Download EE595_Team4_P2_Fall07

Remote Controlled Car
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Team #: 4
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Jordan Acevedo
Phosay Bouapha
Corey Preuss
Ben Reider
Lee Strauss
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BSEE
BSEE
BSEE
BSEE
BSEE
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Team #4: Expertise & Experience
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Jordan Acevedo
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Phosay Bouapha
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Corey Preuss
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Ben Reider
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Lee Strauss
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Expertise: Digital: PLD/FPGA VHDL, Soldering,
Troubleshooting
Experience: 2 Year Internship at Rockwell
Automation
Expertise: Analog: Amplifier, Filter Design
Experience: None
Expertise: Hardware, Software Validation,
Mathematics Minor
Experience: 3 Internship Terms at GE
Healthcare
Expertise: Power Supplies & Systems,
Soldering, Business Minor
Experience: 2 Co-Ops at Kohler Corp.
Expertise: Power Supplies & Amplifiers
Experience: None
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Team #4: Total Resources
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10 Manhours/week
$200 budget
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Proposed Product Summary
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Selected Product
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Remote Controlled Car
Entertainment
Details
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Miniature toy replica of a car, controlled remotely.
Primary use of product is for entertainment and
educational purposes.
With proximity sensors, user is less likely to break
product by running it into a wall.
Yes there are similar products, but not identical due to
fact of added damage protection and intended future
use.
Major industry family the product belongs to is
consumer toys.
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Project Selection
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Overall Selection Process
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The remote controlled car project provided more
challenges and involved more complex aspects than
the other projects.
Major risks involve making sure all of our components
work together well. Because our product contains
moving parts, it is important that they work according
to our specifications because safety concerns.
Our other projects were rejected because they did not
have enough blocks in the diagrams to satisfy our
electronic requirements.
This project was unanimously supported by all five
members of our group.
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System Level Performance
Requirements
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Remote controlled (frequency band)
– Forward and Reverse, left and right steering, power
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Proximity sensors
– Detection of distance from nearby objects and emergency
power shut off if car gets too close
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Headlights
– Headlights attached to front of car for illumination
purposes. Can be turned on or off by the user from the
remote control. Lights will also have dimming capability.
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Blinkers
– Array of 10 LEDs will click on or off based on user input to
represent turn direction.
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System Level Standard
Requirements
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Max Parts Count
Max Unique Parts Count
Parts/Mat $ Allocation
Asm/Test $ Allocation
Product Life, Reliability
Full Warranty Period
Service Strategy
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100 Total Parts
30 Unique Parts
$150 (Parts+Mfg=Product Cost)
$50 (Parts+Mfg=Product Cost)
4 yrs
6 months
Repair
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System Level Standard
Requirements
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Min Oper Temp Range
Min Oper Humidity Range
Min Oper Alt or Press Range
Min Storage Temp Range
Min Storage Humidity Range
Min Storage Alt or Press Range
Max Storage Duration
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o
0-60 C
20-95% non-condensing
0-3500 Meters
10-65Co
0-90% non-condensing
0-3500 Meters
1 year
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System Level Standard
Requirements
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Estimated Annual Income
Min List Price
Max Product Material Cost
Max Product Mfg Cost
Estimated Annual Contribution
Operating Voltage Range
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$100000
300
$80
$30
$50000
12V to 48V
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Team Block Diagram
DC-DC
Converters
Battery
Motor
PWM
Microprocessor
Proximity
Sensor
Dimming
HeadLights
Blinkers
RF Signal
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Block Diagram Description
Block
#
Block Name
Owner
Brief Description
Of Block Function
Power
Interfaces
Digital
Interfaces
Analog
Interfaces
1
Power Supply
Lee
Converts Battery 12-48VDC
Power to 5, 12, -12 VDC
In: DC12-48V
Out: 5 VDC
Out: 12 VDC
Out: -12VDC
None
None
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PWM Controller/
Micro-Processor
Jordan
Receives the RF signal
controls the PWM signal to
relate to the speed and
direction desired by the user.
In: 5VDC
Out: 5VDC
PWM Signal
None
3
Blinkers
Ben
Receives the RF signal and
controls the cars blinkers.
In:5VDC
Out:5VDC
On/Off pulse
None
4
Proximity Sensor
Corey P.
Senses distance from nearby
objects and stops the car
through the main PWM
signal.
In:5VDC
Out:5VDC
On/Off
None
5
Dimming
Headlights
Phosay
Brightness of the headlights
controlled external
environment.
In:5VDC
Out:5VDC
None
Photo Sensor
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Ethics Considerations
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Since this is an entertainment product, the group did not see much
room for conflicts of interest, bribery, and kickbacks.
Safety can be an issue though; since children could play with the car,
we’d have to make sure that the moveable parts are safe.
While driving the car, someone could be hit, which could cause
potential injury.
 To mitigate this, we need to make sure our proximity sensor switch
works effectively.
Legally, our remote controlled car could have problems if it is not
differentiated enough from other cars in the market.
 Since remote controlled cars have been being manufactured for
years, the idea is probably in the public domain.
 To stray from this, we will be using a remote controlled car of a
larger size.
Environmentally, the group doesn’t see any major considerations that
must be made.
 We could try to find a more efficient power source, since batteries
must be thrown away or recharged.
 Also, we could use more environmentally friendly solder and
materials to minimize the effects of lead and other hazardous
materials found in many components.
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Applicable Patents
Title: Radio control car
•Document Type and Number: United States Patent 5334076
•There is no work around with this patent, royalties will be
determined.
Title: Recreational electric vehicle
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•Document Type and Number: United States Patent 7243746
•This patent involves an indoor or outdoor vehicle for one or two people with a
space for personal goods.. REV is driven using a joystick and is able to turn on
the spot. Our design will not use a joystick that can control the vehicle in a 360
degree manner, but only in forward and reverse. Also our vehicle will not be
primarily used for people to ride
Title: Children's ride-on vehicle
•Document Type and Number: United States Patent: D393888
•This is the actual patent for a power wheels vehicle that we
will be using, therefore we must pay royalties.
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Team Gantt Chart
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Tasks
Start Date
Completed
Remaining
Planning
10/1/07
9.00
6.00
Product Design and Development
10/3/07
10.00
15.00
Process Design and Development
10/22/07
0.00
25.00
Product and Process Validation
11/12/07
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15.00
Feedback Assessment and Corrective Action
11/26/07
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15.00
Production
12/3/07
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15.00
Planning
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback Assessment and
Corrective Action
Production
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Block 1: Power Supplies
Owner: Lee Strauss
Power the system that runs and
controls the car.
 Looking for +5 volts for operation
 Input of 12 volts from battery
 Buck Regulator used to achieve 5
volt output
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Block Diagram
Buck Regulator
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LM5005
Current: 250mA – 2.5A
Operating Frequency: 50kHz to 500kHz
Integrated 75V, 2.5A N-Channel Buck
Switch
Ultra-wide input voltage range from 7V to
75V
Internal high voltage bias regulator
Current mode control with emulated
inductor current ramp
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Wide bandwidth error amplifier
5V Buck Regulator
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Bill of Materials
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High Voltage Buck Regulator – LM5005
Capacitor 0.022uF – Part#: 08051C223JAT2A
Capacitor 1uF – Part#: 08053D105KAT2A
Capacitor 0.027uF – Part#: 08053D105KAT2A
Capacitor 6.8 uF, 1.8ohms – Part#: EEV-FC1V6R8R
Capacitor 10uF, 2ohms – Part#: EEV-FC1H100P
Capacitor 0.003uF – Part#: GRM2165C1H302JA01D
Capacitor 0.0082uF – Part#: 08055C822KAT2A
Diode 0.5v – Part#: B130B-13
Inductor 330uH, 0.574ohms – Part#: DR127-331-R
Resistor 1.43K ohms – Part#: ERJ-6ENF1431V
Resistor 1K ohms – Part#: ERJ-8ENF1001V
Resistor 2.26K ohms – Part#: ERJ-6ENF2261V
Resistor 21K ohms – Part#: ERJ-6ENF2102V
Block 2: PWM Controller/
Micro-Processor
Owner: Jordan Acevedo
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Block 2: PWM Controller/Micro-Processor
Description and Purpose
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The PWM Controller will receive a digital pulse
transmitted from remote control and the width
of the pulse will determine the desired speed of
the car and the width of another pulse will
determine the driving direction of the car
(forward/reverse).
Purpose:
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Control the speed and direction of the car.
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Block 2: PWM Controller/Micro-Processor
Block Diagram
In From Proximity Sensors
Input RF Signals
Micro Processor
In From Power Supply (+5V)
Pulse Width
Modulation
(PWM) Chip
Output to Motor
Controller
In From Power Supply (+5V)
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Block 2: PWM Controller/Micro-Processor
Block Signal Definitions
Block Name:
Block Number:
PWM Controller/MicroProcessor
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Power Signals
To - From
Block #'s
Power2 5VDC
2
Direction
DC Power Input
Freq
Nominal
60Hz
Digital Signals
Type
To - From
Freq Range
Min
Max
55Hz
Type
65Hz
Dir
Block #'s
Digital 1 RF Signal Processor Receiver
Digital 2 PWM Signal
Mot.
Controller
Contr.
Digital 3 Proximity Sensors 5
5V
5V
5V
Connector-Cable
% V-Reg
Max
<10%
Block-Block
Interconnect
Voltage
Nominal
5V
V-Ripple
Max
<10%
Output
Voltage Range
Min
Max
4.5V
5.5V
Current
Max
200mA
Input
Tech
Structure Structure
Freq
Logic
Voltag
Nominal
e
Digital
Input
PCB Trace
N/A
Standard
TTL
Variable 5V
Digital
Digital
Output
Input
PCB Trace
Cable
Standard
N/A
N/A
Standard
TTL
TTL
Variable 5V
Variable 5V
Logic
Voltage
Block-Block
Interconnect
Input Characteristics
Vih Min
0-1.8V
0-1.8V
0-1.8V
Iih Max
0-0.7A
0-0.7A
0-0.7A
ViL Max
3.7-5.0V
3.7-5.0V
3.7-5.0V
IiL Max
1.4-2.0A
1.4-2.0A
1.4-2.0A
Vth Min
N/A
N/A
N/A
Output Characteristics
Ioh
VoL
Vth Max Voh Min Max
Max IoL Max
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
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Block 2: PWM Controller/Micro-Processor
Theory of Operation
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As the user presses forward on the remote
control, the remote transmits pulses to the
receiver.
The width of two of these pulses will determine
the speed and driving direction of the car.
As the control stick on the remote is pressed
further, the width of the pulses increases and
the car will move faster in the desired direction.
If the IR Proximity Sensors are tripped “ON”, the
car will no longer be able to drive forward, when
the sensors are “OFF” and then full operation will
be restored.
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Block 3: Blinkers
Owner: Ben Reider
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Description - To receive and interpret a
RF signal from controller and output a
pulse that blinks either the right or left
side blinkers on the car.
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Purpose – An accessory used to indicate
which direction the car turn.
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Block 3:
Block Level Requirements
• Must work off of a 5 Vdc power supplied
• Must be able to handle a max current input of 150mA if needed
to meet power supplies min current output.
• Needs to operate within system temp. requirements of 0-60°C
• Must read and interpret RF signal
• Needs to relay power from battery in order to ensure brightness
of lights
• Needs to blink lights once every other second
• Robustly build to protect against driving collisions
• Low power dissipation
• Low cost
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Block #3
Blinkers Block Diagram
#2
12V Battery
#1
5 VDC Power Supply
#4
MOSFET
#5 Front
Light Array
12V
#5 Rear
Light Array
12V
#3
Microprocessor
PIC12F509
8 Pin, DIP
RF Signal
#6
MOSFET
#7 Front
Light Array
12V
#7 Rear
Light Array
12V
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Block #3
Blinkers Block Specifications
Block Name: Blinkers
Block Number: #3
Power Signals
To
Blocks
Power1 12-48VDC Battery
Power2 12-48VDC Battery
Power3 5VDC
5Vdc Converter DC Power N/A
Transistors
DC Power N/A
Microprocessor DC Power Output
Digital Signals
To
Blocks
Digital 1 Microprocessor
Transistors
Digital 2 MOSFET Transistor LEDs
Digital 3 MOSFET Transistor LEDs
Type
Type
Digital
Digital
Digital
Direction
Direction
Output
Input
Input
Block-Block
Interconnect
Voltage Voltage Range % V-RegV-Ripple Current
Nominal Min
Max
Max
Max
Max
Connector-Cable 12-48V
Connector-Cable 12-48V
Connector-Cable 5V
Block-Block
Interconnect
10.8V
10.8V
2V
13.2V
13.2V
5.5V
0.05% 0.10% 500mA
0.05% 0.10% 500mA
0.05% 0.10% 150mA
Freq
Logic
Nominal Voltage
Connector-Cable 1 Hz
Connector-Cable 1 Hz
Connector-Cable 1 Hz
5V
12V
12V
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Block #3
Microprocessor Program Flow Diagram
Start
Check for pulse Signal
Read in 5th pulse
Measure width of
5th pulse
Compare width to
nominal value
Check zero flag
Output
Z=0
LeftBlink=1
Z=1
Output
RightBlink=1
1 Sec Delay
1 Sec Delay
Output LeftBlink=0
Interrupt
1 Sec Delay
RightBlink=0 Output
1 Sec Delay
Interrupt
Block #3 Component Selection
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LEDs
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Transistors
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Selected because in a series connection they could meet the change in
source voltage(12-48V)
Low cost and Long Lifetime
Robustly built
Low Power (144mW each)
60V Source to drain Voltage which meets the max source voltage of
48V
Low power dissipation at 350mW Max
Microprocessor
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Least expensive yet meet programming requirements
6 output/input
Can handle the max current input of 150mA
Lower Power (800mW Max)
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Block #3 Component
Specifications
Microprocessor
PIC12F509-I/P-ND
Voltage Range
2 - 5.5V
I Max In
150mA
I Max Out
200mA
Total P Dissipated
800mW
Frequency
4 MHz
MOSFET Transistor Drain to Source V Id Continous Drain Gate to Source V Max Total P Dissipated Gate Threshold V
BS170RLRAGOSCT-ND
60V
500mA
20V
350mW
0.8 - 3
LEDs
SSL-LX3044YD-12V
Forward V
12V
Forward I
12mA
Size
3mm Round
Resistor
1.0KQBK-ND
Ohms
1k
Power
0.25W
Tolerance
+/- 5%
Power Dissipated
144mW
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Block #3 Preliminary Schematic
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Block #3 Bill of Materials
Component
Quantity
Cost Each
Quantity Cost
Microprocessor
PIC12F509-I/P-ND
1
1.28
1.28
MOSFET Transistor
BS170RLRAGOSCT-ND
2
0.375
0.75
LEDs
SSL-LX3044YD-12V
40
0.263
10.52
Resistor
1.0KQBK-ND
2
0.054
0.108
Total Cost 12.658
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Block 4: Proximity Sensor
Owner: Corey Preuss
Part #: GP2Y3A003K0F
(from Digikey)
Wide Angle Distance Measuring
sensor unit (40 – 300cm)
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Block 4: Proximity Sensor
Preliminary Bill of Materials
Part
1
2
Mfg Part #
Description
Qty.
GP2Y3A003K0F
Wide Angle Distance
Measuring Sensor Unit
1
Package
Dimensions
53x20x18mm
Capacitor 10uF
1
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Block 4: Proximity Sensor
Calculations and Specifications
Absolute Maximum Values/Limits
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Measuring Distance Range: 40-300cm
# of Outputs/Type: 5 Analog Outputs
Detection Angle: 25 Degrees
Supply Voltage Range (Vcc): -0.3 to +7V
Output Terminal Voltage(Vot): -0.3 to Vcc(+0.3V)
Input Voltage(Vin H/L and LED H/L): -0.3 to +Vcc(0.3V)
Operating Temperature(Topr): -10 to +60 Degrees
Celcius
Storage Temperature: -40 to +70 Degrees Celsius
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Block 4: Proximity Sensor
Calculations and Specifications
Electro-optical Characteristics
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Average Supply Current(Icc Ave./Max.): 30/50mA
Ideal Supply Voltage(Vcc): 4.5 to 5.5V
Output Voltage(Vo): Min: 2.0 Ave: 2.3 Max: 2.6V
Output Voltage Differential(ΔVo):
Min: 0.9 Ave: 1.2 Max: 1.5V (between 40cm and 100cm)
Input Voltage: VinH: 4.5V(min.) VinL: 0.3V(max.)
LED H: 4.5V(min.)
LED L: 0.5V(max.)
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Block 4: Proximity Sensor
Theory of Operation
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Proximity switch receives input voltage and
current from power supply via the
microprocessor
Sensor measures distance to nearby object
If object is close enough to trigger the sensor
“ON”, an interrupt will be sent through the
microprocessor to the motor disabling the car’s
forward position movement
Vehicle will be allowed to move in reverse
direction until proximity sensor is switched
“OFF”, and the car will then be allowed to move
forward
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Block 4: Proximity Sensor
Description and Purpose
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Sensor used for measuring distance from
the car to nearby objects and sending a
signal to the motor via the
microprocessor to shut off if it gets too
close to the object. Car will then only be
allowed to move in reverse until it is a
safe distance away from the object and
will then be allowed to move forward.
Operation is used for safety concerns
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Block 4: Proximity Sensor
Block Diagram Breakdown/Schematic
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Block 5: Dimming Headlights
Owner: Phosay
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Block 5: Dimming Headlights
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Description – Circuit to dim the
headlights when the car is in a bright
environment, while operating in a
bright environment, the head lights
will be at max brightness.
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Purpose – An accessory used to allow
the car to automatically control the
headlights by it self.
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P722-5R
Block 5: Dimming Headlights
Block Diagram
+12V
Battery
+5V Power
Supply
-12V Power
Supply
Photoresister
2x
Inverting
op-amps
Left Head
light
Right Head
Light
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Block #5 Detailed Design
Calculations and Component
Selection
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Lights
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Photo-Resistor
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Selected because of price and efficiency.
Long Lifetime
Low Power (144mW each)
Type(P722-5R)
Resistance range of 15KOhms at 1 lux to 1.1KOhms at 100 lux
Has desired performance range
Power dissipated (70mW)
Op-amp
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Inexpensive and meets performance requirements
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Block 5: Proximity Sensor
Preliminary Bill of Materials
•
Part #
• Description
276-1657(Radio Shack)
Photo-resistor
LM741CN
Op-amp
1.0KQBK-ND
Resistor
SSL-LX3044YD-12V
Lights(LED)
• Qty
.1
• Price(each)
$0.40
2
$0.22
4
$0.054
60
$0.23
Total cost = $14.86
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Block 5
Bright environment (100lux) max photocell
resistance(Rp)
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Block 5
Output Voltage in bright environment (100lux) max
photocell resistance
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Block 5
Dark environment (1lux) min photocell
resistance(Rp)
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Block 5
Output Voltage in dark environment (1lux) min
photocell resistance
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Block 5
Output Voltage in medium environment, 7KOhms
photocell resistance
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