Vinay Barde : Program Manager Alexis Reusch: Program Facilitator Jason Marks: Lead EE Alfred Lee: Lead CE Project Overview • Seated balance to help physical therapist teach wheel chair bound patients to improve the strength of their core muscles. • Currently have a tower that is built that has seven large panels in a vertical line that are separated by 3 tri-colored LEDs. • When activated the LED’s will be blue, if the patient touches the target they will turn green and if they miss they will become red. • There are two games in the MCU : Random & Timed Trial • Second tower will be added to the game to add more challenges for the patients. This tower will be a slave to the first tower and help to increase a patients side to side reaching distance. Scope & Deliverables Scope: Deliverables: • Design and build the electrical components of two towers so that they may communicate wirelessly to one another • Two functional towers • Perfect software that was developed by team P10005 for the towers to add in a second tower as well as more games and components • Wireless Communication between towers • Add a measuring device to the outside of the tower so the therapist can measure the distance between the tower and the patient • Upgrade current wiring in Tower #1 • Populate Tower #2 • Distance Sensor on each tower Customer Needs Engineering Specifications Metric No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Need Nos. 7,8 5 9 1,3,14 1,20 6 2,22,23 6,23 9 4,14 2 9,11 2,9,11 12 10,22 9,24 1,3,4,6,19 1,4,12 13 21 16 15 17, 18 Engineering Specifications Metric Time to sanitize game response time set up time ( movement of towers) Proximity to activate panels Number of game options (rounds, endurance, competition, duration) Accuracy of measurement between person and tower Functional reach measurement range Functional reach measurement accuracy Time to program games Delays for wireless Range of heights where proximity measurements can be taken Size of box for the Ultra Sonic Ping sensor (Length and width) Weight for entire system (per tower) Wireless range (Maximum tower separation without the use of wires) Range of Ping sensor Time between maintenance (replace or recharge batteries) Total number of games Towers involved in games LED indication to be ready to use volume of audio ( indication of sucessful touch) Size of LCD screen so that it fits in the tower (width ) LED Indication for which buttons are selected Device will display results (hit, miss, average time, separate results per tower) Imp 1 9 1 3 3 3 9 9 3 9 3 1 1 1 9 3 9 9 1 1 1 1 3 Units sec ms mins in # complete in ft in minutes ms ft in lbs ft ft min # of games # of towers sec db in. sec boolean Desired Direction down down down down up down up down down down target down down up up down up up down target down down yes Marginal Value 90 60 2 0.75 2 1 3 2 5 25 2 3 20 20 7 2 2 1 5 65-70 3.5 7 yes Ideal Value 60 40 1 0.25 4 0 5 0 2 10 5 3 15 40 15 1 3 2 3 50-60 4 5 yes Metric No. 1 2 3 Need Nos. 7 7,8 7,8 Safety Metric Fillet of track corners Optical Visibility ( % of lights seen by the client) Cleanliness of the towers Imp 3 3 3 Units Degs % % Desired Direction Down up Down Marginal Value 30 75 15 Ideal Value 15 100 5 System Architecture Capacitive Touch Chip Choice Capacitive Chip Layout Schematic Capacitive Chip Schematic Distance Sensor Selection Sensor Schematic Wireless Communication between Towers (Ez430-RF2500 ) Tower #2 (Slave) Tower #1 (Master) RF Communication ( Transmit/Receive) User Input Ex430-RF2500 • Frequency @ 2.4 GHZ • Communicates with Evaluation boards through I2C via SimpliciTi protocol Ez430-RF2500 • 16-MIPS performance • 200-ksps 10-bit SAR ADC • Two built-in operational amplifiers • Watchdog timer, 16-bit Timer_A3 and Timer_B3 • USCI module supporting UART/LIN, (2) SPI, I2C, or IrDA • Five low-power modes drawing as little as 700 nA in standby • 2.4-GHz radio-frequency (RF) transceiver • Programmable data rate up to 500 kbps • Low current consumption • USB debugging and programming interface featuring a driverless installation and application backchannel • 18 available development pins • Highly integrated, ultra-low-power MSP430 MCU with 16-MHz performance RGB LED Schematic LED Drive Circuit MSP-EXP430F5438 Evaluation Board MCU I/O Map Tower 1 MCU I/O Map Tower 2 UML Class Diagram Balance Tower State Diagram Sequence Diagram Sequence Diagram Sequence Diagram Power Layout Schematic Power Estimate Component MSP-EXP430F5438 LEDs LCD Capacitive Buttons Wireless Ultra Sound Ping Sensor Case Defintion AVG Max Min Input Voltage (V) 2.2 2.5 4.7 2 1.8 5 Max Input Voltage (V) 3.6 4 5.5 5.5 3.6 5 Avg Supply Current (mA) 1 20 5 5 18 30 Max Supply Current (mA) 2 25 15 10 22 35 Usage (mAh) Usage (mWh) Total Power (mW) Battery Life (%) Supply Current*Hours Used Supply Current* Vout*Hours Used Power Usage/Hours Used 598.000 840.667 1973.40 2774.20 493.35 693.55 Voltage Output (V) Hours Used per day 3.3 4.00 Total hours of Life (Battery PowerPower Used in Minimum Battery Hour/Battery Power in Hour Req)/Total Power 3.43 111.13 4.82 79.05 Days Total Hours/ Hours Used per day 13.89 9.88 Note: Ping sensor calculations take into account the brief time it will be active. Battery V 6 mAh 9600 mWh 57600 Minimum Battery requirement 5 462.37 2774.2 Only 6 LEDs are assumed to be on Test Plan Test 1: Subsystem/ Function/ Feature Name: Tower Setup Date Completed: _________________ Performed By: __________________ Description: Test the time it will take to set up and perform maintenance on tower(s) for next use. Engr. Spec. # 1 3 10 17 Engr. Spec. # 1 3 10 17 Specification (description) Time to Sanitize Set up Time Time to program games Time to change out the batteries Unit of Measure Marginal Value sec 90 mins 2 mins mins 2 2 Instrumentation or equipment (description) Clorox disinfectant wipe, stop watch Stop watch Stop watch Stop watch Comments/Status Test Plan Test 2: Subsystem/ Function/ Feature Name: PCB Date Completed: _________________ Performed By: __________________ Description: Perform tests on PCB to verify correct operating conditions . Engr. Spec. # Specification (description) Unit of Measure Marginal Value - Check voltage rails on PCB V 5, 3.3 - Check for physical damage - - - Check continuity Ohms Open - Cross check with schematics for functionality - - Engr. Spec. # - Instrumentation or equipment (description) Multimeter Visual Inspection Multimeter Visual Inspection Comments/Status Test Plan Test 3: Subsystem/ Function/ Feature Name: Hardware Test of MCU Connections Date Completed: _________________ Performed By: __________________ Description: Checking input/output lines from MCU for correctness. Engr. Spec. # Specification (description) Unit of Measure Marginal Value - Check I2C lines Check power lines V 5, 3.3 - Check LED lines V 3.3 Engr. Spec. # - Instrumentation or equipment (description) Oscilloscope Multimeter Multimeter Comments/Status Test Plan Test 4:Subsystem/ Function/ Feature Name: Software Date Completed: _________________ Performed By: __________________ Description: Testing functionality of program, and interaction between peripherals and MCU. Engr. Spec. # Specification (description) 2 Program functionality test Game response time 4 Proximity to activate panels Unit of Measure Marginal Value ms works 60 in 2 ft 20 Delays for wireless 15 Wireless range (Maximum tower separation without the use of wires) 20 LED indication to be ready to use sec 5 23 LED Indication for which buttons are selected sec 7 Engr. Spec. # 2 4 15 20 23 Instrumentation or equipment (description) Computer Stop watch Tape measure Tape measure, computer Stop watch Stop watch Comments/Status Test Plan Test 5: Subsystem/ Function/ Feature Name: Ping Sensor Setup Date Completed: _________________ Performed By: __________________ Description: Test the functional reach test of the sensor for accuracy and distance. Use a piece of black plastic with a bulls eye to test the reach of the laser. Observe the sensor can detect the patient’s hand. Test should be completed 10 times. Engr. Spec. # 7 8 12 13 Engr. Spec. # 7 8 12 13 Specification (description) Accuracy of measurement between person and tower Functional reach measurement range Range of heights where proximity measurements can be taken Size of box for the Ultra Sonic Ping sensor (Length and width) Unit of Measure Marginal Value in 1 ft 3 ft 1.25 in 3 Instrumentation or equipment (description) Tape measure Tape measure, laser pointer Tape measure Tape measure Comments/Status Test Plan Test 6:Subsystem/ Function/ Feature Name: Games Date Completed: _________________ Performed By: __________________ Description: User will play the game and test it for game response, activation time, and if correct operation Engr. Spec. # 2 4 5 9 19 Engr. Spec. # 2 4 5 9 19 Specification (description) Game response time Proximity to activate panels Number of game options (rounds, endurance, competition, duration) Functional reach measurement accuracy Towers involved in games Unit of Measure Marginal Value ms in #complet e 60 2 in 2 sec 5 Instrumentation or equipment (description) Stop watch Tape measure Count Tape measure Stop watch 2 Comments/Status Test Plan Test 7: Subsystem/ Function/ Feature Name: Functionality of the Capacitive Chip Date Completed: _________________ Performed By: __________________ Description: We will test to see what power we need for all outputs to work reliably. Power and Clock will be applied to the chip. The voltage will and we will vary the sinusoidal signal to make sure all eight outputs are functional. Engr. Spec. # 4 Engr. Spec. # 4 Specification (description) Proximity to activate panels Unit of Measure Marginal Value in .75 Instrumentation or equipment (description) Power supply, oscilloscope, function generator, Tape Measure Comments/Status Project Plan Responsible Member Start Date Expected Date MSD II Close Remaining Action Items from PMR Order rest of material needed for build Group 3/12/2012 3/16/2012 Alexis 3/12/2012 3/16/2012 Software Code STUBS Alfred 3/12/2012 3/16/2012 Jason, Vinay Vinay, Alexis Jason Jason Jason, Vinay, Alexis Jason, Vinay, Alexis Jason, Alexis 3/12/2012 3/16/2012 3/12/2012 3/16/2012 3/19/2012 3/19/2012 3/26/2012 4/9/2012 3/19/2012 3/26/2012 3/19/2012 3/26/2012 Wire Up both ping sensor boards Vinay 3/19/2012 3/26/2012 LED portion of Code Complete Alfred 3/19/2012 3/26/2012 Software Development Initial main code for MCU ( Panels, LED, LCD code) ie. One Button Code System Code (Expanding One Button Code) Unit / Integration Tests for Touch panels, LEDs, LCD) with Cap Chip/LED proto baord Alfred 3/12/2012 4/13/2012 Alfred 3/12/2012 3/30/2012 Alfred 3/30/2012 4/6/2012 Vinay, Alfred 3/26/2012 4/12/2012 Vinay Alfred, Vinay, Jason Alfred 3/19/2012 3/26/2012 4/13/2012 4/23/2012 4/13/2012 4/23/2012 Alfred 4/20/2012 4/23/2012 Task PCB Layout prep for sending Cap touch Chip/LED prototype board Send out PCB For Fabrication Receive PCB and Begin Testing Preliminary Builds Wire Up Led Banks (all 16) Ping Sensor Code Integration of MCU code with sensor and wireless EZ430-RF2500 Wireless Code Test Wireless Date Completed Dependency 21 21 24 Comments Component Testing Group 3/26/2012 4/6/2012 Test PCB Functionality (Test plan #2) Group 3/26/2012 3/30/2012 Test MCU Functionality (Test plan #3 ) Group 3/30/2012 4/6/2012 24 Group Alexis, Vinay, Jason 4/6/2012 4/23/2012 24,25,26 4/6/2012 4/9/2012 Jason, Alexis 4/9/2012 4/13/2012 Group 4/9/2012 4/23/2012 Group Alexis, Vinay, Jason 4/20/2012 4/27/2012 4/20/2012 4/23/2012 Jason, Alexis 4/23/2012 4/25/2012 Integration Testing ( Test Plan #4) Group 4/25/2012 4/27/2012 Complete System Integration Acceptence Testing (System functionality Test # 6) Project Planning ( Continuously through quarter) Updated Risk Assessment Group 4/27/2012 5/4/2012 Group 4/27/2012 5/4/2012 Group 3/16/2012 3/16/2012 Alexis 3/16/2012 5/18/2012 Update Project Plan Vinay 3/16/2012 5/18/2012 Update Edge Group 3/16/2012 5/18/2012 Poster Group 5/4/2012 11-May Final Paper Group 5/11/2012 5/18/2012 User Manual Group 5/10/2012 5/11/2012 Performance Review With Customer Group 5/11/2012 5/11/2012 FINAL Project Management Review Group Tower 1 Build Electronic Population Machine Tower for Sensor box attachment Integration Testing ( Test Plan #4) Tower 2 Build Electronic Population Machine Tower for Sensor box attachment 23, 25 27,28,29 29 Effect Cause Importance Risk Item Severity ID Likelihood Risks Action to Minimize Risk Owner L*S What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring? Who is responsible for following through on mitigation? Going to see the faculty that is versed in these areas as well as looking up sample code on how to add these to the existing code. Prioritize sections of code. Group Describe the risk briefly What is the effect on any or all of the project deliverables if the cause actually happens? What are the possible cause(s) of this risk? 1 Adding all of the new elements into the code This would cause our project to not work correctly and not meet the customer needs Team members coding things they are not familiar with 3 9 27 2 Arguments within team Effect over all outcome and time management Teammates disagree on decisions 3 3 9 3 Unable to finish product design Will lose total completion time on project 1 9 9 4 Customer feedback Prevent optimal design Different parts of project plan not completed on time Inability to contact customer 3 9 27 5 Current power not sufficient for new parts Affect budget, new parts Using new parts in design 3 1 3 6 Scheduling conflicts Effect over all outcome of the project Number of classes everyone is taking outside of MSD 3 3 9 Would affect customer satisfaction Some measuring tools are more reliable than others we will need to do plenty of research before choosing 3 3 9 7 Reliability of measuring tool Everybody has a say, discuss everything as a group. Learn to compromise Follow the project plan and frequently keep up to date with everybody’s work Make multiple attempts to talk with customer, email, call, etc. Not a big risk, can be accounted for buy increasing power with more batteries etc. We will set long term goals so that as the deadline approaches we will have time to ask another group member for help if needed. Test the part that we choose and make sure that we have research to support our choices Group Group Alexis Jason Vinay, Alexis Vinay Risks 8 Part Availability Would slow down progress Lead times 3 3 9 Plan ahead, find substitute parts Alexis 9 Budget Prevent completion of project Ineffective budgeting/lack of funding 1 3 3 Only purchase parts when 100% sure they will be used Alexis 10 Group member becomes unavailable permanently Loss of resource Dropping class/becomes ill 1 3 3 11 Loss of Towers No longer have a deliverable product Stolen/Misplaced 1 3 3 12 Group member fails to deliver critical component Would slow down progress Preoccupied with other classes 1 3 3 13 Products purchased are insufficient for Design Prevent accurate modeling, and better design Insufficient research before purchasing 3 9 27 Research needed parts, talk to experts in area of need Group 14 Wireless module delay Slow down rate of games 3 3 9 Know how to optimize wireless communication device Alfred, Vinay 15 PCB does not work correctly Bad design 3 9 27 Have team/prof review PCB layout Jason Wireless communication not fast enough Would have to redesign and reorder Attempt to convince the member to not drop the course. Major redesign project plan may be needed Major redesign project plan may be needed/Reconstruct the tower. Have midweek and full week progress reports. This allows personal, and team evaluation of progress, as well as allowing others to assist if deemed necessary. Group Group Group BOM Bill of Materials 1 2 3 17 Quantity Needed 754-1492-ND $1.37 60 $82.20 - $149.00 2 $298.00 All-Battery.com 8 Bay charger and 16 Batteries $36.49 1 $36.49 SparkFun COM-00526 $1.95 4 $7.80 - $49.00 1 $49.00 Manufacturer Manufacturer Part # Distributor Distributor Part # RGB LED's Kingbright WP154A4SUREPBGVGAW DigiKey Microprocessor Board Rechargeable Batteries and Charger Voltage Regulator (3.3v) TI MSP-EXP430F5438 - Tenergy - 4 EZ430-RF2500 TI 5 Ultra Sonic Ping Sensor Parallex 6 MSP430 USB JTAG TI 7 PCB Advanced Circuits 8 EZ RF Header Mill-Max 9 LCD Screen Sparkfun 10 Transistors Faichild Semiconductor 11 Panasonic 12 Surface Mount Resistors 4.7K Panasonic 13 Surface Mount Resistors 820K Surface Mount Resistor 56 Panasonic 14 15 Surface Mount Capacitors .1uF Murata Electronics 16 Unit Price Part Name Surface Mount Capacitors 10uF Header EZ430-RF2500 Total Price 28015 DigiKey 28015-ND $29.99 2 $59.98 MSP-FET430UIF - - $99.00 1 $99.00 850-10-006-20-001000 GDM12864H 2N4401D75ZCT-ND P4.7KGDCT-ND P820KGCT-ND P56GCT-ND 490-1524-1-ND Advanced Circuits ARROW Sparkfun Digikey Digikey DigiKey DigiKey DigiKey GDM12864H 2N4401TAR ERJ-3GEYJ472V ERJ-3GEYJ820V ERJ-3GEYJ560V GRM188R71E10KA01D $33.00 $1.14 $19.95 $0.21 $0.02 $0.01 $0.01 $0.03 3 $99.00 2 1 30 20 50 100 20 $2.28 $19.95 $6.30 $0.40 $0.46 $0.70 $0.52 TDK Corporation 445-6853-1-ND DigiKey C1608X5R1A106M $0.46 TE Connectivity A36395-ND DigiKey 1-5164713-0 $1.28 10 35 $4.57 $44.88 Totals $811.53 Questions???