EE 318-595 Capstone Design Project Spring 2005 Team #3
Team #3: Staff • Nole Martin • Paul Simons • Eric Ritzke • Tom Reuter • Steven Krol • Murtadha B. Tunis • BSEE • BSEE • BSEE • BSEE • BSEE • BSEE
Team #3: Expertise & Experience • Nole Martin • Paul Simons • Eric Ritzke • Thomas Reuter • Steven Krol • Murtadha B. Tunis • Expertise: Power distribution Experience: Cooper Power Systems • Expertise: Organizational skills, wiring hardware, Product Development Experience: Honeywell FM&T • Expertise: Computers / Law Experience: MPC Computers • Expertise: Computers and Communications Experience: JCI Internship • Expertise: Amplifier / Filter Design Experience: Academic • Expertise: Drives, Power Systems Controls and Professional Presentations Experience: P & H Mining Equipment
Team #3: Weekly Availability Worksheet • Nole Martin • Paul Simons • Eric Ritzke • Tom Reuter • Steven Krol • Murtadha B Tunis • Time: Wednesday 3:15PM – 6:30PM • Time: Wednesday 3:15PM – 6:30PM • Time: Wednesday 3:15PM – 6:30PM • Time: Wednesday 3:15PM – 6:30PM • Time: Wednesday 3:15PM – 6:30PM • Time: Wednesday 3:15PM – 6:30PM
Team #3: Weekly Project Meeting Plan • Weekly Meeting 1: 3rd Floor Lab, Wednesday 3:15-6:30 Everyone, Organization Note: Meeting Owners Send Weekly Email Notices, Record Business-Issues-Actions, Keep Weekly Attendance Records
Team #3: Total Resources • 1200 Man hours • $1000 for material and prototyping • Based on our individual experiences and knowledge our team will strive to exceed all project expectations.
Team #3: Decision Making • Majority Vote • In event of a tie, project leader will decide.
Roles to Define & Assign • Project Integrator: (Paul Simons) Owns weekly progress reports to TA. Logistics and communication of team meetings. Develops and Tracks overall project plan. Integrates Block design plans. Tracks expenditures. Owns project level verification and validation plan, capture and documentation of results. • Presentation Mgr: (Murtadha B. Tunis) Owns master MS Powerpoint slide set for team including formats, logos, fonts, colors, header/footer, backgrounds, rev control, submission of master floppy or CD for P1-P4 and Final Presentation. • Report Mgr: (Steven Krol) Owns master MS Word document for team including revision control, formats, logos, fonts, colors, header/footer, table of contents, submission of master floppy or CD for Final report. • Archive Web Mgr: (Eric Ritzke) Owns weekly backup of all electronic material generated that week. Backup for Presentation Mgr and Report Mgr. Management of any team Web site resources. • Assembly & Proto Mgr: (Nole Martin) Owns overall assembly level definitions, basic assembly drawings, master prototype & product parts lists, collection of block parts lists, procurement of proto components. Overall prototype mechanical and electrical assembly • PCB Layout Mgr: (Tom Reuter) Owns overall PCB layout, Block to PCB mapping, PCB tools, PCB design drawings, PCB procurement, PCB assembly including special tools, soldering, wire-wrapping, drilling, and gluing.
Weather Buoy: Features • This is a buoy which takes in weather data, such as wind speed, air temperature, water temperature, and barometric pressure and transmits the data remotely to a digital display via RF. • The buoy will also beacon a light source during night time hours. • Power will be generated from sunlight
Weather Buoy: Benefits • Low maintenance. • Long-term and short-term cost benefits. • Efficiency improved over current designs. • Innovative and challenging design concept with a practical application.
Weather Buoy Block Diagram High Intensity LEDs mounted on buoy. Mechanical Buoy Design and Assembly Weather detecting devices and transmission. Battery Charger / Power Distributor Solar Panels Battery
Proposed Selected Product • Wireless Weather Buoy • Primary Benefit: Real-time Local Weather Information • Intended for use by private water-front property owners. • Product will report air and water temperature, barometric pressure and wind speed via RF communications. • Similar weather stations exist, but not for private use. • Maritime Consumer Market
Similar Existing Product • Features • Wind speed • Wind direction • Barometer • Safety lights • GPS • Solar power • Humidity sensor • Water quality analyzer • Advantages of our product: • Cost effective • Only essential sensors • will be implemented
Project Selection Process Interest: • Project feasibility. • Common interest among team members. • Similar products exist but in a different market and for a different application. • A unique Capstone project. Block Diagram: • Available skills and resources match up well with the project blocks. • There is at least two design blocks for each team member. • Diagram is not too complex, but ideas present sufficient challenges.
Project Selection Process • Major project risks include: potentially high base costs and lack of time for research and development. • Other project ideas were rejected due to complexity issues. • Design issues arose and were resolved with modification of design. • The project decision was made by a majority vote.
Block Diagram Solar Recharging Battery Pressure Sensor 4 5 7 6 1 11 Microprocessor 2 3 LED w/ Controls 8 10 9 12 Outdoor Unit (Buoy) Indoor Unit (Display) Eric – GreenPaul - Yellow Murtadha – OrangeSteve – Light Blue Nole – RedTom – Dark Blue Data Lines Power Lines
System Level Requirements System Performance Requirements: • Product integrates wireless technology with the advantages of a personal weather station. • Self-sustaining, long-life power supply. • Reliable information on current weather conditions. • Transmits weather data to a remote display with the aid of wireless technology.
System Level Requirements System Standard Requirements: Market: • Est. Total Market Size $700,000 • Est. Annual Vol. 1,000 • Min. List Price $700 • Max. Product Materials Cost $300 • Max. Product MFG Cost $50 Power: • Power Sources: - Buoy Power 8V to 18V - Solar Panel 8V to 18V - AC/DC Adapter 3.3V to 8.7V • Max. Total Power 50W
System Level Requirements System Standard Requirements: Mechanical: • Max. Product Vol. 1,000,000 • Max. Shipping Container Vol. 1,100,000 • Max. Product Mass 40kg • Max. # of PCB’s 4 • Max. Total PCB Area 500 • Max. Shock Force 12.0 G’s • Max. Shock Repetitions 6 Environmental: • Operating Ambient Temp. Range -5°C to 70°C • Operating Ambient Humidity Range 0%Rh to 100%Rh • Operating Altitude Range -1000m to 20000m • Storage Ambient Temp. Range -20°C to 80°C • Storage Ambient Humidity Range 0%Rh to 100%Rh • Storage / Shipping Altitude Range -1500m to 30000m
System Level Requirements System Standard Requirements: Manufacturing: • Min. Total Parts Count 150 • Max. Unique Parts Count 65 • Max. Parts & Materials Cost $300 • Max. MFG Assembly / Test Cost $50 Life Cycle: • Est. Max. Production Lifetime 5 years • Product Life Reliability in MTBF 15years • Full Warranty Period 1 years
Safety Standards • UL 458 - Power Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles and Marine Crafts • UL 1196 - Standard for Safety for Floating Water Lights • 61010-1 - Electrical Equipment For Measurement, Control, and Laboratory Use • ISO 14000 • ISO 9001
Basic Business Case • Estimated Average Product Selling Price: $700 • Estimated Product Annual Sales Volume: 1000 Units • Estimated Per Unit Cost of Parts and Materials: $300 • Estimated Per Unit Cost of Assembly, Testing and Mfg: $50 • Estimated Total Development Cost (Labor + Material): $494,000 • Calculated Annual Sales (ASP$ x Annual Volume): $700,000
Basic Business Case • Calculated Per Unit Cost Margin (ASP$ - [Parts + Materials + Mfg] x Costs$): $350 • Calculated Cost Margin (Per Unit CM$ / ASP$): 50% • Calculated Annual Cost Margin (CM% x Annual Sales$): $350,000 • Calculated Return On Investment (Est. Dev. Cost$ / Annual CM$): 1.411 Years.
Block Diagram Solar Recharging Battery Water Temperature Sensor Pressure Sensor Microprocessor Light Controller Circuits Outdoor Unit (Buoy) Indoor Unit (Display) Data Lines Power Lines
Functional Purpose To receive Infra red rays from the sun to charge the solar panels To regulate the solar voltage for the charging circuit To recharge the available power for the battery through an intelligent regulator To output the required regulated voltage for the power conversion circuit
Standard Requirements • Block cost <$120 • Parts count <30 • Unique parts count <20 • PCB Area <350mm2 • Operating temperature range -5 to 70 C • Storage temperature range -20 to 80 C • Reliability MTBF 6 years • Operating Humidity 0 – 100% • Percent Allocations 43% of cost 45% of mass 33% of parts 17% of total area
Performance Requirements • Battery Life 15 years • Battery Type 12V Deep cycle battery • Rated Capacity < 7AH • Supply voltage 12Vdc ± 3% • Supply current <50mA • Solar Panel <17V
Block Interface Infra-Red Rays SUN Intelligent Voltage Regulator Solar Panels Detail Design of Charging Circuit Voltage Regulator Power Conversion Circuit Deep Cycle Marine Battery
Task Estimates • Cost of components $120 • Estimated Man Hours 100
Block #2: Power Regulation and Switching
12V Battery 5V DC Switching Regulator LED, Transmitter Switching Circuit MPU Sensors Power Regulation and Switching
Functional Purpose • To convert battery voltage from 12V to 5V • To distribute power to sensors, LED display, transmitter, and MPU. • To include a switch so that the processor can power down the sensors.
Power Regulation and Switching Standard Requirements • Block Cost <$10 • Parts Count <20 • Mass < 1Kg • Voltage Provided 5V +/- 4% • Operating Temperature -5C to +70C • Storage Temperature -20C to +80C • Reliability Range 5 years • Operating Humidity 0-100%
Power Regulation and Switching Performance Requirements • Output Voltage 5V +/- 4% • Supply Current >800 mA • User Interface-On/Off Toggle Switch • Minimum Life 5years
Task Estimates • Cost of components $10 • Estimated Man Hours 20
MPU 5V DC Microprocessor Wind Sensor Pressure Sensor Transmitter Air Temperature Sensor Switching Circuit Water Temperature Sensor
Functional Purpose • Read analog outputs of the sensors and convert them to digital. • Process the results to obtain meaningful data. • Send meaningful data to the transmitter. • Control power to sensors.
MPU Flowchart Start Initialization Active mode Power on sensors Read senor data and process results Transmit Data Power off sensors Sleep mode Watchdog Wake-up
MPU Standard Requirements • Block Cost $7 • Parts Count <10 • Unique Parts <5 • Operating Voltage 5V+/- 4% • Operating Temperature -5 to +70C • Operating Storage Temperature -20 to +80C • Reliability 5 years • Operating Humidity 0-100% • Disposal Throw Away
MPUPerformance Requirements • Operating Modes Off/Sleep/Active • User Interface Push-Button Reset Switch
Task Estimates • Cost of components $10 • Estimated Man-hours 100