W.I.N.C. ‘S Smart Controller

EE 4522 Senior Design II

Department of Electrical and Computer Engineering

April 18, 2002

Pre-final Design Review

W.I.N.C. Team

Michael Nestler

Dr. J.W. Bruce, Faculty Advisor Tim Willis, Team Leader

Naquisha Causey

Block Diagram

Digital Components

SwitchingNetwork

AC Loads

Inputs

Design Problems

• Replace 2 DC loads for 2 AC loads

• Digital components draw too much power

• PCB’s manufacturing process

Replace Loads

Digital Components

SwitchingNetwork

AC Loads

Replace 2 DC loadsWith 2 AC loads

Inputs

Why Replace the Loads?

• Lack of documentation from manufacturer

• Incorrect component identification

• Component loads were not available for testing in late December

Replacing the Loads

• Add 2 more switching circuits

• Modify connectors from the PCB to each load

High Power Consumption

Digital Components

SwitchingNetwork

AC Loads

Digital Components Draw Too Much Power

Inputs

Power Usage of Digital Components

• Specification calls for no more than 2.5 watts of power to be consumed

• Digital components consume a total of 2.7 watts at maximum power

Dishwasher Pan

OriginalDesign

Heater Element

NewDesign

1”

Remove One Thermistor

• Reduces digital power consumption to meet design specification

• Frees up more memory for programming

• Reduces complexity of overall design

• Effect on dishwasher is negligible

QA Deficiencies

Digital Components

SwitchingNetwork

AC Loads

PCB Manufacturing

Inputs

PCB Manufacturing Process

• Build in-house or send off

• Proper spacing of AC and DC components

• QA deficiencies

Build In-house

• Less expensive to build

• Have better access to PCB manufacturer

• Experienced people

Separation of AC and DC

QA Deficiencies

• Designations of thru-hole vs. surface mount swapped

• Some traces too close together

• Holes had to be custom fitted

First PCB

A/DConverter

MAX 1618

Second PCBA/D

Converter

MAX 1618

Traces Before

Traces After

QA Corrections

• Have a briefing before each manufacturing step

• Ensure all steps done have approval of 2 people

Test Data

Coming Soon !!!

Timing Chart of SX 28Started Stopped Expected length

State 0: Inlet Valve 0:00 0:58 1 minState 1: Circ Pump 0:58 1:55 1 minState 2: Circ Pump 1:55 2:53 1 min

Dispensors State 3: Circ Pump 2:53 3:50 1 minState 4: Circ Pump 3:50 4:47 1 min

HeaterState 5: Circ Pump 4:47 8:33 4 minsState 6: CircPump 8:33 9:30 1 min

Drain Pump State 7: Circ Pump 9:30 10:27 1 min

Inlet ValveState 8: Circ Pump 10:27 11:25 1 minState 9: Drain Pump 11:25 1:20 2 min

Lessons Learned

• Get a professional board with all components surfaced mounted

• Use a Ubicom SX 52

• QA is a necessity

• Maintain good communication

The Good

• Viking dishwasher is still intact

• Project goal can be done

• Design is flexible

Acknowledgements

Special Thanks Extended to:-MSU Faculty Dr. J. W. Bruce, Dr. R. Winton, Dr. Harden, and Dr. Joe Picone [MSU Faculty]-Viking Range, Inc: Mr. John Picardat – Engineer, Mr. Martin Wesemann – General Manager, Ms. Beth Williams- Assist. Product Manager- Rick King, Aimee Imparato

Q/A Session

Switching Circuit

• nMOSFET (enhancement)

(ID=17A ,VGS=100V+) • Diode (1 Watt, 100V)

• Resistor (1 Watt, 10 ohms)

• Relay (High Capacity, SPST-

NO)

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[4] V.V. Badami, N.W. Chbat, “Home Appliances Get Smart,” IEEE Spectrum, Vol. 35, No. 8, pp. 36-43, August 1998.

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[8] Wang Yi-Min, W. Russell, A. Arora, Xu Jun,”Toward Dependable Home Networking,” Proceedings International Conference On Dependable Systems and Networks, pp. 44-48, Microsoft Corp., Redmond, WA, USA, June 2000.

[9] Barbara Mayer,” Smart Appliances are the Wave of the Future, ” http://www.tcpalm.com/home/15sapplij.shtml, Home & Garden, USA, July 2001.

REFERENCES-(4)[10] T. Erickson,” Turbidity Sensing as a Building Block for Smart Appliances,” IEEE Industry Applications Magazine, Vol.3, No. 3, pp. 31-36, May-June 1997.

[11] J.W. Bruce,” Microprocessors II,” Mississippi State University, Mississippi, MS, USA, 2001.

[12] K. Rexford, “Electrical Control for Machines,” 5th ed., Delmar Publishing, Albany, New York 1997.

[13] C. Okey & P.M. Ruane “Advances in Appliance Control: The Breaking of a Paradigm.” Proceedings of the 1996 IEEE International Conference On Control Applications, Dearborn, MI ; 91-94, September 1996.