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IR Sensor System for
Aquatic Neurobehavioral
Research – Presentation 2
Team 4
October 25th, 2006
1
Team 4: Members

Jeff Mueller: LPI – BSEE

Chad Due: LMM – BSEE

Jon Reisner: LPM – BSEE

Aleks Plavsic: LSD – BSEE

John Schwittay: LRN – BSEE
2
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
3
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)
Advantages of Project for Team #4:



Previous research and experience in optics
Prior microprocessor design and buildup
Knowledge of control devices
4
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
5
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
 Detailed Design Tasks
 Verification Tasks
 Documentation Tasks
25%
35%
10%
30 %
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): 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: 0 -1500 m
 Max Storage Duration: 10 yrs.
7
System Level Requirements

Standard Requirements

Mechanical:







Manufacturing:





Max Volume: 94390 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
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
8
System Level Requirements

Standard Requirements
 Safety

Safety Standards



Electric Aquarium Equipment (UL1018)
RF Emissions (CLSPR11)
EMC Standards








Guidance on Laser Products (IEC-60825)
ESD Immunity (IEC-61000-4-2)
E Field Immunity (IEC-61000-4-3)
EFT (IEC-61000-4-4)
Power Input Surge Immunity (IEC-61000-4-5)
RF Conducted Immunity (IEC-61000-4-6)
Voltage Dip (IEC-61000-4-11)
Voltage Fluctuate (IEC-61000-3-3)
9
System Level Requirements

Performance Requirements


External on/off switch
Operation Modes:



Two Feeder Mechanisms:


Food volume: to be determined
Optical Indicator:




Power Modes: On, Off
Function Modes: Test 1, Test 2
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
10
System Level Requirements

Performance Requirements
 User display
 Inputs:



interface:
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
11
Safety Devices

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.
12
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:
ESD Contact:
ESD Coupling Planes:

15 kV
8 kV
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
13
Standards Limits and Guidelines Summary

IED61000-4-5: Power Input Surge Immunity

Power Supply
Common Mode:
Differential Mode:

IEC 61000-3-3: Voltage Fluctuate


3 kV
5 kV
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
14
IR Sensor System for Aquatic
Neurobehavioral Research
User Interface
User Ctrls
8 bit
Display Data
IR Rx
Feeder Ctrl
Feeders
MPU
w/ RS232 Port
2 bit
IR Sensors
IR Tx
On/Off
2 bit
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Indicator
Light
PC
Power Supply
15
Block Diagram Description
Block
#
Block Name
Owner
Brief Description
Of Block Function
Power
Interface
Digital
Interfaces
Analog
Interface
1
Power Supply
J. Reisner
Converts Commercial AC Power
both 120 and 240VAC to 12VDC,
and 3VDC
In: AC
Out: 12VDC,
3VDC
None
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
None
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
None
4
IR Sensors
A. Plavsic
Detect the direction of motion of
fish specimen
In: 12VDC,
3VDC
Out: IR Rx
In: IR Tx On/Off
None
5
Feeders
J.
Schwittay
Drive and control operation of
fish tank feeders
In: 12VDC,
3VDC
In: Feeder Ctrl
None
16
High Level Project Plan
17
Block Level Prototyping Plan
Block
Name
Block Area Located
(cm2)
on
Board #
(1, 2, ..
etc)
Board
Substrate
Type
Comp
Attachment
Type
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
PCB
Solder less
Thru hole
8X8
Ribbon
Cable,Wire
Leads
Feeders &
Control
300
2
PCB
Solder less
Thru hole
5X5
Wire Leads
IR
Sensors
250
3,4
PCB
Soldered
Thru hole
15X15
Wire Leads
Display &
User
Inputs
175
5
Vectorboard
Solder less
Thru hole
10X10
Ribbon
Cable, Wire
Leads
18
Power Supply
Team 4
Jon Reisner
19
Power Supply
User Interface
User Ctrls
Display Data
IR Rx
Feeder Ctrl
Feeders
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
MPU
w/ RS232 Port
Indicator
Light
IR Sensors
IR Tx
On/Off
Power Supply
PC
20
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
21
Block Requirements - Standard

AC Input:




±12VDC



Voltage Range: 11.88V – 12.12V
Max Current: 4.2A
3.3VDC



120V/240V
Voltage Range: 102V – 264V
Frequency Range: 47Hz – 63Hz
Voltage Range: 3.135V – 3.465V
Max Current: 0.4mA
Max Total Power Consumption: 40W
22
Block Requirements - Standard





Max 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: 18878 cm3 (20%)
Max Mass: 0.6 kg (20%)
Max Total PCB Area: 96.75 cm2 (15%)
Max Shipping Container Volume: 44245 cm3 (20%)
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
23
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
24
Block Requirements - Performance
Operation Modes: On/Off
 Safety Features:

 Input
Surge Protection Fuse
 Over-temperature Shut Down Circuit
 Reverse Voltage Protection
25
Block Signal I/O Summary

Power Signals
 Inputs:
120/240VAC
Range: 102V – 264V
Frequency = 47 – 63 Hz
Imax = 0.7A/0.35
V-RegMAx = -15%/10%
Connector - NEMA 5-15
26
Block Signal I/O Summary

Power Signals
 Outputs:
Vcc ±12VDC
Vcc 3.3VDC
Range: 11.88V – 12.12V (± 1%)
Vripple = 0.01V
Imax = 4.2A
Connector - Cable
Range: 3.135V – 3.465V (± 5%)
Vripple = 0.1V
Imax = 0.4mA
Connector - Cable
27
Block Breakdown Diagram
120V/240V
AC Input
Current
Protection
Transformer
Rectifier
Regulator
Regulator
Regulator
12V
-12V
3.3V
28
Block Prototype Schematic
29
Block Theory of Operation


Takes in AC Voltage Via Power Cord
Fuse:


Transformer:


Protect circuit from high frequency response brought on by the AC to DC
Rectification
Voltage Regulators:


Reduce Voltage Ripple Left by rectifier
Capacitors C5-C8:


Changes the Voltage from Ac to DC for use by Voltage regulators
Capacitors C-C4:


Steps Down Input Voltage to a more Manageable Voltage
Bridge Rectifier:


Acts as Over Current Protection
Each regulator is chosen to match the required voltage needed by the product.
(±12V,3.3V)
Diode D2:

Reverse Voltage Protection
30
Detailed Design

Selected Transformer:
 115V/230V
at 50/60Hz
 Series Connection 48V @ 0.75mA

Selected Fuse:
 125V,
1.5A
 Over Current Protection

Selected Diode:
 Fast
SWT, 75V
 Reverse Voltage Protection
31
Detailed Design
 Voltage Regulator
+12VDC
Vout(max) = 12.24V
Vout(min) = 11.76V
Output Voltage:
+3.3VDC
Vout(max) = 3.432V
Vout(min) = 3.168V
−12VDC
Vout(max) = -11.64V
Vout(min) = -12.36V
32
Detailed Design

Capacitance Calculations:
Vripple ≤ 2V
IL = 0.75A
f = 60 Hz
Vripple = IL / 2fC → C = 0.75 / (2)(60)(2)
C = 3125uF
By choosing 4700uF at ±20% we achieve the needed
capacitance.
33
Block Prototype BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
U1
LM2591HVT-3.3
3.3V Switching Voltage Regulator
1
TO-220
U2
LM2576-12
12V Switching Voltage Regulator
2
TO-220
U3
LM2576-12
12V Switching Voltage Regulator
2
TO-220
U4
LM320T-12
-12V Switching Voltage Regulator
1
TO-220
F
045901.5UR
125V, 1.5A Over-Current Protection Fuse
1
SMT
T
DST-7-48
Step-down Transformer
1
TH
D1
DB102
Rectifier Diode Bridge
1
DB-1
D2
1N4148 T/R
Reverse Voltage Protection Diode
1
DO-35
C
EKMH500VSN472M
R30T
4700uF, 45V,±20%, electrolytic capacitors
2
Radial
(snap-in)
C1,2,3,4
T491B105K035AS
1uF, 35V, ±10%, tantalum capacitors
4
SMT
C5,6,7,8
EMVH350ADA100MF
60G
10uF, 35V, ±20%, alum. electrolytic capacitors
4
SMT
6’6”, 220V, 18AWG
1
N/A
AC Power
Cord
34
Block Production BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
U1
LM2591HVT-3.3
3.3V Switching Voltage Regulator
1
TO-220
U2
LM2576-12
12V Switching Voltage Regulator
2
TO-220
U3
LM2576-12
12V Switching Voltage Regulator
2
TO-220
U4
LM320T-12
-12V Switching Voltage Regulator
1
TO-220
F
045901.5UR
125V, 1.5A Over-Current Protection Fuse
1
SMT
T
DST-7-48
Step-down Transformer
1
TH
D1
DB102
Rectifier Diode Bridge
1
DB-1
D2
1N4148 T/R
Reverse Voltage Protection Diode
1
DO-35
C
EKMH500VSN472M
R30T
4700uF, 45V,±20%, electrolytic capacitors
2
Radial
(snap-in)
C1,2,3,4
T491B105K035AS
1uF, 35V, ±10%, tantalum capacitors
4
SMT
C5,6,7,8
EMVH350ADA100MF
60G
10uF, 35V, ±20%, alum. electrolytic capacitors
4
SMT
6’6”, 220V, 18AWG
1
N/A
AC Power
Cord
35
Block Prototype Netlist
Net
Interconnections
−12Vout
+12Vout(1)
+12Vout(2)
+3.3Vout
Va
U4-P3, C8-P1, D2-P2
U2-P3, C6-P1
U3-P3, C7-P1
U1-P3, C5-P1
D1-P1, C-P1, C1-P1, C2-P1, C3-P1,
C6-P1, U2-P1, U1-P1, U3-P1
D1-P3, C-P2, C4-P1, D2-P1, U4-P1
F-P1
Vb
VAC
36
Block Prototype Layout
2.525”
1.6”
37
Block Reliability Estimation
Component Description
Qty
Base λ
Total λ
IC Voltage Regulator (3.3V)
1
50
23.29634
IC Voltage Regulator (12V)
2
50
59.26176
IC Voltage Regulator (-12V)
1
50
29.63088
Transformer
1
5
283.1314
Diode Bridge Rectifier
1
4.8
1.769135
Electrolytic Capacitor
6
120
477.4554
Tantalum Capacitor
4
10
26.5253
Diode
1
1
0.213577
Fuse
1
70
49.8740
AC Power Cord
1
105
442.9243
38
Block Reliability Estimation




Total λ = 1394.1
MTBF = 81.829 yrs
Warranty of 0.5 yrs
Electrolytic Capacitors most likely to fail
λ
= 120 (Base)
 Could be replaced with filter package
39
Block Verification Plan

Using Detailed Design:
 Simulate
and verify results in Spice
 Construct Prototype
 Verify results in the lab
 Modify if needed
40
MPU w/ RS232 Port
Team 4
Chad Due
41
MPU w/ RS 232
User Interface
3 bits
2 bit Feeder
selection
Feeders
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
8 bit data line
2 bit
high/low
MPU
w/ RS232 Port
Indicator
Light
IR Sensors
interrupt
Bidirectional
data line
Power Supply
PC
42
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
43
Block Requirements - Standard





Max Parts & Material Cost: $30
Max Mfg Cost: $24
Max Total Parts Count: 25
Max Unique Parts Count: 15
Mechanical:
Volume: 4719.5 cm3
 Max Mass: 0.15 kg
 Max PCB Area: 193.5 cm2
 Max
44
Block Requirements - Standard

Environmental:







Safety and EMC Standards:



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
Electric Aquarium Equipment (UL1018)
ESD Immunity (IEC-61004-2)
Life Cycle

Minimum MTBF: 0.5 yrs
45
Block Requirements - Performance


Operational Modes: Start, Reset, P1,P2
Speed:


Rate:


8 MHz Clock
Optical Indicators:




9600 Baud
One White LED
6000 mcd
20 degree
Mechanical Interfaces: DB9 Connector
46
Block Signal I/O Summary

Power Signals

Inputs:
Vcc 12VDC
Vcc 3.3VDC
Range: 11.88V – 12.12V
Vripple = 0.01V
Imax = 300mA
Range: 3.135V – 3.465V
Vripple = 0.1V
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)
47
Block Breakdown Diagram
1 – 8 Bit Data Line (Display)
2 - 3 bits to receive/send data to user CTRLs
3 – 2 bit Bi-directional Pc Interface data line
LED
Indicator
4 – 2 bit signal denoting both direction and IR
Sensor break
DISPLAY/CTRLS
5 – Interrupt on/off for IR Sensors
6 – Enable signal to Feeder 1 or Feeder 2
7
1
7 – Enable LED
2
FEEDER CONTROL 1
6
3
MPU
MAX232
DB9
FEEDER CONTROL 2
5
IR TRANSMITTER
4
IR RECIEVER
48
Block Prototype Schematic
49
Block Theory of Operation



1 – 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
50
Detailed Design

R1 – R2: thick film chip resistors
 Nominal
Value:
 % Tolerance:

10 KΩ
1%
C1 – C5: electrolytic caps
 Nominal
Value:
 % Tolerance:
0.1 uF
20 %
51
Detailed Design

PIC processor: PIC18F4420
 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
52
Detailed Design

Equations of Baud Rate Error




N = [(Fosc/Desired Baud Rate)/64] – 1
Calculated Baud Rate = Fosc / [64(N+1)]
Error(%) = (Calculated – Desired) / Desired Baud Rate
Desired Baud Rate of 9600 @ Fosc of 8 MHz



N = 12
Calculated Baud Rate = 9615.38
Error(%) = .16 %
53
Block Prototype BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
C1-C5
.1 uF, Ceramic Capacitor
1
Axial 2
D1
White, 100mW, 6000mcd
1
J1
DB9
Serial Connector
1
OC1
ECS-40-20-4X
4 Mhz oscillator
1
10 pin connector
1
P1-10
U1
MAX232ACPE
Serial interface
1
DIP16
U2
PIC18F4420-IP-ND
Microcontroller
1
DIP44
10K, 1%, ¼ W Film Res.
1
Axial2
R1
54
Block Production BOM
Device
Number
Mfg Part
Number
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
SMT
R1-R2
ERJ-14NF10R0U
10 k, 1% Tol., ¼ W, chip resistor
1
SMT
J1
1008-9S
DB9 serial connector
1
SMT
J2
1-640453-0
10 pin right angle connector
1
SMT
U1
MAX3232ECPE
Serial driver, DIP 16
1
SMT
U2
PIC18F4420-IP-ND
Microcontroller
1
SMT
55
Block Prototype Netlist
Net
+3.3 V
Interconnections
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
56
Block Prototype Layout
3 in. X 2.5 in.
57
Block Production Schematic
58
Block Production Netlist
Net
+3.3 V
Interconnections
D1-P1 U1-P16 C1-P1 C4-P2
GND
U2-P12 U2-P31 U1-P15 J1-P5
C5-P1
59
Block Reliability Estimation





Total λ : 977.80
MTBF: 116.67 yrs.
Warranty of 0.5 yrs
Failure @ 1 period: 0.009
Failure @ 10 yrs.: 0.082
Part
QTY
Model E
-λ
Total
λ
PIC18F4420
1
13.3
13.3
MAX3232
1
13.3
13.3
White LED
1
1.0
1.0
Electrolytic Cap
5
120
600
Resistor
2
0.2
0.4
DB9 Connector
1
35.0
35.0
8 pin Connector
1
35.0
35.0
Wire Connections
8
35.0
280.0
Total Fits
977.8
60
Block Verification Plan



Check for proper delay time of feeder to LED
turn on
Verify that both program sequences are
operating properly
Test for serial port errors
61
IR Sensors
Team 4
Aleks Plavsic
62
IR Sensors
User Interface
User Ctrls
Display Data
IR Rx
Feeder Ctrl
Feeders
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
MPU
w/ RS232 Port
Indicator
Light
IR Sensors
IR Tx
On/Off
Power Supply
PC
63
Block Description and Purpose

Description:


Generates 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
64
Block Requirements - Standard





Max 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: 23598 cm2 (25%)
Max Mass: 0.75 kg (25%)
Max PCB Area: 96.75 cm2 (15%)
Max # of PCBs: 2
Max Shock Force: 0.1 G
Max Shock Repetitions: 1
65
Block Requirements - Standard

Environmental Reqs:








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: 0 – 15000 m
Max Storage Duration: 10 yrs
Safety and EMC Standards:

UL1018: Electric Aquarium Equipment
 IEC-60825-1: Guidance on Laser Products
 IEC-61000-4-3: E Field Immunity
 IEC-61000-4-6: RF Conducted Immunity

Life Cycle:

Est. Max Production Lifetime: 8yrs
66
Block Requirements - Performance




IR 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 = 15.24 cm
 Beams’ Coverage Height: 6 in = 15.24 cm
67
Block Requirements - Performance

Mechanical Reqs:

LEDs and Phototransistors need to be fixed by appropriate plastic
holder
 Holder’s Max. Dimensions: 15.24 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
68
Block Signal I/O Summary

Power Signals
 Inputs:
Vcc ±12VDC
Vcc 3.3VDC
Range: 11.88V – 12.12V (± 1%)
Vripple = 0.01V
Imax = 800mA
Connector - Cable
Range: 3.135V – 3.465V (± 5%)
Vripple = 0.1V
Imax = 60µA
Connector - Cable
69
Block Signal I/O Summary

Digital Signals
 Input:
 Output:
IR Tx On/Off
IR Rx
Standard Input
CMOS
f = 1 kHz
V = 3.3V
Vth min = 0.5V
Vth max = 2V
Wire
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
70
Block Breakdown Diagram
IR Tx On/Off
2 x 12
LEDs
Drivers
IR Rx
2 bits
2 x 12
IR BEAMS
Logic
PhotoSensors
Summing
Op-Amps
Comparators
Vcc ±12 VDC
Vcc 3.3 VDC
71
Block Prototype Schematic
TX
RX
72
Block Theory of Operation

Transmitter:



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
73
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
74
Block Prototype BOM
Device
Number
Mfg Part
Number
Description
Qty
U1,2,3,4
Opamp
8
U5
Comparator
2
DIP-8
DIP-14
U6
CD4013
D Flip-Flop
1
U7
74LS02
NOR gate
1
R1
10%, 1/2 W, Potentiometer
2
R2-10
5%, 1/8 W, Ceramic Resistor
18
C1-10
20% Ceramic Capacitor
18
D1-11
IR Led
22
Q1
MOSFET
2
PT1,2,3
Phototransistor
3
Package
T1
T1
75
Block Production BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
U1,2,3,4
LT1128
Opamp
24
SOIC
U5
MC3302P
Comparator
2
TSSOP
U6
CD4013
D Flip-Flop
1
TSSOP
U7
74LS02
NOR gate
1
R1
10%, 1/2 W, Cermet Potentiometer
2
R2-10
1%, 1/8 W, Metal Film Resistor
50
Chip
C1-10
5%, 30V, Ceramic Capacitor
22
Chip
D1-11
IR Led
22
T1
MOSFET
4
PT1,2,3
Phototransistor
22
P1
4 pin Connector
1
Q1
FDS4072N3
T1
76
Block Prototype Netlist
Net
Interconnections
+3.3V
+12V
−12V
Gnd
U6-P14
D1-P1
Q1-P3
U6-P7
PT1-P2
U6-P1
IR Rx
U7-P14
U1-P4
U1-P8
U7-P7
PT2-P2
U7-P1
R2-P1
U2-P4
U2-P8
R1-P3
PT3-P2
R3-P1
U3-P4
U3-P8
R10-P2
C1-P2
R4-P1
U4-P4
U4-P8
C8-P2
C2-P2
U5-P4
U5-P8
77
Block Prototype Layout
3.8 in
2.5 in
78
Block Reliability Estimation
Component Description
Qty
Base λ FITs
Total λ
IR LEDS
22
1
41.29
Phototransistor
22
4
118.35
Metal Film Resistor
50
0.2
4.50
Ceramic Capacitor
22
1.2
22.22
MOSFET
4
4
10.54
Op Amp
24
50
2076.24
NOR Gate
1
13.3
9.60
D Flip-Flop
1
13.3
9.60
Comparator
2
13.3
194.67
Potentiometer
2
0.2
0.47
Connector
1
20
39.61
79
Block Reliability Estimation





Total λ = 2527.1
MTBF = 45.142 yrs
Warranty of 0.5 yrs
Failures at 1 warranty period = 0.011
Components most likely to fail:



Op Amp – λ = 2076.24
Comparator – λ = 194.67
Improvements:

Use dual or quad ICs packages
80
Block Verification Plan

Check IR LEDs current and its change as
potentiometer resistance is changed


Check output voltage of every phototransistor
and summing amplifier


Current Meter / Multimeter
Voltage Meter / Multimeter
Check outputs of comparators, D flip-flop, and
NOR gate

Oscilloscope
81
User Interface &
Display
Team 4
Jeff Mueller
82
User Display & Interface
User Interface
User Ctrls
Display Data
IR Rx
Feeder Ctrl
Feeders
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
MPU
w/ RS232 Port
Indicator
Light
IR Sensors
IR Tx
On/Off
Power Supply
PC
83
Block Description and Purpose

Description:


User 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
84
Block Requirements - Standard

Max Parts & Material Cost: $180
Max Mfg Cost: $36
Max Total Parts Count: 75
Max Unique Parts Count: 15

Mechanical:








Max Volume: 18000cm3
Max Mass: 300 g
Max PCB Area: 35 cm2
Max Shock Force: 0.1 G
Interface: LCD Ribbon Cable, PCB traced to MPU
85
Block Requirements - Standard

Environmental:







Safety and EMC Standards:


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
UL1018; CISPR11; IEC-60825-1; IEC-61000
Life Cycle

Minimum MTBF: 0.5 yrs
86
Block Requirements - Performance

User 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
87
Block Requirements - Performance

User 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
88
Block Signal I/O Summary

Power Signal 1











Vcc =
Type:
Direction:
Interconnect:
Vnom:
Vmin:
Vmax:
Nom Freq:
%V-Reg Max:
V-Ripple Max:
Max Current:

+/-12 V
DC power
Output
Cable
12V
11.88V
12.12V
DC
1.0%
0.01V
3mA
Power Signal 2











Vcc =
Type:
Direction:
Interconnect:
Vnom:
Vmin:
Vmax:
Nom Freq:
%V-Reg Max:
V-Ripple Max:
Max Current:
+ 3.3 V
DC power
Input
Cable
3.3V
3.135V
3.465V
DC
5%
0.1V
55uA
89
Block Breakdown Diagram
LCD Screen
Segment
Signal and
Common
Signal
Segment
Driver
Timing Signal
and Serial Data
DB0-DB7
LCD
Driver/Controller
RS
R/W
E
8-Bit CMOS
Microcontroller
D0/D7
Keypad
D0/D7
D0/D7
Vcc 3.3V
MPU
PIC Micro
Programmer
90
Detailed Design: LCD

LCD Screen
 10uF
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
91
Detailed Design: LCD
92
Detailed Design: Processor

PIC 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
93
Detailed Design: Processor
94
Detailed Design: Keypad Encoder

Keypad Encoder






Utilizes 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
95
Detailed Design: Keypad Encoder
96
Block Prototype Schematic
97
Block Theory of Operation







User 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.
98
Block Prototype BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
N/A
LM018L
LCD Display Module
1
DIP
U1
HD44780
LCD Controller/Driver
1
DIP
R1-4
CF1/4W103JRC
10K, 1%, 1/4W Metal Film Res
4
C1
CD100000/1000
0.1uF, 50V, 20%, Ceramic Mono Capacitor
1
C2
CD100000/10
100uF,100V,20%, Radial Capacitor
1
U2
PIC16F628
8-Bit CMOS Microcontroller
1
U3
96AB2-102-FS
3X4 Button Keypad
1
U4
WISP628
In-Circuit Flash PICMicro Programmer
1
R5
308N5K
5K Potentiometer
1
99
Block Production BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
U1
L1642B1L
16 X 2 LCD Screen
1
DIP
U2
MM74C922
Keypad Decoder
1
DIP
U3
PIC16F873
PIC Processor
1
DIP
C1
CD100000/1000
0.1uF, 50V, 20%, Ceramic Mono Capacitor
1
TH
C2
P10R103K5
0.01uF, 50V, 20%, Ceramic Mono Capacitor
1
TH
C3-C4
CD15/50
15pF, 50V, 20%, Ceramic Mono Capacitor
2
TH
U4
4CTX006-ND
4MHZ Oscillator,4CTX006-ND
1
TH
R1
CF1/4W103JRC
10K, 1%, 1/4W Metal Film Res
1
TH
R2
CF1/4W101JRC
100, 1%, 1/4W Metal Film Res
1
TH
R3
308N5K
5K Potentiometer
1
TH
U5
96AB2-102-FS
3X4 Button Keypad
1
100
Block Prototype Netlist
Net
+5V
GND
Keypad
LCD
PIC16F628
WISP628
Interconnections
U1-P2
R5-P1
C2-P2
C1-P1
U3-P1 TO U2-P18
U3-P4 TO U2-P9
U3-P7 TO U2-P6
U1-P1 TO R5-P2
U1-P4 TO U2-P2
U1-P11 TO R1-P1
U1-P14 TO R4-P3
U2-P1 TO U1-P6
U2-P16 TO U3-P2
U2-P7 TO U3-P7
U2-P10 TO R1-P2
U2-P13 TO R4-P2
U2-P16 TO U3-P2
U4-P1 TO U2-P4
U4-P4 TO R4-P4
U2-P14 C2-P1
U2-P5
U1-P1
U3-P2 TO U2-P16
U3-P5 TO U2-P8
C1-P2
U2-P1
U1-P6
U3-P3 TO U2-P15
U3-P6 TO U2-P7
U1-P2 TO R5-P1 U1-P3 TO R5-P3
U1-P5 TO R5-P2 U1-P6 TO U2-P1
U1-P12 TO R2-P1 U1-P13 TO R3-P2
U2-P2 TO U1-P4
U2-P18 TO U3-P1
U2-P8 TO U3-P5
U2-P11 TO R2-P2
U2-P14 TO R5-P1
U2-P18 TO U3-P1
U4-P2 TO R1-P2
U2-P4 TO U4-P1
U2-P6 TO U3-P7
U2-P9 TO U3-P4
U2-P12 TO R3-P2
U2-P15 TO U3-P3
U2-P5 TO C2-P2,C1-P1
U4-P3 TO R3-P2
101
Block Prototype Layout
102
Block Reliability Estimation



Total λ = 11540
MTBF = 9.9 years
Failure rate:



High Risk Components:



4.9% (per 6 months)
9.6% (per year)
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
103
Block Verification Plan






Verify 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
104
Feeder System
Team 4
John Schwittay
105
Your Block Name
User Interface
User Ctrls
Display Data
IR Rx
Feeder Ctrl
Feeders
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
MPU
w/ RS232 Port
Indicator
Light
IR Sensors
IR Tx
On/Off
Power Supply
PC
106
Block Description and Purpose

Description:
 Two
Parts:
Feeder Control
 2 Feeders


Purpose:
 Activate
2 stepping motors to distribute feed
to specimen at specific intervals.
107
Block Requirements - Standard

Max Parts & Material Cost: $120
Max Mfg Cost: $48
Max Total Parts Count: 50
Max Unique Parts Count: 10

Mechanical:



Max Volume: 23597.5 cm3
 Max Mass: 0.75 g
 Max PCB Area: 64.5 cm2

108
Block Requirements - Performance





Operational Mode: Off, Forward, Off
Steps per Revolution: 48
Motor Torque: 10mNm
Step Angle: 7.5
4-Wire Lead Connection
109
Block Signal I/O Summary

Power Signals
 Inputs:
Vcc 12VDC
Vcc 3.3VDC
Range: 11.88V – 12.12V
Vripple = 0.01V
Imax = 300mA
Range: 3.135V – 3.465V
Vripple = 0.1V
Imax = 0.2mA

Digital Signals
 Inputs:
Vih = 2V(max)
Vil = 0.5V(min)
Iil = -5mA(max)
Iih = 5mA(max)
Outputs:
Voh = 2.4V(min)
Vol = 0.8V(max)
Ioh = -50µA(max)
Iol = 50µA(min)
110
Block Breakdown Diagram
Feeder Control
and Drivers
3.3v
Motor #1
Feeder Ctrl
MPU
3.3v
Motor #2
Power Supply
111
Detailed Design

Microstepping
 PWM
 Half-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
112
Detailed Design

Chosen PIC16F684
 Internal
Oscillator
 Wide operating range (2.0V-5.5V)
 10-bit PWM
 16-bit ECCP (Enhance Capture Compare
PWM)
113
Detailed Design - 3

Two logic-input CMOS quad drivers
 TC4467
(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 noninverting MOSFET driver
114
Block Prototype Schematic
115
Block Theory of Operation
Utilize signals from MPU
 Send signals to the appropriate driver
 To activate the proper windings.

116
Block Prototype BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
C16
ARA25B104KGS-ND
0.1uf passive Cap.
1
Axial 2
Q1-7
FDC6420C-ND
MOSFET
7
Dip 6
R1-8
OX103K-ND
10K passive Resistor
8
Axial 2
R10
OX101K-ND
100 Ω passive Resitor
2
Axial 2
R13
91KEBK-ND
90.9K passive resitor
1
Axial 2
U1
PIC16F684-E/P-ND
PIC16F684 microprocessor
1
Dip 14
U2
TC4467CPD-ND
TC4467 NAND gates
1
Dip 14
U3
TC4468CPD-ND
TC4468 AND gates
1
Dip 14
117
Block Production BOM
Device
Number
Mfg Part
Number
Description
Qty
Package
C16
08055C104KAT2A
Capacitor
1
Chip
Q1-7
FDC6420C
MosFET
4
Chip
26M048B1B
Stepper Motor
2
R1-8
ERA-14EB103U
Resistor
8
Chip
R10
ERA-14EB101U
Resistor
2
Chip
R13
ERA-14EB913U
Resistor
1
Chip
U1
PIC16F684-I/P
PIC Microprocessor
1
TSSOP
U2
TC4467COE
PIC logic CMOS
1
SOIC
U3
TC4468COE
PIC logic CMOS
1
SOIC
118
Block Prototype Netlist
Net
Interconnections
3.3V
U1-P1, U2-P5, U2-P1
Gnd
U1-P14, U2-P7, U3-P7
5V
Motor 1, Motor 2
119
Block Prototype Layout
2.175 inches X 2.3 inches
120
Block Reliability Estimation




Total λ : 832.11
MTBF : 5.918 yrs
Warranty of 0.5 yrs
Failures at 1 warranty period : 0.081
lower the total λ, quality of the manufacture of the
stepper motors.
 To
121
Reliability Assessment





Target Warranty Length: 6 months
Current Failure rate (1 period) = 7.3%
Maximum Allowable Failure (1 period) = 10%
t @ R(t) = 99%: t = 3 weeks
Anticipated FIT design accountability:






MPU W/ RS232
IR Sensors
Power Supply
User Interface/Display
Feeders/Control
↑ 2%
↑ 4%
↑ 4%
↓ 2%
↑ 1%
PFMEA Approach and Solution: Change reliability problem
components
122
Manufacturing Process Diagram
Procure Parts
(All)
PCB Board
Fabrication (All)
Fab, Comp prep,
Bake, Clean (All)
Thru Hole
1,2,4
Mechanical Hand
Operations (1,5)
1
2
3
4
5
PSU
MPU
IR Sensors
Disp/Ctrls
Feeders
Lead Trim
All
Screen Solder
Auto Component
Insertion
Wave Solder
SMT
Visual
Inspection
Final Assembly
Conduct Safety
Tests
Auto Component
Placement
Reflow solder
Pack and Ship
123