Lighting Tool Box Cost & Safety Analysis Winter 2004 ECE 498 Team Members: Nick Sitarski Blaine...

Lighting Tool BoxCost & Safety Analysis

Winter 2004ECE 498

Team Members:Nick Sitarski

Blaine ThompsonBrandon HarrisDave Chronicle

Vladi Gergov

Advisor: Professor John W. Miller

ECE 498 Winter 2004 2

Introduction

• The Lighting Toolbox is a Collection of Unique Lighting Controllers used in Machine Vision Applications

• The Goal of the Project is to Have Remote and Local Control of Lighting Parameters

• The Tool Box Consists of an Incandescent, Fluorescent, and LED System

• A Linux Based Embedded Controller is Used as the Web Server for Remote Operation

ECE 498 Winter 2004 3

Incandescent System Material Cost Analysis

Part Qty Unit Cost Total Cost Our Cost

Transformer 1 70.00$ 70.00$ DonatedLight Enclosures 4 30.00$ 120.00$ Donated

Cables 4 5.00$ 20.00$ 20.00$ Heat Sinks 5 5.00$ 25.00$ 25.00$

Fans 2 14.00$ 28.00$ 28.00$ Case 1 90.00$ 90.00$ 90.00$

Light Bulbs 4 5.00$ 20.00$ 20.00$ Terminal Strips 3 5.00$ 15.00$ 15.00$

5 Pin Din Connectors 8 0.79$ 6.32$ 6.32$ 25 Pin D Connector 1 1.50$ 1.50$ 1.50$

Switches 5 2.50$ 12.50$ 12.50$ Knobs 4 2.50$ 10.00$ 10.00$

Misc. Hardware 1 70.00$ 70.00$ 70.00$ Misc Components 1 60.00$ 60.00$ 60.00$

Shipping And Handling 5 8.00$ 40.00$ 40.00$ Tools 1 120.00$ 120.00$ 120.00$

Total 708.32$ 518.32$ Note:

Transformer Donated by Stancore

Light Enclosures Donated by Professor Miller

ECE 498 Winter 2004 4

Incandescent System Labor Cost Analysis

Engineer AVG HRS / Week Weeks Rate / Hour Total Total HoursNick Sitarski 10 29 25.00$ 7,250.00$ 290

Professor Miller 0.25 29 100.00$ 725.00$ 7.25

Labor Cost 7,975.00$ Material Cost 708.32$

Total Cost 8,683.32$

ECE 498 Winter 2004 5

Incandescent System Pricing Information

•Total R&D Will Not be Charged to First Customer

•Each Incandescent System Will be Sold For $2,900 Which Will Include Minor Modifications

•We Expect To Sell 20 Units Per Year Totaling $58,000.00 In Sales, However, Material for 20 Units Will be $14,166.40

•Assembly For Each Unit Will be 10 Hours at $15 Per Hour Equaling $150.00 Per Unit, This Totals $3,000.00 Per year

•We Will Have R&D Paid For Within First YearNote: Prices Are For Incandescent System Only, Not Including Micro Controller For Remote Operation Feature

ECE 498 Winter 2004 6

LED System Material Cost Analysis

Part Qty Unit Cost Total Cost Our Cost

Case 1 79.00$ 79.00$ DonatedTransformer 1 49.00$ 49.00$ Donated

Electronic components 1 60.00$ 60.00$ 60.00$ Misc. Hardware 1 50.00$ 50.00$ 50.00$

Connectors 1 10.00$ 10.00$ 10.00$ Leds 21 3.00$ 63.00$ 63.00$

Cables 2 25.00$ 50.00$ 50.00$ Paint 1 3.00$ 3.00$ 3.00$

PVC Plastic 1 4.00$ 4.00$ 4.00$ Switches 3 10.00$ 30.00$ 30.00$ Sockets 4 5.00$ 20.00$ 5.00$

Total 418.00$ 275.00$

Note:

Transformer Donated by Stancore

Case Donated by Bud Industries

ECE 498 Winter 2004 7

LED System Labor Cost Analysis

Engineer AVG HRS / Week Weeks Rate / Hour Total Total HoursBlaine Thompson 10 29 25.00$ 7,250.00$ 290Professor Miller 0.25 29 100.00$ 725.00$ 7.25

Labor Cost 7,975.00$ Material Cost 418.00$

Total Cost 8,393.00$

ECE 498 Winter 2004 8

LED System Pricing Information

•Total R&D Will Not be Charged to First Customer

•Each LED System Will be Sold For $2,600 Which Will Include Minor Modifications

•We Expect To Sell 20 Units Per Year Totaling $52,000.00 In Sales, However, Material for 20 Units Will be $8360.00

•Assembly For Each Unit Will be 10 Hours at $15 Per Hour Equaling $150.00 Per Unit, This Totals $3,000.00 Per year

•We Will Have R&D Paid For Within First YearNote: Prices Are For Incandescent System Only, Not Including Micro Controller For Remote Operation Feature

ECE 498 Winter 2004 9

Fluorescent Material Cost Analysis

Part Qty Unit Cost Total Cost Our Cost

Transformer 1 10.00$ 10.00$ 10.00$ Ballast Enclosure 1 30.00$ 30.00$ 30.00$

Cables 2 5.00$ 10.00$ 10.00$ Ring Fluorescent Light 1 7.00$ 7.00$ 7.00$ Fluorescent Tube Light 1 7.00$ 7.00$ 7.00$ Electronic Ballast Kit 1 350.00$ 350.00$ 350.00$

Terminal Strips 2 5.00$ 10.00$ 10.00$ 5 Pin Din Connectors 3 0.79$ 2.37$ 2.37$ 25 Pin D Connector 1 1.50$ 1.50$ 1.50$

Shadow Box Materials 1 25.00$ 25.00$ 25.00$ Tubular Light Enclosure 1 25.00$ 25.00$ 25.00$

Misc Components 1 60.00$ 60.00$ 60.00$ Total 537.87$ 537.87$

ECE 498 Winter 2004 10

Fluorescent SystemLabor Cost Analysis

Engineer AVG HRS / Week Weeks Rate / Hour Total Total HoursBrandon Harris 8 29 25.00$ 5,800.00$ 232Professor Miller 0.25 29 100.00$ 725.00$ 7.25

Labor Cost 6,525.00$ Material Cost 537.87$

Total Cost 7,062.87$

ECE 498 Winter 2004 11

Fluorescent SystemPricing Information

• Total R&D Will Not be Charged to First Customer• Each Fluorescent System Will be Sold For $2,900 Which

Will Include Minor Modifications• We Expect To Sell 20 Units Per Year Totaling $58,000.00

In Sales, However, Material for 20 Units Will be $10,757.40• Assembly For Each Unit Will be 10 Hours at $15 Per Hour

Equaling $150.00 Per Unit, This Totals $3,000.00 Per year• We Will Have R&D Paid For Within First Year

Note: Prices Are For Fluorescent System Only, Not Including Micro Controller For Remote Operation Feature

ECE 498 Winter 2004 12

Microcontroller System Material Cost Analysis

Part Qty Unit Cost Total Cost Our Cost

PC104 GX1-300 1 549.00$ 549.00$ 549.00$ 37e12 Digital I/O 1 150.00$ 150.00$ 150.00$ RMA Shipping 2 15.00$ 30.00$ 30.00$

PCD-39e00 expansion card 1 50.00$ 50.00$ 50.00$ IBM Webcam 1 26.16$ 26.16$ 26.16$

Total 805.16$ 805.16$

ECE 498 Winter 2004 13

Microcontroller System Labor Cost Analysis

Engineer AVG HRS / Week Weeks Rate / Hour Total Total HoursDavid Chronicle 7 29 25.00$ 5,075.00$ 203

Vladi Gergov 7 29 25.00$ 5,075.00$ 203Professor Miller 0.15 29 100.00$ 435.00$ 4.35

Labor Cost 10,585.00$ Material Cost 805.16$

Total Cost 11,390.16$

ECE 498 Winter 2004 14

Microcontroller System Pricing Information

• First 20 units will be priced higher to recoup R & D losses

• Each Microcontroller System will sell for $2,000• We expect to sell 40 units in the first year, which

would be $80,000, less materials ($16,000) and labor ($3,000)

• This would give us $61,000, minus R & D of ~$11,000, would give us a net profit of $50,000

• Every lighting system sold needs a Microcontroller to function properly

ECE 498 Winter 2004 15

Safety Analysis

• All Systems are Enclosed Within Metal Enclosures to Conform National Electrical Safety Codes

• All Systems Are Fused to Ensure Short Circuit Protection

• Hazardous Voltages are not Directly Accessible to the User

• A Placard Has Been Place On the Cabinet Exterior to Warn Service Personal of Hazardous Voltages Inside

• There are no Significant Ignition SourcesInside the Enclosures

• Enclosures are Noncombustible

ECE 498 Winter 2004 16

Socio-Economic Impact

• Machine Vision Applications will be More Accurate Which will Lead to Higher Quality Products

• Companies will See Less Warranty Issues Driving the Cost of Products Down

• Accurate Machine Vision Systems can Replace Human Inspections in Certain Applications Which can Lead to Lower Labor Costs for a Product

• Remote Controlled Lighting Systems Can be used to Control Lighting Levels in Hazardous Areas that are Unsafe for humans to Enter

ECE 498 Winter 2004 17

Consequences of Failure

• Failure Could Result in Inaccurate Machine Vision Result, Allowing Bad Parts to Pass Through Inspection Areas

• If Bad Parts Reach the Public, injury and/or death may result from faulty parts

• If Severe Enough, a Nonfunctional Machine Vision Station Could Shut a Plant Down

• Although our Project Does Not Involve Machine Vision Processing Directly, Lighting Conditions Directly Affects Machine Vision Processing

Questions