bryan sonnier – project managerjulian coleman – software engineer jonathan tindall – hardware...

Project: S.A.M.U.R.A.I.March 2, 2009

Bryan Sonnier – Project Manager Julian Coleman – Software EngineerJonathan Tindall – Hardware Engineer Tam Bui – Test Engineer

TEAM MEMBERS:

Introduction

Bryan Sonnier – Project Manager

Jonathan Tindall – Hardware Engineer

Julian Coleman – Software Engineer

Tam Bui – Test Engineer

Project Advisor – Dr. Wei ZhanProject Sponsor – OI Analytical

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&

SAM Unit Redesign and Integration

Project SAMURAI:

A Silent Killer

CO2 concentration increases due to: Poorly ventilated areas Combustion of fossil fuels Human respiration

Exposure to elevated levels can lead to hypercapnia, resulting in possible death

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CO2 (ppm)

Warning Level

Side Effects

300-400 None None

10,000 Low Slight drowsiness, headache

20,000 Medium Chest heaviness, more frequent and deeper respirations

30,000 High Breathing rate doubles, heart rate increases, risk acidosis

50,000 Critical Sensory dysfunction, unconsciousness, death

http://en.wikipedia.org/wiki/File:Carbon-dioxide-3D-vdW.svg

Information from http://www.inspect-ny.com/hazmat/CO2gashaz.htm

Background

SAM filters can detect various gases including CO2 and refrigerants

Detects leaks sooner and at lower levels to avoid air quality fines Section 609 of EPA’s Clean Air Act

allows for fines of $32,500 per day!

OSHA Indoor Air Quality Standards

Wide range of industrial and commercial applications

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http://www.oico.com

Project Objectives

Fully integrate Windows CE environment

Develop remote configuration application

Create peripheral interface board

Develop standalone remote monitor with LCD

Design power inverter for pump

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SAMURAI: SAM Unit Redesign and Integration

Justification

Final product has the potential to save lives

Opportunity to give new face to product line

Installation cost is currently too high for some customers

Reduce operating costs by eliminating avoidable fines 6

Project Design

Problem Statement

Functional Requirement

s

Conceptual Block

Diagram

Functional Block

Diagram

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Problem Statement

“How can Dynamic Design revitalize OI Analytical’s SAM Unit product line by adding features and functionality while reducing cost to the customer?”

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Functional Requirements

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Power Inverter Board- Convert 24V DC to 115V AC

Peripheral Interface- Provide multiple RS-485 connections- Provide 24V DC connector to the internal unit

CE Board- Control Modbus slaves- Provide GUI interface- Monitor CO2 levels- Activate alarms corresponding to PPM levels

Functional Requirements

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Expansion Module- Provide up to 8 gas sample channels- Monitor temperature around sample area

Remote Monitor- Display channel and PPM levels- View Sam Unit settings

Conceptual Block Diagram

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WWW

Remote Application

Ethernet

10 PPM

Remote Monitor

RS-485

SAM

MODBUS

Zero Intake

Inverter

Main Board

Gas Sensor

24V DC

Gas Pump

Windows CE Interface

10 PPM

Alarm

Interface Board

New Boards

Old Boards

Conceptual Block Diagram

Carbon Dioxide Source

Gas Valves

Microprocessor

Expansion Unit

RS-485

Functional Block Diagram

…12

Functional Block Diagram

Expansion Module13

Work Plan – System

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Work Plan – Research

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Work Plan – Design

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Work Plan – Fabrication

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Work Plan – Test

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Work Plan – Documentation

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Work Plan – Wrap-up

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Milestones

1. Approval of completed test plan2. Approval of initial hardware designs3. Acceptance of final hardware designs4. Acceptance of remote monitor application5. Acceptance of Windows CE application6. Acceptance of the expansion module

application7. Acceptance of the final test results8. Acceptance of completed user manual9. Acceptance of fully functional working

prototype

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Deliverables Hardware

1. Schematics with Revisions

2. PCB layout3. Bill of Materials4. PCB boards

Software5. GUI Mockup6. Hierarchy Chart7. Flow Chart8. Documented Source

Code

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Deliverables

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System9. Weekly TAT Meetings

(not represented on timeline)

10. Test Plan11. Critical Design

Review12. Test Report

13. Final Presentation and Demonstration

14. User Manual15. Fully Functional and

Working Prototype 16. Final Project Report

Resources

Description Cost

Labor• 4 engineers x $30/hr x 25 hrs/week x 16 weeks (1,600 Total Hours)

$40,000

Software• OrCAD – $9,995 • PADS – $3,495• Visual Studio .NET 2008 – $800

$14,290

Hardware and Materials• PCBs and components – $600• SAM Unit – CFE

$600

Workstation $1,000

Lab Equipment• Oscilloscope – $2,000• Other – $2,000

$4,000

Total $59,89024

Team Qualifications

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Tam Bui – Test

Testing Experience Two years of experience as a Dell

representative diagnosing and testing damaged laptops

Three years using various testing equipment Involved in frequent testing of small

components and printed circuit boards

Technical Qualifications Previous experience with RS-485 and Modbus

communication Experience with the designing process and

layout of a PCB26

Jonathan Tindall - Hardware

Hardware Experience Circuit design using Multisim and PSpice PCB design using Ultiboard Two years experience in hardware

troubleshooting

Software Experience Has experience with C,C++, and assembly

languages

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Julian Coleman - Software

Technical Qualifications Extensive knowledge in C, C++, Java, PHP and

assembly as well as other programming languages

A+ Certified Computer Technician

Engineering Experience Experienced with the Microchip PIC24

microcontroller and Freescale MPC 555

Designed temperature monitor with signal conditioning that utilized Modbus communications over RS-485

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Bryan Sonnier - Manager

Management Experience Advertising manager for 4.0 & Go▪ Responsible for advertising schedules for 12

employees▪ Recommended solutions that increased profits

over 30% Account manager for AmeriCommerce▪ Handled accounts for 20 online retailers▪ Developed Web pages and graphic design

Technical Qualifications Six years experience with various programming

languages Two years experience with PCB design

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Technical Merit Evaluation

Technical Merit Factor Weight

Project Contains:

A clearly described and completely understood technical challenge 0.1

A requirement for system integration 0.2

A requirement for system testing 0.2

A requirement for analysis 0.2

Hardware design, development and test 0.3

Software design, development and test 0.3

A hardware fabrication requirement, typically a prototype 0.2

Preliminary Technical Merit Evaluation: 1.5

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Technical Merit FactorWeight

Project Contains:


Windows CE environment Remote Configuration Application Must adapt to OI Analytical’s Modbus specifications

Preliminary Technical Merit Evaluation: 0.1 31



Project Contains:



Transition system to Windows CE environment Peripheral interface board Expansion module board Adapt to OI Analytical’s Modbus specifications




Project Contains:




Includes current test procedures


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Project Contains:





Characterize temperature sensor


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Project Contains:






Power inverter Peripheral interface board Expansion board Remote Monitor


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Project Contains:







Windows CE environment Remote configuration application Remote monitoring display interface


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Project Contains:








Modify expansion module enclosure to accommodate communication and power connectors

Remote monitor will need an enclosure


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Project Contains:








A requirement for documentation other than the project report 0.2

A requirement for intellectual property protection 0.1


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Conclusion

Thank you for your time!

Questions?

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bryan sonnier – project managerjulian coleman – software engineer jonathan tindall – hardware...

Documents

integration slide

ppm remote monitor rs

sam unit redesign

standalone remote monitor

peripheral interface

sam modbus

expansion module application

sam filters