Senior Design Project
P06201: Modified Home Entry
Project Sponsor: National Science
Foundation
Team Members:
Robert Karpowicz (ME) Team Leader
Brian Long (ME) Chief Engineer
Jeff Webb (ME)
Josh Ribbeck (ME)
Team Coordinator:
Dr. Alan Nye
Team Mentors:
Dr. Margaret Bailey
Dr. Elizabeth DeBartolo
Introduction
 Client: Arc of Monroe County
 Sponsor: National Science Foundations (NSF)
– This material is based upon work supported by the National Science
Foundation under Award No. BES-0527358
– Any opinions, findings, and conclusions or recommendations expressed
in this material are those of the author and do not necessarily reflect the
views of the National Science Foundation.
 Goal: To create a system to open and close
main doors automatically for residents with
disabilities at assisted living locations.
 Locations – Arc of Monroe County Assisted
Living Locations
– Rush, NY (priority)
– Penfield, NY (if resources allow)
Rush Location –
View from outside
Penfield Location –
View from outside
Business Analysis
 Primary Stakeholders – Members of the Arc
of Monroe County
 Complete goals of project while staying
within the limits of grant ($1500)
 Primary Business Goal
– Design a working prototype for the Arc residents
to use in their assisted living locations.
Background Research
 Costs of current commercial systems
 Price Quote from www.privatedoor.com
– Costs start at $600 (door only)
– Additional $600 for actuating lock system
 Michigan State performed similar project
– 2 doors for $10,000
 RIT cost approximately $3000 per door
Design Objectives
 Design with off-the-shelf components
– Makes assembly and integration simplistic
– Minimize costs
 Modularize design - “Plug and Play”
– Only connections
 AC power
 Door mechanism
 Locking mechanism
 Sensors
Design Process for Senior Design I
1) Determine end-user needs with Needs
Assessment
2) Quantify needs with specific goals
3) Brainstorm concepts to meet goals
4) Perform feasibility assessments (Pugh Chart)
5) Select best concept
6) Perform engineering analysis
7) Select components
Needs Assessment Objectives








Door open/close with only single input from user
Remote activation by specified users only
User input ignored during system operation
Preserve regular door function
Door remains open until closed or close on its own
Door stopped when object in path detected
High reliability
Easy maintenance
Major Design Requirements
Line
Requirement
Source
Spec
Units
1
Object Detection
Customer
5 - 15
Inches
2
Time to Automatic Closing
Customer
30
Seconds
3
Activation Force
Customer
2
Lbf
Maximum
4
Activation Distance
Customer
10
Feet
Minimum
5
Manual Operation Resistance
Customer
5
Lbf
Maximum
6
Time to Full Open
4
Seconds
Minimum
7
Force to Stop Door
15
Lbf
Maximum
Americans with Disabilities
Act Accessibility Guidelines
Americans with Disabilities
Act Accessibility Guidelines
4 Concepts for Door Opening




Linear Actuator
Motor / Gear
Hydraulic Ram
Pulley System
Linear Actuator Design Concept Sketch
•Pros:
•Cons:
•Complete electrical control
•Long travel
•Low resistance to manual operation
•Cost
•Simple integration
•Low maintenance
Motor / Gear System
•Pros:
•Off-the-shelf components
•Ease of integration
•Low cost
•Quiet operation
•Low maintenance
•Cons:
•High resistance
Hydraulic System
•Pros:
•Off-the-shelf components
•Simple design
•Cons:
•Noise
•High power consumption
•Cost
•High maintenance
Pulley System
•Pros:
•Cost
•Cons:
•Integration
•Complicated
•Fragile operation
•Complicates manual
operation
•Aesthetics
Door Mechanism Pugh Chart
Cost
Resistance
Power Consumption
Torque Generated
Maintenance
Integration
Aesthetics
Noise
Totals
Motor
Concept
Linear
Actuator
Pulley
System
Hydraulic
Ram
2
1
2
3
1
4
3
2
4
3
1
4
1
1
2
1
3
4
2
2
4
3
1
4
3
2
4
3
2
12
3
1
4
20
21
27
3 Concepts for Lock Actuation
 Electromagnetic actuation
 Rack and pinion with motor
 Electric solenoid
1 Concept for System Activation
 Wireless transmitter and receiver
Existing Door Frame (Rush Location)
Lock Bypass Mechanism
The door frame will be modified to allow
the door to open without moving the
latch.
A movable piece (shown in red) will be
installed to allow normal operation of
the door.
Electromagnetic Unlocking
•Pros:
•Ease of maintenance
•1 Moving part
•Quiet
•Cheap
•Cons:
•Questionable effectiveness
Rack and Pinion with Motor Unlocking
•Pros:
•Cons:
•Off-the-shelf components
•Moving parts
•Reliability
•Bulky assembly
Solenoid Unlocking
 Pros
– Easy set up, and maintenance
– Only 1 moving part.
– Quiet
– Cheap
 Cons
– Reliability (continuous duty)
Latch Mechanism Pugh Chart
Electromagnet
Rack & Pinion
Cost
2
3
Reliability
3
1
Size
2
3
Life Expectancy
3
1
Aesthetics
2
3
Power Consumption
3
1
Integration
2
3
Totals
17
15
Solenoid
1
2
1
2
1
2
1
10
Engineering Analysis and Synthesis







Motor selection
Design of door lock bypass
Use of sensors
Logic controller
Logic and wiring diagrams
Transmitter / receiver
Electrical accessories
Box
Containing:
-Motor
-Receiver
-Stamp
-Electrical
Components
Electromagnets
Locking Mechanism
IR Sensors
Electromagnetic
Clutch
Clutch
Actuation and Unlocking Systems
 Parallax Logic Stamp
for programming
 Rolling code
transmitter / receiver
– Similar to garage door
– Security
– About 1 trillion possible
codes
Motor Selection
 Motor used
– 90 VDC
– 250 in-lbf max
– 3.2 RPM max
 DC Motor Controller
–
–
–
–
Powers motor only
Speed adjustability
Fused control protection
Surge suppression
Motor Verification
Working Model simulation
Force
Hinge
Motor
Motor Verification
 Inputs
– Motor speed: 3.2 RPM (19.2 º/s)
– Resistance: 5 lbf
 Output
Electromagnets
Push Electromagnet
Pull Electromagnet
Magnetic Plate
 Force to overcome door seal = 8 lbf
 Motor output = 6 lbf max
 Electromagnets installed
– One for each direction
– Provides additional force
ELECTROMAGNETIC
SLIP CLUTCH
 Disconnects drive when system not in
operation
– Allows for low resistance to manual operation
 Slip if torque exceeds 250 in-lbf torque
 Protects motor from overload
– Clutch slips at max motor torque
Link FEA Analysis
Finite Element Analysis
12” Bar Linkage
1500 lbf Tensile Load
Ferric Stainless Steel (25ksi Yield)
Factor of Safety: 1.59
Motor Position
 A digital encoder used to
monitor door position during
operation
– Determines when door
opened/closed
– Determines when door manually
stopped/moved
Design of the Door lock Bypass
 Solenoid (1” Stroke) to clear door latch
 4 lbf lift capacity
 Custom brackets machined from 303 stainless
– Ease of machinability
– Corrosion resistant
– High strength
Lock bypass in the open position
Lock bypass in the closed position
Fixed Plate FEA Analysis
Surface A
Finite Element Analysis
Constrained by 4 Mounting Holes
1000 lbf Load Applied to Surface A
Ferric Stainless Steel (25ksi Yield)
Factor of Safety: 1.25
Object Detection
 Infrared analog distance
sensors
 Range of 10 to 80 cm
 A-D converter to change
analog signal to digital
 Sensor arrangement – as
shown
– Outside - 3 across the span
of the door and 2 feet up
from the floor
– Inside – 2 across the span of
the door and 2 feet from the
floor
Location of sensors – Front
of door
Location of sensors –Back of
door
Electrical Analysis
Component
Wireless Receiver
DC Motor **
Stamp
Solenoid
Clutch - SO42
Electromagnet
Mode 1
24VDC Supply
Solenoid
Electromagnet
Voltage
(DC unless noted)
Resistance
(Ohms)
Current
(Amps)
Power
(Watts)
120 VAC
90
9
24
24
24
-112.5
-0.8
0.322
0.458
0.469
0.233
1.48
-72
Amps
Watts
0.458
0.233
0.691
11.0
5.6
16.6
52.4
51.2
102.9
Mode 2
24VDC Supply
Solenoid
Clutch
11.0
11.3
5.6
27.8
Amps
Watts
0.458
0.469
0.927
11.0
11.3
22.2
Selected DC Power Supply (McMaster # 7009K75)
Input Voltage (AC)
100 - 240
Output Voltage (DC)
24
**Powered by Separate Motor Controller
Amps
1.3
Watts
30
A/D Converter
Wiring
Diagram
A/D Converter
Infrared Sensor
A/D Converter
Infrared Sensor
A/D Converter
Infrared Sensor
A/D Converter
Infrared Sensor
Infrared Sensor
DC Motor
+
Relay
Electromagnetic
+ Clutch -
Relay
+
Solenoid
-
Relay
Relay
Out
Encoder
+
Electromagnet
Signal
Out
Transmitter
+
9 VDC Battery
Receiver
-
-
120 VAC – 90 VDC
DC Motor Controller
Relay
+
24 VDC
120 VAC
Source
In
Out
Voltage Regulator
120 VAC – 24 VDC
Transformer
9 VDC
+
-
Modified Home Entry
Bill of Materials
Item
Component
Supplier
Part #
Qty.
1
DC Gearmotor
Grainger
4Z723
1
$238.75
$238.75
2
DC Speed Controller
Grainger
4Z527
1
$75.75
$75.75
3
Wireless Trasmitter
McMaster Carr
8129A81
2
$23.88
$47.76
4
Wireless Receiver
McMaster Carr
8129A57
1
$33.66
$33.66
5
Solenoid - 24VDC
McMaster Carr
70155K6
1
$12.80
$12.80
6
Basic Stamp Kit
Parallax
228802
1
$99.00
$99.00
7
Slip Clutch
Minarik Electric
SO42
1
$179.00
$179.00
8
Electromagnet
McMaster Carr
5698K216
2
$49.75
$99.50
9
DC Power Supply
McMaster Carr
7009K75
1
$109.00
$109.00
10
IR Sensor / Cable
Parallax
805-00005-605-00003
5
$13.95
$69.75
11
A/D Convertor
Parallax
ADC0831
5
$6.00
$30.00
12
Encoder
Bourns Inc.
ECW1J-B24-AC0024
1
$2.74
$2.74
13
Drive Link **
Custom
--
1
$20.00
$20.00
14
Driven Link **
Custom
--
1
$20.00
$20.00
15
Door Hinge **
Custom
--
1
$8.00
$8.00
16
Door Latch **
Custom
--
1
$70.00
$70.00
17
Fixed Plate **
Custom
--
1
$50.00
$50.00
18
Magnetic Block **
Custom
--
1
$45.53
$45.53
19
Electromagnet Block **
Custom
--
1
$49.75
$49.75
20
Transition Shaft **
Custom
--
1
$3.00
$3.00
21
Misc Electrical Components
Various
--
1
$75.00
$75.00
** Approximate Price for Raw 303 Stainless
Price Per Total Price
$1,338.99
Senior Design 2 Project Plan
(tentative)
1)
2)
3)
4)
5)
6)
Order parts after Thanksgiving holiday
Plan installation and test procedure
Parts acquired before winter recess
Start test assembly in the new year
Install at Arc location in January
Troubleshoot during remainder of quarter
Summary
 This project provides a unique opportunity to
improve the quality of life for the inhabitants
of the Arc of Monroe County’s assisted living
locations.
Box
Containing:
-Motor
-Receiver
-Stamp
-Electrical
Components
Electromagnets
Locking Mechanism
IR Sensors
Electromagnetic
Clutch
Questions?
Clutch