ECE 477 Final Presentation ECE 477 Final Presentation Group 7 Group 7 Fall 2005 Fall 2005

TarunSiripurapu

NicholeMattson

ColleenShea

SiddharthSen

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

• Pan and tilt camera platform Pan and tilt camera platform – 2 ° accuracy 2 ° accuracy – +/-180 ° pan and +/- 45° tilt+/-180 ° pan and +/- 45° tilt– Absolute and relative motionAbsolute and relative motion– Controllable through either a cell phone or Controllable through either a cell phone or

keypadkeypad– Voice feedbackVoice feedback– Image visible via local monitorImage visible via local monitor

Block DiagramBlock DiagramBlock DiagramBlock Diagram

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

• Microcontroller• Motor Selection

– Brushless DC, DC, Stepper– Stepper chosen for price, accuracy, fixed step

size, speed flexibility

• Position Encoder Options– Absolute, Relative, Potentiometers

• User Interface

Constraint AnalysisConstraint AnalysisMicrocontrollerMicrocontroller

• Constraints (initial estimate)– Motor Control

• 2 x Pulse Width Modulators (speed)• 2 x GPIO (direction)

– Position Feedback• 2 x Pulse Accumulators (position)• 2 x GPIO (direction)

– Text to Speech Feedback• Serial Communications Interface

– User Input• 4 x GPIO (12 key, hex encoded)• 1 x IRQ

• Selection Rationale (9S12C)

– 5 x PWM

– 8 x TIM / PA

– SCI

– 6 x GPIO (8 required)• unused module pins can be

repurposed as GPIO

– 8 x ADC• not required in the initial

estimate but useful for a backup position feedback system

Constraint AnalysisConstraint AnalysisMicrocontrollerMicrocontroller

• Final Usage– PWM (2)

• motor speed (2)– GPIO (6)

• motor direction (2)• user input (4)

– IRQ (1)• user input (1)

– ADC (2)• motor position (2)

– SCI• text to speech (Tx)

Constraint AnalysisConstraint AnalysisMotorsMotors

• Constraints– Must be unipolar– Run off a 5V (preferred) or

12V power supply– Small physical dimensions– High internal resistance to

prevent limit current draw– Between 1º to 5º step size– Price

• Selection Rationale (Danaher 12V DC Unipolar Stepper)– 3.6º step size– Half stepping capability– Small physical dimensions – Importance of fine step size– Added current limiting

resistors– $17/each

Constraint AnalysisConstraint AnalysisPosition EncodingPosition Encoding

• Constraints– 2º accuracy– GPIO pins– Pulse Accumulators – Speed– Absolute position detection

• Selection Rationale (Potentiometers)– ADC availability– Ability to detect absolute

position– Linearity– Faster when compared to

pulse accumulation– Lower I/O pin requirement

when compared to 8 bit (required for 2º accuracy) position encoders.

Constraint AnalysisConstraint AnalysisUser InterfaceUser Interface

• Constraints– Audio Feedback– Communication over cell

phone network– Enable the user to input

numbers and direction– Local and Remote control– Simplicity

• Selection Rationale – Audio feedback (text to speech)

• Dynamic• SCI• DIP form factor for early

testing and debugging.– DTMF decoder for cell phone

communication• Maps cell phone keypad to

user interface • Generic DTMF decoder will

suffice– Keypad encoder for local control

• Keypad to mimic cell phone keypad

Patent Liability AnalysisPatent Liability Analysis• Potential Patent InfringementsPotential Patent Infringements

– Patent 5,633,681: Electrically controlled camera positioning Patent 5,633,681: Electrically controlled camera positioning system system

• Claims capacitive sensor assembly and specific Claims capacitive sensor assembly and specific packagingpackaging

– Patent 6,913,403: Integrated enclosure and controller for Patent 6,913,403: Integrated enclosure and controller for video surveillance cameravideo surveillance camera

• Claims a heating elementClaims a heating element

– Patent 6,880,987: Pan and tilt positioning unit (Quickset Patent 6,880,987: Pan and tilt positioning unit (Quickset International)International)

• Claims housing, platform, and unique drive systemClaims housing, platform, and unique drive system• Most similar to present designMost similar to present design

Reliability/Safety AnalysisReliability/Safety Analysis

• Acceptable level of failures per hour: less than 10^-5Acceptable level of failures per hour: less than 10^-5• Predicted number of failures per hour: 2.47 X 10^-6Predicted number of failures per hour: 2.47 X 10^-6• Three components analyzedThree components analyzed

– MicrocontrollerMicrocontroller• MTTF = 4.766 X 10^6 hoursMTTF = 4.766 X 10^6 hours

– Voltage RegulatorVoltage Regulator• MTTF = 8.96 X 10^6 hoursMTTF = 8.96 X 10^6 hours

– MotorsMotors• MTTF = 8.724 X 10^6 hoursMTTF = 8.724 X 10^6 hours

Reliability/Safety AnalysisReliability/Safety Analysis

• FMECAFMECA• High CriticalityHigh Criticality

– Motor circuit failure (motor, transistor, PLD)Motor circuit failure (motor, transistor, PLD)– Voltage regulator failureVoltage regulator failure– Micro failureMicro failure

• Low CriticalityLow Criticality– DTMF, Keypad failureDTMF, Keypad failure– TTS failureTTS failure

Ethical/Environmental AnalysisEthical/Environmental Analysis• EthicalEthical

– SafetySafety• Warning labelsWarning labels

– Prominent placement Prominent placement – ““Do not open or tamper with device.” Do not open or tamper with device.” – ““Motors may heat up.”Motors may heat up.”– ““Do not touch the gears while they are spinning.”Do not touch the gears while they are spinning.”– “ “In case of emergency call 911 NOT manufacturer!”In case of emergency call 911 NOT manufacturer!”

– PrivacyPrivacy• Voice heard both over cell phone and locally Voice heard both over cell phone and locally

• EnvironmentalEnvironmental– Ferric Chloride used to etch PCB’sFerric Chloride used to etch PCB’s

• Alternative: Cut PCB traces mechanicallyAlternative: Cut PCB traces mechanically

– Lead SolderLead Solder– End of Lifetime Disposal:End of Lifetime Disposal:

• Reuse components if possibleReuse components if possible• Incentive provided for returning the device to Incentive provided for returning the device to

the manufacturer the manufacturer

Ethical/Environmental AnalysisEthical/Environmental Analysis

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

• ConstraintsConstraints– CompactCompact– SturdySturdy– Range of motionRange of motion– Easy access of UI devicesEasy access of UI devices– Should not block the field of view of the Should not block the field of view of the

camera or any mounted device.camera or any mounted device.

Packaging DesignPackaging Design

• Platform motion designPlatform motion design• Allows ±180° range of Allows ±180° range of

motion for panningmotion for panning• Allows 360Allows 360° range of

motion for tilting. • Brackets to hold Brackets to hold

potentiometers stationary potentiometers stationary during motor motion (not during motor motion (not shown). shown).

Packaging DesignPackaging Design

1.1. Easy keypad access Easy keypad access for user input.for user input.

2.2. Easy addition of cell Easy addition of cell phone to platform.phone to platform.

3.3. Local and Remote Local and Remote control switch.control switch.

4.4. Attached speaker for Attached speaker for local voice feedback.local voice feedback.

Schematic DesignSchematic Design

• Power CircuitPower Circuit

0

910k

R8

390kR9

.1u C10

5V gnd

100uFC8

220uFC9

12

Wall Wart Connector 12VDC

J3

J3

5V gnd

+12V

D10

DIODE SCHOTTKY

VCC5V gnd12V GND

VCC +5V

BST1

VD2

SGND3

FB4

ON/!OFF5GND6Vin7LX8

U5

MAX5035

100 uHL1

5V gnd

5V gnd

.1uC7

Schematic DesignSchematic Design• Motor CircuitMotor Circuit

5V gnd

M2_C

U9_6

M2_A

+12V

R16

1k

PWM M1

M2_D

5V gnd

U9_5

DIR M1

+12V

M1_D

12V GND

+12V

PWM M2

phase C M2

R17

1k

M2_C

DIR M2

1 2D3

M2_B

1k

R10

VCC +5V

1kR24

123456

Motor 1

J7

1k

R11+12V

M2_D

phase A M1

123456

Motor 2

J8

VCC +5V

1 2D4

phase C M2

12V GND

phase D M2

+12V

1 2D5

1kR25

1k R221k

R23

phase B M1

phase D M1

1k

R12

1kR26

+12V

phase B M1

phase C M1

+12V

VCC +5V

U10_5U10_6

phase A M2

1kR27

phase A M1

1k

R13

1 2D6

5V gnd

+12V

M1_B

U9_6U9_5

VCC +5V

1 2D7Q8

IRL530N/TO

phase A M1

1kR30

phase D M2

phase D M2

Q11

IRL530N/TO

phase B M1

+12V

phase A M2

phase C M1

1kR31

1234

J11

M1 debug

1k R20

phase D M1

1234

J12

M2 debug

C14

.1u phase A M2

1kR32

Q12

IRL530N/TO

1kR21

phase B M2

5V gnd

phase B M2

C15.1u

1kR33

Q6

IRL530N/TO

phase B M2

I/CLK1

I/OE11

I/O12

I/O13

I/O14

I/O15

I/O16

I/O17

I/O18

I/O19

VCC20

GND

10

I2

I3

I4

I5

I6

I7

I8

I9

U9

PALCE16V8

M1_C

M1_A

I/CLK1

I/OE11

I/O12

I/O13

I/O14

I/O15

I/O16

I/O17

I/O18

I/O19

VCC20

GND

10

I2

I3

I4

I5

I6

I7

I8

I9

U10

PALCE16V8

1kR34

1234

J13

PLD inputM1_B

+12V

1kR28

1 2D2

M1_C

1kR35 phase C M1

M1_D

1kR29

M1_A

phase C M2

Q10

IRL530N/TO

Q7

IRL530N/TO

U10_5

M2_A

1 2D8

R14

1k Q13

IRL530N/TO

phase D M1

U10_6

M2_B

R15

1k

Q9

IRL530N/TO

1 2D9

Schematic DesignSchematic Design• Microcontroller CircuitMicrocontroller Circuit

5V gnd

VCC +5V5V gnd VCC +5V

V+14

V-12

V-17

VCC7

GND6GND9T1

OUT

5

T2OU

T18

R1IN

4

R2IN

19

C1+

8

C1-

13

C2+

11

C2+

15

C2-

16

T1IN

2

T2IN

1

R1OU

T3

R2OU

T20

C2-

10

U13

MAX233A

SW4

SW SPDT

5V gnd

M3

VCC +5V

STNDBY

M4

IRQ

TX1

RX2

DTR3

RS232 GND4

AN05

AN16

AN27

AN38

AN49

AN510

AN611

AN712

PM513

PM414

PM315

PM216

VIN32

GND31

!RES30

VCC29

PE028

PE127

PT019PT120PT221PT322PT423PT524PT625PT726

PM018

PM117

M1

5V gnd

9S12C32

TTS

INPU

T

M2

C13

1u

DIR M1DIR M2PWM M1

5V gnd

PWM M2M1123456

Pots

J15

5V gnd

Schematic DesignSchematic Design• Text to Speech CircuitText to Speech Circuit

S_output

C12.1u

1kR36

RES#1

TS2

AN33

AN24

AN15

AN06

AMPOUT7

AMPIN8

LINE9

MUTE #10

SP+11

SP-12

VPA13VCC14BRS315BRS216BRS117BRS018TXD19RXD20CTS#21STBY#22SUSP#23VSS24

TTS

+IN

3

-VS4

-IN2

NC1

VOUT

6

DISABLE*/SELECT8

+VS7

NC5

U12A

AD8027AR-REEL

5V gnd1 2

Speaker J10

1kR19

VCC +5V

.1u

C4

5V gnd

TTS INPUT

5V gnd

12V GND

12V GND

STNDBY

POT R4

47kR3

C11

1u

VCC +5V

5V gnd

5V gnd

1u

C3

Schematic DesignSchematic Design• User Interface User Interface

CircuitCircuit

1 2 3 4

J9Cell phone

U8_21D0

IN+1

IN-2

ST/GT17

Q111

Q212

Q313

Q414

VREF4

OSC17

OSC28

TOE10 INH

5

GND

6

GND

9

EST16

GS3

STD15

U4

CM8870C

U8_22D1

5V gnd

5V gnd

D2

100k

R5

5V g

nd

D3

100kR6

300k R7

D4

1 2

22V10 Input

J14

5V gnd

ROWY11ROWY22ROWY33ROWY44

OSC5KBONSMSK6

CLMX210

CLMX111

DAVBL12

OE13

OD14

OC15

OB16

OA17

CLMX38CLMX47

VCC

18

GND

9 U2

MM74C922

.1uC5

.1uC6

3.58 MHzY1

U8_2

1U8

_22

SW3

SW SPDT

5V gnd

S_output

M1

VCC +5V

5V gnd

5V gnd

M2

IRQ

VCC +5V

D0

C11u

CLK/I01

GND

12

I/O014

I/O115

I/O216

I/O317

I/O418

I/O519

I/O620

I/O721

I/O822

I/O923

I12

I23

I34

I45

I56

I67

I78

I89

I910

I1011

I1113

U8

PALCE22V10

C210u

D4

5V gnd

D3D2D1

C16.1u

12345678

J1

M3

VCC +5V

5V gnd

M4

PCB Layout DesignPCB Layout Design

• Design ConsiderationsDesign Considerations• Reduce Electromechanical Interference (EMI)Reduce Electromechanical Interference (EMI)

– Physically separate analog and digital circuitryPhysically separate analog and digital circuitry– Tie analog and digital grounds together at a single pointTie analog and digital grounds together at a single point

• Trace length, width, and placement Trace length, width, and placement – Length from ICs to decoupling capacitorsLength from ICs to decoupling capacitors– 40 mils for motor current, VCC, and GND40 mils for motor current, VCC, and GND

• Number of vias Number of vias • Header placement Header placement

– Incorporate debug headers when possibleIncorporate debug headers when possible– Place close to side of board Place close to side of board

PCB Layout DesignPCB Layout Design

Software DesignSoftware Design

• Mixture of Polling and Interrupt Mixture of Polling and Interrupt • Written in AssemblyWritten in Assembly• Modules Used:Modules Used:

– ATDATD– PWMPWM– TIMTIM– SCISCI

START

Infinite Loop to wait for Interrupt

Check Validity

If Key pressed is “#”, Execute Command

Determine which Key has been pressed

Interrupt Received

Software Design: Program FlowSoftware Design: Program Flow

Start

Add 100 values of ATD Readings

Compare Current Value with Value Desired

If Value is Close Enough, Slow Down

If Value is Extremely Close, Stop Motors and wait for next Interrupt

Software Design Software Design (Execute Command)(Execute Command)

main

Startup_Code Button_Pressed

PWM_Init

TIM_Init

SCI_Init

ATD_Init

Port_Init

outchar

Execute_Commandpmsgx

Software Design Software Design (Function Hierarchy)(Function Hierarchy)

Success Criteria DemonstrationsSuccess Criteria Demonstrations1.1. Ability to position the camera platform at a rotation angle Ability to position the camera platform at a rotation angle

ranging from -180 ° to +180 ° and at an elevation angle ranging from -180 ° to +180 ° and at an elevation angle ranging from -45 ° to +45 °, both within an accuracy of ± 2 °ranging from -45 ° to +45 °, both within an accuracy of ± 2 °

2.2. Ability to position the platform at absolute rotation and Ability to position the platform at absolute rotation and elevation angles via a local keypad elevation angles via a local keypad

3.3. Ability to control relative movement of the platform via a local Ability to control relative movement of the platform via a local keypad keypad

4.4. Ability to control absolute or relative movement of the Ability to control absolute or relative movement of the platform via a cell phone platform via a cell phone

5.5. Ability to provide audio feedback both locally as well as Ability to provide audio feedback both locally as well as through a cell phone concerning the platform’s status. through a cell phone concerning the platform’s status.

Video 1Video 1

Video 2 Video 2

Individual ContributionsIndividual Contributions

• Team Leader – Tarun SiripurapuTeam Leader – Tarun Siripurapu• Team Member 2 – Nichole MattsonTeam Member 2 – Nichole Mattson• Team Member 3 – Siddharth Sen Team Member 3 – Siddharth Sen • Team Member 4 – Colleen Shea Team Member 4 – Colleen Shea

Team Leader – Tarun SiripurapuTeam Leader – Tarun Siripurapu

• Software DevelopmentSoftware Development• Worked on DTMF DecoderWorked on DTMF Decoder• Helped with Text to Speech EncoderHelped with Text to Speech Encoder• Design Constraints AnalysisDesign Constraints Analysis• Packaging DesignPackaging Design• PackagingPackaging• Feedback CalibrationFeedback Calibration

Member 2 – Nichole MattsonMember 2 – Nichole Mattson

• Helped select motors and design motor driverHelped select motors and design motor driver• Researched encoder optionsResearched encoder options• Schematic DesignSchematic Design• Helped with PCB layoutHelped with PCB layout• Reliability and Safety AnalysisReliability and Safety Analysis• Selected and ordered various componentsSelected and ordered various components• Helped with Patent LiabilityHelped with Patent Liability• Populated PCBPopulated PCB• CAD drawingCAD drawing

Member 3 – Siddharth SenMember 3 – Siddharth Sen

• Software DevelopmentSoftware Development• PackagingPackaging• Worked on Text to Speech EncoderWorked on Text to Speech Encoder• Helped with DTMF DecoderHelped with DTMF Decoder• Software DebuggingSoftware Debugging• Ethical / Environmental AnalysisEthical / Environmental Analysis• Software DesignSoftware Design• Feedback CalibrationFeedback Calibration

Member 4 – Colleen SheaMember 4 – Colleen Shea• PCB component placement and layout PCB component placement and layout • Helped with ORCAD schematic design Helped with ORCAD schematic design • Populated PCB Populated PCB • Developed motor driver and associated Developed motor driver and associated

circuitrycircuitry• Motor circuit debugging Motor circuit debugging • Selected and ordered components Selected and ordered components • Patent Liability AnalysisPatent Liability Analysis

Project SummaryProject Summary

• Important lessons learnedImportant lessons learned– Component selectionComponent selection

• Thorough documentation Thorough documentation • There are some things they don’t teach you to There are some things they don’t teach you to

look for (DC resistance of inductor)look for (DC resistance of inductor)• Notice specific part numbers and packageNotice specific part numbers and package

– Hire an ME to do packagingHire an ME to do packaging– You can never have enough headersYou can never have enough headers– SpecializeSpecialize

Project SummaryProject Summary

• Second iteration enhancementsSecond iteration enhancements– Higher torque motorsHigher torque motors– Cover exposed gearsCover exposed gears– Battery poweredBattery powered– Add a microphone to enable two-way Add a microphone to enable two-way

communicationcommunication– Remotely switch between cell phone and Remotely switch between cell phone and

keypad keypad

Questions / DiscussionQuestions / Discussion