Remote Control Car

1
TEAM 2

• Remote Control Car

2
Team 2 Total Resources

• LPI-Sean Murphy (BSEE)
• LSD-Russ Diamond (BSEE)
• LPM-Adam Wozniak (BSEE)
• LRM-Brad LaCount (BSEE)
• LMM-Barry Gentz (BSEE)

3
Project Features

• The remote control car has a two-way antenna that
  can transmit to and receive data from the car.
• Control of the car will come from the controller.
• The car can turn its lights on and off manually,
  and automatically if it gets dark enough.
• The display will tell us the speed and direction
  of the car, and the battery life remaining.

4
Estimation Slide

• As of 3rd Week
• Manhours-500
• Material 500
• 2 for design
• 86 for detailed design
• 2 for verification
• 10 for documentation

• End of Project
• Manhours-1702
• Material 1031
• These values may be off due to overlapping of
  projects.

5
Competitors Slide
Requirement Units to Specify

• Traxxus, Tra5510
• 600 million, website
• 200
• World-Wide
• 6 yr. old to adult, boys
• Home, toy
• 80 / unit
• 20 / unit
• 6 million / yr
• Included

• Competitors
• Market Size
• Average List Price
• Market Geography
• Market Demography
• Intended Application
• Material Cost
• Manufacturing Cost
• Annual Volume
• User Manual

6
System - Std Reqs Mfg Life Cycle
Requirement Units to Specify

• 200 Total Parts
• 100 Unique Parts
• 80 (PartsMfgProduct Cost)
• 20 (PartsMfgProduct Cost)
• 3 yrs
• 6 months
• Repair

• Max Parts Count
• Max Unique Parts Count
• Parts/Mat Allocation
• Asm/Test Allocation
• Product Life, Reliability
• Full Warranty Period
• Service Strategy

7
System - Std Reqs Production
Requirement Units to Specify

• Max Volume
• Shipping Container Size
• Max Mass
• Max of PC Bds
• Max PCB Circuit Area
• Max Shock

• 12,000 cm3
• 18,000 cm3
• 2 Kilograms
• 5
• 500 cm2 Total
• 50 G force

8
System - Std Reqs Power Interfaces
Requirement Units to Specify

• Min Oper Voltage Range
• Max Power Consumption
• Max Energy Consumption
• Car Battery Chemistry
• Car Battery Capacity
• Controller Battery Pack
• Controller Display Segments
• Controller Accuracy
• Modes of Operation

• 5-9.0 V and 5-15.0 V
• 18.0 Watts Total
• 6000 mAH Total
• Nimh
• 6000 mA-Hrs
• i.e. AA 1.5V
• 10 bars
• 15 battery life
• On/Off

9
System - Std Reqs Enviroment
Requirement Units to Specify

• Min Oper Temp Range
• Min Oper Humidity Range
• Min Oper Altitude
• Min Storage Temp Range
• Min Storage Humidity Range
• Min Storage Altitude
• Max Storage Duration

• 10-45 Co
• 10-90 non-condensing
• 0-3000 Meters
• 0-80Co
• 10-90 non-condensing
• -200-3500 Meters
• 1 year

10
System Perf Reqs Display

• LCD Display
• Display size
• Max. Display Distance
• Viewing Environment
• Display Char Matrix
• Display Size
• Display Illumination

• Mono Color
• 150mm x 70mm
• 1 meter
• Any
• 20 Total Char/Row, 4 Total Rows
• 20cm x 10cm
• LED

11
System Perf Reqs
Requirement Definition

• ON/OFF/AUTO
• None
• 3 mph
• 200 ms
• 0-40 mph
• 8 Directional Units
• 200 ms
• 0-5V logic levels
• .005 s
• 300 ft

• Lights
• Power Saving Modes
• Speed Accuracy
• Microprocessor Updates
• Speed Range
• Controller Accuracy
• Response Time
• Input/Output
• Max. Delay
• Min EM Transmission Distance

12
System Perf Reqs Safety Standards

• We will be using the standards UL 2202 1.5,
  UL2111 1.5, UL 1977, Cispr 61000-6-3, EMC
  61000-4-2, EMC 61000-4-4, and EMC 61000-4-5 in
  order to make sure that our product is safe.
• These standards insure that there is no risk to
  the user from the product and vice versa.
• The EMC standards protect our product from ESD
  and power surges.

13
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
14
Signal Input

• Designed by Barry Gentz

15
Block 1 Signal Input

• Theory Of Operation
• Signal input takes in the users desires for the
  speed, direction and light position and
  implements them to the cars motion, direction or
  state.

16
Block 1 - Std Reqs Environmental
Requirement Units to Specify

• Min Oper Temp Range 10-45 Co
• Min Oper Humidity Range 10-90 non-condensing
• Min Oper Alt or Press Range 0-3000 Meters
• Min Storage Temp Range 0-80Co
• Min Storage Humidity Range 10-90 non-condensing
  
• Min Storage Alt Range 0-3000 Meters

17
Block 1 - Std Reqs Safety
Requirement Units to Specify

• Max Storage Duration 1 year
• Safety Standards 61000-4-2
• 61000-4-4

18
Block 1 - Std Reqs Power Interfaces
Requirement Units to Specify

• Source Connection List Permanent
• Operating Voltage Range 4.9-5.1 V
• Max Power Consumption 3.0 Watts
• Max Energy Consumption 100 mAH
• Max Potential 0V

19
Block 1 - Std Reqs Mechanical
Requirement Units to Specify

• Max of PC Bds 1
• Max PCB Circuit Area 100 cm2 Total
• Max Volume 200 cm3 Total
• Max Weight .5 lbs
• Max Shock 50 G force

20
Block 1 - Std Reqs Manufacturing Costs
Requirement Units to Specify

• Parts/Mat Allocation 25
• Asm/Test Allocation 50

21
Block 1 - Std Reqs Parts Count Reliability
Requirement Units to Specify

• Max Parts Count 30 Total Parts
• Max Unique Parts Count 10 Unique Parts
• Product Life, Reliability 3 yrs
• Full Warranty Period 6 months
• Product Disposition Dispose
• Service Strategy Dispose or Repair

22
Block 1 Perf Reqs I/O Requirements-Modes
Requirement Definition

• Max Error Voltage .25V
• Operational Modes - Fast/Slow/Stopped
• - Left/Right/Straight
• - On/Off/Auto

23
Block 1 Perf Reqs Signal Interface Reqs
Response time lt 250ms
Digital Signals
Vol max Voh min Iol max Ioh Min
.4 2.4 8mA -.4mA
Analog Signals

• Noise must be -40dB at 10 Hz
• Power input Vref DC (AA batteries)

24
Block 1 Perf Reqs User Interfaces
Requirement Type

• Speed Control Vertical Pot wheel
• Direction Control Vertical Pot trigger
• Light Switch 3 position switch

25
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
26
Block 1- Detailed Design Sub-Block Design
Analysis Plan
Steering1
5K Pot
ESD
LP Filter
Speed1
Processor
5K Pot
ESD
LP Filter
Lights
Switch
De-Bounce
ESD
S.T.
Digital Signal Analog Signal Power Signal
Power
27
Block 1- Detailed Design Signal Type
Digital
Analog

28
Block 1- Detailed Design Speed Direction
29
Block 1- Detailed Design Filter Calculations

• Transfer Function
• 2nd order filter is need to increase the
  steepness of curve.

30
Block 1- Detailed Design Filter Calculations

• Transfer Function
• Since R1R2130k and C1C21.5uF
• (1/R2C2)/s2 s(3/RC) (1/R2C2)
• fc .816 Hz

31
Block 1- Detailed Design Light Switch

• Switch logic
• Debounce Calculations
• TDB RC 2000010(-6)
• 20ms

32
Block 1- Detailed Design Schmitt Trigger 74HS14

• Vutp 2.85V
• Vltp 1.85V
• VHYST max 1.5V
• VHYST min 1.0V

33
Block 1- Detailed Design DFM-Worst Case Analysis
Plan

34
Block 1- Detailed Design DFM-Power Dissipation
Analysis
Passive Discrete Specifications Passive Discrete Specifications Passive Discrete Specifications Passive Discrete Specifications Passive Discrete Specifications Passive Discrete Specifications Passive Discrete Specifications
Nominal Value or Max Value Adjustment Range, /Turn Tolerance Around Nominal Derated Power Capacity Maximum Working Voltage Composition Dielectric or Form Package
Component
Resistor 130KO   5 1/8W 250V Thick Film 0805
Resistor 20KO   5 1/8W 250V Thick Film 0805
Fixed Capacitor .1uF   10   10V Tin/Nickel Axial
Fixed Capacitor 1uF   10   10V Ceramic Axial
Fixed Capacitor 1.5uF   10   10V Ceramic Axial
Potentiometer 5k? 0.5 20 1W 10V Ceramic 6mm Rnd
Key
Not Applicable  
35
Block 1- Detailed Design DFM-Capacitor Specs

• Capacitors
• Rated to 10V
• 10 tolerance in Capacitance rating
• Axial packaging

36
Block 1- Detailed Design DFM-Packaging Selections

• The switch is mounted on the PCB.
• The pots are aux mounted on the controller.
• All other parts are SMT.

37
Block 1- Detailed Design Safety Features

• Provided Shock Protection ESD gt 15 kV
• Over Voltage Protection Diode gt 20 kVR
• Safety Standards 61000-4-2
• 61000-4-4

38
Block 1 Mfg Design BOM
39
Block 1- Detailed Design Light Switch
40
Block 1- Detailed Design Reference Voltage
Bandgap Vref
41
Block 1- Detailed Design DFM-DC Drive Analysis
Table
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters
Vil max Vih min Iil (-) Max Iih max Vol max Voh min Iol max Ioh Min Checked
S.T. Std TTL 1.2 3.5 -.4m 20u .5V 2.7 8mA -.4mA
Switch Std na TTL na na na na .4V 2.4 8mA -.4mA

• Vxx in Volts, Ixx in mA
• Source Currents Listed as Negative
• Std Standard

42
Block 1 Mfg Design PCB Layout
43
Block 1 Mfg Design Flow Chart/Assembly
Order/Receive Parts
Initial Assembly
Testing
Final Assembly
Ship to Customers/Stores
Final Testing
44
Block 1 Mfg Design Testing

• Functional tests are needed after initial
• assembly which include
• Checking outputs of block to look for desired
  voltage levels.
• Make sure all Functions work before final assembly

45
Block 1 Reliability Analysis Summary Table
46
Block 1 Reliability Analysis Unreliability

• Worst parts
• (According to Calculated FITS)
• Resistors at 72.8
• Potentiometers at 50
• OP-Amps at 38

47
Block 1 Obsolescence Analysis Summary
Worst part
48
Block 1 Legal/Societal/Ethical Aspects Summary

• Entire Block is ROHS compliant.
• Block includes no Hazardous materials.
• Due to automated placement of parts, block can be
  assembled anywhere.
• Most common failure i.e. pot breaking, will
  result if abused.

49
Controller Power Supply

• Designed by Brad LaCount

50
Controller Power SupplyDescription

• Converts a 9V DC input into a regulated 5V DC
  output.
• Distribute the output to the display, CPU,
  Rec/Tran circuit, and input signals.

51
Controller Power Supply Std Reqs Life Cycle
Requirement Units to Specify

• Product Life, Reliability
• Full Warranty Period
• Service Strategy

• 3 yrs
• 6 months
• Repair

52
Controller Power Supply Std Reqs Parts
Allocation

• Percent of Total
• 5
• 5
• 1
• 15
• 1
• 2

• Amount
• 10
• 4
• 1
• 50 cm2
• 72 cm3
• 50 g

• Allocation
• Component Count
• Component Cost
• Mfg Cost
• PCB Area
• Volume
• Mass

53
Controller Power SupplyStd Reqs Operation
Requirement Units to
Specify

• 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
• Standards

• 10-45 Co
• 10-90 non-condensing
• 0-3000 Meters
• 0-80Co
• 10-90 non-condensing
• 0-3000 Meters
• 1 year
• UL 1977

54
Controller Power SupplyStd Reqs Voltage and
Current
Requirement Units to Specify

• Max Input Voltage
• Min Input Voltage
• Max Input Current
• Max Output Voltage
• Min Output Voltage
• Max Output Current

• 9.0 V
• 6.0 V
• 1000 mA
• 5.05 V
• 4.95 V
• 1000 mA

55
Controller Power SupplyPerf Reqs Block

• Safety Features
• Reverse Voltage Protection
• Reverse Battery Protection
• Contain Two Operational Modes
• On/Off
• Power Input Type
• Six AA Batteries (1.5V)
• Power Input Minimum Life
• 4 Hours

56
Controller Power Supply Perf Reqs Power Signals
57
Controller Power Supply Perf Reqs Mechanical

• All but one power supply connection will be
  contained on the controller circuit board.
• The power connection to the display will be made
  using a 6 pin board to wire connector. It will
  contain the power and control lines.

58
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
59
Controller Power SupplyDesign Bill Of Materials
60
Controller Power SupplyDesign Block Diagram
61
Controller Power SupplyDesign Passive
Components

62
Controller Power SupplyDesign DFM Plan
Sub Circuit Type Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan
Task 1 Task 2 Task 3
5VDC Regulator Power Dissipation Junction Temperature Battery Life
63
Controller Power SupplyDesign Calculations

• Worst Case Power Dissipation of Regulator
• Input Voltage(Vin) 8.3V
• Output Voltage(Vout) 5V
• Input Current(Iin) 1000mA
• Ground Pin Current(IAD) 10mA
• Power Dissipated(PD) (Vin Vout)(Iin) Vin
  (IG) 4.2W

64
Controller Power SupplyDesign Calculations

• Junction Temperature
• Junction Temperature With Heat sink

65
Controller Power SupplyDesign Calculations
Battery Life Calculations
Using a standard 2500mAh battery we obtain the
following results for battery life
BLOCK TYPICAL MAX
Light Switch 500uA 800uA
CPU 2.5A 4.0mA
User Input 500uA 800uA
Display 6.0mA 525mA
TOTAL 9.5mA 530.6ma
CURRENT DRAW PER BLOCK
66
Controller Power SupplyBlock Reliability Analysis
67
Controller Power SupplyManufacturing Process

• Trace
• Width 5mils
• Spacing .1 mm

68
Controller Power SupplyManual Manufacturing
Processes

• Manual Attachment
• Place heat sink on regulator and secure with a
  screw.
• Attach the circuit board to the controller
  housing
• Create a 5 inch wire harness.
• Six wires Female connector on both ends
• Attach one to J1 on the controllers main circuit
  board and the other end to the display

69
Controller Power SupplyManufacturing Test Process

• Test 1 Battery Power Verification
• Action 2 Apply 9V to the power supply input
• Verify Output voltage 4.95-5.05 VDC

70
Controller Power SupplyBlock Obsolescence
Analysis
QTY Part Sigma V V2.5(Theta)-P V3.5(Theta)-P
    SIGMA      
           
1 Fixed Regulator 2004 6.5 3010.6 5014.6
           
2 Tantalum Capacitor 1985 10 2966.6 4951.6
           
2 Diode 1975 12.5 2944.1 4919.1
71
Controller Processor and Display

• Designed by Brad LaCount

72
Controller CPU and Display Description

• CPU
• The Processor is used to coordinate and executed
  the functions of the Controller
• Display
• Four line display
• Mounted on the controller
• Used to relay information to the user
• Able to view in dim/dark environment backlight

73
Controller CPU and Display Std Reqs Operation

• Requirement
• Min Oper Temp Range
• Min Oper Humidity Range
• Min Oper Alt or Press Range
• Min Oper Range (Distance)
• Min Storage Temp Range
• Min Storage Humidity Range
• Min Storage Alt or Press Range
• Max Storage Duration

• Value
• 0-45 Co
• 10-90 non-condensing
• 0-3000 Meters
• Line of Sight
• 0-80Co
• 10-90 non-condensing
• 0-3000 Meters
• 1 year

74
Controller CPU and Display Std Reqs Voltage and
Current
Requirement Units to Specify

• Max Input Voltage
• Min Input Voltage
• Max Input Current
• Max Output Voltage
• Min Output Voltage
• Max Output Current

• 5.1 V
• 4.9 V
• 600 mA
• 5.1 V
• 0 V
• 5 mA

75
Controller CPU and Display Std Reqs Mfg Life
Cycle

• Percent of Total
• 13.5
• 50
• 15
• 11
• 1
• 2

• Amount
• 27
• 40
• 3
• 36 cm2
• 72 cm3
• 50 g
• 3 yrs
• 6 months
• Dispose
• Repair

• Allocation
• Component Count
• Component Cost
• Mfg Cost
• PCB Area
• Volume
• Mass
• Product Life, Reliability
• Full Warranty Period
• Product Disposition
• Service Strategy

76
Controller Power SupplyPerf Reqs User Interface

• Lcd Screen
• Characters
• 20 characters X 4 Lines
• Resolution
• 120 X8 Dots per line
• Color
• Backlight - Green
• Characters - Black

77
Controller CPU and Display Perf Reqs Interface
Signals

• Analog
• Digital
• Power

78
Controller CPU and DisplayPerf Reqs Mechanical

• The power and control lines will be connected to
  the display using a 6 pin board to wire
  connector.
• The display will need to be mounted to the
  controller housing

79
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
80
Controller CPU and DisplayBill of Materials
81
Controller CPU and Display Design Block Diagram
82
Controller CPU and Display CPU Flow Chart
83
Controller CPU and Display Design Passive
Components

84
CPU and DisplayDFM Plan
Sub Circuit Type Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan Applicable Worst Case Analysis Plan
Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10
8 Bit A-D Converter R C Tol RC Specs Max Offset Error Max Gain Error Max DNL Error Max INL Error Input Impedance Worst Case Total Error Bits, Volts Sample/Hold Required? Conversion Speed
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters
Vil max Vih min Iil (-) Max Iih max Vol max Voh min Iol max Ioh (-) Min
CFA634-NFA-KS Std .8 2.0 1uA 1uA NA NA NA NA
PIC16F77 Std .75 2.0 1uA 1uA .6 4.3 3mA 3mA
85
CPU and DisplayDFM Plan
Digital Timing Analysis Table
Dig Signal Output Type Input Type Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters
Tsu Setup Th Thold Tsu Margin Th Margin Fmax F Margin Tpulse Min Tpulse Margin
CPU Siganl Std Std 200n 400n .1 .1 20M .1 5M .01
86
Controller Power SupplyBlock Reliability Analysis
87
Controller CPU and Display Manual Manufacturing
Processes

• Soldier 6 pin surface to cable connector
• Manual Attachment
• Mount the Display to the controller housing

88
Controller Power SupplyBlock Obsolescence
Analysis
QTY Part Sigma V V2.5(Theta)-P V3.5(Theta)-P
    SIGMA      
           
1 PIC 1990.5 9.2 2979.55 4970.05
           
1 Tantalum Cap 1985 10 2966.6 4951.6
2 Polyester Cap 1985 10 2966.6 4951.6
           
1 Crystal Oscillator 1975 12.5 2944.1 4919.1
           
24 Film Resistor 1985 10 2966.6 4951.6
89
RF Transceivers

• Designed by Sean Murphy

90
Block 4 - RF

• Two way real time digital communication between
  controller and car processors
• Feeds information to car such as speed,
  direction, and light control
• Feedback information to controller on battery
  life, speed, and direction
• Server - client configuration 50 Tx/Rx

91
Block 4 - RF Standard Requirements

• Value
• 10 - 45 Co
• 10-90 non-condensing
• 300ft
• 0-80 Co
• 10-90 non-condensing
• 1 year
• 0 - 80 Co

• Requirement
• Min Oper Temp Range
• Min Oper Humidity Range
• Min Oper Range Min
• Storage Temp Range
• Min Storage Humidity Range
• Max Storage Duration
• Max Storage Temp Range

92
Block 4 - RF Standard Requirements Continued

• Requirement Value Of Total
• Total Parts lt15 5
• Area 64cm2 20
• PCB Area 75cm2 22
• Weight 16oz 13
• Product Mat. Cost -- 30

93
Block 4 Performance Requirements

• Requirements
• Modes
• Input Power
• Current Consumption
• Packet Size
• Operating frequency
• Antenna
• Regulations
• Standards
• Connectors

• Value
• On/Off Tx/Rx
• 5V DC 2, 50mVpp ripple
• 115mA
• 3 bytes
• 2.4GHz
• ½ Wave Dipole
• FCC Parts 15 and 27
• CISPR 61000-6-3 IEC, 47CFR2
• 20 Pin Mini Connector
• MMCX

94
Antenna

• Current consumption
• Transmit 115mA
• Receive 85mA
• Input Characteristics
• Sensitivity -90dBm
• Gain 3dBi
• Output Power
• Conducted 10mW
• EIRP 20mW
• (Effective Isotropic Radiated Power)

95
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
96
Block 4 Signals RF
Car Processor
Digital
5V DC
Transmitted Bit Package Car To Controller Speed
Indicator Direction Indicator Battery Life
Power Supply
RF Transceiver
Digital
Transmitted Bit Package Controller To Car Speed
From User Dir From User Lights On/Off/Ambient
Power Supply
RF Transceiver
5V DC
Digital
Ctrlr Processor
97
Transmit/Receive Flow Chart
Processor
Demodulation, Decoding
8 data bits 1 start bit 1 stop bit
CTS Condition
Buffer
Buffer
Modulation, Encoding
RTS Low
24 bits
8 data bits 1 stop bit 1 start bit
Transmit Data
Processor
Hop Frame
Receive Data
Full duplex mode prevents transceivers from
transmitting at the same time
98
Block 4 BOM
Total Cost 205.72
99
Block 4 Transceiver, Processor, and PS Interface
100
Block 4 - Timing Analysis
Interface time out specifies byte gap, adjustable
in decrements of 160µs.
RF Mode Interface Baud Rate Duplex Direction Throughput (bps)
Acknowledge 115,200 Full Both Ways 40k
101
RF Transceiver Power
RF Transceiver Digital
102
Block 4 - RF
103
Block 4Reliability
104
Power Source

• Designed by Sean Murphy

105
Theory Of Operation

• Monitors voltage drop across sense resistor to
  determine discharge activity.
• The fuel gauge is a coulomb counter, initial
  nominal capacity is preprogrammed. Recalibrated
  after full discharge cycle.
• Accounts for temperature, self-discharge, and
  rate of discharge.
• Capacity is recalibrated in course of discharge.
• Nominal capacity is indicated through serial
  link.
• Registers include energy, temp, voltage, current,
  and status.

106
Block 5 Car Power Source

• Provides power to all on car devices and
  functions
• Indicates battery life remaining to processor
• Will require voltage regulation

107
Standard Requirements

• PS Type
• Source Type mAh
• Oper Temp Range
• Storage Temp Range
• Vo Regulator
• Vp-p Ripple Max
• Io(Max)
• Connection
• Safety

• Nimh Battery Pack
• DC, 6000mAh max
• 10 - 45 Co
• 0 - 80 Co
• 5V 2
• 50mV
• 350mA
• Temporary
• UL 2054,1989 (Batteries)

108
Standard Requirements Continued

• Requirement Value Of Total
• Total Parts lt25 15
• Area 200cm2 50
• PCB Area 100cm2 30
• Weight lt16oz 13
• Prdct Mat. Cost lt80 10

109
Performance Requirements

• Voltage Regulator
• VR Type LDO High Discharge
• Vin Min/Max 5.3V/10V
• Vo Nominal 5V
• Vo Max Tol 2
• Vp-p Ripple Max 50mV
• Io Max 200mA
• Dropout Voltage 300mV

• Fuel Gauge
• Type Gas Gauge
• Vin Battery Min/Max 5V/10V
• Vin Supply 4.95/5.05V
• Accuracy 15

110
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
111
Block 5 Car Power Source Block Diagram
Nimh Battery Pack
0-9.6V
Fuel Gauge
Back-up Battery
3.8V
Voltage Regulator (5V Nominal)
Car Processor
Direction Sensor
5.5-9.6V
Speed Sensor
Lights
RF Trans / Rec
Electromechanical Control
0-9.6V For Motor
112
Block 5 Voltage Regulator Detailed Design

• Want Cout large due to large changes in current.
• Want ESR low to reduce ripple
• Start up time inversely a CBYP (15ms CBYP
  .01µF, COUT10µF)
• With CBYP .01µF, output settles within 1 for
  10mA to
• 500mA load step in less then 10µs.

113
Voltage Regulator
114
Block 5 Fuel Gauge Detailed Design

• Rsense is chosen by looking at the lowest
  current representing the majority of the battery
  drain so that the voltage across it is 5-7mV
• 85mA _at_ 6mV, Rsense .0705
• RB1 and RB2
• Back-up battery
• 3V 170mAh
• 1.5V 163mAh
• Storage cap 4F 24.7hrs

115
Block 5 Fuel Gauge Detailed Design
PFC BatCapRsense231
116
Fuel Gauge Operational Overview
117
Block 5 BOM
Total cost 66.00
118
(No Transcript)
119
Power Source Power
Fuel Gauge Digital
120
Block 5 Car Power Supply
121
Block 5Reliability
Component Type FIT pT pV pE pQ Total FIT Qty Total
Resistor-10V Metal Film 0.7 1.48 0.82 5 1.25 5.31 4 21
Resistor-5V Carbon 18.2 1.96 0.83 5 1.25 185 3 555
Capacitor Va5V,Vr100 Ceramic 2 2.11 0.86 5 1.25 24 1 24
Capcitor-Va10V,Vr100V Ceramic 2 2.11 0.91 5 1.25 24 5 120
Capacitor Va5V,Vr50V Ceramic 2 2.11 0.91 5 1.25 24 1 24
Capacitor Tantulum 15 10.6 2.22 5 1.25 2081 1 2081
Diode-5V Schottky 2.4 1.55 2.23 5 1.25 51.8 1 51.8
Diode-10V Schottky 2.4 1.55 2.23 5 1.25 51.8 1 51.8
Battery NimhLi-ion 7 1 1 5 1 35 2 70
LED Bulb 9 10.6 0.818 5 1.25 488 1 488
Fuel Gauge Gas Gauge 19 270 9.97 5 1 5179 1 5179
Voltage Reg. Linear 14 2.11 2.22 5 1 328 1 328
Total FIT 8946
122
Car Processor

• Designed by Russ Diamond

123
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
124
Block 6 Car Processor Function and Purpose

• Interprets signals from the transceiver and
  outputs control signals to the rest of the board.
• Data sensed on the car is sent to the transceiver.

125
Block 6 Car Processor - Standard Requirements

• Parts Count
• Block Area
• Block Weight
• Voltages and current requirements
• EMC standards

• lt 25 parts
• lt 15 cm2
• lt 1 ounce
• 1, 5V input
• Imax 10mA
• Radiated Emissions CISPR11

126
Block 6 Car Processor - Standard Requirements
Environmental

• 10-45 Co
• 10-90 non-condensing
• 0-3000 Meters
• 0-80Co
• 10-90 non-condensing
• 0-3000 Meters
• 1 year

• 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

127
Block 6 Car Processor Performance Requirements

• Operational modes
• Mechanical Interfaces
• Serial interface
• CPU Frequency
• Maximum interrupt length

• On, Off
• Transceiver
• 115,200 KBaud interface
• 20 MHz
• 50 inst. cycles .00001s

128
Block 6 Car Processor Performance
RequirementsSignal Table

129
Block 6 Car Processor Detailed DesignBlock
Diagram
Inputs
Outputs
5V from Power Supply
CPU for Car
DO to steering servo
Analog Input from Battery Sense circuit
DI Speed Indicator
3 DO for Lights
DI data from Transceiver
Transceiver Data Request
DI from Compass
4 DO for Motor Control
DI from Photocell
Clock signal from Crystal
DO to Transceiver
130
Block 6 Car Processor - Detailed DesignSchematic
131
Block 6 Car Processor Detailed DesignTheory
of Operation

• Main Processor tasks
• Control Motor Speed and direction.
• Output servo control pulse for steering system.
• Receive and transmit data to transceiver.
• Poll compass for direction data and translate
  received data to direction in degrees.
• Count pulses from speed sensor.
• Communicate with fuel gauge for battery life
  readings.
• Check photo sensor input when in automatic
  lighting mode.

132
Block 6 Car Processor Detailed DesignReceive
and transmit data to transceiver

• Calculations
• The PIC16F777 has a built in AUSART.
• Used asynchronously
• Timing based off the 20 MHz oscillator
• Required 115,200 -3 Baud Rate to communicate to
  the transceiver.
• Set up gt SPBRG (Fosc/(16115,200))-1 10
  
  BRGH 1
• Baud Rate 113636.36 1.4 difference
  acceptable
• Data is packaged 8 data bits, 1 start bit, 1 stop
  bit 10 bits
• Timing calculations
• 8.89u seconds/bit 10 88.9u seconds till
  possible overflow occurs or 444 instruction
  cycles.

133
Block 6 Car Processor Detailed DesignReceive
data from transceiver

• Flowchart and Code
• Receive
• btfsc Rec_Data_Counter, 1
• goto lights
• btfsc Rec_Data_Counter, 0
• goto steering
• Speed

134
Block 6 Car Processor Detailed DesignData
Requested by Transceiver/TXREG Interrupt

• Theory of Operation
• Interrupt from PORTB interrupt on change pin
• Interrupt generated when CTS pin from transceiver
  goes low
• Outputs first byte of data to the AUSART
• Starts secondary interrupt TXREG request
• Interrupt occurs when TXREG empties after data is
  sent
• Timing Calculations
• 10,000 instruction cycles between data being sent
  by transceiver.
• .002 / 2e-7
• 444 inst. Cycles between bytes loaded into
  register
• 8.89e-6 s / bit at 115,200 baud 225 bits sent
  possible

135
Block 6 Car Processor Detailed DesignData
Requested by Transceiver/TXREG Interrupt
Transceiver requests data
136
Block 6 Car Processor Detailed DesignData
Requested by Transceiver/TXREG Interrupt
TXREG requests next byte
137
Block 6 Car Processor Detailed DesignDFM
Analysis
Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide)
Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10
Crystal oscillator Voltage vs Freq Phase vs Freq Slew rate BW Step Resp Input Impedance Output Impedance DC Offset V Total Noise
Input Capacitor C Tol C spec Voltage vs Freq Phase vs Freq Slew rate BW Input Impedance Output Impedance DC Offset V Total Noise


138
Block 6 Car Processor Detailed DesignDFM
Analysis
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters
Vil max Vih min Iil (-) Max Iih max Vol max Voh min Iol max Ioh (-) Min Vhyst Checked
Micro TS TS .75 2.0 -1u 1.0u .6 4.3 8.5m -.3m 1.25

Dig Signal Output Type Input Type Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Other
Tsu Setup Th Thold Tsu Margin Th Margin Fmax F Margin Tpulse Min Tpulse Margin Checked
Micro signals TS TS 200n 400n .1 .1 20M .1 5M .01
139
Block 6 Car Processor Detailed
DesignComponent DFM Analysis
140
Block 6 Car Processor Detailed DesignAnalog
DFM Analysis
141
Block 6 Car Processor ManufacturingBill of
Material
142
Block 6 Car Processor ReliabilityBlock Summary

• The crystal oscillator is the main driver of
  unreliability. A larger temperature range would
  improve its reliability.
• The CPU also has low reliability. It could be
  improved by operating it at a lower voltage.

143
Block 6 Car Processor ReliabilityObsolescence
Block 6 Obsolescence Block 6 Obsolescence Block 6 Obsolescence Block 6 Obsolescence Block 6 Obsolescence Block 6 Obsolescence
  v sigma p 2.5 3.5
CPU 1994.5 7 2005.9 6.1 13.1
crystal 2001.5 7.8 2005.9 15.1 22.9
Capacitor 1980 14 2005.9 9.1 23.1
Resistor 1980 8.5 2005.9 -4.65 3.85
144
Electromechanical Control

• Designed by Russ Diamond

145
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
146
Block 7 Electromechanical ControlFunction and
Purpose

• Generates an analog voltage across the voltage
  terminals of the motor
• Controls the steering of the car

147
Block 7 Electromechanical ControlStandard
Requirements

• Parts Count
• Block Area
• Block Weight
• Voltages and current requirements
• EMC standards

• lt 20 parts
• lt 15 cm2
• lt 2 ounces
• 5V, 1 input, Imax 10mA
• Vbatt input, 5.3V 12V
• Imax 10A
• Radiated Emissions CISPR11

148
Block 7 Electromechanical ControlStandard
Requirements - Environmental

• 10-45 Co
• 10-90 non-condensing
• 0-3000 Meters
• 0-80Co
• 10-90 non-condensing
• 0-3000 Meters
• 1 year

• 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

149
Block 7 Electromechanical ControlPerformance
Requirements

• Operational modes
• Mechanical Interfaces
• Safety features
• Digital interface
• PWM Frequency
• Maximum pulse width error

• Forward, Reverse, Stopping Stopped
• Motor
• Warning labels
• 50 Hz interface
• 15 kHz
• .00001s 1

150
Block 7 Electromechanical ControlPerformance
Requirements Signal Table

151
Block 7 Electromechanical ControlDetailed
Design - Block Diagram
Motor Control Circuit
4 Digital inputs
2 Analog outputs
To Motor
Steering Servo
1 Digital Input
152
Block 7 Electromechanical ControlDetailed
DesignMotor Drive Schematic (H-bridge)
153
Block 7 Electromechanical ControlDetailed
Design Theory of Operation
State Table

• This system creates an analog voltage
• across a permanent magnet DC motor
• using Pulse Width Modulation.
• The n-channel mosfets are driven
• with a variable duty cycle 15KHz signal.
• Direction control is achieved by turning on the
  correct mosfet pattern.
• This method achieves continuous current through
  the motor and a very high efficiency.
• The BJT transistors provide a simple method of
  controlling the upper p-channel mosfets.

  Q1 Q2 Q3 Q4
Forward off on on off
Reverse on off off on
Coast off off off off
Brake on on off off
154
Block 7 Electromechanical ControlDetailed
Design Calculations

• Rise time N-channel 180ns
• Fall time N-channel 80ns
• Power loss calculations
• I 10A, F 15KHz
• On time .6W at 100 dc
• Off time 0W
• Turning off .135W
• Turning on .12W
• Max power dissipation .6W
• Heat rise 62.5.6 37.5C

155
Block 7 Electromechanical ControlDetailed
Design Calculations

• The TMR2 module controls the PWM frequency
• Desired frequency 15KHz
• Period (PR2)1 4 Tosc TMR2prescale
• TMR2prescale 2, PR2 165
• Achieved frequency 15060Hz

156
Block 7 Electromechanical ControlDetailed
Design Flowcharts
Forward
Reverse
157
Block 7 Electromechanical ControlDetailed
Design Flowcharts
Forward
158
Block 7 Electromechanical ControlDetailed
Design Code

• Speed
• movf RCREG, 1 RCREG -gt W
• movwf speed_var W -gt speed_var
• btfss speed_var, 7 test bit seven to check
  direction
• goto Reverse if bit is clear direction is
  reverse
• Forward
• btfsc F_R, 0 test bit 0 to see if unit is
  stopped
• goto drive_f if bit 0 is set goto forward
  drive
• btfsc F_R, 1 test bit 1 to see if unit is
  stopping
• goto F_PSS if bit 1 is set goto further
  checks
• btfss F_R, 2 test bit 2 to determine current
  direction
• goto stop if bit 2 is clear stop the car
• goto update_FPWM if bit 2 is set update the
  duty cycle
• Reverse
• btfsc F_R, 0 test bit 0 to see if unit is
  stopped
• goto drive_r if bit 0 is set goto reverse
  drive
• btfsc F_R, 1 test bit 1 to see if unit is
  stopping
• goto R_PSS if bit 1 is set goto further
  checks
• btfsc F_R, 2 test bit 2 to determine
  direction moving

159
Block 7 Electromechanical ControlDetailed
Design more Code

• movwf CCPR1L puts reult in CCPR1L to set duty
  cycle of PWM
• clrf F_R clear F_R
• bsf F_R, 2 set forward bit
• goto end_speed
• R_PSS
• btfsc F_R, 2 test bit 2 to check direction
  moving
• goto end_speed if bit 2 is set continue
  stopping
• drive_r if bit 2 is clear drive car reverse
• bcf PORTD, RD0 turn off Q3
• movlw clear 0 -gt W
• movwf CCPR1L put 0 into CCPR1L
• bsf PORTD, RD1 turn on Q4
• update_RPWM
• movf speed_var, 0 puts temp_variable into w
• addwf speed_var doubles speed_var
• comf speed_var, 0 complements speed_var
• movwf CCPR2L puts result in CCPR2L to set
  duty cycle of PWM
• clrf F_R update info in F_R - clear all bits
  in this case
• goto end_speed

160
Block 7 Electromechanical ControlDetailed
Design Steering Schematic
Position Control is achieved by sending a pulse
to the servo every 20ms. The length of the pulse
determines the positioning of the servo.
161
Block 7 Electromechanical ControlDetailed
Design Theory of Operation

• This system receives a control signal in from the
  CPU in the form of a pulse from 1 to 2 ms in
  length at a rate of 50Hz.
• How its Implemented
• TMR1 is set up to overflow every 20ms.
• TMR0 is then preloaded with a value that will
  cause it to overflow between 1 and 2ms based on
  input.
• When TMR0 overflows it is turned off until TMR1
  overflows and sets it again.
• Maximum interrupt length is set to 50 instruction
  cycles to keep error of output pulse 1 or less.

162
Block 7 Electromechanical ControlDetailed
Design Calculations

• TMR1 increments every
• instruction cycle.
• It is a 16 bit timer so with
• a pre-scaler of 2 it will overflow every
  26.2ms.
• Preload the upper byte of the timer with
  15616 b00111101 -gt TMR1H
• Setup TMR0 using a pre-scaler of 64.
• 28 2e-7 64 overflows after 3.28 ms
• Input 78 .9984 ms (full right steering)
• Input 156 1.997 ms (full left steering)

163
Block 7 Electromechanical ControlDetailed
Design Code
steering movf RCREG, 1 RCREG -gt
W movwf steering W -gt steering end_steering
incf Rec_Data_Counter goto end_Receive
this routine turns off the servo output after a
specific time TMR0_int bcf PORTB, RB1 turn
off output pin bsf OPTION_REG, 5 turns off
tmr0 end_TMR0 reset interrupt goto
end_isr this routine starts the servo output
and checks the lights if they're in auto mode
this routine moves temp_speed to speed_sensor and
resets temp_speed this routine causes an
interrupt every 20 ms TMR1_int movf temp_speed,
0 temp_speed -gt W movwf speed_sensor W
-gt speed_sensor btfsc status, Z check
zero bit in status register bsf F_R, 0 if
temp speed 0 set stopped bit in
F_R clrf temp_speed clear temp_seed for next
period movf steering, 0 steering -gt
W movwf TMR0 W -gt TMR0 bsf PORTB, RB1
set servo output pin bcf OPTION_REG, 5 turns
tmr0 on
164
Block 7 Electromechanical ControlDetailed
Design - DFM Analysis
Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide) Applicable Worst Case Analysis Plan (See DFM Analysis Guide)
Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10
Mosfet Drivers R, L C Tol RLC Specs Gain vs Freq Phase vs Freq Slew rate BW Step Resp Input Impedance Output Impedance DC Offset V Total Noise
Current Diodes R, L C Tol RLC Specs Gain vs Freq Phase vs Freq Slew rate BW Step Resp Input Impedance Output Impedance DC Offset V Total Noise
Resistor R, L C Tol RLC Specs Max Offset Error Max Gain Error Max DNL Error Max INL Error Input Impedance Worst Case Total Error Bits, Volts Sample/Hold Required? Conversion Speed


165
Block 7 Electromechanical ControlDetailed
Design - DFM Analysis
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters
Vil max Vih min Iil (-) Max Iih max Vol max Voh min Iol max Ioh (-) Min Vhyst Checked
Traxxas 2015 servo Mec Std. .80 3.5 -.1m .1m n/a n/a n/a n/a 2.7
Digital Signal Output Type Input Type Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Other
Tsu Setup Th Thold Tsu Margin Th Margin Fmax F Margin Tpulse Min Tpulse Margin Checked
Q1 Std. n/a n/a n/a n/a 15KHz n/a n/a n/a
Q2 Std. n/a n/a n/a n/a 15KHz n/a n/a n/a
Q3 Std. n/a n/a n/a n/a DC n/a n/a n/a
Q4 Std. n/a n/a n/a n/a DC n/a n/a n/a
Servo Std. 1m 2m 50 Hz 1m

166
Block 7 Electromechanical ControlDetailed
Design - Component DFM Analysis
Analog DFM Analysis
167
Block 7 Electromechanical ControlDetailed
Design - Safety

• The largest safety concern is the motor which can
  get extremely hot after continued use. There are
  warning labels on it ,but a guard around it may
  be a good idea.
• Justify wire gauge
• 10 gauge wire to the motor to handle the current
  demands
• Board trace width between the motor and power and
  ground 200 mills

168
Block 7 Electromechanical ControlManufacturing
Bill of Materials
169
Block 7 Electromechanical ControlReliability -
Block Summary

• The main driver of unreliability in this
  situation is the servo. A higher maximum voltage
  rated part would improve its performance.

170
Block 7 Electromechanical ControlReliability -
Obsolescence
Block 7 Obsolescence Block 7 Obsolescence Block 7 Obsolescence Block 7 Obsolescence Block 7 Obsolescence Block 7 Obsolescence
  v sigma p 2.5 3.5
Resistor 1980 8.5 2005.9 -4.65 3.85
MOSFET 2004.5 8.3 2005.9 19.35 27.65
BJT 2004.5 8.3 2005.9 19.35 27.65
Capacitor 1980 14 2005.9 9.1 23.1
servo 2001.5 7.8 2005.9 15.1 22.9
171
Car Signals

• Designed by Adam Wozniak

172
Block 6 Car Sensing

• Signals if the lights are on or off
• Uses light detection to determine if lights
  should turn on or off
• Signals how fast the car is going
• Signals in which direction the car is moving

173
Standard Requirements

• Conforms to EMC Standard EN 61800-3
• (Adjustable speed electrical power drive
  systems )

174
Standard Reqs Car Sensor
Requirement Definition

• Max of PC Boards
• Max PCB area
• Max Parts Count
• Operating Temp
• Storage Temp
• Operational Mode
• Mechanical Interface
• Safety Feature
• Voltage Range
• Max Current

• 3 (10)
• 30 cm2 (4)
• 20 (5)
• 10-60 C
• 0-80 C
• ON
• Sensors
• Withstands up to 50Gs
• 5.7 V
• 7mA

175
Performance Reqs Car Sensor
Requirement Definition

• Direction Sensor
• Accuracy
• Response Time
• Speed Sensor
• Accuracy
• Updates
• Speed Range
• Light Sensor
• Sensitivity

• 8 Directional Units
• 200 ms
• 3 mph
• 200 ms
• 0-40 mph
• 100fc

176
Team 2 Project 1Block Assignment
Digital
RF Trans / Rec Sean 4
RF Trans / Rec Sean 4
Digital
Digital
Digital
Car Processor Russ 6
On Car Sensing Adam 8
Ctrlr Processor Brad 3
Power Supply Brad 2
Digital
Analog
Analog
Electromechanical Control Russ7
Digital
Signal Input Display Barry 1
Power Source Sean 5
PCB 2, power supply will be connected to all
blocks
PCB 1, power supply will be connected to all
blocks
177
Block 8 Car Sensing
Car Processor
Direction Digital
Direction Sensor
Controller Processor
Transmit to/from Processor
Speed Sensor
Speed digital
Lights digital
Light Sensor
Comparator
Lights digital
Power
Lights
Lights digital
178
Bill Of Materials

I have approximately 10 of the budget for Parts
179
Diagrams
CLK from Processor
180
Block 6 Car Processor Detailed DesignSpeed
Sensor

• Calculations
• Miles per pulse
• 2piradius / 3663360
• Time period
• TMR1 rollover 19.97ms
• Speed per pulse
• miles per pulse / time period (hrs) .993
  mi/hr
• Theory of Operation
• Every time a pulse occurs the firmware increments
  a variable.
• Every time TMR1 overflows the variable is saved
  as the cars speed.
• If the variable 0 set the stopped bit in the
  F_R variable.
• Max interrupt frequency 2000 Hz
• 40 mph max 40 pulses / .02 seconds

181
Car Sensor Power
Car Sensor Digital

182
Digital Block DFM - DC Drive Analysis Table
Dig Device Output Type Input Type Tech Type DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters DC Drive Device Parameters
Vil max Vih min Iil (-) Max Iih max Vol max Voh min Iol max Ioh (-) Min Vhyst Checked
Direction Sensor Std NA TTL NA NA NA NA 5.2V 4.8V 7mA 3mA NA
Speed Sensor Std NA TTL NA NA NA NA 5.2V 4.8V 7mA 3mA NA
Comparator Std NA TTL NA NA NA NA 5.2V 4.8V 7mA 3mA NA

• Std Standard, OC Open Collector/Drain, TS
  Tristate, ST Schmitt Trigger

183
Passive Component Specifications
184
Digital Block DFM - Timing Analysis Table
Dig Signal Output Type Input Type Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Timing Parameters Other
Tsu Setup Th Thold Tsu Margin Th Margin Fmax F Margin Tpulse Min Tpulse Margin Checked
HM55B Std Std 30ns 30ns 100ns 30ns 5MHz 1MHz 30mS 40mS

185
Reliability Slide
186
Reliability Conclusions Block 8

• The total FITs are 204, thus the MTBF is 559
  years
• The most unreliable parts are the resistors, and
  the comparator
• The reliability could be better if we could get
  better resistor reliability

187
Component Life Parameters
188
Obsolescence Table

• None of my parts are obsolete
• The capacitors are going to be obsolete
• BUT we have many vendors for that part

189
Special Mfg and Testing

• The Photocell will need to be mounted such that
  it is able to sense outside light.
• The speed sensor will need to be mounted within a
  ¼ inch of the wheel gear

190
Prototyping Slides
191
Product Assembly

• We will try to use as many SMT components as we
  can.
• We will use a Perfboard to connect all components.

192
Master Parts List
193
Master Parts List
194
Assembly Steps

• Step 1- Program processors
• Step 2- Assemble components on PCB1/PCB2
• Step 3- Construct Car, Mount Battery, Mount PCB,
  Mount sensors to appropriate locations, Mount
  Display on Controller
• Step 4- Perform performance tests
• Step 5- Place car and manual in package

195
Life Stress Model

• Over 1 year the product will be turned on and off
  365 times
• It will go through 100 thermal cycles ranging in
  Temperature from -20C 80C
• It will go through 3650 shock cycles on the
  magnitude of 20 Gs

196
Reliability Growth Plan
197
Reliability Conclusions

• The total FITs are 17909, thus the MTBF is 6
  years and 4 months
• 7.5 of products will fail in the warranty period
• The most unreliable parts are the servo and the
  crystal oscillator

198
Patents

• Radio-controlled toy car, United States Patent
  4457101 Matsushiro, Yukimitsu
• Remote-control toy car set , United States Patent
  6746304 Liu, Shu-Ming
• Remote control toy car control system , United
  States Patent 6585618 Lu, Ke-Way

199
We would like to thank

• Jeff Kautzer
• Chris Merkl

For their help with this project
200
Any Questions?
201
The End