2010
Automatic Counting
Device
Team Ability3
Nick Steffan (PM), EE
Trevor Blackburn, EE
Adam Cook, EE
Luke Leisheidt, EE
Erik Napientek, EE
Jason Wagner, EE
1|Page
F10-42-SMARTGRN
Southern Illinois University
College of Engineering – Mailcode 6603
Carbondale, Il 62901-6604
November 18, 2010
Mrs. Kay Purcell
Southern Illinois University
College of Engineering – Mailcode 6603
Carbondale, Il 62901-6604
Dear Mrs. Purcell,
On September 15, 2010, we received your request for a proposal. We would like to thank you
for the opportunity to bid on this project. Attached is a comprehensive proposal of deliverables and
engineering design for this project.
The AbilityOne Network Design Challenge, sponsored by the National Industries for the Severely
Handicapped, has given the members of this university to create a technological solution to a barrier
that prevents people with disabilities from entering the workplace. In cooperation with Specialized
Training for Adult Rehabilitation of Murphysboro, we will design and build an automatic counting device
built into a cutting jig for cutting metal strips. The design will be tested through START to ensure it is
effective.
The design will increase the amount of workers that are able to work on this station at the
START facility. A successful project will also increase efficiency and productivity of this cutting station.
Once again, I would like to thank you for providing us with the opportunity to bid on this Saluki
Engineering Company project. Please feel free to contact me at the information provided if you have any
questions.
Sincerely,
Nick Steffan
Saluki Engineering Company
ABILITY3 Project Manager
nsteffan@siu.edu
(618) 329-0476
2|Page
SEC F10 – 42 ABILITY3
Executive Summary (EN)
The Ability One Challenge is an initiative, sponsored by National Industries for the Severely
Handicapped (NISH), in which engineering students design a system or device that will aid people with
disabilities in the work field. Our project’s goal is to develop a counter that will count the amount of
aluminum strips being cut instead of them being counted by hand. The non-profit organization that is
sponsoring our project is S.T.AR.T., which is located in Murphysboro, Illinois.
At the moment, S.T.A.R.T has an order from a client that they cut strips of aluminum to a certain
length. They need to package these strips in mass quantities (1000 strips per package). S.T.A.R.T.’s
current method of counting these strips is to have an employee cut the strips all day and later have
either a supervisor or someone in management count the strips after the employee is finished. This
method is inefficient because the supervisor could be more productive spending his or her time
elsewhere and they might not have an accurate count. Our project is to create a device that will
automatically count the amount of strips that have been cut automatically. Our project is to design a
counter that will increment every time the sheers cut through a strip of aluminum. This will not only
save time, but it will also ensure that the amount of aluminum strips is accurate.
In order to enter our design and prototype into the contest, we expect our project to be
completed by Friday April 15, 2011. This design could be used for any application that involves counting
the amount of cuts made with either sheers or scissors. However, our design is being specifically
designed for S.T.A.R.T.’s specifications.
3|Page
SEC F10 – 42 ABILITY3
Statement of Non-Disclosure (NS)
The information provided in or for this proposal is the confidential, proprietary property of the Saluki
Engineering Company of Carbondale, Illinois, USA. Such information may be used solely by the party to
whom this proposal has been submitted by Saluki Engineering Company and solely for the purpose of
evaluating this proposal. The submittal of this proposal confers no right in, or license to use, or right to
disclose to others for any purpose, the subject matter, or such information and data, nor confers the
right to reproduce, or offer such information for sale. All drawings, specifications, and other writings
supplied with this proposal are to be returned to Saluki Engineering Company promptly upon request.
The use of this information, other than for the purpose of evaluating this proposal, is subject to the
terms of an agreement under which services are to be performed pursuant to this proposal.
Validity Statement (NS)
This proposal is valid for a period of 30 days from the date of the proposal. After this time, Saluki
Engineering Company reserves the right to review it and determine if any modification is needed.
4|Page
SEC F10 – 42 ABILITY3
Table of Contents (NS)
Executive Summary (EN) ............................................................................................................................... 3
Statement of Non-Disclosure (NS) ................................................................................................................ 4
Validity Statement (NS) ................................................................................................................................. 4
Table of Figures (NS) ..................................................................................................................................... 6
Literature Review .......................................................................................................................................... 7
Introduction (AC) ...................................................................................................................................... 7
The Problem Definition from S.T.A.R.T. (NS) ........................................................................................ 7
Information on Disabilities and NISH: (AC) ........................................................................................... 8
About START (Specialized Training for Adult Rehabilitation): (AC)....................................................... 9
Counters and Counting Devices (EN) ...................................................................................................... 10
Output Displays (LL) ................................................................................................................................ 11
Magnetic Switches (NS) ....................................................................................................................... 12
Micro Switches (TB) ................................................................................................................................ 13
Electrical Conditions (Load) (TB) ......................................................................................................... 14
Terminal Connections (TB) .................................................................................................................. 15
Break-Beam Sensors (JW) ....................................................................................................................... 16
Conclusion (LL) ........................................................................................................................................ 19
Project Description (NS) .............................................................................................................................. 20
Block Diagram (JW) ..................................................................................................................................... 21
Engineering Specifications (EN & AC) ......................................................................................................... 22
Subsystem Description (TB) ........................................................................................................................ 23
Sensor/Switching Mechanism................................................................................................................. 23
Counter ................................................................................................................................................... 24
Sheers/Snips............................................................................................................................................ 25
Display ..................................................................................................................................................... 25
Aluminum Spool Weight Reduction ........................................................................................................ 26
Directions for Use ................................................................................................................................... 27
List of Analyses and Experiments to be Performed (Group) .................................................................. 29
List of Deliverables (Group) .................................................................................................................... 30
Design Basis (AC) ......................................................................................................................................... 31
5|Page
SEC F10 – 42 ABILITY3
Product Organization Chart (JW) ................................................................................................................ 31
Action Item List (NS) ................................................................................................................................... 32
Spring Schedule (Group) ............................................................................................................................. 33
List of Resources (LL)................................................................................................................................... 34
Item Number ........................................................................................................................................... 34
Description .............................................................................................................................................. 34
Unit Price................................................................................................................................................. 34
Quantity .................................................................................................................................................. 34
Line Total................................................................................................................................................. 34
Appendix A: References (JW) ...................................................................................................................... 35
Appendix B: Resumes.................................................................................................................................. 38
Nick Steffan ............................................................................................................................................. 38
Lucas M. Liescheidt ................................................................................................................................. 39
Jason Wagner .......................................................................................................................................... 40
Adam Cook .............................................................................................................................................. 41
Trevor Blackburn ..................................................................................................................................... 42
Erik M. Napientek ................................................................................................................................... 43
Table of Figures (NS)
Figure 1.1 – Cutting of Aluminum Strips…………………………………………………………………………………………….10
Figure 2.1 - HED251 Counter with Display [6]……………………………………………………………………………………..11
Figure 3.1 – Directed 8600 Magnetic Switch [14]……………………………………………………………………………….13
Figure 4.1 - Structural Diagram of Typical Basic Switch [16]……………………………………………………………….13
Figure 4.2 – Switch Operating Ranges [18]………………………………………………………………………………………….15
Figure 4.3 – Terminal Types [17]…………………………………………………………………………………………………………16
Table 5.1 - Safety of laser products 1 [21]……………………………………………………………………………………………18
Table 5.2 - Safety of laser products 2 [21]……………………………………………………………………………………………19
6|Page
SEC F10 – 42 ABILITY3
Literature Review
Introduction (AC)
Across the United States, people with disabilities face a much tougher task in finding and
maintaining jobs than those without disabilities. A nonprofit organization called NISH, The
National Industry for the Severely Handicapped, is addressing this problem by creating jobs for
the disabled through its AbilityOne program. In order to further increase the working
capabilities of the disabled, NISH has created a design competition to bring in creative ideas
from all over the country. One problem encountered at S.T.A.R.T., a local AbilityOne Network
organization, is the counting of metal strips that are cut in large quantities. The goal of this
project is to create a method of keeping an accurate count of the strips produced, which would
increase the efficiency of the work station. This paper will go into further detail of the strip
counting problem along with general information on people with disabilities. Also, more
information about NISH as well as the AbilityOne program will be provided. The remainder of
the paper will be based around the components and subsystems that are foreseen to likely be
included in the project. These include electronic counters, display types, and switch types for
signaling a cut has been made. The switch types reviewed are magnetic switches, microswitches, and break beam sensors.
The Problem Definition from S.T.A.R.T. (NS)
One large issue at S.T.A.R.T. is the counting of high volume items. In particular, there is a station
in which a worker cuts strips of aluminum to a specific length, as seen in Figure 1.1. The supervisors
have tried many different methods of counting the items, but all previous attempts have failed. The
7|Page
SEC F10 – 42 ABILITY3
current solution involves having the floor supervisor count the strips at the end of the day. The workers
and supervisors both express an interest in having a counting mechanism right there. We were told that
the workers were constantly interested in how many they produced in one day and that if they could
count them they would probably be able to pace themselves and potentially be more motivated. Since
the counting gets to such high numbers, S.T.A.R.T. is only able to put certain people on this particular
station. With the counting done for them, the employees would be able to do multiple jobs within the
facility. This could potentially lead to them being more enthusiastic about work since they could do
more than one task.
Information on Disabilities and NISH: (AC)
According to census data from 2005, roughly 18 percent of Americans are considered to
have a disability. This amounts to over 54 million people. Twelve percent of Americans are
considered to have a severe disability, and the significance of this is that the employment rate
drops drastically between those who have non-severe and severe disabilities. The employment
rate of non-severely disabled people age 21-64 is 75.2 percent, while the employment rate of
severely disabled people in the same age range is only 30.7 percent. Limited by their
disabilities, the severely disabled are unable to compete in a highly competitive job market.
This is where organizations like NISH, The National Industry for the Severely Handicapped, come
in to employ the disabled in doing tasks to produce goods that can be supplied to companies
that outsource certain materials. [1]
NISH is a non-profit organization based in Vienna, Virginia whose mission is to create
employment opportunities for people with significant disabilities. Through its AbilityOne
Program, NISH secures federal contracts to fund a network of smaller non-profit organizations
8|Page
SEC F10 – 42 ABILITY3
that share the same mission of employing the disabled. The AbilityOne Program is the nation’s
largest source of employment for people with severe disabilities, employing over 45,000
through more than 600 non-profit organizations. The goal of the AbilityOne Program is to
provide not only jobs to people whose disabilities prevent them from competing in the job
market, but also to give them training so that they may go on to work in public and private
sectors in the future.[2]
However, the problem still remains that many disabled people employed by AbilityOne
nonprofit groups have difficulty performing even the simplest tasks their jobs require. This
problem is the reason for the AbilityOne Network Design Challenge, a nationwide contest in
which students design devices that help AbilityOne employees accomplish their daily tasks more
effectively.[ 3]
About START (Specialized Training for Adult Rehabilitation): (AC)
For our project we will be working closely with Specialized Training for Adult Rehabilitation
(S.T.A.R.T.) located in Murphysboro Illinois. S.T.A.R.T. is a non-profit organization that serves many
adults with different disabilities. They provide six different types of rehabilitation and have over 150
individuals participating in their program. The work opportunities that they provide include mobile
custodial crews, subcontracting services for area businesses, janitorial services at the rest area on
Interstate 57, and microfilming and digital scanning services. They also offer job placement services to
help disabled individuals in finding employment.
9|Page
SEC F10 – 42 ABILITY3
Figure 5.1 – Cutting of Aluminum Strips
Counters and Counting Devices (EN)
A basic counter is an electrical device that increments when it receives an electrical
signal. However, most counters have other inputs that are built in such as a clear function
(resets the counter to zero) or a load function (lets the user set what number the counter is at).
This project will require either a production counter or a custom counter may have to be
built. One of the pros of creating our own counter is that it won’t have any unnecessary
functions. This will help to make the device more user-friendly. Another pro is that it will be
easier to troubleshoot problems if we create our own counter because we will know exactly
how it works. However further research on how to implement this onto a circuit board would be
required. This circuit board would then have to be connected to a seven-segment-display or an
LCD display.
The other alternative is to use a counter that is already being manufactured. Some of
the more inexpensive counters only require an input between 1µA and 10µA [4]. This would
allow the workers to be perfectly safe because it takes less than 100 mA to kill someone [5].
They also come with a built in LCD display or seven-segment-display which can be seen in Figure
2.1 of the HED251 counter from Abtek Controls. They require low power as well since they are
10 | P a g e
SEC F10 – 42 ABILITY3
powered by a 1.5V battery. Most models also come with a reset input as well. Other things that
need to be considered in our design are the cost of each counter and how avoid an accidental
reset.
Figure 6.1 - HED251 Counter with Display [6]
Output Displays (LL)
In order for the counter device to provide useful data to the user, some sort of display
will be needed. The options for a display include, but are not limited to; a liquid crystal display
(LCD) and a light emitting diode array (LED) in 7-segment or other form. Each of these display
devices have their benefits and their negative aspects, of which some will be discussed in this
section.
LCD’s have some qualities which are superior to LED’s. An alphanumeric LCD display
can be very small and use very little power. Also, this low power consumption means very little
heat production during use [7]. LCD’s, however, have a limited viewing angle which means the
display will have a different amount of contrast depending on how far from perpendicular the
display is relative to the user’s eyes. Custom display units can be made with different viewing
angles to meet the needs of specific applications. Another downside of LCD’s is they must be
operated within a somewhat small temperature range [8].
11 | P a g e
SEC F10 – 42 ABILITY3
Another formidable option is an LED display which could entail either a large array of
LED’s or a display containing multiple 7-segment display units. The seven segment displays are
very inexpensive with costs as low as $0.35 for a single digit display [9]. An added benefit to a 7segment device is the availability of a production binary to 7-segment decoder chip which can
take in binary coded decimals and convert them into data usable by the display units [10].
Either type of display will require a processor to convert data from the counting
device into a usable form for the display. The 7-segment display would be aided by the
aforementioned binary to 7-segment decoder chip. If an LCD display is used, a likely necessity
would be a programmable microprocessor. An LCD driver is a requirement of an LCD device. The
driver controls the LCD’s alternating current (AC) requirements and refresh rates.
Magnetic Switches (NS)
Magnetic switches are contact-less magnetic sensitive switches. Magnetic switches are
nearly maintenance free, have a high switching capacity, a large temperature range and can be
installed in a variety of positions [11]. Magnetic switches are used in two different varieties.
They are either deployed as normally open or normally closed. Normally open refers to when
the magnets are far enough away to not be in contact with each and the circuit is considered
open. In the case they are brought to a close enough range the circuit is then closed. This is
best for when you want to turn something off when the two halves are apart. The normally
closed option works in the opposite fashion. The normal state of the circuit is the magnets
connected and the circuit is broken when they are pulled apart. This option is best used if you
want to turn something on when the two halves are apart. This is a very common application in
12 | P a g e
SEC F10 – 42 ABILITY3
burglar alarms [12][13]. Figure 4.1 shows an example of a magnetic switch that operates in this
fashion and is very common in protecting sliding doors and windows [14].
Figure 7.1 – Directed 8600 Magnetic Switch [14]
Micro Switches (TB)
Micro switch is a broad term that refers to any electric switch and that can be activated
by a very small amount of force. They are actuated through the use of tipping-point mechanism,
Figure 8.1 - Structural Diagram of Typical Basic Switch [16]
13 | P a g e
SEC F10 – 42 ABILITY3
which allows for the switching to happen reliably and at very specific positions of the actuator.
Micro switches are very popular and widely used in many industries due to their durability and
very low cost. Most models can experience more than a million cycles while heavy-duty models
can experience up to 10 million cycles. The very simple design leads to the high durability of this
device [15].
Inside the case of a micro switch is a flat metal spring, known as the snap-action
mechanism, which must be bent to activate the switch and can be seen in Figure 5.1. When the
actuator in Figure 5.1 is pressed, the flat conductive spring is displaced to close the gap in the
contact section. The contact section open and closes the electrical circuit [16]. The small
movement of the actuator produces a relatively large movement at the electrical contents and
most are designed that a small reversal movement of the actuator will not reverse the electrical
contacts. There must be a distinct and significant movement of the actuator to open up the
electrical contacts [15]. A basic switch has three terminals to connect to an external circuit and
their locations vary depending on manufacturer and model. These terminals are labeled
terminal section in Figure 5.1 [16].
Electrical Conditions (Load) (TB)
The operation of a switch is significantly different depending on whether it is being used
to break an alternating current or a direct current. If the load of the switch is direct current, the
control capacity of the switch will drop significantly. The drop is caused by the fact that a DC
load has no current zero cross point like an AC load has. If an arc is generated between the
contact points of the switch, it may continue for a long time compared to if the load was AC due
14 | P a g e
SEC F10 – 42 ABILITY3
to the no current zero cross point. Also, since the current of a DC load is always in the same
direction, the contacts may hold to each other and not separate due to contact relocation
phenomena [17]. Figure 5.2 shows the operating points for micro load models of a switch as
well as general load models.
Figure 4.2 – Switch Operating Ranges [18]
Terminal Connections (TB)
There are several terminal types, as shown in Figure 5.3, which vary on different models
of micro switches. If the model has a solder terminal, lead wires must be soldered to the
terminals of the switch to ensure a secure and uninterrupted connection. The lead wire must
first be inserted into the terminal hole, which can be seen in Figure 5.3, before soldering.
15 | P a g e
SEC F10 – 42 ABILITY3
Figure 4.3 – Terminal Types [17]
The soldering iron must have a capacity of 30 Watts maximum and the temperature of soldering
iron tip is approximately 300ºC but no more than 350ºC. Soldering of the wire to the terminal
must be completed within 3 seconds to avoid damaging the terminal. Using a soldering iron on
a terminal for more than 3 seconds or one that is rated for more than 30 Watts can deteriorate
the switch characteristics [19].
Break-Beam Sensors (JW)
One method to detect when the shears are used is to use what is called a break-beam
sensor. A break-beam sensor is a device that shoots a laser beam at a receiver and whenever
the beam is broken by something interrupting the flow, the receiver is able to detect it. To
implement this project we could do one of two things. We could either build our own laser
using LEDs or we could use an existing laser such as a laser pointer or the laser from a DVD
player. We will just have to ensure these lasers are safe enough to be used in a work place.
There are two different types of lasers, continuous constant-amplitude output and pulsed
16 | P a g e
SEC F10 – 42 ABILITY3
output [20]. Obviously, for this we would want to use a continuous constant-amplitude output
laser so that the laser is always beamed to the receiver. We would use the break-beam sensor
on the shears and place the beam above it. That way every time the shears are opened, the
beam will be broken and the receiver will sense this and add to the total of times the beam has
been broken. For this we would need to either design the receiver to be able to count itself, or
attach a counter to the receiver, which will feed data into the counter and tell it when to add
one to the total. This method would be nice in the fact that if the shears were to get loose or
break, neither the receiver or the laser is attached to it, so they would not be damaged.
However, this method does have some issues that would have to be worked out. For
instance, the laser has to be below a certain wavelength and power output.(Table 6.1) Lasers
also have a safety classification system.(Table 6.2) Also, depending on the wavelength and
power, laser beams can only be received from a limited distance. So, we would have to find the
appropriate wavelength, power, and distance from the receiver to optimize the detection of the
beam by the receiver. Another problem is the ambient lighting from the sun and lights in the
work area. This can be easily fixed using a filter on the receiver that limits the ambient lighting
around it and allows it to receive the laser beam with limited interference.
17 | P a g e
SEC F10 – 42 ABILITY3
Wavelength
180-315 nm
315-400 nm
400-780 nm
780-1400 nm
1.4-3.0 µm
3.0µm-1mm
Pathological Effect
Inflammation of
cornea(equivalent to sun burn)
Clouding of eye lens
Damage to retina, retinal burn
Cataract, retinal burn
Aqueous flare(protein in the
Aqueous Humour), cataract,
corneal burn
Corneal burn
Table 5.1 - Safety of laser products 1 [21]
Class
1
1M
2
2M
3R
3B
Description
Safe under all conditions of
normal use
Safe for all conditions except
when passed through
magnifying optics such as
microscopes and telescopes.
Lasers have large diameter
beams or beams that are
divergent.
Safe because blink reflex limits
exposure to no more than 0.25
seconds. This only applies to
visible light lasers(400-700nm).
Limited to 1mW continuous
wave.
Safe because of blink reflex if
not viewed through optical
instruments. Lasers have large
diameter or large divergence
beams.
Considered safe if handled
carefully with restricted
viewing. It is limited to 5mW
output.
Hazardous if eye is exposed
18 | P a g e
SEC F10 – 42 ABILITY3
4
directly. Continuous lasers in
wavelength range from 315nm
to far infrared are limited to
0.5W.
All lasers with beam power
greater than class 3B by
definition can burn the skin, in
addition to potentially
devastating and permanently
damaging the eye as a result of
direct or diffuse beam viewing.
Table 5.2 - Safety of laser products 2 [21]
Conclusion (LL)
There are several counter designs that are already in production but none meet the
demands of the workplace at S.T.A.R.T. The main thing that is lacking in current counters is
durability and most would not last very long before breaking if it were to be implemented in this
manner. There are really no counters out there that are built to be used in a method like this
without very heavy modification as well. The key part of the project is the detector we use to
count the cuts in that it must be durable as well as extremely reliable. The preceding research
will ultimately aid in the project design. The background information on NISH as well as
S.T.A.R.T. helps to keep the overall aim of helping disabled workers in mind for the rest of the
project. Research was done on production counters as well as benefits of creating a custom
electronic counter. Display types were also researched as well as input sensor types. The
specifications of magnetic switches, micro switches, and break beam sensors were reviewed. At
this point, these are the subsystems and components that are likely applicable to this counting
project.
19 | P a g e
SEC F10 – 42 ABILITY3
Project Description (NS)
Upon completion of the project, the product will accurately count the number of times the
shears make a cut to the desired material. It will contain a switch and counting device that should
greatly reduce the down time of the entire process. By having an automatic counting mechanism, the
entire job can be done by the worker and will not need any additional counting to be done by
management. Within the system there will be a reset button to be used when the desired number of
cuts has been reached. However the system will not be easily resettable as it will have protection
against accidental resets. The device will have a clear display allowing the user to know how many cuts
they have made and how close they are to the desired number.
The subsystems of the product include the shears, the switch and the counting mechanism. The
shears have already been previously included in the current system. They will be connected to the
switch that will activate the counter.
20 | P a g e
SEC F10 – 42 ABILITY3
Block Diagram (JW)
21 | P a g e
SEC F10 – 42 ABILITY3
Engineering Specifications (EN & AC)
Our project must meet several different specifications in order for it to be usable by
S.T.A.R.T.. The first specification is that we design a device that is safe to use for the mentally
disabled. This means that we must run a very small amount of current through our device. This
includes the power supply, switch/sensor, and the counter. The micro-switches that we are
using are rated at 1mA. Both of the counters that we are considering using require a minimum
input signal between 1-10µA. These components would ensure that our device would be safe to
use since it requires 100mA to kill someone.
The second specification that our project must meet is that it must be able to count to
high numbers and count accurately. Our client needs to package the aluminum strips in sets of
1000. Therefore we will need a counter that can count to a number that is higher than this. The
HED251 counter has 4-digits in its display which means that it can count as high as 9999. The
LA8N counter has an 8-digit so it can count as high as 99,999,999. Since these specifications
have exceeded the required specifications, our client could easily change the amount of strips
in each package. Since the sheers are able to cut through the aluminum strips in one cut, the
counting will be accurate because the counter will increment every time the sheers are in the
closed position.
The last specification is that the device is easy to use. The counter will be easy to power
on because it will require the user to either push a button or flip a switch. The use of the sheers
will not be effected we will attach the micro-switch to the handle. This will not get in the way of
the user because the micro-switch is about the size of a cubic centimeter.
22 | P a g e
SEC F10 – 42 ABILITY3
Subsystem Description (TB)
Sensor/Switching Mechanism
The sensor for determining when a strip of the metal is cut and placed into the box is very
important to get a reliable count for the START employees. The primary concern with this sensor is that
it will be experiencing varying amounts of stress in this application and it must be durable to continue to
function properly. If the sensor fails it could lead to errors, which would result in inaccurate final counts
of the item. The sensor also needs to be implemented properly so that it is actuated on a consistent
basis to also ensure a correct final count. Any failure of the sensor will lead to errors in the later stages
in the process so it is vital that it provides consistent results. The switch must be mounted in a way to
not interfere with cutting by any means and will be tested with START employees to ensure that the
cutting mechanism is still comfortable to use. The sensor will be actuated automatically through the
operation of the cutting device so the sensor should go unnoticed to the user operating said device.
List of Activities:

Assemble prototype of sensor on cutting device

Test durability during cutting

Test consistency during cutting

Test device with START employee
Deliverables:

Working prototype of sensor on cutting device

Actuating of sensor consistency
23 | P a g e
SEC F10 – 42 ABILITY3
Counter
The counting device will take the input from the sensor and turn this into useful info to the user
of the device. Currently the worker tries to count the number of metal strips cut manually, which is not
only inefficient but also very inaccurate. There are too many opportunities for an error in the final count
with this method, which leads to the inefficiency of the process. Another employee needs to do a
second count of the metal strips at the very end to get a more accurate count. This can become very
time consuming and wastes time. The counter will keep track of the amount of metal strips cut without
any extra effort from the user. It would provide a much more accurate final count without the need for
another worker to double check the count. The counter could also provide further information about
the efficiency of the job like cuts per minute and possibly more.
The counter would work in the background along with the sensor so as there is no direct involvement
from the worker other than cutting the metal strips.
List of Activities:

Create a prototype of counter

Test accuracy of final count compared with current method

Time efficiency analysis

Determine useful information to obtain from count
Deliverables:

Working prototype counter

Accuracy compared with current counting method

Time efficiency compared with current counting method
24 | P a g e
SEC F10 – 42 ABILITY3
Sheers/Snips
The current snip setup is very unstable which could lead to errors in the count. Any unwanted
movement of the snips could lead to either a missed count or an extra count, which would invalidate the
final count. Also having the snips consistently cut through the aluminum without the need for a second
attempt would help reduce the probability of error as well. The mounting of the snips is key to keeping
the device stable and operating properly. It is also very important for the comfort of the worker. A
poorly placed and mounted snips could lead to discomfort in the worker which could further lead to a
reduced productivity.
List of Activities:

Test different sheers and snips

Test different mounting options
Deliverables:

Comparison of sheers and snips

Comparison of stability of mounting options
Display
The counting results need to be displayed in an easily accessible manner for all workers. The
count needs to be readily accessible and visible at all times for easy monitoring and can be done easily
with a small display. Reading the display should be very easy so the type of display should be bright and
unobstructed. The display should also however consume very small amounts of power for the device to
remain efficient. The input of the display in this case is the current count of metal strips so it should be
25 | P a g e
SEC F10 – 42 ABILITY3
able to show the maximum amount of digits of the count as well. The size of the display is important in
not only power consumption but also the readability for the user. The count must be shown large
enough for the user to easily read while working. The display must also be mounted in a location for the
worker to easily see to ensure no time is lost while checking the count.
List of Activities:

Determine appropriate display type

Test displays with START workers

Determine power consumption
Deliverables:

Display unit prototype

Analysis of power consumption
Aluminum Spool Weight Reduction
Reducing the strength needed to pull the aluminum spool is required due to limitations of the
workers at START. Currently the aluminum spool requires a great deal of strength to pull to allow the
cutting of the metal strips, which limits the amount of workers at START who can work at this station.
Providing mechanical advantage to the worker would allow the spool to be pulled with less force
currently required which in turn would allow more employees to be able to work this station. The ability
to switch out workers on this station could increase efficiency as well as worker happiness.
List of Activities:

Develop method to reduce force needed to pull spool

Test method with START workers
26 | P a g e
SEC F10 – 42 ABILITY3
Deliverables:

Comparison of amount of workers who can now work station
Directions for Use
To ensure that efficiency of the station is increased; the employees of START must be trained to
use the prototype. It is also necessary that repair of the prototype is covered as well ensure that the
prototype remains working at all times. Repairs may involve replacing a sensor or display for the
prototype to remain operational. The repairs may be simple but extreme detail is necessary to ensure
they are done correctly. Although direct interaction of the prototype is minimal, training manuals can be
used to ensure correct usage of the cutting device to ensure accurate counting and eliminate errors.
Considerations must be made due to the disabilities of the client at the START facility to ensure that the
manual is effective in assisting the worker. Simple instructions could be placed at the workstation as a
simple source on how to operate the prototype.
List of Activities:

Consider learning styles compared with the disabilities of the clients

Step by step use of the device

Provide sources of parts for repair

Consider all possible repairs and develop troubleshooting
Deliverables:

Training Manual

Repair Manual

Parts for minor repairs
27 | P a g e
SEC F10 – 42 ABILITY3
28 | P a g e
SEC F10 – 42 ABILITY3
List of Analyses and Experiments to be Performed (Group)
1. Assemble prototype of sensor on cutting device
2. Test durability during cutting
3. Test consistency during cutting
4. Test device with START employee
5. Create a prototype of counter
6. Test accuracy of final count compared with current method
7. Time efficiency analysis
8. Determine useful information to obtain from count
9. Test different sheers and snips
10. Test different mounting options
11. Determine appropriate display type
12. Test displays with START workers
13. Determine power consumption
14. Develop method to reduce force needed to pull spool
15. Test method with START workers
16. Consider learning styles compared with the disabilities of the clients
17. Step by step use of the device
18. Provide sources of parts for repair
19. Consider all possible repairs and develop troubleshooting
29 | P a g e
SEC F10 – 42 ABILITY3
List of Deliverables (Group)
1. Working prototype of sensor on cutting device
2. Actuating of sensor consistency
3. Working prototype counter
4. Accuracy compared with current counting method
5. Time efficiency compared with current counting method
6. Comparison of sheers and snips
7. Comparison of stability of mounting options
8. Display unit prototype
9. Analysis of power consumption
10. Comparison of amount of workers who can now work station
11. Training Manual
12. Repair Manual
13. Parts for minor repairs
30 | P a g e
SEC F10 – 42 ABILITY3
Design Basis (AC)
Our finished design will be based on the specifications of the following documents:





Request For Proposal
National Electric Code (NEC)
Team 42 SMARTGRN Proposal (this document)
NISH AbilityOne Contest Rules and Regulations
Design Requirements given by S.T.A.R.T.
PRODUCT ORGANIZATION CHART (JW)
Nick Steffan
Project Manager
Trevor Blackburn
Adam Cook
Luke Liescheidt
Erik Napientek
Jason Wagner
31 | P a g e
SEC F10 – 42 ABILITY3
Action Item List (NS)
Project: Ability One Group 2
SEC F10 – 42 ABILITY3
Action Item List
Team
Members:
Nick Steffan, EE (PM)
Adam Cook, EE
Luke Liescheidt, EE
Trevor Blackburn, EE
Erik Napientek, EE
Jason Wagner, EE
#
Activity
Person
1
Research Switch Options
Luke, Trevor
2
Begin Collecting Pre-system data
Nick, Adam
3
Research Counter Options
Erik, Jason
4
Pruchase Items
Everyone
5
Begin Tests on switches
Luke, Trevor
6
Incorporate Counter Into Tests
Erik, Jason
Assigned
16-Nov10
16-Nov10
16-Nov10
16-Nov10
16-Nov10
16-Nov10
Due
Status
21-Jan-11
21-Jan-11
21-Jan-11
0%
0%
21-Jan-11
28-Jan-11
28-Jan-11
32 | P a g e
SEC F10 – 42 ABILITY3
0%
0%
0%
Spring Schedule (Group)
Task
Week
1
Week
2
Week
3
Week
4
Week
5
Week
6
Week
7
Week
8
Spring
Break
Week
10
Week
11
Week
12
Week
13
Week
14
Week
15
Week
16
Design Phase
Select Sensor
Select Counter
Friction Reduction
Design
Meet with S.T.A.R.T.
Integrate Subystems
Testing Phase
Create User Guide
Build 1st Prototype
Test Prototype
Modify Design
Build Second
Prototype
Test Second
Prototype
Design Reports
ABILITY 1 Report
Final Report
Final Presentation
SEC Final Design
Report
33 | P a g e
SEC F10 – 42 ABILITY3
List of Resources (LL)
Item Number
1a
Description
Electronic Counter
Unit Price
Quantity
Line Total
285.00
1
285.00
50.00
1
50.00
2.00
10
20.00
On Hand
-
0.00
25.00
1
25.00
20.00
-
OR
1b
Arduino Board
2
Switch/Sensor
3
Wiring
4
Metal Shears
5
Misc. Parts
20.00
Subtotal (Counter)
350.00
Subtotal (Arduino)
115.00
34 | P a g e
SEC F10 – 42 ABILITY3
Appendix A: References (JW)
[1] U.S. Department of Commerce. Americans With Disabilities: 2005 Household Economic
Studies.
U.S. Census Bureau, Dec. 2008. 13 Oct. 2010.
<http://www.census.gov/prod/2008pubs/p70-117.pdf>
[2] NISH. Web. 13 Oct. 2010. <http://www.nish.org>
[3] S.T.A.R.T.. Web. 13 Oct 2010. <www.startinc.org>
[4] “LA8N Series (LCD Type).” Autonics Corporation, Bucheon Techno Park, Korea, 2007.
[5] “OSHA Construction eTool.”
http://www.osha.gov/SLTC/etools/construction/electrical_incidents/eleccurrent.html#w
et
_conditions. Accessed October 11, 2010.
[6] “Falcon HED251.” Abtek Controls.
http://www.abtekcontrols.com/Principals/trumeter/Products/falcon/hed251/hed251.pd
f
Accessed October 11, 2010.
[7] “LCD Basics.” Energy Star. http://www.energystar.gov/index.cfm?c=monitors.lcd
Accessed October 6, 2010.
[8] “LCD Viewing Angles” Pacific Display Devices.
http://www.tstonramp.com/~pddwebacc/lcd_view_angles.htm Accessed October 6,
2010.
[9] (2010). Futurlec. http://www.futurlec.com/LEDDisp.shtml Accessed October 6, 2010
[10] Crenshaw, J. (2004). Shedding Light on Seven-Segment Displays. Programmer's Toolbox , 9.
35 | P a g e
SEC F10 – 42 ABILITY3
[11] “Magnetic Switches.” Tiefenbach USA.
http://www.tiefenbach.com/store/product_detail_pages/magnetic.htm Accessed
October 7,
2010.
[12] “Switch Blog.” http://www.iheartswitch.com/blog/choosing-right-magnetic-switch-yourproject
Accessed October 6, 2010.
[13] “Basic Electricity.” http://www.1728.com/project2.htm Accessed October 7, 2010.
[14] “Directed 8600 Magnetic Micro Switch.” RadioShack
http://www.radioshack.com/product/index.jsp?productId=2419297# Accessed October
7, 2010
[15] “American Switches Product Categories.” American Switches. http://www.americanswitches.com/index.html Accessed 9 October 2010.
[16] “Overview of Basic Switches.” OMRON Industrial Automation.
http://www.ia.omron.com/support/guide/28/overview.html Accessed 6 October 2010
[17] “General Information – Basic Switches.” OMRON Industrial Automation.
www.omron.com/ecb/products/pdf/sw_pre_1.pdf Accessed 6 October 2010
[18] “D2F-01FL Omron Electronics Basic/ Snap Action/ Limit Switches” Mouser Electronics.
http://www.components.omron.com/components/web/PDFLIB.nsf/0/5673FC48B47CDC
9C
85257201007DD56F/$file/D2F_1109.pdf Accessed 6 October 2010
[19] “D2F Ultra Subminiature Basic Switch.” OMRON Electronic Components Web.
36 | P a g e
SEC F10 – 42 ABILITY3
http://www.omron.com/ecb/products/pdf/en-d2f.pdf Accessed 8 October 2010
[20] “Schawlow and Townes invent the laser”. Lucent Technologies.1998.
[21] Safety of laser products- Part 1: Equipment classification and requirements(2nd edition).
International Electrotechnical Commission.2007.
37 | P a g e
SEC F10 – 42 ABILITY3
Appendix B: Resumes
NICK STEFFAN
Cell: (618) 319-0476
Email: nsteffan@siu.edu
College Address:
603 W. Elm St.
Carbondale, IL 62901
Permanent Address:
911 S. Glenview Dr.
Carbondale, IL 62901
EDUCATION
Bachelor of Science in Electrical Engineering
May 2011
Southern Illinois University Carbondale (SIUC), Carbondale, IL
GPA: 3.703 / 4.0
Minor: Business and Administration
EXPERIENCE
Intern
Spring 2009
Caterpillar Inc., Peoria, IL
 Worked in the ECM (Electronic Control Module) core hardware section of the ECM division of
Cat Electronics
 Created and executed test plans for ECM’s.
Peer Mentor
Fall 2007 – Spring 2008
College of Engineering, SIUC, Carbondale, IL
 Assist mentees with homework and provide assistance in helping students adapt to college
environment.
 Organize events to promote campus involvement.
 Promote College of Engineering to help increase retention in the college.
Tutor
Fall 2008- Present
College of Engineering, SIUC, Carbondale, IL
 Provided tutoring services in math, physics and other courses related to engineering
SKILLS
Microsoft Office: Word, PowerPoint, Excel, Visio; Basic knowledge of MATLAB
HONORS / AWARDS:
Dean’s List
Dean’s Scholarship
National Science Foundation Scholarship
Caterpillar Excellence Scholarship
Fall 2006 – Spring 2009
Fall 2006 – Spring 2008
Fall 2006 – Spring 2008
Fall 2010 – Spring 2011
ACTIVITIES
Tau Beta Pi - The Engineering Honors Society
Vice President, SIUC Chapter
Southern Illinois Ultimate Frisbee Team
President and captain
Golden Key International Honour Society
American Society of Mechanical Engineers (ASME)
Sigma Alpha Lambda Honors Organization
Fall 2009 – Present
Fall 2010 – Present
Fall 2006 – Present
Summer 2009 – Present
Fall 2009 – Present
Fall 2007 – Present
Fall 2007 – Present
38 | P a g e
SEC F10 – 42 ABILITY3
Lucas M. Liescheidt
lukeliescheidt@hotmail.com
Permanent Address:
619 W. Jefferson
Washington, IL 61571
(309) 444 6398
Objective: To gain an entry level electrical engineering position.
Education:

Bachelor of Science in Electrical & Computer Engineering (May 2011)
Southern Illinois University Carbondale, IL 62901

Associate of Applied Science (May 2009)
Illinois Central College, East Peoria, IL 61571
GPA: 3.2/4.0
Experience:
Cashier, Brecklin’s BP Service Station



Assisted customers with purchases
Performed vehicle repairs
Maintained the shop and lobby
Subassembly, CoBatCo, Inc.

Worked with a team in the first leg of production of industrial waffle
irons

Created new methods to increase efficiency
Skills:



Mathworks Matlab version 7.9
Orcad PSpice version 9.2
Xilinx version 11.1
Honors/Activities

Dean’s list 4 semesters, 3 of which while working 15-25 hours per week

Member: Tau Beta Pi, May 2010
39 | P a g e
SEC F10 – 42 ABILITY3
Jason Wagner
jwags88@siu.edu
Permanent Address:
College Address:
2103 Jackson St. Renault, IL 62279
290 Warren Rd. #60 Carbondale, IL 62901
Phone: (618) 458-7207
Phone: (618) 334-6529
Objective
Internship or job in the field of Electrical Engineering.
Education
BS in Electrical Engineering, Minor in Mathematics, May 2011
Southern Illinois University Carbondale
Grade-Point Average: 3.289 (on a 4.0 scale)
Related Courses: Circuit Analysis, Electronic Devices, Signals, Oral Communication,
Technical Writing and Presentation Seminars, Physics, Calculus I, II, III, Differential
Equations, Electromagnetics, Electric Machines, Power Systems Analysis, Wireless and
Personal Communication, Control and Feedback Systems, Senior Design.
Employment
8/2005-8/2010
Zone Manager/Crew Trainer
McDonald’s Corporation, Red Bud, IL 62278



Managed area working while ensuring proper procedures were being used.
Trained new crew members in specific area
Was relied on to produce quality produces quickly.
Honors and Organizations
Dean’s List Fall 2007 and Fall 2009
Alpha Lambda Delta Honors Society Member
Relay for Life Team Member
Two Times Cross Country Captain (2005-2006)
Track Captain (2007)
References
Available upon request
40 | P a g e
SEC F10 – 42 ABILITY3
Adam Cook
800 E Grand Ave. Apt. 12E, Carbondale IL 62901, (217) 493-1025, acook45@siu.edu
Objective: To acquire an entry level engineering position.
Skills and Honors





Proficient with MATLAB, Simulink, Xilinx, Excel, Word, Powerpoint, Access, and basic CAD.
Courses Taken: Circuits, Electronics, Electromechanical Energy Conversion, Electric Power Distribution,
Electronic Circuit Design, Biomedical Imaging, Signals and Systems, Systems and Control, Digital Circuit
Design, and Technical Writing.
Leadership, teamwork, and organizational experience as a founding father and the vice-president of a
chapter of the Sigma Chi fraternity at SIUC.
Dean’s List 4 semesters, Provost Scholarship, Caterpillar Excellence Scholarship, initiated into the Tau Beta
Pi Engineering Honor Society on April 2010.
Excellent communication and teamwork skills gained from internship with Littelfuse.
Work Experience
Summer Engineering Intern
May 2010 - Aug
2010Littelfuse POWR GARD R&D Lab, Champaign, IL
 Was responsible for testing and designing a line of solar panel fuses.
 Helped with construction of high power testing lab by drawing wiring schematics.
SIUC College of Engineering Tutor/Supplemental Instructor
SIUC College Of Engineering, Carbondale IL
 Tutor freshman and sophomore engineering students.
 TA for Calculus 1 and Calculus 2 classes.
Jan 2010 – present
SIUC Intramural Sports Official
Jan 2010 - present
SIUC Student Recreation Center, Carbondale, IL
 Officiate Intramural Basketball, Softball, and Flag Football.
 Learned leadership, communication, and people skills concerned with handling confrontations.
SIUC College of Engineering Peer Mentor
Aug 2008 - May 2009
SIUC College Of Engineering, Carbondale IL
 Served as a mentor for freshman engineering students of SIUC.
 Position of leadership that helps students set and achieve goals for school and life after graduation.
Education
Bachelor of Science in Electrical Engineering
Southern Illinois University, Carbondale IL
 3.656 GPA cumulative, 3.8 GPA in major on a 4.0 scale.
 Minor in Mathematics.
May 2011 (anticipated graduation)
41 | P a g e
SEC F10 – 42 ABILITY3
Trevor Blackburn
trevorw.blackburn@gmail.com
Permanent Address:
117 Seeser Street
Joliet, IL 60436
(815) 722-7916
College Address:
1101 E Grand Ave., Apt. W12
Carbondale, IL 62901
(815) 409-6764
Objective
An entry-level electrical engineering position in the area of power and control systems.
Education
Bachelor of Science in Electrical Engineering
Southern Illinois University, Carbondale, IL 62901
Anticipated 7/2011
Grade-Point Average: 3.529 (on a scale of 4.0)
Relevant Coursework



Electromechanical Energy Conversion
Intro to Electromagnetic Fields
Electric Circuits
 Digital Circuit Design
 Electronics
 Signals and Systems
Experience
Assistant Manager, CPX Sports




April 2006-present
Maintained the facility, heavy machinery, and high pressure air systems
Provided excellent support to customers
Organized game schedules for 700+ customers
Helped design high pressure compressor setup to meet peak demands
Skills


Microsoft Visual C++, Java
UNIX Operating Systems
Honors and Organizations




College of Engineering Scholarship, 2007, 2008, 2010
Omron’s Electronics Inc. Scholarship, 2009, 2010
IEEE
Tau Beta Pi (General Engineering Honor Society)
Activities
Member, Southern Illinois University in Carbondale Paintball Club
References
Available upon request
42 | P a g e
SEC F10 – 42 ABILITY3
Erik M. Napientek
enap@siu.edu
______________________________________________________________________________
OBJECTIVE: To obtain an entry level electrical engineering position.
EDUCATION
Southern Illinois University Carbondale (SIUC), Carbondale, Illinois
Bachelors of Science in Electrical Engineering
Minor in Mathematics (Completed)
GPA 3.7/4.0
August 2007 – Spring 2011
RELATED COURSEWORK
Completed: , Digital Circuit Design,Computer Organization and Design
Signals and Systems, Electronics, Signals and Control, Electromechanical Energy Conversion
Enrolled in Fall 2010: Digital VLSI Design, Electronic Circuit Design, Photonics 1, Senior Design
Enrolled in Spring 2011: Senior Design, Electronic Devices,
EMPLOYMENT
Tutor/Supplemental Instructor
SIUC College of Engineering, Carbondale, Illinois


Help students to complete their in-class worksheets
Help students with math and science at predetermined study sessions
Peer Mentor
SIUC College of Engineering, Carbondale, Illinois


August 2008 - Spring 2010
Help freshmen adjust to college living and develop effective study habits.
Conduct study sessions and assist students with homework and various questions.
Baseball Umpire
Independent Contractor, Chicago land area



August 2010 - Present
Umpired Carol Stream Little League Allstar Games in 2007 and 2008
Umpired Championship Game for Tournaments in 2008-2010
Registered by the IHSA
Spring 2004 - Summer 2010
Spring 2007- Present
COMPUTER SKILLS
Microsoft Office Suite: Word, Excel, PowerPoint, Xilinx, Matlab, Cadence
AWARDS & HONORS
Dean’s List, SIUC
Tau Beta Pi Honors Society

Recording Secretary
Heta Kappa Nu Honors Society
Fall 2007 - Spring 2010
Fall 2009 - Present
Fall 2010 – Present
Spring 2010-Present
CLUBS
SIUC Baseball Club

Treasurer
Fall 2007 - Present
Fall 2010
43 | P a g e
SEC F10 – 42 ABILITY3