ECE 477 Final Presentation ECE 477 Final Presentation Group 11 Group 11 Fall 2004 Fall 2004

Jeff Killen

Brandon Ade

Drew Whipple

Matt Compton

OutlineOutline

• Project overviewProject overview• Block diagramBlock diagram• Professional componentsProfessional components• Design componentsDesign components• Success criteria demonstrationsSuccess criteria demonstrations• Individual contributionsIndividual contributions• Project summaryProject summary• Questions / discussionQuestions / discussion

Project OverviewProject Overview

• ““Cold as Ice” RefrigeratorCold as Ice” Refrigerator• Intelligent applianceIntelligent appliance

– RFID scanning for real-time inventoryRFID scanning for real-time inventory– Digital temperature controlDigital temperature control– Remote user interface through EthernetRemote user interface through Ethernet– Local user interface with LCD and keypadLocal user interface with LCD and keypad

• RFID is an emerging technologyRFID is an emerging technology– Current productsCurrent products– Many future applicationsMany future applications

Block DiagramBlock Diagram

9V DC wall-wart

Texas Instruments Housed S6350 Midrange RFID Reader

RabbitCore RCM2200 C-Programmable Module

12V DC wall-wart

National Semiconductor LM2676S – 5.0 3A step-down voltage regulator

Maxim +/- 15kV ESD-Protected, Signle/Dual/Octal, CMOS Switch Debouncers Storm

3K0421 4-button keypad

Microchip TC72 Digital Temperature Sensor with SPI Interface

Potter & Brumfield T77S1D10-05 Sealed Power Relay

Compressor

Ethernet Port

120V AC wall outlet

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9

2

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5

4

8

Reset Switch

4

2

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Crystalfontz America, Inc. Mod. CFAH2004A-NYA-JP 4x20 LCD

RFID Button

Professional ComponentsProfessional Components

• Constraint analysis and component selection Constraint analysis and component selection rationalerationale

• Patent liability analysisPatent liability analysis• Reliability and safety analysisReliability and safety analysis• Ethical and environmental impact analysisEthical and environmental impact analysis

Constraint AnalysisConstraint Analysis

• MicrocontrollerMicrocontroller– Ethernet InterfaceEthernet Interface– SimplicitySimplicity

• RFID KitRFID Kit– Range - IdeallyRange - Ideally– ProblemsProblems– AlternativesAlternatives

Patent Liability AnalysisPatent Liability Analysis

• Possible Literal InfringementsPossible Literal Infringements– 6,327,5766,327,576: System and method for managing expiration-dated : System and method for managing expiration-dated

products utilizing an electronic receiptproducts utilizing an electronic receipt• Recommend to pay licensing fees to FujitsuRecommend to pay licensing fees to Fujitsu

• Possible Doctrine of Equivalents InfringementPossible Doctrine of Equivalents Infringement– 6,793,1276,793,127: Internet enabled resource constrained terminal for : Internet enabled resource constrained terminal for

processing RFID tagsprocessing RFID tags• Recommend to continue with developmentRecommend to continue with development

– 6,802,1866,802,186: Refrigerator system and software : Refrigerator system and software architecture for 2 refrigerated compartments architecture for 2 refrigerated compartments with user specified temperaturewith user specified temperature

• Recommend to pay licensing fees to GERecommend to pay licensing fees to GE

Reliability/Safety AnalysisReliability/Safety Analysis

• 5 critical components analyzed5 critical components analyzed– LM2676 Step-down Regulator – MTTF 9.8 yearsLM2676 Step-down Regulator – MTTF 9.8 years– T77 Power Relay – MTTF 19 yearsT77 Power Relay – MTTF 19 years– TC72 Temperature Sensor – 51 yearsTC72 Temperature Sensor – 51 years– Rabbit 2000 Microcontroller – MTTF 52 yearsRabbit 2000 Microcontroller – MTTF 52 years– TIP122 NPN Transistor – 575 yearsTIP122 NPN Transistor – 575 years

• High criticality failuresHigh criticality failures– Voltage regulator power supplyVoltage regulator power supply– Compressor control involving Compressor control involving

temperature sensortemperature sensor

Ethical/Environmental AnalysisEthical/Environmental Analysis

• Ethical IssuesEthical Issues– Protect electrical components from food spills / condensationProtect electrical components from food spills / condensation– Warning label on main board enclosureWarning label on main board enclosure– Compressor blowout prevention moduleCompressor blowout prevention module– Cold environment component ratingsCold environment component ratings– High temperature/food spoilage prevention moduleHigh temperature/food spoilage prevention module

• Environmental IssuesEnvironmental Issues– PCB fabrication (high material consumption) & disposal PCB fabrication (high material consumption) & disposal

(lead, hazardous waste)(lead, hazardous waste)• Dry plasma metal deposition Dry plasma metal deposition

– Refrigerator coolantRefrigerator coolant• Substitute for Freon and other CFC/HCFC Substitute for Freon and other CFC/HCFC

refrigerantsrefrigerants

Design ComponentsDesign Components

• Packaging design considerationsPackaging design considerations• Schematic design considerationsSchematic design considerations• PCB layout design considerationsPCB layout design considerations• Software design considerationsSoftware design considerations

Packaging DesignPackaging Design

• Packaging ComponentsPackaging Components– Mini-fridge, LCD, Mini-fridge, LCD,

keypad, RFID, scan-keypad, RFID, scan-request pushbuttonrequest pushbutton

• Weight: 58 lbsWeight: 58 lbs• Cost: $854.30Cost: $854.30

Schematic DesignSchematic Design

PCB Layout DesignPCB Layout Design

PCB Layout DesignPCB Layout Design

• 6.706” x 3.030” 6.706” x 3.030” • 12 mil / 40 mil tracings12 mil / 40 mil tracings• Decoupling caps for all ICsDecoupling caps for all ICs• Single point ground/powerSingle point ground/power• 3 segments 3 segments (power supply, relay driver, micro/all else)(power supply, relay driver, micro/all else)

• Off-board relayOff-board relay• Result: no burnt traces or EMI problemsResult: no burnt traces or EMI problems

Software DesignSoftware Design

• Interrupt Driven/PollingInterrupt Driven/Polling• ModulesModules

– Keypad Control ModuleKeypad Control Module– RFID Control ModuleRFID Control Module– Temperature Control ModuleTemperature Control Module– Web ServerWeb Server

Success Criteria DemonstrationsSuccess Criteria Demonstrations

1. Ability to sense and decode RFID tags affixed to 1. Ability to sense and decode RFID tags affixed to ‘food’ items‘food’ items

2. Ability to query ‘food inventory’ via web 2. Ability to query ‘food inventory’ via web Demonstration of 1 & 2Demonstration of 1 & 2

3. Ability to update/maintain a food inventory3. Ability to update/maintain a food inventoryDemonstration of 3Demonstration of 3

4. Ability to display status information on an LCD 4. Ability to display status information on an LCD display – display – Demonstration of 4Demonstration of 4

5. Ability to control cabinet temperature5. Ability to control cabinet temperature via keypad and web via keypad and web

Demonstration of 5Demonstration of 5

Individual ContributionsIndividual Contributions

• Team Leader – Drew WhippleTeam Leader – Drew Whipple• Team Member 2 – Matt ComptonTeam Member 2 – Matt Compton• Team Member 3 – Brandon AdeTeam Member 3 – Brandon Ade• Team Member 4 – Jeff KillenTeam Member 4 – Jeff Killen

Team Leader – Drew WhippleTeam Leader – Drew Whipple

• Packaging DesignPackaging Design• Patent Liability AnalysisPatent Liability Analysis• Software implementationSoftware implementation• Software/hardware interactionSoftware/hardware interaction

Member 2 – Matt ComptonMember 2 – Matt Compton

• Component Selection RationaleComponent Selection Rationale• SoftwareSoftware

– Design of Software StructureDesign of Software Structure– Software ImplementationSoftware Implementation

• Hardware/Software InteractionHardware/Software Interaction• Hardware DebugHardware Debug

Member 3 – Brandon AdeMember 3 – Brandon Ade

• Reliability/Safety AnalysisReliability/Safety Analysis• SchematicSchematic• Hardware components selectionHardware components selection• PCB solderingPCB soldering• Hardware testing and modificationsHardware testing and modifications

Member 4 – Jeff KillenMember 4 – Jeff Killen

• PCB Layout and DesignPCB Layout and Design• Ethical and Environmental Impact AnalysisEthical and Environmental Impact Analysis• Refrigerator Refrigerator

selection/preparation/modificationselection/preparation/modification• Hardware testing/debuggingHardware testing/debugging• Adapt to separate temperature compartmentsAdapt to separate temperature compartments

Project SummaryProject Summary

• Important lessons learnedImportant lessons learned– Division of labor and individual Division of labor and individual

accountabilityaccountability– Get parts as early in the project as Get parts as early in the project as

possiblepossible– Peer reviews of other team members’ workPeer reviews of other team members’ work– Plan in-depth earlyPlan in-depth early– Understand components’Understand components’

soldering temperature limitssoldering temperature limits

Project SummaryProject Summary

• Second iteration enhancementsSecond iteration enhancements– Better optimized product packagingBetter optimized product packaging– More robust/secure web server and LCDMore robust/secure web server and LCD– Online recipe databaseOnline recipe database– More powerful RFID scannerMore powerful RFID scanner

Questions / DiscussionQuestions / Discussion