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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 -20C to 65C 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 -20C to 65C 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 -20C to 65C 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 -20C to 65C 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 ±3C (max) over a range of 5C to 55C 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 ±3C over full range .195C / 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 55C -20C to 65C 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 -20C to 65C 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 -20C to 65C 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.