ECE 495 – Integrated System Design I

ECE 495 - INTEGRATED SYSTEMS I

Lecture - Introduction to the Course and

Overview of the Engineering Design Process

ECE 495 – Integrated System Design I

Timothy Burg

• Michelin R&D• Classes– Senior Design– Nonlinear Systems– Intro to EE

• Research– Unmanned Aerial Vehicles– Tissue Engineering– Haptics

ECE 495 – Integrated System Design I

Design Example - Camera Flash

• Design 1– Mounted in a disposable camera– Few parts, simple– Larger than Design 2

• Design 2– More parts than Design 1– More sophisticated components– More features (red-eye reduction)– Mounted in a “good quality” camera

• Some components are exactly the same– Capacitor same in both

• Both perform well in the intended application.

Which is the better design ?

ECE 495 – Integrated System Design I

The best design is the one that meets the customer needs.

Design Example – Camera Flash

• Each application will have a unique set of needs:– Cost– Size– Weight– Speed– Quality (accuracy, resolution, repeatability)– ….

ECE 495 – Integrated System Design I

Design Example – Camera Flash

• Customer needs may be contradictory

Best design is the one that provides the best compromise between the customer needs.

Four proposed designs, none are “perfect” for the customer needs.

http://peltiertech.com/WordPress/spider-chart-alternatives/

Cost

SizeLight Intensity

Reset Time

Reliability

Safety

ECE 495 – Integrated System Design I

ECE495 Course Rationale

ECE 495 – Integrated System Design I

ECE495 Course Rationale

• What is the purpose of 495?– Gain confidence in integrating the technical skills you have

developed to this point in your career to synthesize solutions to new classes of problems.

– Practice core skills that define expectations of a “professional” engineer that “Graduates at graduation will have”

ECE 495 – Integrated System Design I

Course Rationale – Practice Professional Communication

Slide Assessing Condition of Heat Shields (Partially Blamedfor crash of Columbia Space Shuttle)

Foam damaged wing

The message you likely get from this slide

The message you need from this slide

ECE 495 – Integrated System Design I

“Intelligent people, when assembled into an organization, will

tend toward collective stupidity.”

Course Rationale – Work on a Team

“Becoming skilled at doing more with others may be the single most important thing you can do” Christopher Avery

“The Power of Minds at Work: Organizational Intelligence in Action” by Karl AlbrechtGraphic from karlalbrecht.com/downloads/AlbrechtsLaw.ppt

ECE 495 – Integrated System Design I

Note on ECE 495 Team Composition

• Take the Myers-Briggs Type Indicator (MBTI) test to provide some insight about your own personality– The test only attempts to measure “preferences” not ability.– ~2 million/year take this test– Many other tests available

• How do you function on a team?– What should people know about your Type?– What should you know about their Type?

ECE 495 – Integrated System Design I

Note on ECE 495 Team Selection

Computer Programmer

Electrical Engineer

Lawyer

Artist

Social Worker

ECE 495 – Integrated System Design I

Course Rationale – Appreciate the Need to Engage in Need for Lifelong Learning

Half-life of technical information

http://www.knight-moore.com/pubs/halflife.html

Skills and knowledge decline -> Need to Continue Learning

Applied knowledge - Industrial processes, software use, specific technical and professional skills,

Basic theoretical knowledge – language, mathematics, logic, reasoning, theoretical parts of professional training

Time

Kno

wle

dge

Acquisition Depreciation

ECE 495 – Integrated System Design I

Course Rationale –Design a System Given Constraints

• Following a disciplined process is likely to yield better results.

New Idea Production Start

Resource Applied

“Build Early”

“Think Early”

ECE 495 – Integrated System Design I

Course Rationale - Knowledge of Contemporary Issues

• Why Amazon Can't Make A Kindle In the USA• Industries lost to the US– Fabless chips; advanced rechargeable batteries for hybrid

vehicles; crystalline and polycrystalline silicon solar cells• Does it matter?– Loss of manufacturing sets off a chain reaction:

loss process-engineering loss advanced research loss next-generation process/products loss infrastructure loss of ability to innovate

• Does it matter to you in your job as an engineer?– You will make or be affected by decisions on outsourcing

ECE 495 – Integrated System Design I

Course Rationale - Understanding Ethical Responsibility

http://en.wikipedia.org/wiki/Boston_molasses_disaster

• Boston Molasses Disaster occurred in 1919• Molasses tank burst killing 21 and injuring

150• Arthur Jell who oversaw the construction,

neglected basic safety tests• Company ignored warnings (the tank leaked

so badly that it was painted brown to hide the leaks)• Company paid at least $6.6 million (in 2005

dollars)

Lead to requirement for formal credentials, professional licensure in the US

Engineers make important decisions and have an obligation to protect workers, public, ..

ECE 495 – Integrated System Design I

Course Rationale - Understanding Ethical Responsibility

“My spiritual pain is unbearable. I keep having the same unsolved question: if my rifle took away people's lives, then can it be that I... am guilty for people's deaths, even if they were enemies?” Mikhail Kalashnikov, designer of the AK-47 assault rifle

ECE 495 – Integrated System Design I

Course Rationale - Understand the Impact of Engineering Solutions

• Understand the impact of engineering solutions in a global, economic, environmental, and societal context

Have you planned for the full life cycle of your product ?

ECE 495 – Integrated System Design I

ECE495 Course Rationale – Understand Standards and Regulations

• Mac Pro was banned from sale in Europe, March 1, 2013 – January 2014.

• Electrical port and fan guard designs that violated an amended European Union regulation IEC 60950-1.– Requirements on computer manufactures to put fan guards

and extra shielding around electrical ports in place.

ECE 495 – Integrated System Design I

Course Rationale – Design a System

• An ability to design a system, component, or process to meet desired needs.

http://www.space.com/13763-x37b-sercret-air-force-space-plane-record-time.html

ECE 495 – Integrated System Design I

The General Design Process

ECE 495 – Integrated System Design I

Generic Design Process

• You will follow these steps in your design this semester.

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Identify Need:Who is willing to pay for the project ?

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Research:Become an Expert

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Requirements Specifications:What must the product do and how well must it do it?

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Concept Generation:What are different ways to solve the problem?

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Design:Develop a technical solution

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Specifications

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Prototype:Demonstrate design

You will follow the design process during the semester to build a prototype of a system that meets a customer need.

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

The design process is not linear and may require iteration on previous steps.

ECE 495 – Integrated System Design I

Generic Design Process

IdentifyNeed Research

Requirements

Concepts

Design

Prototype

Testing

Retire

Maintain

Use by Customer(s)

Distribute and Sell

Manufacture

Cradle to Grave Engineering is the phrase applied to designing for all phases in a product’s life.

ECE 495 – Integrated System Design I

ECE495 Course Layout

ECE 495 – Integrated System Design I

Overview of class, syllabus and schedule

• Class Structure• Lecture at 4:40 on topic that supports a component of the current

project• 5:30 is an opportunity to answer specific questions about upcoming

projects.• You work with your team to complete projects

• Schedule is up to you (there is no assigned laboratory times). You have full access to your assigned laboratory workbench in a room in the basement of Riggs. • Keypad access to Riggs 12,19: 1495#• Keypad access to Riggs 19: 31452

• Some components are supplied: motors, cameras, amplifiers• Groups must supply or purchase smaller components that are

specific to their design – wood, transistors, acrylic• TAs will be available to answer implementation questions

ECE 495 – Integrated System Design I

How Will We Meet all of The Course Goals?

SystemControllerUser

Interface

Sensors

Actuators

SoftwareHardwareAlgorithms

Lab 1

Lab 2

Lab 3

Lab 4Lab 5

Build an Intelligent System

Lab 6Richard Boyd Lockheed Martin : F35 is basically open-source but when they add the hard-disk (software) it becomes export controlled.

ECE 495 – Integrated System Design I

Sources of Information

• Blackboard– Grades– Team assignments– Door code– Surveys

• Course Website (http://www.clemson.edu/ces/crb/ece495/index.htm)– Assignments– Syllabus and Schedule– Instruction Manuals– Sample Code and Tutorials

ECE 495 – Integrated System Design I

Overview of Class, Syllabus and Schedule

• Overall grade:– (75%) 6 Team projects and website– (10%) Individual assignments (Quizzes, Essays)– (15%) Teamwork assessment (Peer evaluation)

• Projects:– Competition Day on SATURDAY of week given in schedule– Questions: Read project materials, Matlab Help file, Email TA

ECE 495 – Integrated System Design I

Real-time Control

ECE 495 – Integrated System Design I

Hardware-in-the-Loop (HIL) System

Can’t model all of the subsystems to build a complete simulation

Physical

Computer simulation of a system containing connected subsystem models

Input SignalsA complex physical subsystem that can’t be effectively modeledConvert

A/D, Buffer

ConvertD/A, Buffer

Input Signals

Simulated

HIL Simulation is a hybrid simulation that incorporates real components

ECE 495 – Integrated System Design I

Hardware-in-the-Loop (HIL) System Example

To determine which ABS module would be best without actually building a car and testing each different module, simulate the car’s dynamics, test different controllers, and analyze simulated response of the car to real ABS braking signals.

HIL Card

Braking SignalsComputer simulation of a car including vehicle dynamics, tire models, driver models, etc.

Anti-Lock Brake Module

Car State Signals(speed, driver command)

A complex physical system that can’t be effectively modeledNeed hardware

and software

ECE 495 – Integrated System Design I

Open-loop Control System

Open-loop control:• Input designed to move the system to a desired state based on current

conditions and model of the system.• Example: Fill a water tank to a specified level based on flow-rate and

time. • If some of the water evaporates during filling then the level will

be wrong • If flow rate is not exactly as expected then the level will be wrong.• Inaccurate time will lead to the wrong level

Desired level

Actual level

No correction for errors

ECE 495 – Integrated System Design I

Closed-Loop Control System

Closed-loop control:• Input changes as the error, difference between the desired output and

the measured output, changes.• Example – fill a tank to a specified level based on measuring the tank

level and turning flow “on” or “off” to reach the desired level.• Anything that prevents the tank from being filled to the desired

level will be compensated.

Desired level = Actual level

SystemOutput

Feedback

Desired level

+_

Input Error = Desired Level – Measured

Measurement

ECE 495 – Integrated System Design I

Real-time (RT) System

Computer-based execution of a program loop:

Instructions or algorithm

System

Speed and predictability of execution times distinguish RT and non-RT systems

Real-time system: the correctness of the system behavior depends not only on the logical results of the computations, but also on the physical instant at which these results are produced. http://www.ece.cmu.edu/~koopman/des_s99/real_time/

input outputτ, response time

ECE 495 – Integrated System Design I

Closed-Loop Control as a RT, HIL Simulation

Amplifier

Motor

If you were using closed-loop control on the position of the motor, you would want the motor to stop at a certain shaft angle.

HIL Card

Motor Position (encoder)

Control Algorithm (like you are learning in ECE409)

Voltage

PhysicalSimulated

ECE 495 – Integrated System Design I

Implementing Closed-Loop Control as a RT, HIL Simulation in ECE495

SystemOutput

Feedback

+_

Input

Target PC • xPC OS from

Mathworks• Q4 HIL Board

Simulation

A/D,D/A, Buffer

ECE 495 – Integrated System Design I

Implementing Closed-Loop Control as a RT, HIL Simulation in ECE495

SystemOutput

Feedback

+_

InputTarget PC • xPC OS from

Mathworks• Q4 HIL Board

Host• MATLAB with

Simulink• C++

• Programming Interface to Target PC• User Interface• Execute High-level Programs

ECE 495 – Integrated System Design I

Implementing Closed-Loop Control as a RT, HIL Simulation in ECE495

MATLAB/SIMULINK have a toolbox called xPC Target

ECE 495 – Integrated System Design I

Implementing Closed-Loop Control as a RT, HIL Simulation in ECE495

Design a Simulink model on the host PC

Program is downloaded to target for real-time execution

Boot CD installs a real-time kernel on target

Build the Simulink model Host and target coordinate for downloading programs

Some parameters can be changed on host. This change is communicated to target.

Host Computer Target ComputerWorkflow

ECE 495 – Integrated System Design I

Implementing Closed-Loop Control as a RT, HIL Simulation in ECE495

• 4 x 14 bit Analog Inputs• 4 x 12 bit D/A Outputs• 4 Quadrature Encoder Inputs• 16 Programmable Digital IO

Channels• 2 x 32 bit dedicated Counter/ Timers• 2 External Interrupt sources• 32 bit, 33MHz PCI Bus Interface

Quanser Q4 card in the Target PC

Terminal board

ECE 495 – Integrated System Design I

Implementing Closed-Loop Control as a RT, HIL Simulation in ECE495

Analog Out (D/A)

Channels

Ext Interrupt and Signal Pins (PWM,Watchdog)

Analog In (A/D)

Channels

Encoder

Channels

Digital I/O Ports

From Q4 board

Q4 Terminal Board

ECE 495 – Integrated System Design I

Why MATLAB/SIMULINK over C++?

• MATLAB is a huge collection of C/C++ libraries for system prototyping and hardware interfacing.

• No need to reinvent the wheel! Would you rather spend weeks writing device drivers and libraries for the Q4 than test your system in a few hours?

• Prototyping ideas is easy and fast.

• Visualization of data is easy.

ECE 495 – Integrated System Design I

Summary

• ECE 495 focuses on practicing engineering skills– Work in teams to implement a solution to meet a customer

need– Practice following the steps of a design process– Grade based on how well your team executes.