1. Capstone Presentation 2
Team 4
October 25th, 2006

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

3. Project Proposal – IR Sensor System for Aquatic Neurobehavioral Research
Project is designed to test the effects of positive reinforcement in a controlled habitat for fish.
Advantages of Project for Team #4:
Previous research and experience in optics
Prior microprocessor design and buildup
Knowledge of control devices

4. Project Proposal – IR Sensor System for Aquatic Neurobehavioral Research
This product will be designed to test the effects of positive reinforcement in a controlled habitat for fish
Automated experiments and data collection
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 Water Institute, Milwaukee, WI
Product could be modified to assist
similar water & marine studies

5. 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)

6. System Level Requirements
Standard Requirements
Power:
One AC Energy Source
Min Oper. Voltage Range: V
Frequency Range: 47 – 63Hz
Max Total Power (AC): 100W
Environmental:
Min. Oper. Temp. Range: °C
Min. Storage Temp. Range: − °C
Min. Oper. Humidity Range: %Rh
Min. Storage Humidity Range: 0 – 100%Rh
Min. Oper. Altitude Range: 0 – 2000m
Min. Storage/Shipping Altitude Range: 0 – 15000m
Max Storage Duration: 10 yrs

7. System Level Requirements
Standard Requirements:
Mechanical:
Max Volume: cm3
Max Mass: 3 kg
Max # of PCBs: 4
Max Total PCB Area: 645 cm2
Max Shock Force: 0.1 G
Safety:
Safety Standards: UL1018; CISPR11
EMC Standards: IEC ; IEC ; IEC ; IEC ; IEC ; IEC ; IEC ; IEC

8. System Level Requirements
Standard Requirements:
Manufacturing:
Max Total Parts Count: 250
Max Unique Parts Count: 100
Max Parts and Material Cost: $600
Max Mfg Cost: $240
Life Cycle:
Estimated Production Life: 8 years
Estimated Product Life / MTBF: 5 years
Full Warranty Period: 0.5 yrs

9. System Level Requirements
Performance Requirements
External On/Off Switch
Operation Modes:
Power Modes: On, Off
Functional Modes: Test1, Test2
Two Feeder Mechanisms:
Food Volume: to be determined
Optical Indicator:
One White LED
Brightness: mcds
Viewing angle: 20 degrees
RS232 Port for PC interface:
Speed: 9600 bauds
Rate: MHz Clock

10. System Level Requirements
Performance Requirements
User display interface:
Input:
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 Reqs: 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 ≤ 1ms
Detection Width: 6 in
IR Beams:
IR Wavelength Range: 700 – 950 nm

11. Product Block Diagram Aleks P. Jeff M. Chad D. Jon R. John S.
User Interface
User Ctrls
Display Data
MPU
w/ RS232 Port
IR Rx
Feeders
Feeder Ctrl
IR Sensors
IR Tx On/Off
Indicator
Light
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Power Supply PC

12. Block Diagram Description
Block Name
Owner
Brief Description
Of Block Function
Power
Interface
Digital
Interfaces
Analog 1
Power Supply
J. Reisner
Converts Commercial AC Power both 120 and 240VAC to 12VDC, and 3VDC
In: AC
Out: ±12VDC, 3.3VDC
None 2
Microprocessor w/ RS232 Port
C. Due
Senses User I/F Switches for command inputs and updates display periodically
In: ±12VDC, 3.3VDC
In: User Ctrls; IR Rx
Out: Display Data;
Addr. Decoder; Feeder Ctrl;
IR Tx On/Off 3
User Interface
J. Mueller
Provides user inputs for selection, duration of experiments. Provides user output display for current experiment selection elapsed time, current iteration, total # of iterations
In: 3.3VDC, ±12VDC
In: Display Data
Out: User Ctrls 4
IR Sensors
A. Plavsic
Detect the direction of motion of fish specimen
Out: IR Rx
In: IR Tx On/Off 5
Feeders
J. Schwittay
Drive and control operation of fish tank feeders
In: Feeder Ctrl

13. 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.

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

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

16. Estimation-Reconciliation Summary
Total Manpower Estimated: 762 hours
Total Manpower Anticipated: hours
Total Material $ Estimated: $535
Total Material $ Anticipated: $1000
Manpower Allocation
System Design Tasks 25%
Detailed Design Tasks 35%
Verification Tasks 10%
Documentation Tasks: 30%

17. High Level Project Plan

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

19. Power Supply
Team 4
Jon Reisner

20. Power Supply Aleks P. Jeff M. Chad D. Jon R. John S. User Interface
User Ctrls
Display Data
MPU
w/ RS232 Port
IR Rx
Feeders
Feeder Ctrl
IR Sensors
IR Tx On/Off
Indicator
Light
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Power Supply PC

21. Block Description and Purpose
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

22. Block Requirements - Standard
AC Input:
120V/240V
Voltage Range: 102V – 264V
Frequency Range: 47Hz – 63Hz
±12VDC
Voltage Range: V – 12.12V
Max Current: A
3.3VDC
Voltage Range: V – 3.465V
Max Current: mA

23. Block Requirements - Standard
Max Parts and Materials Cost: $60
Max Mfg Assembly/Test Cost: $36
Max Total Parts Count: 62
Max Total Unique Parts Count: 8
Mechanical Reqs:
Max Volume: cm3
Max Mass: 0.6 kg
Max Total PCB Area: cm2
Max Shipping Container Volume: cm3
Max Storage Duration: 10 yrs
Environmental Reqs:
Min Oper Temp: °C
Min Storage Temp: -10 – 60 °C
Min Oper Humidity: 0 – 80%Rh
Min Operating Altitude Range: 0 – 2000 m
Min Storage Altitude Range: 0 – m
Max Total Power Consumption: 40W

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

25. Block Requirements - Performance
Operation Modes: On/Off
AC Power Input: 120V/240V
DC Power Outputs: ±12 VDC; 3.3 VDC
AC Power Frequency Tolerances: 47Hz-63Hz
Input Connector: NEMA 5-15 (15A/125V Grounded)
Safety Features:
Input Surge Protection Fuse
Over-temperature Shut Down Circuit
Reverse Voltage Protection

26. 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

27. Block Signal I/O Summary
Power Signals
Outputs:
Vcc ±12VDC
Range: 11.88V – 12.12V (± 1%)
Vripple = 0.01V
Imax = 4.2A
Connector - Cable
Vcc 3.3VDC
Range: 3.135V – 3.465V (± 5%)
Vripple = 0.1V
Imax = 0.4mA
Connector - Cable

28. Block Breakdown Diagram
Current
Protection
120V/240V
AC Input
Transformer
Rectifier
Regulator
Regulator
Regulator
12V
4.2A
-12V
4.2A
3.3V
0.4mA

29. Block Prototype SchematicVa

30. Block Prototype BOM Device Number Mfg Part Description Qty Package U1LM
12V Switching Voltage Regulator 1
TO-220-5 U2
PT79SR112S
-12V Switching Voltage Regulator
3 pin SIP U3
LM2591HVT-3.3
3.3V Switching Voltage Regulator R
1%,1/4W, Metal Film Resistor
Axial2
C2,3
1uF Capacitors 3
D2,3
Zener Diode 2 T
Step-down Transformer F DR
Surge Protection Fuse SM D1
GBU4A
Rectifier Diode Bridge
GBU
C7,8,9
10uF Capacitors C1
4700uF Capacitor
C4,5,6

31. Block Prototype Netlist
Net Interconnections
−12Vout U2-P3, C8-P1
+12Vout U1-P3, C7-P1
+3.3Vout U3-P3, C9-P1
Va D1-P1, C2-P1, C3-P1, C4-P1, C5-P1,
C6-P1, D2-P1, D3-P1, U2-P1, U1-P1
U3-P1
VAC F-P1

32. Block Prototype Layout

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

34. MPU w/ RS232 Port
Team 4
Chad Due

35. MPU w/ RS232 Port Aleks P. Jeff M. Chad D. Jon R. John S.
User Interface
User Ctrls
Display Data
MPU
w/ RS232 Port
IR Rx
Feeders
Feeder Ctrl
IR Sensors
IR Tx On/Off
Indicator
Light
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Power Supply PC

36. Block Description and Purpose
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

37. Block Requirements - Standard
Max Parts & Material Cost: $30
Max Mfg Cost: $24
Max Total Parts Count: 13
Max Unique Parts Count: 8
Mechanical:
Max Volume: cm3
Max Mass: 0.15 kg
Max PCB Area: cm2

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

39. Block Requirements - Performance
Operational Modes: Start, Reset, P1,P2
Speed: Baud
Rate: Mhz Clock
Optical Indicators:
One White LED
6000 mcd
20 degree
Mechanical Interfaces: DB9 Connector

40. Block Signal I/O Summary
Power Signals
Inputs:
Vcc 12VDC
Range: 11.88V – 12.12V
Vripple = 0.01V
Imax = 300mA
Vcc 3.3VDC
Range: 3.135V – 3.465V
Vripple = 0.1V
Imax = 0.2mA

41. Block Signal I/O Summary
Digital Input Interface 1,2,4: VIH = 2v(min), VIL = 0.5v(max)
(User Controls, IR sensors, IIH = 5uA(max), IIL = -5uA(max)
RS232)
Digital Output Interface 6: VOH = 2.4v(min), VOL = 0.8v(max)
(Feeders) IOH = -50uA(max), IOL = 50uA(max)
Digital Output Interface 5: VOH = 2.4v(min), VOL = 0.8v(max)
(Display) IOH = -.1mA(max), IOL = .1mA(max)
Digital Output Interface 2: VOH = 2.4v(min), VOL = 0.8v(max)
(IR On/Off) IOH = -25uA(max), IOL = 25uA(max)
Digital Output Interface 7: VOH = 2.4v(min), VOL = 0.8v(max)
(LED Indicator) IOH = -100uA(max), IOL = 100uA(max)

42. Block Breakdown Diagram
LED
Indicator
DISPLAY/CTRLS 7 1
FEEDER CONTROL 1 4
MAX232
DB9
MPU 6
FEEDER CONTROL 2 2 2
IR TRANSMITTER
IR RECIEVER

43. Block Prototype Schematic

44. Block Prototype BOM Device Number Mfg Part Description Qty Package
15 pF, Ceramic Capacitor 2
Axial2
C3-6
10 uF, Ceramic Capacitor 4 C7
.1 uF, Ceramic Capacitor 1
Axial 2 D1
White, 100mW, 6000mcd J1
DB9
Serial Connector
OC1
3.86 Mhz oscillator
P1-10
10 pin Ribbon Cable U1
MAX232
Serial interface
DIP16 U2
PIC16F877
Microcontroller
DIP44 R1
10K, 1%, ¼ W Film Res.

45. Block Prototype Netlist
Net Interconnections
+3.3 V D1-P1 U2-P12 U2-P35
U1-P16
GND U2-P13 U2-P34 C1-P1
C2-P1 C6-P2 U1-P15 J1-P5

46. Block Prototype Layout

47. Block Reliability Estimation
Total λ :
MTBF: yrs.
Warranty of 0.5 yrs
1 period: 0.1 percent
10 yrs.: 1.9 percent

48. IR Sensors
Team 4
Aleks Plavsic

49. IR Sensors Aleks P. Jeff M. Chad D. Jon R. John S. User Interface MPU
User Ctrls
Display Data
MPU
w/ RS232 Port
IR Rx
Feeders
Feeder Ctrl
IR Sensors
IR Tx On/Off
Indicator
Light
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Power Supply PC

50. Block Description and Purpose
2 columns of IR LEDs matched with 2 columns of IR Photosensors – 2 IR beam curtains
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

51. Block Requirements - Standard
Max Parts & Material Cost: $150
Max Mfg Cost: $72
Max Total Parts Count: 75
Max Unique Parts Count: 20
Mechanical Reqs:
Max Volume: cm2
Max Mass: 0.75 kg
Max PCB Area: cm2
Max # of PCBs: 2
Max Shock Force: 0.1 G
Max Shock Repetitions: 1

52. Block Requirements - Standard
Environmental Reqs:
Min Oper Temp Range: °C
Min Storage Temp Range: − °C
Min Oper Humidity Range: 0 – 80 %Rh
Min Storage humidity Range: 0 – 100 %Rh
Min Oper Altitude Range: 0 – 2000 m
Min Storage/Shipping Altitude Range: 0 – m
Max Storage Duration: 10 yrs
Safety and EMC Standards:
UL1018; IEC ; IEC ; IEC
Life Cycle:
Est. Max Production Lifetime: 8yrs
Block Life: 0.5 yrs

53. Block Requirements - Performance
IR Wavelength Range: 700 – 950 nm
IR Signals Output Min. Power = 10 mW
IR Signals Input Min. Power = 5 μW
Operational Modes:
Power Modes: On/Off
Functional Modes: Test1, Test2
Functional Features: Start, Reset

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

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

56. Block Breakdown Diagram
IR Tx On/Off
Mod
LEDs
PhotoSensors
Summing
Op-Amp
IR BEAMS
Comparator
Differentiator
Demod
BP Filter
Logic
IR Rx
Vcc ±12 VDC
Vcc 3.3 VDC

57. Block Prototype Schematic

58. 5%, 1/4W, Metal Film Resistor
Block Prototype BOM
Device
Number
Mfg Part
Description
Qty
Package U1
PIC12C509
PIC Processor 1
DIP-8 U2
CD4013
D Flip-Flop
DIP-14
U3,4,5
LF412
Opamp 3 U6
Comparator
R1-16
5%, 1/4W, Metal Film Resistor 16
C1-6
20% Ceramic Capacitor 6
D1-4
IR Led 4
D5,6
Diode 2 Q1
MOSFET
PT1,2,3
Phototransistor

59. Block Prototype Netlist
Net Interconnections
+3.3V U1-P1 U2-P14 R3-P1 R4-P1 R5-P1
+12V D1-P1 U3-P4 U4-P4 U5-P4 R12-P1
−12V PT1-P3 PT2-P3 PT3-P3
Gnd U1-P8 U2-P7 U3-P5 U5-P5 R2-P2 R11-P2 C2-P2
C1-P2 R13-P2 C6-P2 R16-P2 R9-P1
IR Rx U2-P1 U6-P7

60. Block Prototype Layout

61. Block Reliability Estimation
Total λ =
MTBF = yrs
Warranty of 0.5 yrs
Components most likely to fail:
OpAmp – λ =
Photodetector – λ = 516.4
Improvements:
Use MOS based IC instead of a BJT based one

62. User Display & Interface
Team 4
Jeff Mueller

63. User Display & Interface
User Interface
User Ctrls
Display Data
MPU
w/ RS232 Port
IR Rx
Feeders
Feeder Ctrl
IR Sensors
IR Tx On/Off
Indicator
Light
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Power Supply PC

64. Block Description and Purpose
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

65. Block Requirements - Standard
Max Parts & Material Cost: $180
Max Mfg Cost: $36
Max Total Parts Count: 38
Max Unique Parts Count: 15
Mechanical:
Max Volume: cm3
Max Mass: 300 g
Max PCB Area: 35 cm2
Max Shock Force: 0.1 G

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

67. Block Requirements - Performance
User Inputs
Input controls: Start, Reset, Test Duration, Test Selection, Iteration Duration
Input Type: Keypad
Type: Alpha-numeric
Minimum size: 3x3
Max view dist: 1m
Viewing environment: Bright light, Indoors
Max Debounce time: 20ms

68. 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

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

70. Block Breakdown Diagram
LCD Screen
Keypad
D0/D7
Vcc 3.3V
LCD
Driver/Controller
D0/D7
8-Bit CMOS
Microcontroller
D0/D7
D0/D7
MPU
PIC Micro
Programmer
D0/D7
Vcc 3.3V

71. Block Prototype Schematic

72. Block Prototype BOM Device Number Mfg Part Description Qty Package N/A
LM018L
LCD Display Module 1 U1
HD44780
LCD Controller/Driver
R1-4
10K, 1%, 1/4W Metal Film Res 4 C1
0.1uF, 50V, 20%, Ceramic Mono Capacitor C2
100uF,100V,20%, Radial Capacitor U2
PIC16F628
8-Bit CMOS Microcontroller U3
96AB2-102-FS
3X4 Button Keypad U4
WISP628
In-Circuit Flash PICMicro Programmer R5
308N5K
5K Potentiometer

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

74. Block Prototype Layout

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

76. Feeder Control
Team 4
John Schwittay

77. Feeder Controls Aleks P. Jeff M. Chad D. Jon R. John S. User Interface
User Ctrls
Display Data
MPU
w/ RS232 Port
IR Rx
Feeders
Feeder Ctrl
IR Sensors
IR Tx On/Off
Indicator
Light
Block Allocation
Aleks P.
Jeff M.
Chad D.
Jon R.
John S.
Power Supply PC

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

79. Block Requirements - Standard
Max Parts & Material Cost: $120
Max Mfg Cost: $48
Max Total Parts Count: 25
Max Unique Parts Count: 8
Mechanical:
Max Volume: cm3
Max Mass: 0.75 g
Max PCB Area: 64.5 cm2

80. Block Requirements - Standard
Environmental:
Min Oper Temp Range: C
Min Oper Humidity Range: %Rh
Min Oper Altitude Range: 0 – 2000 m
Min Storage Temp Range: −10-60 C
Min Storage Humidity Range: % Rh
Min Storage Altitude Range: m
Safety and EMC Standards:
UL1018; IEC , IEC , IEC
Life Cycle
Minimum MTBF: 0.5 yrs

81. Block Requirements - Performance
Operational Mode: Off, Forward, Off
Steps per Revolution: 48
Motor Torque: 10mNm
Step Angle: 7.5

82. Block Signal I/O Summary
Power
DC, 12V Nom., Vmin = 11.88V,
Vmax = 12.12V, Vripple = 0.01V, Imax = 300mA
DC, 3.3V Nom., Vmin = 3.135V, Vmax = 3.456V, Vripple = 0.1V, Imax = 0.2mA
Digital
Voh = 2.4V(min), Vol = 0.8V(max), Ioh = -50µA(max), Iol = 50µA(min)

83. Block Breakdown Diagram
Feeder Control
and Drivers
MPU
Feeder Ctrl
3.3v
3.3v
Motor #1
Motor #2
Power Supply

84. Block Prototype Schematic

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

86. 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

87. Block Prototype Layout

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

89. Product Reliability Assessment
Target Warranty Length: 0.5 yrs.
Current Failure rate (1 period) = 8.2%
Maximum Allowable Failure (1 period) = 10%
R(t) = 99%: t = 3 weeks
Anticipated FIT design accountiblilty:
MPU W/ RS232 ↑ 2%
IR Sensors ↑ 4%
Power Supply ↑ 4%
User Interface/Display ↓ 2%
Feeders/Control ↑ 1%
PFMEA Approach and Solution: Change reliability problem components