1 IR Sensor System for Aquatic Neurobehavioral Research – Presentation 2Team 4 October 25th, 2006

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

3 Project Proposal This product will be designed to test the effects of positive reinforcement in a controlled habitat for fish Automated experiments and data collection Test different health concerns in fish 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 Institute, Milwaukee, WI Product could be modified to assist similar water & marine studies

4 Risks and Problem AreasInfrared 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) Advantages of Project for Team #4: Previous research and experience in optics Prior microprocessor design and buildup Knowledge of control devices

5 US Patents US 6,627,892 - Infrared detector packaged with improved antireflection element; September 30, 2003 US 6,082,299 - Automatic fish feeder; July 4, 2000 US 6,433,684 - Device for detecting and signaling or indicating status as regards contents in a container, and in particular a letterbox; August 13, 2002

6 Estimation-Reconciliation SummaryTotal 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 %

7 System Level RequirementsStandard Requirements Power One AC Energy Source Min Oper. Voltage Range: V Frequency Range: 47-63Hz Max Total Power (AC): 84W 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 – 2000 m Min. Storage/Shipping Altitude Range: m Max Storage Duration: 10 yrs.

8 System Level RequirementsStandard Requirements Mechanical: Max Volume: cm3 Max Mass: 3 kg Max # of PCB’s: 4 Max Total PCB Area: 645 cm2 Max Shock Force: 0.1 G Std. AC plug connector Manufacturing: Max Total Parts Count: 500 Max Unique Parts Count: 100 Max Parts and Material Costs: $600 Max Mfg Cost: $240 Life Cycle: Estimated Production Life: 8 years Estimated Product Life/MTBF: 5 years Full Warranty Period: 0.5 years

9 System Level RequirementsStandard Requirements Safety Safety Standards Electric Aquarium Equipment (UL1018) RF Emissions (CLSPR11) EMC Standards Guidance on Laser Products (IEC-60825) ESD Immunity (IEC ) E Field Immunity (IEC ) EFT (IEC ) Power Input Surge Immunity (IEC ) RF Conducted Immunity (IEC ) Voltage Dip (IEC ) Voltage Fluctuate (IEC )

10 System Level RequirementsPerformance Requirements External on/off switch Operation Modes: Power Modes: On, Off Function Modes: Test 1, Test 2 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 9 pin Serial Connector

11 System Level RequirementsPerformance Requirements User display interface: Inputs: 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 Req’s: 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 <= 1 ms Detection width: 6 in. IR Beams: IR Wavelength Range: 700 – 1000 nm

12 Safety Devices AC Line Input FusesDescription: 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.

13 Standard Limits and Guidelines SummaryCISPR 11: RF Emissions Power Supply Conducted Radiated IEC : ESD Power Supply, MPU w/ RS232, User Inputs/Display ESD Air: 15 kV ESD Contact: 8 kV ESD Coupling Planes: 8 kV IEC : E Field Immunity Power Supply, MPU w/ RS232, User Inputs/Display, IR Sensors, Feeders MHz AM 80% 1 kHZ IEC : EFT Power Supply, User Inputs/Display, Feeders To plug connection supply: 4 kV

14 Standards Limits and Guidelines SummaryIED : Power Input Surge Immunity Power Supply Common Mode: 3 kV Differential Mode: 5 kV IEC : Voltage Fluctuate IEC : RF Conducted Immunity Power Supply, MPU w/ RS232, User Inputs/Display, IR Sensors, Feeders Mhz AM 1 kHz IEC : Voltage Dip 0.5 0% Vnom 5.0 10% Vnom 25 70% Vnom 5 0% Vnom

15 IR Sensor System for Aquatic Neurobehavioral ResearchUser Interface User Ctrls 8 bit Display Data MPU w/ RS232 Port IR Rx Feeders Feeder Ctrl IR Sensors 2 bit IR Tx On/Off Indicator Light 2 bit Block Allocation Aleks P. Jeff M. Chad D. Jon R. John S. Power Supply PC

16 Block Diagram DescriptionBlock Name Owner Brief Description Of Block Function Power Interface Digital Interfaces Analog 1 Power Supply J. Reisner Converts Commercial AC Power both 120 and 240VAC to 12VDC, and 3VDC In: AC Out: 12VDC, 3VDC None 2 Microprocessor w/ RS232 Port C. Due Senses User I/F Switches for command inputs and updates display periodically In: 12VDC, 3VDC In: User Ctrls; IR Rx Out: Display Data; Addr. Decoder; Feeder Ctrl; IR Tx On/Off 3 User Interface J. Mueller Provides user inputs for selection, duration of experiments. Provides user output display for current experiment selection elapsed time, current iteration, total # of iterations In: 3VDC, 12VDC In: Display Data Out: User Ctrls 4 IR Sensors A. Plavsic Detect the direction of motion of fish specimen Out: IR Rx In: IR Tx On/Off 5 Feeders J. Schwittay Drive and control operation of fish tank feeders In: Feeder Ctrl

17 High Level Project Plan

18 Block Level Prototyping PlanName Block Area (cm2) Located on Board # (1, 2, .. etc) Board Substrate Type Comp Attachment Board Dimensions (cm x cm) Types of Connectors Power Supply 200 1 PCB Solder less Thru hole 15X10 Wire Leads MPU w/RS232 100 2 8X8 Ribbon Cable,Wire Leads Feeders & Control 300 5X5 IR Sensors 250 3,4 Soldered Thru hole 15X15 Display & User Inputs 175 5 Vectorboard 10X10 Ribbon Cable, Wire Leads

19 Power Supply Team 4 Jon Reisner

20 Power Supply Aleks P. Jeff M. Chad D. Jon R. John S. User InterfaceUser Ctrls Display Data MPU w/ RS232 Port IR Rx 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 PC

21 Block Description and PurposeTakes 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 - StandardAC Input: 120V/240V Voltage Range: 102V – 264V Frequency Range: 47Hz – 63Hz ±12VDC Voltage Range: V – 12.12V Max Current: 4.2A 3.3VDC Voltage Range: V – 3.465V Max Current: 0.4mA Max Total Power Consumption: 40W

23 Block Requirements - StandardMax Parts and Materials Cost: $60 (10%) Max Mfg Assembly/Test Cost: $36 (15%) Max Total Parts Count: 125 (25%) Max Total Unique Parts Count: 15 (15%) Mechanical Reqs: Max Volume: cm3 (20%) Max Mass: 0.6 kg (20%) Max Total PCB Area: cm2 (15%) Max Shipping Container Volume: cm3 (20%) Max Storage Duration: 10 yrs Environmental Reqs: Min Oper Temp: °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 – m

24 Block Requirements - StandardSafety Standards: UL 1018: Electric Aquarium Equipment CISPR 11: RF Emissions EMC Standards: IEC : ESD IEC : E Field Immunity IEC : EFT IED : Power Input Surge Immunity IEC : Voltage Fluctuate IEC : RF Conducted Immunity IEC : Voltage Dip

25 Block Requirements - PerformanceOperation Modes: On/Off Safety Features: Input Surge Protection Fuse Over-temperature Shut Down Circuit Reverse Voltage Protection

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

27 Block Signal I/O SummaryPower Signals Outputs: 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 DiagramCurrent Protection 120V/240V AC Input Transformer Rectifier Regulator Regulator Regulator 12V -12V 3.3V

29 Block Prototype Schematic

30 Block Theory of OperationTakes in AC Voltage Via Power Cord Fuse: Acts as Over Current Protection Transformer: Steps Down Input Voltage to a more Manageable Voltage Bridge Rectifier: Changes the Voltage from Ac to DC for use by Voltage regulators Capacitors C-C4: Reduce Voltage Ripple Left by rectifier Capacitors C5-C8: Protect circuit from high frequency response brought on by the AC to DC Rectification Voltage Regulators: Each regulator is chosen to match the required voltage needed by the product. (±12V,3.3V) Diode D2: Reverse Voltage Protection

31 Detailed Design Selected Transformer: Selected Fuse: Selected Diode:115V/230V at 50/60Hz Series Connection 0.75mA Selected Fuse: 125V, 1.5A Over Current Protection Selected Diode: Fast SWT, 75V Reverse Voltage Protection

32 Detailed Design Voltage Regulator Output Voltage: +12VDC +3.3VDCVout(max) = 12.24V Vout(max) = 3.432V Vout(min) = 11.76V Vout(min) = 3.168V −12VDC Vout(max) = V Vout(min) = V

33 Detailed Design Capacitance Calculations: Vripple ≤ 2V IL = 0.75Af = 60 Hz Vripple = IL / 2fC → C = 0.75 / (2)(60)(2) C = 3125uF By choosing 4700uF at ±20% we achieve the needed capacitance.

34 Block Prototype BOM Device Number Mfg Part Description Qty Package U1LM2591HVT-3.3 3.3V Switching Voltage Regulator 1 TO-220 U2 LM 12V Switching Voltage Regulator 2 U3 U4 LM320T-12 -12V Switching Voltage Regulator F UR 125V, 1.5A Over-Current Protection Fuse SMT T DST-7-48 Step-down Transformer TH D1 DB102 Rectifier Diode Bridge DB-1 D2 1N4148 T/R Reverse Voltage Protection Diode DO-35 C EKMH500VSN472MR30T 4700uF, 45V,±20%, electrolytic capacitors Radial (snap-in) C1,2,3,4 T491B105K035AS 1uF, 35V, ±10%, tantalum capacitors 4 C5,6,7,8 EMVH350ADA100MF60G 10uF, 35V, ±20%, alum. electrolytic capacitors AC Power Cord 6’6”, 220V, 18AWG N/A

35 Block Production BOM Device Number Mfg Part Description Qty Package U1LM2591HVT-3.3 3.3V Switching Voltage Regulator 1 TO-220 U2 LM 12V Switching Voltage Regulator 2 U3 U4 LM320T-12 -12V Switching Voltage Regulator F UR 125V, 1.5A Over-Current Protection Fuse SMT T DST-7-48 Step-down Transformer TH D1 DB102 Rectifier Diode Bridge DB-1 D2 1N4148 T/R Reverse Voltage Protection Diode DO-35 C EKMH500VSN472MR30T 4700uF, 45V,±20%, electrolytic capacitors Radial (snap-in) C1,2,3,4 T491B105K035AS 1uF, 35V, ±10%, tantalum capacitors 4 C5,6,7,8 EMVH350ADA100MF60G 10uF, 35V, ±20%, alum. electrolytic capacitors AC Power Cord 6’6”, 220V, 18AWG N/A

36 Block Prototype NetlistNet Interconnections −12Vout U4-P3, C8-P1, D2-P2 +12Vout(1) U2-P3, C6-P1 +12Vout(2) U3-P3, C7-P1 +3.3Vout U1-P3, C5-P1 Va D1-P1, C-P1, C1-P1, C2-P1, C3-P1, C6-P1, U2-P1, U1-P1, U3-P1 Vb D1-P3, C-P2, C4-P1, D2-P1, U4-P1 VAC F-P1

37 Block Prototype Layout2.525” 1.6”

38 Block Reliability EstimationComponent Description Qty Base λ Total λ IC Voltage Regulator (3.3V) 1 50 IC Voltage Regulator (12V) 2 IC Voltage Regulator (-12V) Transformer 5 Diode Bridge Rectifier 4.8 Electrolytic Capacitor 6 120 Tantalum Capacitor 4 10 Diode Fuse 70 AC Power Cord 105

39 Block Reliability EstimationTotal λ = MTBF = yrs Warranty of 0.5 yrs Electrolytic Capacitors most likely to fail λ = 120 (Base) Could be replaced with filter package

40 Block Verification PlanUsing Detailed Design: Simulate and verify results in Spice Construct Prototype Verify results in the lab Modify if needed

41 MPU w/ RS232 Port Team 4 Chad Due

42 MPU w/ RS 232 Aleks P. Jeff M. Chad D. Jon R. John S. User Interface3 bits 8 bit data line 2 bit high/low 2 bit Feeder selection MPU w/ RS232 Port Feeders IR Sensors interrupt Bidirectional data line Indicator Light Block Allocation Aleks P. Jeff M. Chad D. Jon R. John S. Power Supply PC

43 Block Description and PurposeTo 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

44 Block Requirements - StandardMax Parts & Material Cost: $30 Max Mfg Cost: $24 Max Total Parts Count: 25 Max Unique Parts Count: 15 Mechanical: Max Volume: cm3 Max Mass: 0.15 kg Max PCB Area: cm2

45 Block Requirements - StandardEnvironmental: Min Oper Temp Range: C Min Oper Humidity Range: %Rh Min Oper Altitude Range: 0 – 2000 m Min Storage Temp Range: −10-60 C Min Storage Humidity Range: % Rh Min Storage Altitude Range: m Safety and EMC Standards: Electric Aquarium Equipment (UL1018) ESD Immunity (IEC ) Life Cycle Minimum MTBF: 0.5 yrs

46 Block Requirements - PerformanceOperational Modes: Start, Reset, P1,P2 Speed: 9600 Baud Rate: 8 MHz Clock Optical Indicators: One White LED 6000 mcd 20 degree Mechanical Interfaces: DB9 Connector

47 Block Signal I/O SummaryPower Signals Inputs: Vcc 12VDC Vcc 3.3VDC Range: 11.88V – 12.12V Range: 3.135V – 3.465V Vripple = 0.01V Vripple = 0.1V Imax = 300mA Imax = 0.2mA Digital Inputs: VIH = 2v(min), VIL = 0.5v(max) IIH = 5uA(max), IIL = -5uA(max) Digital Outputs: VOH = 2.4v(min), VOL = 0.8v(max) IOH = -.1mA(max), IOL = .1mA(max)

48 Block Breakdown Diagram1 – 8 Bit Data Line (Display) 2 - 3 bits to receive/send data to user CTRLs 3 – 2 bit Bi-directional Pc Interface data line 4 – 2 bit signal denoting both direction and IR Sensor break 5 – Interrupt on/off for IR Sensors 6 – Enable signal to Feeder 1 or Feeder 2 7 – Enable LED LED Indicator DISPLAY/CTRLS 7 1 2 FEEDER CONTROL 1 MAX232 DB9 MPU 3 6 FEEDER CONTROL 2 5 4 IR TRANSMITTER IR RECIEVER

49 Block Prototype Schematic

50 Block Theory of Operation1 – PIC will enable IR Sensors, Get info from User Ctlrs telling program info, display all indicated info, start experiment 2 – When time delay timer gets to zero turn on LED, enable proper feeder, monitor IR senor pins, send data to PC when needed 3 – reset timer and continue experiment, monitor IR sensors, turn off LED, wait for next delay timer zeroing, repeat steps until program sequence ends

51 Detailed Design R1 – R2: thick film chip resistorsNominal Value: 10 KΩ % Tolerance: 1 % C1 – C5: electrolytic caps Nominal Value: 0.1 uF % Tolerance: 20 %

52 Detailed Design PIC processor: PIC18F4420 Clock Speed:Internal Oscillator w/ RS232 compatibility Enhanced USART module for RS232 operation 36 I/O, 16 K flash, C++ compatible Clock Speed: 8 MHz with capability up to 32 MHz for higher serial baud rates

53 Detailed Design Equations of Baud Rate ErrorN = [(Fosc/Desired Baud Rate)/64] – 1 Calculated Baud Rate = Fosc / [64(N+1)] Error(%) = (Calculated – Desired) / Desired Baud Rate Desired Baud Rate of Fosc of 8 MHz N = 12 Calculated Baud Rate = Error(%) = .16 %

54 Block Prototype BOM Device Number Mfg Part Description Qty PackageC1-C5 .1 uF, Ceramic Capacitor 1 Axial 2 D1 White, 100mW, 6000mcd J1 DB9 Serial Connector OC1 ECS X 4 Mhz oscillator P1-10 10 pin connector U1 MAX232ACPE Serial interface DIP16 U2 PIC18F4420-IP-ND Microcontroller DIP44 R1 10K, 1%, ¼ W Film Res. Axial2

55 10 pin right angle connectorBlock Production BOM Device Number Mfg Part Description Qty Package C1-C5 UWX1H0R1MCL2GB Electrolytic, 0.1 uF, 20 % Tol. 5 SMT D1 LTW-102C4 White LED, 3.5 V, 6000 mcd 1 R1-R2 ERJ-14NF10R0U 10 k, 1% Tol., ¼ W, chip resistor J1 1008-9S DB9 serial connector J2 10 pin right angle connector U1 MAX3232ECPE Serial driver, DIP 16 U2 PIC18F4420-IP-ND Microcontroller

56 Block Prototype NetlistNet Interconnections +3.3 V D1-P1 U2-P11 U2-P32 U1-P16 C4-P2 GND U2-P12 U2-P31 C1-P2 C2-P2 C6-P1 U1-P15 J1-P5

57 Block Prototype Layout3 in. X 2.5 in.

58 Block Production Schematic

59 Block Production NetlistNet Interconnections +3.3 V D1-P1 U1-P16 C1-P1 C4-P2 GND U2-P12 U2-P31 U1-P15 J1-P5 C5-P1

60 Block Reliability EstimationTotal λ : MTBF: yrs. Warranty of 0.5 yrs 1 period: 10 yrs.: Part QTY Model E -λ Total λ PIC18F4420 1 13.3 MAX3232 White LED 1.0 Electrolytic Cap 5 120 600 Resistor 2 0.2 0.4 DB9 Connector 35.0 8 pin Connector Wire Connections 8 280.0 Total Fits 977.8

61 Block Verification PlanCheck for proper delay time of feeder to LED turn on Verify that both program sequences are operating properly Test for serial port errors

62 IR Sensors Team 4 Aleks Plavsic

63 IR Sensors Aleks P. Jeff M. Chad D. Jon R. John S. User Interface MPUUser Ctrls Display Data MPU w/ RS232 Port IR Rx 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 PC

64 Block Description and PurposeGenerates 2 vertical and parallel “curtains” of Infrared beams that cover the width and height of fish tank 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

65 Block Requirements - StandardMax Parts & Material Cost: $150 (25%) Max Mfg Cost: $72 (30%) Max Total Parts Count: 150 (30%) Max Unique Parts Count: 20 (20%) Mechanical Reqs: Max Volume: cm2 (25%) Max Mass: 0.75 kg (25%) Max PCB Area: cm2 (15%) Max # of PCBs: 2 Max Shock Force: 0.1 G Max Shock Repetitions: 1

66 Block Requirements - StandardEnvironmental Reqs: Min Oper Temp Range: °C Min Storage Temp Range: − °C Min Oper Humidity Range: 0 – 80 %Rh Min Storage humidity Range: 0 – 100 %Rh Min Oper Altitude Range: 0 – 2000 m Min Storage/Shipping Altitude Range: 0 – m Max Storage Duration: 10 yrs Safety and EMC Standards: UL1018: Electric Aquarium Equipment IEC : Guidance on Laser Products IEC : E Field Immunity IEC : RF Conducted Immunity Life Cycle: Est. Max Production Lifetime: 8yrs

67 Block Requirements - PerformanceIR Wavelength Range: 700 – 1000 nm IR Signals Output Min. Power = 10 mW/sr IR Signals Input Min. Power = 5 μW Sensitivity: Min. Detectable Specimen Height: 2 cm Min. Detectable Specimen Length: 2 cm Effectiveness: Min. Time for Correct Detection: 1 ms Beams’ Coverage Width: 6 in = cm Beams’ Coverage Height: 6 in = cm

68 Block Requirements - PerformanceMechanical Reqs: LEDs and Phototransistors need to be fixed by appropriate plastic holder Holder’s Max. Dimensions: x 4 x 10 cm (H x W x D) Transmitter Connector: Wire; Max. Current 100 mA Receiver Connector: Min. 2 pins; Max. 4 pins; Max. Current 50 mA Operational Modes: Power Modes: On/Off Functional Modes: Test1, Test2 Functional Features: Start, Reset Safety: Over Current Protection for LEDs

69 Block Signal I/O SummaryPower Signals Inputs: Vcc ±12VDC Range: 11.88V – 12.12V (± 1%) Vripple = 0.01V Imax = 800mA Connector - Cable Vcc 3.3VDC Range: 3.135V – 3.465V (± 5%) Vripple = 0.1V Imax = 60µA Connector - Cable

70 Block Signal I/O SummaryDigital Signals Input: Output: IR Tx On/Off Standard Input CMOS f = 1 kHz V = 3.3V Vth min = 0.5V Vth max = 2V Wire IR Rx Open Collector CMOS f = 0.5 MHz Voh min = 2.4V Ioh max = 20 µA Vol max = 0.8V Iol max = −20 µA Connector - Cable

71 Block Breakdown DiagramIR Tx On/Off 2 x 12 2 x 12 LEDs PhotoSensors Summing Op-Amps Drivers IR BEAMS Logic Comparators IR Rx 2 bits Vcc ±12 VDC Vcc 3.3 VDC

72 Block Prototype SchematicTX RX

73 Block Theory of OperationTransmitter: IR LEDs in series driven by a single MOSFET (single column) Potentiometer in series with LEDs to control current flowing through LEDs Receiver: Phototransistors have pull-up resistors connected to collectors All Phototransistor outputs (single column) are summed up by Summing Amplifier with gain of 0.5 Inputs to Summing Amp are buffered in order to provide high input impedance Output of Summing Amp is compared with predefined voltage level in Comparator Output of D flip-flop provides specimen motion direction info Output of NOR gate provides specimen crossing info

74 Detailed Design MOSFET driver biasing:From spec sheet for chosen n-channel FET: Vth = 1.3V Max. Drain Voltage: VD = 12 – (1.7 x 11) = − 6.7 V Max. VDS = − 6.7 − (− 12) = 5.3 V

75 Block Prototype BOM Device Number Mfg Part Description Qty PackageOpamp 8 U5 Comparator 2 DIP-8 U6 CD4013 D Flip-Flop 1 DIP-14 U7 74LS02 NOR gate R1 10%, 1/2 W, Potentiometer R2-10 5%, 1/8 W, Ceramic Resistor 18 C1-10 20% Ceramic Capacitor D1-11 IR Led 22 T1 Q1 MOSFET PT1,2,3 Phototransistor 3

76 Block Production BOM Device Number Mfg Part Description Qty PackageLT1128 Opamp 24 SOIC U5 MC3302P Comparator 2 TSSOP U6 CD4013 D Flip-Flop 1 U7 74LS02 NOR gate R1 10%, 1/2 W, Cermet Potentiometer R2-10 1%, 1/8 W, Metal Film Resistor 50 Chip C1-10 5%, 30V, Ceramic Capacitor 22 D1-11 IR Led T1 Q1 FDS4072N3 MOSFET 4 PT1,2,3 Phototransistor P1 4 pin Connector

77 Block Prototype NetlistNet Interconnections +3.3V U6-P14 U7-P14 R2-P1 R3-P1 R4-P1 +12V D1-P1 U1-P4 U2-P4 U3-P4 U4-P4 U5-P4 −12V Q1-P3 U1-P8 U2-P8 U3-P8 U4-P8 U5-P8 Gnd U6-P7 U7-P7 R1-P3 R10-P2 C8-P2 PT1-P2 PT2-P2 PT3-P2 C1-P2 C2-P2 IR Rx U6-P1 U7-P1

78 Block Prototype Layout3.8 in 2.5 in

79 Block Reliability EstimationComponent Description Qty Base λ FITs Total λ IR LEDS 22 1 41.29 Phototransistor 4 118.35 Metal Film Resistor 50 0.2 4.50 Ceramic Capacitor 1.2 22.22 MOSFET 10.54 Op Amp 24 NOR Gate 13.3 9.60 D Flip-Flop Comparator 2 194.67 Potentiometer 0.47 Connector 20 39.61

80 Block Reliability EstimationTotal λ = MTBF = yrs Warranty of 0.5 yrs Failures at 1 warranty period = 0.011 Components most likely to fail: Op Amp – λ = Comparator – λ = Improvements: Use dual or quad ICs packages

81 Block Verification PlanCheck IR LEDs current and its change as potentiometer resistance is changed Current Meter / Multimeter Check output voltage of every phototransistor and summing amplifier Voltage Meter / Multimeter Check outputs of comparators, D flip-flop, and NOR gate Oscilloscope

82 User Interface & DisplayTeam 4 Jeff Mueller

83 User Display & InterfaceUser Interface User Ctrls Display Data MPU w/ RS232 Port IR Rx 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 PC

84 Block Description and PurposeUser interface and display to allow control of system remotely from apparatus Purpose: LCD Screen will display: Program Selection Time Remaining Iterations of experiment Keypad will allow users to remotely select program selection, time, and iterations

85 Block Requirements - StandardMax Parts & Material Cost: $180 Max Mfg Cost: $36 Max Total Parts Count: 75 Max Unique Parts Count: 15 Mechanical: Max Volume: cm3 Max Mass: 300 g Max PCB Area: 35 cm2 Max Shock Force: 0.1 G Interface: LCD Ribbon Cable, PCB traced to MPU

86 Block Requirements - StandardEnvironmental: Min Oper Temp Range: C Min Oper Humidity Range: %Rh Min Oper Altitude Range: 0 – 2000 m Min Storage Temp Range: −10-60 C Min Storage Humidity Range: % Rh Min Storage Altitude Range: m Safety and EMC Standards: UL1018; CISPR11; IEC ; IEC-61000 Life Cycle Minimum MTBF: 0.5 yrs

87 Block Requirements - PerformanceUser Inputs Input controls: Start, Reset, Test Duration, Test Selection, Iteration Duration Operation Modes: LCD On/Off, Backlight On/Off Input Type: Keypad Type: Alpha-numeric Minimum size: 3x3 Max view dist: 1m Viewing environment: Bright light, Indoors Max Debounce time: 20ms

88 Block Requirements - PerformanceUser Indicators and Displays Indicator parameters: Display test type, total time, total # of iterations Type: Alpha-numeric Max perception distance: 2m Viewing environment: Bright light, indoors Indicator technology: LCD Indicator min char/line: 11 Indicator line count: 2 Display min viewing width: 5 cm Display min viewing height: 2 cm Display min X-resolution: 33 pixels Display min Y-resolution: 10 pixels

89 Block Signal I/O SummaryPower Signal 1 Vcc = +/-12 V Type: DC power Direction: Output Interconnect: Cable Vnom: 12V Vmin: V Vmax: V Nom Freq: DC %V-Reg Max: 1.0% V-Ripple Max: 0.01V Max Current: 3mA Power Signal 2 Vcc = V Type: DC power Direction: Input Interconnect: Cable Vnom: 3.3V Vmin: V Vmax: V Nom Freq: DC %V-Reg Max: 5% V-Ripple Max: 0.1V Max Current: 55uA

90 Block Breakdown DiagramLCD Screen Keypad Segment Signal and Common Signal Segment Driver Timing Signal and Serial Data DB0-DB7 RS R/W E LCD Driver/Controller 8-Bit CMOS Microcontroller D0/D7 D0/D7 MPU PIC Micro Programmer D0/D7 Vcc 3.3V

91 Detailed Design: LCD LCD Screen10uF capacitor added between power supply terminals to eliminate noise 10K resistor for backlight P = 5mW V = 5V Rpot = V(V)/P = (5V)(5V) / 5mW Rpot = 5K

92 Detailed Design: LCD

93 Detailed Design: ProcessorPIC Processor Selection Compatible with HD44780 LCD interface Compatible with Keypad Decoder Low Power Consumption Improved FIT over other PIC processors Features: Watchdog Timer Low voltage in-circuit programming Offers wide operating voltage range (2.0 – 5.0 V) Package: PDIP

94 Detailed Design: Processor

95 Detailed Design: Keypad EncoderUtilizes CMOS key encoders Offers key bounce elimination with only a single capacitor Low Power consumption Compatible with PIC processor Supports up to a 4x4 keypad Package: DIP Debounce Theory: CKBM = 0.1uF such that Debounce Period is minimized

96 Detailed Design: Keypad Encoder

97 Block Prototype Schematic

98 Block Theory of OperationUser inputs selections via keypad Keypad encoder implements logic necessary through SPST key switch matrix Encoder will output a high pulse on the data available pin whenever a key is pressed Encoder outputs 4 bits of data to the PIC (Based on which key is pressed) Code in PIC decodes signal and registers key selection. Key selection are interpreted through PIC and displayed on LCD screen. Data received from RS232 (Via Main Processor) is output to LCD screen.

99 Block Prototype BOM Device Number Mfg Part Description Qty Package N/ALM018L LCD Display Module 1 DIP U1 HD44780 LCD Controller/Driver R1-4 CF1/4W103JRC 10K, 1%, 1/4W Metal Film Res 4 C1 CD100000/1000 0.1uF, 50V, 20%, Ceramic Mono Capacitor C2 CD100000/10 100uF,100V,20%, Radial Capacitor U2 PIC16F628 8-Bit CMOS Microcontroller U3 96AB2-102-FS 3X4 Button Keypad U4 WISP628 In-Circuit Flash PICMicro Programmer R5 308N5K 5K Potentiometer

100 Block Production BOM Device Number Mfg Part Description Qty Package U1L1642B1L 16 X 2 LCD Screen 1 DIP U2 MM74C922 Keypad Decoder U3 PIC16F873 PIC Processor C1 CD100000/1000 0.1uF, 50V, 20%, Ceramic Mono Capacitor TH C2 P10R103K5 0.01uF, 50V, 20%, Ceramic Mono Capacitor C3-C4 CD15/50 15pF, 50V, 20%, Ceramic Mono Capacitor 2 U4 4CTX006-ND 4MHZ Oscillator,4CTX006-ND R1 CF1/4W103JRC 10K, 1%, 1/4W Metal Film Res R2 CF1/4W101JRC 100, 1%, 1/4W Metal Film Res R3 308N5K 5K Potentiometer U5 96AB2-102-FS 3X4 Button Keypad

101 Block Prototype NetlistNet Interconnections +5V U1-P2 R5-P1 U2-P14 C2-P1 C1-P2 GND C2-P2 C1-P1 U2-P5 U1-P1 U2-P1 U1-P6 Keypad U3-P1 TO U2-P18 U3-P2 TO U2-P16 U3-P3 TO U2-P15 U3-P4 TO U2-P9 U3-P5 TO U2-P8 U3-P6 TO U2-P7 U3-P7 TO U2-P6 LCD U1-P1 TO R5-P2 U1-P2 TO R5-P1 U1-P3 TO R5-P3 U1-P4 TO U2-P2 U1-P5 TO R5-P2 U1-P6 TO U2-P1 U1-P11 TO R1-P1 U1-P12 TO R2-P1 U1-P13 TO R3-P2 U1-P14 TO R4-P3 PIC16F628 U2-P1 TO U1-P6 U2-P2 TO U1-P4 U2-P4 TO U4-P1 U2-P16 TO U3-P2 U2-P18 TO U3-P1 U2-P6 TO U3-P7 U2-P7 TO U3-P7 U2-P8 TO U3-P5 U2-P9 TO U3-P4 U2-P10 TO R1-P2 U2-P11 TO R2-P2 U2-P12 TO R3-P2 U2-P13 TO R4-P2 U2-P14 TO R5-P1 U2-P15 TO U3-P3 U2-P16 TO U3-P2 U2-P18 TO U3-P1 U2-P5 TO C2-P2,C1-P1 WISP628 U4-P1 TO U2-P4 U4-P2 TO R1-P2 U4-P3 TO R3-P2 U4-P4 TO R4-P4

102 Block Prototype Layout

103 Block Reliability EstimationTotal λ = 11540 MTBF = 9.9 years Failure rate: 4.9% (per 6 months) 9.6% (per year) High Risk Components: LCD Screen Keypad Potential Improvements Choose components with high Tr/Ta ratios Modify manufacturing process such that the majority of parts are preassembled in house by machined processing

104 Block Verification PlanVerify proper debounce period with oscilloscope Test LCD with microcontroller to display time and characters Verify LCD illuminates properly Utilize pulse detector to check operation of interrupt signal Verify results from simultaneous keypad entry Verify that max power consumed <8.4W

105 Feeder System Team 4 John Schwittay

106 Your Block Name Aleks P. Jeff M. Chad D. Jon R. John S. User InterfaceUser Ctrls Display Data MPU w/ RS232 Port IR Rx 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 PC

107 Block Description and PurposeTwo Parts: Feeder Control 2 Feeders Purpose: Activate 2 stepping motors to distribute feed to specimen at specific intervals.

108 Block Requirements - StandardMax Parts & Material Cost: $120 Max Mfg Cost: $48 Max Total Parts Count: 50 Max Unique Parts Count: 10 Mechanical: Max Volume: cm3 Max Mass: 0.75 g Max PCB Area: 64.5 cm2

109 Block Requirements - PerformanceOperational Mode: Off, Forward, Off Steps per Revolution: 48 Motor Torque: 10mNm Step Angle: 7.5 4-Wire Lead Connection

110 Block Signal I/O SummaryPower Signals Inputs: Vcc 12VDC Range: 11.88V – 12.12V Vripple = 0.01V Imax = 300mA Digital Signals Inputs: Vcc 3.3VDC Range: 3.135V – 3.465V Vripple = 0.1V Imax = 0.2mA Outputs: Vih = 2V(max) Vil = 0.5V(min) Iil = -5mA(max) Iih = 5mA(max) Voh = 2.4V(min) Vol = 0.8V(max) Ioh = -50µA(max) Iol = 50µA(min)

111 Block Breakdown DiagramFeeder Control and Drivers MPU Feeder Ctrl 3.3v 3.3v Motor #1 Motor #2 Power Supply

112 Detailed Design Microstepping Current Limiting and Detection: PWMHalf-Bridge output Modulated two pins simultaneously (P1A, P1B) Current Limiting and Detection: I = D X Imax, Rated motor ½ amp at 5V, Driven at 12V Vmax = Rmax * Imax, Vmax = 0.5V when Imax reached Vmax = (R1/(R1+R2))Vcc, P = Imax^2 X Rmax, P = ¼ W IC’s Tied to ground 1ohm, ½ W Resistor

113 Detailed Design Chosen PIC16F684 Internal OscillatorWide operating range (2.0V-5.5V) 10-bit PWM 16-bit ECCP (Enhance Capture Compare PWM)

114 Detailed Design - 3 Two logic-input CMOS quad driversTC4467 (NAND) Four on-chip TC4468 (AND) Four on-chip Inputs of the AND gates on the TC4468 tied together because IC is used as a non-inverting MOSFET driver

115 Block Prototype Schematic

116 Block Theory of OperationUtilize signals from MPU Send signals to the appropriate driver To activate the proper windings.

117 Block Prototype BOM Device Number Mfg Part Description Qty Package 1 7ARA25B104KGS-ND 0.1uf passive Cap. 1 Axial 2  Q1-7 FDC6420C-ND MOSFET 7 Dip 6  R1-8 OX103K-ND 10K passive Resistor 8 R10 OX101K-ND 100 Ω passive Resitor 2  Axial 2 R13 91KEBK-ND 90.9K passive resitor U1 PIC16F684-E/P-ND PIC16F684 microprocessor Dip 14  U2 TC4467CPD-ND TC4467 NAND gates  Dip 14 U3 TC4468CPD-ND TC4468 AND gates

118 Block Production BOM Device Number Mfg Part Description Qty Package08055C104KAT2A Capacitor 1 Chip Q1-7 FDC6420C MosFET 4 26M048B1B Stepper Motor 2 R1-8 ERA-14EB103U Resistor 8 R10 ERA-14EB101U R13 ERA-14EB913U U1 PIC16F684-I/P PIC Microprocessor TSSOP U2 TC4467COE PIC logic CMOS SOIC U3 TC4468COE

119 Block Prototype NetlistNet Interconnections 3.3V U1-P1, U2-P5, U2-P1 Gnd U1-P14, U2-P7, U3-P7 5V Motor 1, Motor 2

120 Block Prototype Layout2.175 inches X 2.3 inches

121 Block Reliability EstimationTotal λ : MTBF : yrs Warranty of 0.5 yrs Failures at 1 warranty period : 0.081 To lower the total λ, quality of the manufacture of the stepper motors.

122 Reliability AssessmentTarget Warranty Length: 6 months Current Failure rate (1 period) = 7.3% Maximum Allowable Failure (1 period) = 10% R(t) = 99%: t = 3 weeks Anticipated FIT design accountability: MPU W/ RS232 ↑ 2% IR Sensors ↑ 4% Power Supply ↑ 4% User Interface/Display ↓ 2% Feeders/Control ↑ 1% PFMEA Approach and Solution: Change reliability problem components

123 Manufacturing Process DiagramProcure Parts (All) PCB Board Fabrication (All) Fab, Comp prep, Bake, Clean (All) Thru Hole SMT Mechanical Hand Operations (1,5) 1,2,4 All Auto Component Insertion Screen Solder Visual Inspection Auto Component Placement Wave Solder PSU MPU IR Sensors Disp/Ctrls Feeders Lead Trim Final Assembly Reflow solder Conduct Safety Tests Pack and Ship