Homework 4: Packaging Specifications and Design

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ECE 477

Digital Systems Senior Design Project

Rev 8/09


Homework
4
:
Packaging Specifications and Design





Team Code Name:


P
-
REV







Group No.

5


Team Member Completing This Homework:


Ram Hudiara

E
-
mail Address of Team Member:
rhudiara

@ purdue.edu



Ev
aluation:


SCORE

DESCRIPTION

10

Excellent



among the best papers submitted for this assignment. Very few
corrections needed for version submitted in Final Report.

9

Very good



all requirements aptly met. Minor additions/corrections needed for
version s
ubmitted in Final Report.

8

Good



all requirements considered and addressed. Several noteworthy
additions/corrections needed for version submitted in Final Report.

7

Average



all requirements basically met, but some revisions in content should
be made

for the version submitted in the Final Report.

6

Marginal



all requirements met at a nominal level. Significant revisions in
content should be made for the version submitted in the Final Report.

*

Below the passing threshold



major revisions required

to meet report
requirements at a nominal level.
Revise and resubmit.

*
Resubmissions are due within
one week

of the date of return, and will be awarded a score of
“6” provided all report requirements have been met at a nominal level.


Comments:



Content
wise the re
port is exhaustive however some
modifications in terms of defining
things prior to use is required to ensure a better reading



Clear
Diagrams

(CAD)

have been provided but labeling needs to be done for the
enclosure box



Section 2 can be
somewhat
i
mproved by a more
in
-
depth

comparison in terms of
number
of
different sensors

used
, types of sensors, etc



Summary section
need to focus more on Packaging

specification and design


NOTE: This is the first in a series of four “design component” homework

assignments, each of
which is to be completed by one team member. The body of the report should be 3
-
5 pages,
not

including this cover page, references, attachments or appendices.

ECE 477

Digital Systems Senior Design Project

Rev 9/10


-
1
-

1.0

Introduction

The P
-
REV data logger and display unit enable the

race
driver

in a Go Kart to view
information from various sensors in the kart during
a

race. This enables him to keep a track of
critical conditions such as remaining battery
life
. Based on the inf
ormation available to the racer
,

he can then make
a
decision
that
if
he needs
to pull into the pit station.
The

display unit will
provide the information to the driver and hence it
would

be mounted in the steering wheel

to
make it easily viewa
ble
. The display unit
should

be small enough so that it doesn’
t impede
the
drive
r’s action
s

when he is trying to make a turn
. The display unit
should

be able to receive data
from the atom board using a USB cable. The atom board and the P
CB

containing the
Microcontroller
would

be placed in a plastic enclosure. Th
is

plastic enclosure
wo
uld

have the
same
base and width dimensions as the Atom board

and it

would be mounted behind the driver’s
seat under a metal board.



2.0

Commercial Product Packaging

Compared to the P
-
REV
’s

product, there are
a
couple of devices which are similar. But,
almo
st all of the devices available in the market are made for gas

powered go karts and hence do
not
have any features to
monitor the battery status.

As all of these products are just data
acquisition units, they
are small, usually mounted on the steering wh
eel and
do not implement
traction control.


2.1

Product #1



MYCHRON 4

One of the products which is quite similar to ours is the MYCHRON 4 by AIM

[3]
.
MYCHRON 4 is basically a data
logging

product
for Go Karts. Without any extension box, the
MYCHRON 4 is a
ble to gather data from three
input

sensors. Namely
,

the temperature sensor, tachometer
and
lap counter
.

We
think this is too few sensors to
report much useful data

and thus we plan on having
10 different sensors
.

The display of the
MYCHRON 4

is small
and cluttered with tiny keys
to navigate. For our product we plan to have a 7 inch
ECE 477

Digital Systems Senior Design Project

Rev 9/10


-
2
-

customizable touch screen display.


An expansion box is available for the MYCHRON 4

at an additional cost to increase the
number of sensor inputs. Data can be downloaded fr
om the
E
-
box
using a special connector
called the data key.
The data can be downloaded from the MYCHRON 4 by connecting it to
a
computer using a cable
. Hence, the kart needs to be stationary before performing such action.

Our product would use wireless t
ransmission to transmit data from the kart

while the kart is
racing on the track.

One thing which is unique to
MYCHRON 4 is that, its manufacturer
also produces a steering wheel which
has a special grove for mounting the
MYC
HRON 4. We would really like to

mount our display in a similar manner
so that it does not interfere
with the
driver.





2.2

Product #2



LAPCOM VX2000 lite 100

Another product which is quite similar to ours is the LAPCOM VX2000 lite100

[4]
. It is
also a data
logger

like the MYCHRON 4

b
ut it comes with a large number of sensor inputs

included
in the standard package.
One feature
we really like about the VX200, and plan to
implement on our product, is the customizable
display based on the numbers of sensor inputs
begin used.
However, we
plan on using a full
color touch screen display inst
ead of a simple
alphanumeric, one color display
.


One of the cons of the VX2000 is that it
is able to log data for only 90 minutes.
Since
we are

be relaying all the data from the kart to
the pit station,

there is no need to store the data
ECE 477

Digital Systems Senior Design Project

Rev 9/10


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3
-

on the kart and hence there is no restriction on the amount of data being logged.


3.0

Project Packaging Specifications


The design for P
-
REV project includes a display unit and an enclosure housing
the
Atom
board and the P
CB. The display unit
consists

of a color touch screen display, which is powered
by USB

cable running
from the Atom board.

As we do not need to have a battery in the display
unit,
the

thickness of our

display

unit

is reduced to
half the thickness of our com
petitor
MYCHRON 4.
As our display unit would be mounted in the steering wheel,
we wanted
it
to

be
compact so that it doesn’t hinder the driver’s performance.
The dimensions of the display are 7
in X 5 in X 1 in

[2]
.

Our main
en
closure
box
which
houses the

Atom Board, PCB

and the battery pack

would be
made of plastic
and will sit underneath
a metal board
behind the driver’s seat.

We chose this spot
for the main enclosure as it is secluded from rest of components of the kart. Any change to the
mechanical
components of the
kart can be
done

easily without
even
having to touch the

enclosure
. As the enclosure is placed under a metal board

holding the motor controllers on the
other side
, o
n
e

of our concerns is about the interference with the GPS and Wireless m
odules. To
resolve this we are planning
on mounting separate antenna
s on the kart for the GPS and w
ireless
communication modules
.

The dimension
s

of the box are 7.1 in X 7.1 in X 3 in. The dimensions
of the PCB are
6.69 in X 3.14 in
.



There would also b
e a compartment in the main enclosure for the battery pack. The
batteries we are using measure 0.75 in X 2.1 in X 2.1 in each

[1]
. The battery compartment that
we have designed to hold the batteries measures 2.1 in X 7.1 in X 1.5 in.

The battery
compartmen
t can hold up to 6 batteries.



4.0

PCB Footprint Layout

As we would be placing the PCB in the same box as the Atom board, our size limitation for the
PCB are
170 cm X 170 cm.

But as our product is targeted for go kart racing market,

we intend to
keep the PCB

as small as possible.
A large portion of the PCB are
a

would be used up by the
inputs from

the 10 sensors. The GPS module,
the wireless module
, power supply rails and the
serial ports

are the other components taking up a large
amount of PCB
area
.

The

area

taken up
ECE 477

Digital Systems Senior Design Project

Rev 9/10


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4
-

by the Microcontroller is relatively small compared to these products.


Our current estimate for
the PCB size is 170 cm X 80 cm.


5.0

Summary

Unlike the
products compared in section 2
, our product is

not just a data logging unit. It
does a lot mor
e
. Especially

in real time, like traction control
.
Our device surpasses the
performance and functions

performed by the MYCHRON 4 or the VX2000. As we are not fitting
the entire device in one case mounted on the steering wheel,
minimizing the size of the en
closure
is not our main concern. However, as the equipment would be place
d on a racing go Kart, we are
very specific about the

weight of the

product and our goal is to keep the weight below 2 lbs.




ECE 477

Digital Systems Senior Design Project

Rev 9/10


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5
-

List of References


[1]

Sparkfun Electronics, “Sparkfun El
ectronics, Polymer Lithium Ion Battery


6Ah.”

[Online]. Available:
http://www.sparkfun.com/commerce/product_info.php?products_id=8484. [Accessed: Sep
23,2010].


[2]


Mimo Monitor,

“Mimo Monitors
-

Mimo 720
-
F Flex
-
Screen Mountable Touchscreen
USB Monitor
.

[O
nline]. Available:
http://www.mimomonitors.com/products/mimo
-
720
-
f
-
flex
-
screen
-
mountable
-
touchscreen
-
usb
-
monitor. [Accessed: Sep 23,2010].


[3]

AIM Sports, “AiM Sports
-
MyChron4 Digital Gauge and Data Logger for Kart Racing
.

[Online]. Available: http://www.ai
msports.com/products/mychron4/index.html. [Accessed:
Sep 23, 2010].


[4]

PERCUL, “LapcomVX
-
2000 All
-
in
-
one Series
.
” [Online]. Available:
http://www.percul.co.jp/english/lapvx_en/index_vx_all_en.htm. [Accessed: Sep 23,2010].












IMPORTANT: Use standard IEEE format for references, and CITE ALL REFERENCES
listed in the body of your
report
.

ECE 477

Digital Systems Senior Design Project

Rev 9/10


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6
-

Appendix A: Project P
ackaging Illustrations


DISPLY UNIT




ECE 477

Digital Systems Senior Design Project

Rev 9/10


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7
-

MAIN ENCLOSURE 3D VIEW





Dimensions 6.69 in X 6.69 in X 2.75 in


(170 cm X 170 cm X 70c m)


















FRONT

VIEW
ECE 477

Digital Systems Senior Design Project

Rev 9/10


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8
-

Appendix B: Project Packaging Specifications


Material

Tooling
R
equirement

Estimated weight

Estimated Unit cost

Touch Screen

Screws, screw driver

1 lb

$200

Microcontroller

Soldering tools

0.01 lb

$8

GPS Module

Soldering tools

0.1 lb

$60

Atom Board

Screws, Screw driver

1 lb

$1000

Xbee wireless module

Soldering too
ls

0.1 lb

$20


Lithium ion battery

Soldering tools

0.2 lb

$40

Voltage regulator

Soldering tools

0.1 lb

$5

Serial Port

Soldering tools

0.1 lb

$4




















ECE 477

Digital Systems Senior Design Project

Rev 9/10


-
9
-

Appendix C: PCB Footprint Layout


PCB 3D View


.



























PCB TOP VIEW

GPS

24 cm X 33 cm

Wireless

module

30 cm X 30
cm

Serial Port

30 cm X 18
cm

Serial Port

30 cm X 18
cm

Power
Supply

30 cm X 30
cm

Microcontroller

10 cm X 10 cm

Accelerometer

10 cm X 13 cm

Sensor Inputs