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Vinay Barde : Program Manager
Alexis Reusch: Program Facilitator
Jason Marks: Lead EE
Alfred Lee: Lead CE
Balance Tower(P12005)
• 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.
Project Overview
Scope:
• Design and build the electrical components of two towers so that they may communicate wirelessly to one another
• Perfect software that was developed by team P10005 for the towers to add in a second tower as well as more games and components
• Add a measuring device to the outside of the tower so the therapist can measure the distance between the tower and the patient
Scope & DeliverablesDeliverables:
• Two functional towers
• Upgrade current wiring in Tower #1
• Populate Tower #2
• Wireless Communication between towers
• Distance Sensor on each tower
Customer Needs
Engineering SpecificationsMetric
No.Need Nos.
Engineering SpecificationsMetric Imp Units
Desired Direction
Marginal Value
Ideal Value
1 7,8 Time to sanitize 1 sec down 90 602 5 game response time 9 ms down 60 403 9 set up time ( movement of towers) 1 mins down 2 14 1,3,14 Proximity to activate panels 3 in down 0.75 0.255 1,20 Number of game options (rounds, endurance, competition, duration) 3 # complete up 2 46 6 Accuracy of measurement between person and tower 3 in down 1 07 2,22,23 Functional reach measurement range 9 ft up 3 58 6,23 Functional reach measurement accuracy 9 in down 2 09 9 Time to program games 3 minutes down 5 2
10 4,14 Delays for wireless 9 ms down 25 1011 2 Range of heights where proximity measurements can be taken 3 ft target 2 512 9,11 Size of box for the Ultra Sonic Ping sensor (Length and width) 1 in down 3 313 2,9,11 Weight for entire system (per tower) 1 lbs down 20 1514 12 Wireless range (Maximum tower separation without the use of wires) 1 ft up 20 4015 10,22 Range of Ping sensor 9 ft up 7 1516 9,24 Time between maintenance (replace or recharge batteries) 3 min down 2 117 1,3,4,6,19 Total number of games 9 # of games up 2 318 1,4,12 Towers involved in games 9 # of towers up 1 219 13 LED indication to be ready to use 1 sec down 5 320 21 volume of audio ( indication of sucessful touch) 1 db target 65-70 50-6021 16 Size of LCD screen so that it fits in the tower (width ) 1 in. down 3.5 422 15 LED Indication for which buttons are selected 1 sec down 7 523 17, 18 Device will display results (hit, miss, average time, separate results per tower) 3 boolean yes yes yes
MetricNo.
NeedNos.
SafetyMetric Imp Units
DesiredDirection
MarginalValue
IdealValue
1 7 Fillet of track corners 3 Degs Down 30 152 7,8 Optical Visibility ( % of lights seen by the client) 3 % up 75 1003 7,8 Cleanliness of the towers 3 % Down 15 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 #1(Master)
Tower #2(Slave)
User Input
RF Communication( Transmit/Receive)
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-MHzperformance
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 Min Input Voltage (V)Max Input Voltage
(V) Avg Supply Current (mA) Max Supply Current (mA) MSP-EXP430F5438 2.2 3.6 1 2
LEDs 2.5 4 20 25 LCD 4.7 5.5 5 15
Capacitive Buttons 2 5.5 5 10 Wireless 1.8 3.6 18 22
Ultra Sound Ping Sensor 5 5 30 35
Case Usage (mAh) Usage (mWh) Total Power (mW) Battery Life (%) Total hours of Life Days
Defintion
Supply Current*Hours Used
Supply Current* Vout*Hours Used Power Usage/Hours Used Power Used in
Hour/Battery Power in Hour(Battery Power-
Minimum Battery Req)/Total Power
Total Hours/ Hours Used per day
AVG 598.000 1973.40 493.35 3.43 111.13 13.89Max 840.667 2774.20 693.55 4.82 79.05 9.88
Voltage Output (V) 3.3 Note: Ping sensor calculations take into account the
brief time it will be active.Hours Used per day 4.00
V mAh mWhBattery 6 9600 57600 Only 6 LEDs are assumed to be on
Minimum Battery requirement 5 462.37 2774.2
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.
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
1 Time to Sanitize
sec 90
3 Set up Time
mins 2
10 Time to program games mins 2
17Time to change out the batteries
mins 2
Engr. Spec. #
Instrumentation or equipment (description)
1 Clorox disinfectant wipe, stop watch3 Stop watch10 Stop watch17 Stop watch
Test 2:
Subsystem/ Function/ Feature Name: PCB
Date Completed: _________________
Performed By: __________________
Description: Perform tests on PCB to verify correct operating conditions.
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
- 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
Test 3:
Subsystem/ Function/ Feature Name: Hardware Test of MCU Connections
Date Completed: _________________
Performed By: __________________
Description: Checking input/output lines from MCU for correctness.
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
- 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
Test 4:Subsystem/ Function/ Feature Name: Software
Date Completed: _________________
Performed By: __________________
Description: Testing functionality of program, and interaction between peripherals and MCU.
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
- Program functionality test - works 2 Game response time ms 60
4
Proximity to activate panels in 2
Delays for wireless
15Wireless range (Maximum tower separation without the use of wires)
ft 20
20LED indication to be ready to use
sec 5
23LED Indication for which buttons are selected
sec 7 Engr. Spec.
# Instrumentation or equipment (description)
- Computer2 Stop watch4 Tape measure15 Tape measure, computer20 Stop watch23 Stop watch
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.
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
7Accuracy of measurement between person and tower
in 1
8 Functional reach measurement range
ft 3
12Range of heights where proximity measurements can be taken
ft 1.25
13Size of box for the Ultra Sonic Ping sensor (Length and width)
in 3 Engr. Spec. #
Instrumentation or equipment (description)
7 Tape measure8 Tape measure, laser pointer12 Tape measure13 Tape measure
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
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
2 Game response time ms 60 4 Proximity to activate panels in 2
5Number of game options (rounds, endurance, competition, duration)
#complete
2
9Functional reach measurement accuracy
in 2
19 Towers involved in games sec 5 Engr. Spec. #
Instrumentation or equipment (description)
2 Stop watch4 Tape measure5 Count9 Tape measure19 Stop watch
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.
Test Plan
Engr. Spec.
#
Specification (description)
Unit of Measu
re
Marginal
ValueComments/Status
4 Proximity to activate panels in .75
Engr. Spec. #
Instrumentation or equipment (description)
4Power supply, oscilloscope, function generator, Tape Measure
Project PlanTask
Responsible Member Start Date
Expected Date
Date Completed Dependency Comments
MSD II
Close Remaining Action Items from PMR
Group 3/12/2012 3/16/2012 21
Order rest of material needed for build Alexis 3/12/2012 3/16/2012
Software Code STUBS Alfred 3/12/2012 3/16/2012
PCB Layout prep for sending Jason, Vinay 3/12/2012 3/16/2012
Cap touch Chip/LED prototype boardVinay, Alexis
Jason3/12/2012 3/16/2012
Send out PCB For Fabrication Jason 3/19/2012 3/19/2012 21
Receive PCB and Begin TestingJason, Vinay,
Alexis3/26/2012 4/9/2012
Preliminary BuildsJason, Vinay,
Alexis3/19/2012 3/26/2012
Wire Up Led Banks (all 16) Jason, Alexis 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 Alfred 3/12/2012 4/13/2012Initial main code for MCU ( Panels, LED, LCD code) ie. One Button Code Alfred 3/12/2012 3/30/2012
System Code (Expanding One Button Code) Alfred 3/30/2012 4/6/2012
Unit / Integration Tests for Touch panels, LEDs, LCD) with Cap Chip/LED proto baord
Vinay, Alfred 3/26/2012 4/12/2012
Ping Sensor Code Vinay 3/19/2012 3/26/2012
Integration of MCU code with sensor and wireless
Alfred, Vinay, Jason
4/13/2012 4/23/2012 24
EZ430-RF2500 Wireless Code Alfred 4/13/2012 4/23/2012
Test Wireless Alfred 4/20/2012 4/23/2012
Component Testing Group 3/26/2012 4/6/2012 23, 25
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
Tower 1 Build Group 4/6/2012 4/23/2012 24,25,26
Electronic PopulationAlexis, Vinay,
Jason4/6/2012 4/9/2012
Machine Tower for Sensor box attachment Jason, Alexis 4/9/2012 4/13/2012
Integration Testing ( Test Plan #4) Group 4/9/2012 4/23/2012
Tower 2 Build Group 4/20/2012 4/27/2012
Electronic PopulationAlexis, Vinay,
Jason4/20/2012 4/23/2012
Machine Tower for Sensor box attachment Jason, Alexis 4/23/2012 4/25/2012
Integration Testing ( Test Plan #4) Group 4/25/2012 4/27/2012
Complete System Integration Group 4/27/2012 5/4/2012Acceptence Testing (System functionality Test # 6) Group 4/27/2012 5/4/2012
Project Planning ( Continuously through quarter)
Group 3/16/2012 3/16/2012
Updated Risk Assessment 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 27,28,29
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 29
FINAL Project Management Review Group
RisksID Risk Item Effect Cause
Likelihood
Severity
Importance Action to Minimize Risk Owner
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?
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?
1Adding 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
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
2Arguments within
team
Effect over all outcome and time
management
Teammates disagree on decisions
3 3 9Everybody has a say, discuss everything as a group. Learn
to compromiseGroup
3Unable to finish product design
Will lose total completion time on
project
Different parts of project plan not completed on
time
1 9 9Follow the project plan and frequently keep up to date
with everybody’s workGroup
4 Customer feedbackPrevent optimal
design
Inability to contact
customer3 9 27
Make multiple attempts to talk with customer, email,
call, etc.Alexis
5Current power not sufficient for new
parts
Affect budget, new parts
Using new parts in design
3 1 3
Not a big risk, can be accounted for buy increasing
power with more batteries etc.
Jason
6 Scheduling conflictsEffect over all
outcome of the project
Number of classes everyone is taking outside
of MSD
3 3 9
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.
Vinay, Alexis
7Reliability of
measuring tool
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
Test the part that we choose and make sure that we have
research to support our choices
Vinay
8 Part AvailabilityWould slow down
progressLead times 3 3 9
Plan ahead, find substitute parts
Alexis
9 BudgetPrevent completion
of project
Ineffective budgeting/lack of
funding1 3 3
Only purchase parts when 100% sure they will be used
Alexis
10
Group member becomes unavailable
permanentlyLoss of resource
Dropping class/becomes ill
1 3 3
Attempt to convince the member to not drop the
course. Major redesign project plan may be needed
Group
11
Loss of TowersNo longer have a
deliverable productStolen/Misplaced 1 3 3
Major redesign project plan may be needed/Reconstruct
the tower. Group
12
Group member fails to deliver critical
component
Would slow down progress
Preoccupied with other classes
1 3 3
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
13
Products purchased are insufficient for
Design
Prevent accurate modeling, and better design
Insufficient research before
purchasing3 9 27
Research needed parts, talk to experts in area of need
Group
14
Wireless module delaySlow down rate of
games
Wireless communication not fast enough
3 3 9Know how to optimize wireless
communication deviceAlfred, Vinay
15
PCB does not work correctly
Bad designWould have to redesign and
reorder3 9 27
Have team/prof review PCB layout
Jason
Risks
BOMBill of Materials
Part Name Manufacturer Manufacturer Part # Distributor Distributor Part # Unit PriceQuantity Needed
Total Price
1 RGB LED's Kingbright WP154A4SUREPBGVGAW DigiKey 754-1492-ND $1.37 60 $82.20
2 Microprocessor Board TI MSP-EXP430F5438 - - $149.00 2 $298.00
3 Rechargeable Batteries and Charger
Tenergy - All-Battery.com 8 Bay charger and 16 Batteries $36.49 1 $36.49
4 Voltage Regulator (3.3v) - - SparkFun COM-00526 $1.95 4 $7.80
5 EZ430-RF2500 TI EZ430-RF2500 - $49.00 1 $49.00
6 Ultra Sonic Ping Sensor Parallex 28015 DigiKey 28015-ND $29.99 2 $59.98
7 MSP430 USB JTAG TI MSP-FET430UIF - - $99.00 1 $99.00
8 PCB Advanced Circuits - Advanced Circuits - $33.00 3 $99.00
9 EZ RF Header Mill-Max 850-10-006-20-001000 ARROW - $1.14 2 $2.2810 LCD Screen Sparkfun GDM12864H Sparkfun GDM12864H $19.95 1 $19.9511 Transistors Faichild Semiconductor 2N4401D75ZCT-ND Digikey 2N4401TAR $0.21 30 $6.3012 Surface Mount Resistors 4.7K Panasonic P4.7KGDCT-ND Digikey ERJ-3GEYJ472V $0.02 20 $0.4013 Surface Mount Resistors 820K Panasonic P820KGCT-ND DigiKey ERJ-3GEYJ820V $0.01 50 $0.4614 Surface Mount Resistor 56 Panasonic P56GCT-ND DigiKey ERJ-3GEYJ560V $0.01 100 $0.7015 Surface Mount Capacitors .1uF Murata Electronics 490-1524-1-ND DigiKey GRM188R71E10KA01D $0.03 20 $0.5216 Surface Mount Capacitors 10uF TDK Corporation 445-6853-1-ND DigiKey C1608X5R1A106M $0.46 10 $4.5717 Header TE Connectivity A36395-ND DigiKey 1-5164713-0 $1.28 35 $44.88
Totals $811.53
Questions???