Download EE595_Team4_P3_Fall07

Remote Controlled Car
1
Team #: 4
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Jordan Acevedo
Phosay Bouapha
Corey Preuss
Ben Reider
Lee Strauss
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•
•
•
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BSEE
BSEE
BSEE
BSEE
BSEE
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Team #4: Expertise & Experience

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
•
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 Terms at Kohler Corp.
Expertise: Power Supplies & Amplifiers
Experience: None
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Proposed Product Summary

Selected Product
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Remote Controlled Power Wheels Car
Purpose: Entertainment
Details

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Miniature toy replica of a car, controlled remotely.
Unique additions:
• Proximity sensors, user is less likely to break product by running
it into a wall.
• Remote control triggered directional blinkers.
• Headlights adjustable to environmental intensity.
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
There are similar products, but not identical due to unique
additions.
The major industry family the product belongs to is consumer
toys.
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Project Selection

Overall Selection Process
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The remote controlled car project provided more
options for individual blocks.
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.
5
System Level Performance
Requirements
 Remote controlled (frequency band)
 Forward, Reverse, and Speed Sensitive
 Proximity sensors
 Detection of distance from nearby objects and emergency
power shut off if car gets too close.
 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 capabilities
dependant on surrounding environment.
 Blinkers
 Array of LEDs that will blink based on RF input from the
remote control 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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142 Total Parts
25 Unique Parts
$105 (Parts+Mfg=Product Cost)
$50
4 yrs
6 months
Repair
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Market
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Common Competitor: No true competitor in similar scale,
though many competitors in the remote controlled car
field.
List Price: $475
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Our Add On Portion: 30% ($142.50)
Market Geography: Worldwide
Market Demography: Adults
Market Industry: Recreation, Education
Material Cost: $105
Manufacturing Cost: $25
Annual Volume: 10,000
Return On Investment
Adjusted to Add On Portion
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Annual Revenue:
$1,425,000
Cost Margin:
$12.50
Cost Margin %:
8.77%
Annual Cost Margin: $125,000
Development Cost: $20,000
ROI: $45,000/$125,000 = 36.0%
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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Performance Requirements
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Remotely Controlled at 75.97 KHz
Able to operate at various battery voltages (12-48V)
Capable of speed regulated forward and reverse
Remote Controlled directional lights
Dimming Headlights
Proximity sensing collision protection
Team Block Diagram
DC-DC
Converters
Battery
Motor
PWM
Microprocessor
Lee Strauss
Jordan Acevedo
Ben Reider
Corey Preuss
Phosay Bouapha
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 and 12
In: DC12-48V
Out: 5 VDC
Out: 12 VDC
None
None
2
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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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
:
•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
15.00
0.00
Product Design and Development
10/3/07
25.00
0.00
Process Design and Development
10/22/07
20.00
5.00
Product and Process Validation
11/12/07
0.00
15.00
Feedback Assessment and Corrective Action
11/26/07
0.00
15.00
Production
12/3/07
0.00
15.00
Planning
Product Design and Development
Process Design and Development
Start Date
Completed
Product and Process Validation
Remaining
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:

Control the speed and direction of the car.
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Block 2: PWM Controller
Block Diagram
Power Supply (+5V)
In From Front Proximity Sensors
NOT Gate
(Direction)
To Motor
AND Gate
In From Rear Proximity Sensors
Input RF Signals
Micro Processor
(Speed) To Motor
Power Supply (+5V)
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Block 2: PWM Controller/Micro-Processor
Block Signal Definitions
Block Name:
Block Number:
PWM Controller/MicroProcessor
4
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
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 the second pulse 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 Front or Rear IR Proximity Sensor are
tripped “ON”, the car will no longer be able to
drive in that direction, when that sensor is “OFF”
again, full operation will be restored.
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Block 3: Blinkers
Owner: Ben Reider
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Description
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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.
Purpose
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An accessory used to indicate which direction
the car turn.
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Performance Requirements
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Power Inputs
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5V Supply
• 2 – 5.5 VDC
• 20mA
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12V Supply
• 10 – 14.8 VDC
• 60mA
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Max Total Power Displaced
• 2.31 Watts
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Operation Modes
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On/Off
User Interface
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Remote Controlled
Standard Requirements
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Electrical Interfaces
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5VDC @ 250mA Power Supply
12V Battery
75.95 KHz Input Frequency
1 Hz Output Frequency
Environmental
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Operating Temp Range
Operating Humidity Range
Operating or Press Range
Storage Temp Range
Storage Humidity Range
Storage Altitude or Press Range
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-40-85 C°
20-95% non-condensing
0-3500 Meters
-65-150C°
0-90% non-condensing
0-3500 Meters
Standard Requirements
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Manufacturing
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Block Cost
Part Count
Unique Part Count
Block Size
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Block Mass
Block Volume
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$5.01
53
4
15X20mm Light Arrays
2.8”X3.8” PCB Board
??
??
Block #3
Blinkers Block Diagram
12V Battery
5 VDC Power Supply
PNP
Transistor
Front
Light Array
Rear
Light Array
Microprocessor
PIC12F509
8 Pin, DIP
RF Signal
PNP
Transistor
Front
Light Array
Rear
Light Array
30
Theory Of Operation
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Micro-Controller receives RF input
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Ignores pulses prior to 5th pulse
Measures pulse width of 5th pulse
Interprets which directional blinkers should be
activated
Outputs a 5V pulse @ 1 Hz
Transistors receives 1 Hz input
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Switches 12V source @ 1 Hz to LEDs
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
1/2 Sec Delay 1/2 Sec Delay
Output LeftBlink=0
RightBlink=0 Output
1/2 Sec Delay 1/2 Sec Delay
Block #3 Component Selection
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LEDs
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Transistors
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40V Source to drain Voltage which meets and well exceeds the source
voltage of 12V
Low cost
Low power dissipation at 350mW Max
Microprocessor
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Low cost and Long Lifetime
Robustly built
Low Power (40mW each)
Least expensive yet meet programming requirements
6 output/input
Can handle the max current input of 150mA
Lower Power (800mW Max)
Resistor
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12V Input with 3 parallel rows of 4 LEDs in series and a transistor
voltage drop
Voltage Applied: 12V-(2V*4)-0.4V = 3.6V
Current Applied: 20mA + 20mA +20mA
3.6/0.06 = 60 Ohms @ 200mW
33
Block #3 Preliminary Schematic
34
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
PNP Transistor
MMBT3906-TPTR-ND
Col. To Em. V
40V
Ic Continous Col.
100mA
LEDs
516-1296-ND
Forward V
2.0V
Forward I Nom.
20mA
Size
3mm Round
Power Dissipated
40mW
Resistor
P60.4FTR-ND
Material
Ceramic
Ohms
60.4
Power
0.25W
Tolerance
+/- 1%
Resistor
P1.0kWTR-ND
Material
Ceramic
Ohms
1k
Power
0.25W
Tolerance
+/- 1%
Capacitor
ECJ-2VF1H104Z
Material
Ceramic
Capacitance
0.1uF
Voltage
50V
Tolerance
+/- 10%
Frequency
4 MHz
Em. To Base Break V. Total P Dissipated Col. To Em. Sat V
5V
350mW
0.4V
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PCB Board Layout
Block #3 Bill of Materials
Production
Component
Quantity
Cost Each
Quantity Cost
Microprocessor
PIC12F509-I/P-ND
1
0.64
0.64
PNP Transistor
MMBT3906-TPTR-ND
2
0.015
0.03
LEDs
516-1296-ND
48
0.09
4.32
Resistor
P60.4FTR-ND
2
0.01
0.02
Total Cost 5.01
37
Block #3 Bill of Materials
Prototype
Component
Quantity
Cost Each
Quantity Cost
Microprocessor
PIC12F509-I/P-ND
1
1.28
1.28
PNP Transistor
2N3906
2
N/A
LEDs
516-1296-ND
24
0.36
Resistor
50 Ohm
2
N/A
8.64
Total Cost 9.92
38
Block 4: Proximity Sensor
Owner: Corey Preuss
Part #: GP2Y3A003K0F
(from Digikey)
Wide Angle Distance Measuring
sensor unit (40 – 300cm)
39
Block 4:
Block Level Requirements
• Must work off of a 5 Vdc power supplied
• Must be able to handle a max current input of 50mA if needed
• Needs to operate within system temp. requirements of -10 to
60°C
• Must be able to detect distance between 2ft and 6ft
• Must supply a voltage output of at least 2V to Microprocessor
for logic operation
40
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
41
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.)
42
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
(40cm to 300cm)
If object is close enough to trigger the sensor
“ON”, the output will be sent through an
inverting gate to the microprocessor disabling
the car’s forward or backward position
movement
Vehicle will be allowed to move in reverse
direction only if front sensor is triggered and
forward direction only if rear sensor is triggered
until the given sensor is switched “OFF”, and the
43
car will then be allowed to move in that direction
Block 4: Proximity Sensor
Purpose and Description
Operation is used for safety
concerns
 Sensors detect objects nearby to
stop vehicle and prevent potential
injury
 Helps prevent damage to the car
itself

44
Block 4: Proximity Sensor
Block Diagram Breakdown/Schematic
45
Block 4: Proximity Sensor
Preliminary Bill of Materials
Part
1
2
Mfg Part #
GP2Y3A003K0F
PCC2169CT-ND
Description
Qty.
Cost
Wide Angle Distance
Measuring Sensor Unit
2
$52.50(each)
Capacitor 10uF
2
$1.44(each)
46
Proximity Sensor Production BOM
Generic Part
Name
QTY
Function
Proximity Sensor
2
Other
10uF Capacitor
2
Capacitor
Nominal
Value
5
10
Production
PCB
Attach
# of
Pins
Packag
e
Unit
Tol%
Attributes
Volts
10%
Infrared
uF
10%
Fixed
Ceramic
PRODUCTION
PlacementSolder
Mfg 1
Mfg 1 Part
#
Mfg 2
Wire
Leads
4
Chassis
Mount
Fully
Automatic
Sharp
GP2Y3A003
K0F
Allen
Bradley
Wire
Leads
2
Radial
Man Insert Auto Solder
TDK
Corp.
FK24X5R0J
106K
Allen
Bradley
Mfg 2
Part #
871TM
201455
Totals
Area mm2
PCB
$Cost
Each
$Cost
Total
1060
$52.50
$105.00
60
$0.52
$1.04
1120
$106.04
Proximity Sensor PCB Schematic
Block 5: Dimming Headlights
Owner: Phosay
49
Block 5: Dimming Headlights

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.

Purpose – An accessory used to allow
the car to automatically control the
headlights by it self.
50
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
51
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
52
Performance Requirements

Power Inputs
+5V Power Supply
 +12V Power Supply
 -12V Power Supply
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Power Output
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+12V Power to power LED lights
Block Level Requirements
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Must use +5V input.
Operate between 0-60 degrees Celsius.
Dim lights during a bright environment.
Max light brightness during a dark environment.
Min and Max operational altitude 0-3500 meters.
Min and Max storage altitude 0-3500 meters.
Min and Max storage temp 10-65 degrees Celsius.
Max storage duration 1year.
Min and max humidity 0-90% non condensing.
Block 5: Dimming Lights
Preliminary Bill of Materials
•
Part #
• Description
• Qty.
• Price(each)
276-1657(Radio Shack)
Photo-resistor
1
$0.40
LM741CN
Op-amp
2
$0.22
1.0KQBK-ND
Resistor
2
$0.054
2.0KQBK-ND
Resistor
2
$0.054
SSL-LX3044YD-12V
Lights(LED)
60
$0.23
Total cost = $14.86
55
Block 5: Dimming lights
Bill of Materials
Block 5: PCB design
Block 5
Bright environment (100lux) max photocell
resistance (Rp)
58
Block 5
Output Voltage in bright environment (100lux) max
photocell resistance
59
Block 5
Dark environment (1lux) min photocell
resistance(Rp)
60
Block 5
Output Voltage in dark environment (1lux) min
photocell resistance
61
Block 5
Output Voltage in medium environment, 7KOhms
photocell resistance
62
Design for Mass Production
Setup
Screen Print
Wash & X-Ray Inspection
In Circuit Test
Stress Screen
Placement
Reflow
Hand Assembly inspection
Functional Test
Pack/Ship
Design for Mass Production
All components are surface mount
 Must be hand soldered

Blinker LED array
 Headlight LED array
