Lighting Tool Box Cost & Safety Analysis Winter 2004 ECE 498 Team Members: Nick Sitarski Blaine Thompson Brandon Harris Dave Chronicle Vladi Gergov Advisor:

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


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


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$


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


LED System Material Cost Analysis


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


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




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


Fluorescent Material Cost Analysis


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$


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




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


Microcontroller System Material Cost Analysis


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$


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




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


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


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


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

Documents

Lighting Tool Box Cost & Safety Analysis Winter 2004 ECE 498 Team Members: Nick Sitarski Blaine Thompson Brandon Harris Dave Chronicle Vladi Gergov Advisor: