillion possible codes

29. Motor Selection • Motor used • 90 VDC • 250 in-lbf max • 3.2 RPM max • DC Motor Controller • Powers motor only • Speed adjustability • Fused control protection • Surge suppression

30. Motor Verification Working Model simulation Force Hinge Motor

31. Motor Verification • Inputs • Motor speed: 3.2 RPM (19.2 º/s) • Resistance: 5 lbf • Output

32. Electromagnets Push Electromagnet • Force to overcome door seal = 8 lbf • Motor output = 6 lbf max • Electromagnets installed • One for each direction • Provides additional force Pull Electromagnet Magnetic Plate

33. ELECTROMAGNETICSLIP CLUTCH • Disconnects drive when system not in operation • Allows for low resistance to manual operation • Slip if torque exceeds 250 in-lbf torque • Protects motor from overload • Clutch slips at max motor torque

34. Link FEA Analysis Finite Element Analysis 12” Bar Linkage 1500 lbf Tensile Load Ferric Stainless Steel (25ksi Yield) Factor of Safety: 1.59

35. Motor Position • A digital encoder used to monitor door position during operation • Determines when door opened/closed • Determines when door manually stopped/moved

36. Design of the Door lock Bypass • Solenoid (1” Stroke) to clear door latch • 4 lbf lift capacity • Custom brackets machined from 303 stainless • Ease of machinability • Corrosion resistant • High strength

37. Lock bypass in the open position Lock bypass in the closed position

38. Fixed Plate FEA Analysis Surface A Finite Element Analysis Constrained by 4 Mounting Holes 1000 lbf Load Applied to Surface A Ferric Stainless Steel (25ksi Yield) Factor of Safety: 1.25

39. Object Detection • Infrared analog distance sensors • Range of 10 to 80 cm • A-D converter to change analog signal to digital • Sensor arrangement – as shown • Outside - 3 across the span of the door and 2 feet up from the floor • Inside – 2 across the span of the door and 2 feet from the floor

40. Location of sensors – Front of door Location of sensors –Back of door

42. Electrical Analysis Selected DC Power Supply (McMaster # 7009K75) **Powered by Separate Motor Controller

43. Wiring Diagram

45. Senior Design 2 Project Plan (tentative) • Order parts after Thanksgiving holiday • Plan installation and test procedure • Parts acquired before winter recess • Start test assembly in the new year • Install at Arc location in January • Troubleshoot during remainder of quarter

46. Summary • This project provides a unique opportunity to improve the quality of life for the inhabitants of the Arc of Monroe County’s assisted living locations.

47. Box Containing: -Motor -Receiver -Stamp -Electrical Components Electromagnets Locking Mechanism IR Sensors Electromagnetic Clutch Clutch Questions?