W.I.N.C.

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W.I.N.C. S Smart Controller

• EE 4522 Senior Design II
• Department of Electrical and Computer Engineering
• April 22, 2002
• Final Design Review

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W.I.N.C. Team
Dr. J.W. Bruce, Faculty Advisor
Tim Willis, Team Leader
Michael Nestler

• Naquisha Causey

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Block Diagram
Digital Components
Switching Network
Inputs
AC Loads
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Electrical Specifications

• The controller must interface six loads that
  will operate on AC.
• The circulation pump requires 120 VAC at 300W.
• The drain pump requires 120 VAC at 100 W.
• The heater requires 120 VAC at 1600 W.
• The exhaust fan requires 120 VAC at 10 W.
• The rinse aid dispenser requires 120 VAC at 46 W.
• The inlet valve will have two solenoids that
  require 120 VAC at 6 W.

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User Interface

• The user interface should consist of the
  following user inputs
• Time Increment toggles 5 VDC/ 0 VDC
• Time Decrement toggles 5 VDC/0 VDC
• Rinse toggles 5 VDC/0 VDC.
• Heat Selection toggles 5 VDC/0 VDC
• Power Switch A SPST switch that turns main
  power on/off.
• 24 character LCD screen.

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Switching Circuit

• nMOSFET (enhancement)
• (ID17A ,VGS100V)
• Diode
• (1 Watt, 100V)
• Resistor
• (1 Watt, 10 ohms)
• Relay
• (High Capacity, SPST-NO)

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(ID) Relay on with MOSFET off
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(ID) Relay off
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Design Problems

• Replace 2 DC loads for 2 AC loads
• Digital components draw too much power
• PCBs manufacturing process

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Replace Loads
Digital Components
Switching Network
Inputs
AC Loads
Replace 2 DC loads With 2 AC loads
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Digital Signal Interface

• Use 1 MAX1618 digital thermostat that use a
  transistor for remote temperature detection.
• This signal will have a resolution of .01

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Why Replace the Loads?

• Lack of documentation from manufacturer
• Incorrect component identification
• Component loads were not available for testing in
  late December

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Replacing the Loads

• Add 2 more switching circuits
• Modify connectors from the PCB to each load

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High Power Consumption
Digital Components
Switching Network
Inputs
Digital Components Draw Too Much Power
AC Loads
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Power Usage of Digital Components

• Specification calls for no more than 2.5 watts of
  power to be consumed
• Digital components consume a total of 2.7 watts
  at maximum power

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Dishwasher Pan
Heater Element
1
New Design
Original Design
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Remove One Thermistor

• Reduces digital power consumption to meet design
  specification
• Frees up more memory for programming
• Reduces complexity of overall design
• Effect on dishwasher is negligible

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QA Deficiencies
Digital Components
Switching Network
Inputs
PCB Manufacturing
AC Loads
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PCB Manufacturing Process

• Build in-house or send off
• Proper spacing of AC and DC components
• QA deficiencies

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Build In-house

• Less expensive to build
• Have better access to PCB manufacturer
• Experienced people

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Electromagnetic Fields Theory

• Maxwell Law.
• External Field Induces Voltage and Current at
  Trace Ends
• Problem Solved by Separating the AC and DC power
  sources

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Separation of AC and DC
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QA Deficiencies

• Designations of thru-hole vs. surface mount
  swapped
• Some traces too close together
• Holes had to be custom fitted

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First PCB (5 X 5.5 X .06)
MAX 1618
A/D Converter
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Second PCB (5 .25 X 7.31X .06)
A/D Converter
MAX 1618
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Traces Before
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Traces After
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QA Corrections

• Have a briefing before each manufacturing step
• Ensure all steps done have approval of 2 people

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AC Test Condition

• Impossible to test the entire system
• Classical Engineering Practice - Sample portions
  of the circuit for signal integrity
• Microscopic Inspection of soldering and
  interconnectivity

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Mechanical Load Test
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Software Changes 1

• Prototype Strategy
• Use 6 interrupt clocks to time individual loads
  loads precisely.
• Clocks start from semaphore from main procedure,
  then set a finished flag after running.
• Devices run from main procedure until the
  finished flag is set by interrupt clock.

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Software Changes 2

• Packaged Strategy
• Use a single interrupt-driven clock to control
  all loads.
• Clock starts at beginning of cycle, and runs to
  end.
• Loads check the clock from the main routine.
  They start and stop when the clock hits certain
  values.
• More efficient use of code space and registers.

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Timing Chart of SX 28
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Lessons Learned

• Get a professional board with all components
  surfaced mounted
• Use a Ubicom SX 52
• QA is a necessity
• Maintain good communication

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The Good

• Viking dishwasher is still intact
• Project goal can be done
• Design is flexible

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Acknowledgements
Special Thanks Extended to -MSU Faculty Dr. J.
W. Bruce, Dr. R. Winton, Dr. Harden, and Dr.
Joe Picone MSU Faculty -Viking Range, Inc
Mr. John Picardat Engineer, Mr. Martin
Wesemann General Manager, Ms. Beth Williams-
Assist. Product Manager - Rick King, Aimee
Imparato
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Q/A Session
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REFERENCES (1)
1 M.N. Huhns, Networking Embedded Agent, IEEE
Internet Computing, Vol.3, No.1, pp. 91-93,
January/February 1999. 2 B. Giacalone, M. Lo
Presti, F. Di Macro, Hardware Implementation
Versus Software Emulation of Fuzzy Algorithm
Application, IEEE World Congress on Computa
Intelligence, Vol. 1, No. 1, pp. 7-12, May 1998.
3 Hiroyoshi Nomura, Noborv Wakami, Shinj,
Kondo, Non-linear Technologies in a Dishwasher,
Proceedings of IEEE, pp. 57-58, Japan-USA, July
1995. 4 V.V. Badami, N.W. Chbat, Home
Appliances Get Smart, IEEE Spectrum, Vol. 35,
No. 8, pp. 36-43, August 1998.
39
REFERENCES (2)
5 J.M. Fenster, The Woman Who Invented the
Dishwasher, Invention Technology, pp. 55-61,
Fall 1999. 6 Daniel S. Query, Gary Tescher,
The Internationalization of Component
Design,presented at the International Appliance
Technical Conference, Columbus, Ohio, USA, May
15-16. 7 Alan T. McDonald, Stephen H.
Frisked, David J. Ulrich, Thermal Model of the
Dishwasher Heater in Air. Proceedings of the
IEEE International Appliance Technology
Conference, IEEE International Appliance
Technology Conference, IEEE Transactions On
Industry Applications. Vol. 25, No. 6, pp.
1176-1180, Madison Wisconsin, USA, November 1988.

40
REFERENCES - (3)
7 Alan T. McDonald, Stephen H. Frisked, David
J. Ulrich, Thermal Model of the Dishwasher
Heater in Air. Proceedings of the IEEE
International Appliance Technology Conference,
IEEE International Appliance Technology
Conference, IEEE Transactions On Industry
Applications. Vol. 25, No. 6, pp. 1176-1180,
Madison Wisconsin, USA, November 1988. 8 Wang
Yi-Min, W. Russell, A. Arora, Xu Jun,Toward
Dependable Home Networking, Proceedings
International Conference On Dependable Systems
and Networks, pp. 44-48, Microsoft Corp.,
Redmond, WA, USA, June 2000. 9 Barbara
Mayer, Smart Appliances are the Wave of the
Future, http//www.tcpalm.com/home/15sapplij.sht
ml, Home Garden, USA, July 2001.
41
REFERENCES-(4)
10 T. Erickson, Turbidity Sensing as a
Building Block for Smart Appliances, IEEE
Industry Applications Magazine, Vol.3, No. 3, pp.
31-36, May-June 1997. 11 J.W. Bruce,
Microprocessors II, Mississippi State
University, Mississippi, MS, USA, 2001. 12 K.
Rexford, Electrical Control for Machines, 5th
ed., Delmar Publishing, Albany, New York
1997. 13 C. Okey P.M. Ruane Advances in
Appliance Control The Breaking of a Paradigm.
Proceedings of the 1996 IEEE International
Conference On Control Applications, Dearborn, MI
91-94, September 1996.
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AC Testing From Point A to B
Hertz 120 VAC Measured
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Ohms Law

• The Voltages of Parallel Components have the same
  voltage.
• No Zero- DC for the Capacitor

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Sample 1- AC Loads-Source to Latching Side of
the EMR-
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AC Circuit 5VDC to Digital Thermostat
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5VDC Test Conditions