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Wireless Lighting System

1. 39 497mW BS EDRed agmi EDRed 7 3 LEDRed PMargin LEDRed 50 629 3 TRANSISTOR i CURRENT AND MARGIN _ VFRedMin MaxCurrentpy MaxDutyCyclep 8 17 24 4 129 499mA Idp 4 CurrentMargin 67 625 XIV 10 4 PC Software Design amp Code 10 4 1 Credit Screen mote PC CONTROL CONSOLE VERSION 1 0 Created By Chris Dan Prince Ryan Truer Dustin Veldkamp LOADING INNOTEC COPYRIGHT 2007 ALL RIGHTS RESERVED NMENI Imports System Imports System IO Public Class CREDITS Inherits System Windows Forms Form Run Credits and Setup Private Sub TimerElapsed ByVal sender As System Object ByVal e As System Timers ElapsedEventArgs Handles Timer Elapsed Call Load Criteria Status Field Text SEARCHING FOR MASTER LAMP Call Master Lamp Search Status Field Text CHECKING ENVIRONMENT CRITERIA Call Check Criteria Status Field Text CREATING USER INTERFACE Call Create User Interface End Sub Load Previous Setup Criteria Private Sub Load Criteria Dim i x y As Integer Create an instance of StreamReader to read from a file Dim sr As StreamReader New St
2. 20 4 4 1 R mote Complications 20 4 4 2 Lamp Base 5 21 4 4 3 Complications 9 21 4 5 Final EAN E ei Rn NR ier 21 4 51 Hardware Solution iiec see tto eoe Eos Une 21 4 5 2 Software SOlUtioDi 26 BUSINGSS T 51 5 1 1 Business 51 5 1 2 Industry Environment ere e eee iid P RE 52 5 1 3 Marketing Strate gy e ee n RR e ede OR E Ta donus RECEN ER xd grata vae qx vi y pads 53 5 14 ied aces boast eee 53 5 125 Financial Projections s ae 54 Project Management s eite OR RE Ree Ee 59 6 1 Team Managementa dae eect tomate 59 6 1 1 Chris eee nie cett 60 6 12 ink dies er ies ee lae erae 60 6 1 3 RYAN TRUCK ax eth A eh a tio 60 6 1 4 Dustin Veldkamp EP pere red es 60 6 2 Schedules io eeu ete deo t ed e eat ER 61 6 2 1 Task Specification ch eet a 61 Testing and VeFificatioh
3. 72 47 2V VGsmin T2 4 DRAIN CURRENT Idi iv MAX JUNCTION TEMPERATURE Spo ap 150C 4 RESISTORS i OHMS ii TOLERANCE gTolerance 1 Ro 16Tolerance 1 R17 24Tolerance 1 Ros 44Tolerance 1 iii P PRatingg g 25W 16 25W PRatingp 7 24 25W PRatingg5os 44 7 IW 5 MAX DUTY CYCLE MaxDutyCycle White 75 MaxDutyCycle pag 75 MaxDutyCycle Green 75 MaxDutyCycle 75 B WHITE LED CIRCUIT CALCULATIONS 1 RESISTORS i OHM VIII Vsource VEWhite 2 Ro5_AdCalc 24440 FWhite Ros 25 44 1 Ros 44 Ros 44 24540 44Min 25 44 1 Ros 44Tolerance 44Min 24069 ii CURRENT VEWhiteMin 2 MaxCurrent _ _ 1 i R25 44 Y YC White Ros 44 1 Ros 4 MaxCurrentp5s 44 0 499 POWER 2 44 R25 25 MaxPR25 44 0 605 MARGINS PRatinga 5 25 44 PMarein 8INRI5 44 PRatingays 44 2 LED i CURRENT amp MARGIN MaxCurrentr EDWhite _ VSourceMax VFWhiteMin R5441 x Ros 44Tolerancd 4 EDWhite 665 087mA TrwhiteMax MaxCurrentr EDWhite CurrentMarginy EDWhit 7 TRWhiteMax CurrentMarginy EDWhite 4 988 POWER AND MARGIN PLEDWhite VFWhite I
4. 10 2 1 LED Array Bill of Materials 10 2 2 Remote Control Bill of 5 IV 10 2 3 Base Bill of Materials V 10 2 4 Base Bill Of Materials Master VI 10 3 LED Array Worst Case Component Analysis 10 0 00 nennen VII 10 44 PC Software Design 6 ER EE E dee XV 10 44 17 Credit SCreen ici hace A a es e tere ERR EH OR Ee de He XV 10 4 2 Schedule 5 dette th pe tee see nit Eee n a et XVII 10 43 iE RD HI XIX 19 44 ip pe eiectus XX 10 5 XLII Table of Figures Figure 1 Team iore ete e te ef ene tete atte te ede ade 2 Figure 2 Original Design Block Diagram 15 Figure 3 Remote Control eene 17 Figure 4 LED Atay iine Roten tmi eee ndn n idee AT 19 5 Lampi BaSe eee ea 20 Figure 6 Prototype Block 21 Figure 5 Prototype Remote Control
5. NewLamp When a lamp button is pressed the NewLamp variable is changed to the desired lamp change The Change Lamp subroutine that is called is Shown below Private Sub Change Lamp Sets the values in user interface to values of the current array If NewLamp ALL LAMPS Then IbICurrentLamp Text ALL LAMPS WhiteBar Value CurrentArray 0 1 Whitelntensity Text WhiteBar Value 100 50 amp 96 chkBlackOutWhite Checked CurrentArray 0 8 chkBlackOutColor Checked CurrentArray 0 9 chkFadeWhite Checked CurrentArray 0 6 chkFadeColor Checked CurrentArray 0 7 chkRainbow Checked CurrentArray 0 10 PictureBox1 BackColor System Drawing Color FromArgb CType CType CurrentArray 0 3 Byte Integer CType CType CurrentArray 0 4 Byte Integer CType CType CurrentArray 0 5 Byte Integer Else Sets the values in user interface to values of the new lamp in current array IbICurrentLamp Text LAMP amp NewLamp 1 WhiteBar Value CurrentArray NewLamp 1 Whitelntensity Text WhiteBar Value 100 50 amp chkBlackOutWhite Checked CurrentArray NewLamp 8 chkBlackOutColor Checked CurrentArray NewLamp 9 chkFadeWhite Checked CurrentArray NewLamp 6 chkFadeColor Checked CurrentArray NewLamp 7 chkRainbow Checked CurrentArray NewLamp 10 PictureBox1 BackColor System Drawing Color FromArgb CType CType CurrentArray NewLamp 3 Byte Integer CType CType CurrentArray
6. CLOCK_FREQ BAUD_RATE 16 1 0x02 0x05 0x06 0x09 0 700 700 75 75 T3 0x01 0x03 0x04 0x07 0x08 0 0 900 75 TXSTAlbits TRMT PIR1bits RC1LIF 8 bit XLIII bits unsigned char Value PowerFlag Function Prototypes void HardwareInit void void USARTInit void void InterruptHandlerHigh void void BT Inquiry CMD void MAIN void main MISC Variable Definitions char opcode int i 0 int j 0 PWM Variable Definitions unsigned char output_config unsigned char output_mode unsigned int pwml_dc unsigned int pwm2_dc unsigned int pwm3_dc unsigned int pwm4_dc unsigned int pwm5_dc char period unsigned int power status USART Configuration XLIV USARTInit Hardware Configurations HardwareInit power status 0 TRISD PORTD 0x00 0x01 while 1 CLRWDT char inputstr 1 opcode 0x00 getslUSART inputstr 1 opcode inputstr 0 switch opcode case POWER PORTDbits RD7 1 if power_status 0 power_status 1 Set up the Period for the PWMs period OxFF OpenPWM1 period Sets the period for PMW1 OpenPWM2 period OpenPWM3 period OpenPWM4 period OpenPWM5 period Extra Setup for Special PWM Registers ECCP1 ECCP2 ECCP3 SetOutputPWM1 SINGLE OUT
7. 0 3 MD CONN Figure 3 Remote Control PCB Design 3 3 4 Control Lamp 3 3 41 Power Supply The power supply for the lamp was designed a lot differently than in the remote control The lamps were designed to be plugged into 120V 60Hz or 240V 50Hz wall socket So the first step was to send the voltage through a switch mode power supply which would cut the voltage down to 12V DC The power supply that was chosen was a ETS120400UTC P5P SZ made by CUI Inc From the datasheet it was found that this power supply could handle currents of up to 50A This was a little over kill because currently the LED array draws a little less than 25A It was chosen a little high in case more LEDs were needed in the future which would ultimately draw more current This power supply would then output 12V as stated above which would be used to drive the 12V LED array But another step down in voltage was needed before it could be run to the microprocessors which ran at 3 3V To make this step down the same voltage regulator that was used in the remote control was again used 3 3 4 2 Bluetooth Module The Bluetooth module that was chosen was the LMX9830 Bluetooth Serial Port Module made by National Semiconductor This Bluetooth module was chosen because it has its own processor embedded into it With its own processor in it the Bluetooth protocol stack does not have to be loaded onto the PIC18F87J10 like the Zigbee Stack does Even thou
8. amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfWeek 3 End If Case 3 If Schedule Tuesday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp 6 Schedule timel Text 6 Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfWeek 4 End If Case 4 If Schedule Wednesday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp 6 Schedule timel Text 6 amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfWeek 5 End If Case 5 If Schedule Thursday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp 6 Schedule timel Text 6 amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfWeek 6 End If Case 6 If Schedule Friday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp amp Schedule timel Text 6 amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfWeek 7 End If
9. 3 6 2 2 Button Array In creating a button array for the prototype the team aimed to create an intuitive user interface A power button served as an on off switch for the display lamp Other buttons consisted of three sets of two buttons to increase or decrease the amount of red green and blue coloration added to the emitted light from the lamps Finally the remote control had increment and decrement buttons for the RGB LEDs and for all the white LEDs simultaneously The buttons that were chosen were from ITT Industries and had the characteristics of normally open single pole single through buttons which can be found on the SPST Momentary Key Switches Datasheet This allows us to connect the 3 3V line to one side of the push button and the other side to the processor and when pushed the button would allow 3 3V to trigger the processor 3 6 2 3 Processor The processor that was chosen was the PIC18F87J10 made by microchip This processor was chosen above other ones mainly because of its five pulse width modulation outputs its two UART port modules and it ran on a common 3 3V input As the search began for the processor it was hard to find one with that many pwm outputs and two UART ports When the project first began the team was under the impression that two UARTs would be needed to connect to the Bluetooth module and the Zigbee module This however changed along the way because it was found out that the Zigbee uses a Serial Port instead
10. 6 BackColor Color White Case 7 BTN 7 BackColor Color White Case 8 BTN 9 BackColor Color White End Select Select Case NewLamp Case ALL LAMPS BTN_all BackColor Color Bisque Case 0 BTN 0 Color Bisque Case 1 BTN_1 BackColor Color Bisque Case 2 BTN 2 BackColor Color Bisque Case 3 BTN 3 BackColor Color Bisque Case 4 4 BackColor Color Bisque Case 5 BTN_5 BackColor Color Bisque Case 6 BTN 6 BackColor Color Bisque Case 7 BTN 7 BackColor Color Bisque Case 8 BTN 9 BackColor Color Bisque End Select CurrentLamp NewLamp XXVII Me Refresh End Sub Private Sub BTN SETUP Click ByVal sender As System Object ByVal e As System EventArgs Handles BTN SETUP Click Setup PresetlBtnName Text PresetlName Setup Preset2BtnName Text Preset2Name Setup Preset3BtnName Text Preset3Name Setup ShowDialog If Setup DialogResult Windows Forms DialogResult OK Then PresetlName Setup PresetlBtnName Text Preset2Name Setup Preset2BtnName Text Preset3Name Setup Preset3BtnName Text Me BTN_PRESET1 Text Strings Left PresetlName 9 Me BTN PRESET2 Text Strings Left Preset2Name 9 Me BTN PRESET3 Text Strings Left Preset3Name 9 Me Refresh End If End Sub Private Sub chkBlackOutWhite Click ByVal sender As Object ByVal e As System EventArgs Handles chkBlackOutWhite Click Dim i As Integer If CurrentLamp ALL LAMPS Then For i 0 To 8 CurrentArray i 8
11. End If Case 7 If Schedule July Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths MTest amp amp Schedule timel Text amp amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 8 End If Case 8 If Schedule August Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths MTest amp amp Schedule timel Text amp amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 9 End If Case 9 If Schedule September Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths MTest amp amp Schedule timel Text amp amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 10 End If Case 10 If Schedule October Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths MTest amp amp Schedule timel Text amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 11 XLI End If Case 11 If Schedule November Checked True Then D2 DateValue DateAdd DateInterval Month amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 12 End If Case 12 If Schedule December Checked True Then D2 DateValue DateAdd DateInterval Month amp Sche
12. Team 2 LEDmote Chris Kreft Dan Prince Ryan Truer Dustin Veldkamp 5 4 2007 Wireless Lighting 1 System Abstract The following report documents the work of Team 2 LEDmote a group of students from Calvin College working with Innotec Corp The team designed and prototyped a wirelessly controlled lighting system during the 2006 2007 school year The system uses multicolor LED lights and can be implemented for office entertainment or home use At the end of the project a collaboration of materials and documentation was passed on to Innotec as a model for development of one of their projected commercial products Table of Contents 1 4 1 1 1 1 1 2 luong 1 1 3 gg rm 1 1 4 LEDmote Team eire e ina e iei eese edite 1 1 5 339 40 crm e re thas ove neve od dun 2 EE 3 Project Scope ec eee eee m c vetet ete ee 3 3 1 The Challenge a a a eet 3 3 11 5 3 3 12 titre itt edite e deu 4 3 2 aa a aa 5 3 3 Project Requirements AiR 6 3 3 1 Prototype Requirements io ere rite 6 3 3 2 Electrical Requiremen
13. 3 5 3 2 Bluetooth Module The Bluetooth module that was chosen was the LMX9830 Bluetooth Serial Port Module made by National Semiconductor This Bluetooth module was chosen because it has its own processor embedded into it With its own processor in it the Bluetooth protocol stack does not have to be loaded onto the PIC18F87J10 like the Zigbee Stack does Even though the price of this Bluetooth module was slightly higher because of the built in processor it paid off because it would only be used in one lamp which would prevent the lighting system to be too expensive The Bluetooth module would connect to the microprocessor using a UART interface The datasheet of the LMX9830 gives explicit directions on how the UART is set up The UART in the LMX9830 supports a four wire connection which operates better because it uses two recognition lines But the LMX9830 can also connect to a two wire UART microprocessor which the PIC18F87J10 only supports this information can be found in the LMX9830 Software Users Guide It requires that the Clear To Send CTS input to be pulled ground This will allow the two processors to properly talk to one another This Bluetooth module was used because it creates a Serial Port with another Bluetooth unit Once it is connected as a Serial Port with another unit the two Bluetooth units can transmit whatever data that is needed 3 5 3 3 Amplifier Circuit An amplifier circuit was needed because the PIC18F87J10 outpu
14. 4 Then Me BTN_4 Enabled Me BTN 4 BackColor 4 ForeColor End If True System Drawing Color White System Drawing Color Black If NumberOfLamps 5 Then Me BTN 5 Enabled Me BTN 5 BackColor Me BTN 5 ForeColor End If True System Drawing Color White System Drawing Color Black If NumberOfLamps 6 Then Me BTN 6 Enabled Me BTN 6 BackColor Me BTN 6 ForeColor End If True System Drawing Color White System Drawing Color Black If NumberOfLamps 7 Then Me BTN 7 Enabled Me BTN 7 BackColor Me BTN 7 ForeColor End If System Drawing Color White System Drawing Color Black NumberOfLamps gt 8 Then Me BTN_9 Enabled Me BTN_9 BackColor Me BTN_9 ForeColor End If Me Refresh End Sub Call Save Data End End Sub Private Sub Save Data Dim x y As Integer True System Drawing Color White System Drawing Color Black Private Sub BTN EXIT Click ByVal sender As System Object Dim textdelimiter As String Dim sw As StreamWriter textdelimiter ByVal e As System EventArgs Create an instance of StreamWriter to read from a file Handles BTN_EXIT Click New StreamWriter System AppDomain CurrentDomain BaseDirectory amp data txt XXII sw Write UserName amp textdelimiter Sw Write PresetlName 6 textdelimiter sw Write Preset2Name amp textdelimiter sw Write Preset3Name amp textdelimiter Sw Write MasterLampName amp
15. 589264 The main reason for not selecting these MOSFETs in the prototype was that all three are surface mount parts and the prototype consisted of bread boarded components 8 1 4 Remote User Interface In hindsight the remote control user interface could be more intuitive One recommendation is to include a symbolic labeling system with the remote control buttons to clarify which buttons control which functions For example the power button could have a standard power symbol added to it while the other buttons could have and symbols added This would increase the costs of the remote control See Section Error Reference source not found but would provide clarity for the user The team looked into purchasing decals stickers to place on the prototype but was unable to locate any vendors able to produce stickers on a small scale prototype without excessively exceeding the budget In an industrial setting the remotes could be mass produced making the addition of decals a more financially feasible option 8 1 5 Motion or Heat Sensor While the team determined that the addition of a motion detector to be included with the prototype would be beyond the scope of the project in the given time frame the team does recommend that the use of motion detectors in a production design be explored Such detectors could prove valuable in minimizing wasted energy from unnecessarily leaving lighting systems on while no person is in a room The only
16. Case 5 If Schedule chk5 Checked True Then Now amp amp Schedule timel Text amp D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule AMPM1 Text AddNumberOfDays D2 D2 DateAdd DateInterval Day EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 6 End If Case 6 Schedule chk6 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths 5 6 Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 7 End Case 7 Schedule chk7 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths ow Now amp amp Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 8 End If Case 8 If Schedule chk8 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp mo amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 9 End If Case 9 XXXIV Schedule chk9 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp
17. Lighting Alternatives Decision Matrix o o E gt o 5 5 ET o Weights out of 10 as Lighting Alternatives Limited Color Option 4 268 256 Color Option 7 277 Limited Dimming Option 4 249 Continuous Dimming 7 253 4 2 3 Button Decision This decision matrix shown in Table 5 6 deals with the physical buttons of the remote control For this project three possible input devices were chosen slides individual buttons and a scroll wheel These 30 three options are shown below in Table 5 6 and weighted according to the criteria discussed above The button alternative ended up slightly higher than the other two options because of its reliability A slider has a preset position which is a disadvantage if when the lighting system is initially turned on the lights automatically turn on to whatever preset position the slider is in A user may not want the lights to be fully bright or fully dark when the lighting system is first turned on The advantage of the other button systems is that when the lighting system is turned on it sets to a default medium brightness that can be adjusted up or down There are no physical limitations on the button or scroll wheel system over the slider system The main advantage of a button system over a scroll wheel system is minimization of costs Table 4 3 Button Alternatives Decision Matrix E 5 o 5 5 c Weights out of 10 222222 3 Button Alternatives
18. NewLamp ALL LAMPS Call Change Lamp End Sub XXIV Private Sub _0_ 11 ByVal NewLamp 0 Call Change Lamp End Sub Private Sub 1 Click ByVal NewLamp i Call Change Lamp End Sub Private Sub 2 Click ByVal NewLamp 2 Call Change Lamp End Sub Private Sub 3 Click ByVal NewLamp 3 Call Change Lamp End Sub Private Sub 4 Click ByVal NewLamp 4 Call Change Lamp End Sub Private Sub BTIN_5_Click ByVal NewLamp 5 Call Change Lamp End Sub Private Sub 6 Click ByVal NewLamp 6 Call Change Lamp End Sub Private Sub BIN_7_Click ByVal NewLamp 7 Call Change Lamp End Sub Private Sub 8 Click ByVal NewLamp 8 Call Change Lamp End Sub Private Sub Change Mode Select Case CurrentMode Case PresetlName sender sender sender sender sender sender sender sender sender As As As As As As As As As PresetlArray CurrentArray Case Preset2Name Preset2Array CurrentArray Case Preset3Name System Object System Object System Object System Object System Object System Object System Object System Object System Object ByVal ByVal ByVal ByVal ByVal ByVal ByVal ByVal ByVal System EventArgs System EventArgs System EventArgs System EventArgs System EventArgs System EventArgs System EventArgs S
19. Resistor Resistor Resistor Resistor Golden DRAGON Hyper Multi TOPLED Connector Inductor DESCRIPTION RES 442 OHM 1 4W 1 1206 SMD RES 412 OHM 1 4W 1 1206 SMD RES 499 OHM 1 4W 1 1206 SMD RES 2 43 OHM 1W 1 2512 SMD LED WHITE DIFFUSED 1WATT SMD LED MULTI TOPLED 617NM AMB CONN HEADER 5POS 7 92MM TIN INDUCTOR THIN FILM 2 2NH 0603 PART NUMBER CRCW1206442RFKEA CRCW1206412RFKEA CRCW1206499RFKEA CRCW25122R43FNEG LW W5SG GY HY 5K8L Z LATBT66C RS 1 ST7 35 P7Q7 35 20 R18 ZB DF22L 5P 7 92DS LO603R2AHLTR MANUFACTURER Dale Vishay Dale Vishay Dale Vishay Dale Vishay OSRAM OSRAM Hirose Electronic Co Ltd AVX Corporation Total Component Costs For Conference Room Total Component Costs For Desk Lamp PACKAGING Tape amp Reel Tape amp Reel Tape amp Reel Tape amp Reel White SMD White P LCC 4 Bulk Tape amp Reel UNIT BULK TOTAL BULK PRICE PRICE 0 005 0 080 0 005 0 080 0 005 0 040 0 044 0 880 2 570 25 700 0 537 4 296 0 480 0 480 0 405 0 405 31 961 18 67 10 2 2 Remote Control Bill of Materials Generic Components Zigbee Components Processor QTY REFERENCE BHO SW1 2 SW3 SW4 5 SW6 7 SW8 9 SWf10 11 PIC18F6XJ1X C3 CA C6 C10 C11 C45 C13 C8 C12 C14 C46 C5 C7 C47 C48 OSC1 MRF24J40 R1 R2 L6 L5 PRODUCT NAME Battery Holder Black Sw itches Yellow Switch Blue
20. Schedule timel Text amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 23 End If Case 23 If Schedule chk23 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp AddNumberOfDays D2 EndLoop True D2 DateAdd DateInterval Day Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 24 End If Case 24 True Then If Schedule chk24 Checked XXXVII amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text Else If Schedule chk27 Checked Else Else amp Schedule timel Text 6 D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 25 End If If Schedule chk25 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 26 End If If Schedule chk26 Checked True Then Now amp amp Schedule timel Text amp D2 DateValue DateAdd DateInterval Month AddNumberOfMonths D2 DateAdd DateInterval Day AddNumberO
21. chkBlackOutWhite Checked Next Else CurrentArray CurrentLamp 8 chkBlackOutWhite Checked End If End Sub Private Sub chkBlackOutColor_Click ByVal sender As Object ByVal e As System EventArgs Handles chkBlackOutColor Click Dim i As Integer If CurrentLamp ALL LAMPS Then For i 0 To 8 CurrentArray i 9 chkBlackOutColor Checked Next Else CurrentArray CurrentLamp 9 chkBlackOutColor Checked End If End Sub Private Sub chkFadeColor_Click ByVal sender As Object ByVal e As System EventArgs Handles chkFadeColor Click Dim i As Integer If CurrentLamp ALL LAMPS Then For 1 0 8 CurrentArray i 7 chkFadeColor Checked Next Else CurrentArray CurrentLamp 7 chkFadeColor Checked XXVIII End End Sub Private Sub chkFadeWhite_Click ByVal sender As Object ByVal e As System EventArgs Handles chkFadeWhite Click Dim i As Integer If CurrentLamp ALL LAMPS Then For i 0 To 8 CurrentArray i 6 chkFadeWhite Checked Next Else CurrentArray CurrentLamp 6 chkFadeWhite Checked End If End Sub Private Sub chkRainbow_Click ByVal sender As Object ByVal e As System EventArgs Handles chkRainbow Click Dim i As Integer If CurrentLamp ALL LAMPS Then For 1 0 8 CurrentArray i 10 chkRainbow Checked Next Else CurrentArray CurrentLamp 10 chkRainbow Checked End If End Sub Private Sub BTN SCHEDULE Click ByVal sender As System Object ByVal As System EventArgs Handles BT
22. te nte eb tee ite end ne 63 7 1 Hardware Testing dete e RD 63 PAA MCU iiss 63 7 2 2 Q 63 7 1 3 DARE S 63 14 Remote net ero nee debate eh e 64 74552 seekers 64 7 126 Em 65 7 2 Soft Ware Testing te Ne ane ee cet ee ede 66 72 14 ee 66 7 2922 ioo rre tee ee eerie orit t ni e ida 66 gt 6 EET 67 81 Recommendations cases alee Atte tercie lee ete 67 arse is pede e lt e inta handed sieeve 67 8 1 2 Working unte ee te ei e edet etie 67 8 1 3 Lamp Base TransistOls a i eere toe tense c e esed ee Se 67 8 14 Remote Yser 68 8 15 Motion or Heat Sensor uet rt e re edet eere ttn 68 8 2 bie fe 68 8 3 Acknowledgemients 5 5 2 5 ev eee 69 95 Bibliography ot ea nahe vei me 70 10 Appendi6es reet tere t P e E ete e 10 1 Microsoft Milestones Project 10 2 etr pe e heri
23. ww1 microchip com downloads en AppNotes 00965c pdf gt 1 1814620 Datasheet 2007 Microchip com March 2007 lt http ww1 microchip com downloads en DeviceDoc 39626C pdf gt PIC18F87J10 Data Sheet 2006 Microchip com 15 January 2007 lt http ww1 microchip com downloads en DeviceDoc 39663d pdf gt PICDEM Z User s Guide 12 November 2004 Microchip com 12 March 2007 lt http ww1 microchip com downloads en DeviceDoc 51524a pdf gt MOSPOWER PDF Datasheet VN88AF 2007 Datasheetarchive com 8 2007 lt http www datasheetarchive com search php q VN88AF amp sType part gt National Semiconductor Corporation LMX9830 Datasheet March 2006 National com January 2007 lt http www national com ds LM LMX9830 pdf gt Osram Golden Dragon 4 October 2006 Osram com 28 January 2007 lt http catalog osram os com media _en Graphics 00040135_0 pdf gt 89 Hyper Multi TOPLED 15 September 2005 Osram com 23 January 2007 lt http catalog osram os com media en Graphics 00032091 O pdf OSRAM OSRAM LEDs 2 December 2006 Digikey com 9 May 2007 lt http dkc3 digikey com PDF T072 P2201 pdf gt Vishay Si231BDS N Channel 20 V D S MOSFET 25 January 2005 Vishay com 8 May 2007 lt http www vishay com mosfets list product 73235 gt VN88AF Data Sheet 16 July 2001 DatasheetArchive com 16 April 2007 lt http www datasheetarchive com search php q vn88af amp
24. 0 014 0 014 0 013 0 021 0 428 1 131 3 590 0 006 0 003 0 043 0 043 0 085 1 486 30 637 10 2 4 Base Bill Of Materials Master Components Bluetooth QTY 4 44 an psa ana REFERENCE OSC4 C29 C15 C17 C23 C27 C16 C18 C19 C20 C24 C25 C26 C21 C22 C28 C30 C31 C32 C33 C34 C35 C36 C37 C38 C39 R4 R5 R6 R7 R8 R13 R14 R9 R10 R11 R12 R16 L3 L7 LED1 PRODUCT DESC Crystal Oscillator Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Inductor LED LED Voltage Regulator EEPROM Oscillator Bluetooth Module DESCRIPTION 13 000MHz CAP CER 10000PF 50V 10 X7R 0603 CAP TANT 1 0UF 10V 10 0603 SMD CAP TANT 2 2UF 16V 20 0603 SMD CER 100PF 50V 5 0603 CAP CER 1UF 16V 10 X7R 0603 CAP CER 4 7PF 50V COG 0603 CAP CER 2 2UF 10V Y5V 0603 CAP CER 12PF 50V 5 COG 0603 CAP CERAMIC 8 2PF 50V COG 0603 CAP CER 220PF 50V 5 0603 2200PF 50V 10 X7R 0603 CAP CER 39PF 50V 5 COG 0603 CAP CER 1UF 16V Y5V 0603 CAP CERAMIC 7PF 50V COG 0603 CAP CER 1000PF 50V 10 X7R 0603 RES 1 00K OHM 1 10W 196 0603 SVD RES 523 OHM 1 10W 196 0603 SVD RES 130 OHM 1 10W 196 0603 SVD RES 1 00K OHM 1 4W 1 0603 SMD RES 100K OHM 1 10W 1 0603 SMD RES 0 0 OH
25. 4 3 2 1 Power Supply The remote control was designed to use 2 AA batteries which would produce a 4 5 V output onto the board This was a little high because the processor and Zigbee module were specified to run at 3 3 V To knock down the voltage to a tolerable level for the processor to handle a REG103GA 3 3 linear voltage regulator was used The datasheet for this regulator states that this voltage regulator can take an input of up to 15 V This was nice to know because it can handle the input from the batteries On an added note the voltage regulator can also handle an input of 12 V which the Lamp Modules run off of This voltage regulator is also rated at 500 mA this is well above the current that the main processor and the Zigbee processor ever pull 4 3 2 2 Button Array In creating a button array for the prototype the team aimed to create an intuitive user interface A power button served as an on off switch for the display lamp Other buttons consisted of three sets of two buttons to increase or decrease the amount of red green and blue coloration added to the emitted light from the lamps Finally the remote control had increment and decrement buttons for the RGB LEDs and for all the white LEDs simultaneously The buttons that were chosen were from ITT Industries and had the characteristics of normally open single pole single through buttons which can be found on the SPST Momentary Key Switches Datasheet This allows us to connect t
26. Case 7 If Schedule Saturday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp 6 Schedule timel Text 6 Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 AddNumberOfWeeks Schedule NumericWeek Value 1 DayOfWeek 1 End If Case Else D2 Now EndLoop True End Select Loop Case Monthly AddNumberOfMonths 0 AddNumberOfDays 0 EndLoop False DayOfMonth DatePart DateInterval Day Now If Today False Then If DatePart DateInterval Month Now 2 And DayOfMonth 28 Then DayOfMonth 1 AddNumberOfMonths Schedule NumericUpDownl Value 1 ElseIf DatePart DateInterval Month Now 4 And DayOfMonth 30 Then XXXII 1 1 1 1 DayOfMonth AddNumberOfMonths Schedule NumericUpDownl Value lseIf DatePart DateInterval Month 6 DayOfMonth 30 Then DayOfMonth AddNumberOfMonths Schedule NumericUpDownl Value lseIf DatePart DateInterval Month Now 9 And DayOfMonth 30 Then DayOfMonth AddNumberOfMonths Schedule NumericUpDownl Value lseIf DatePart DateInterval Month Now 11 And DayOfMonth 30 Then DayOfMonth AddNumberOfMonths Schedule NumericUpDownl Value lseIf DayOfMonth 31 Then DayOfMonth AddNumberOfMonths Schedule NumericUpDownl Value TE DayOfMonth DayO
27. Enabled True CurrentArray Preset2Array Case Preset3Name Me BTN_PRESET1 Enabled True Me BTN_PRESET2 Enabled True Me BTN_PRESET3 Enabled False Me BTN_MANUAL Enabled True CurrentArray Preset3Array Case MANUAL Me BTN_PRESET1 Enabled True Me BTN_PRESET2 Enabled True Me BTN_PRESET3 Enabled True Me BTN_MANUAL Enabled False End Select CurrentMode NewMode NewLamp ALL LAMPS Call Change Lamp Me Refresh End Sub PRESET BUTTON OPERATION d NEWMODE P NEWMODE PRESET2 NEWMODE PRESET1 PRESET3 D S PRSTIARRAY CURRENT ENABLE amp DISABLE CHANGE PRST2ARRAY PRST3ARRAY CURRENT CURRENT ARRAY lt LAMP TO ALL LAMPS Figure 18 Mode Buttons Operation and Code 4 5 2 1 2 3 5 SETUP BUTTON The setup dialog form allowed the user to change some of the program s global variables In PC Console Version 1 0 only the button names of the Preset1 buttons can be adjusted This dialog could be expanded to include many other variables as the program grows and expands 53 Private Sub BTN_SETUP_Click ByVal sender As System Object ByVal As System EventArgs Handles BTN_SETUP Click Setup Preset1BtnName Text PresetiName Setup Preset2BtnName Text Preset2Name Setup Preset3BtnName Text Preset3Name Setup ShowDialog If Setup DialogResult Windows Forms DialogResult OK Then
28. Feburary Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 3 End If Case 3 If Schedule March Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 4 End If Case 4 If Schedule April Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 5 End If Case 5 If Schedule May Checked True Then MTest MTest MTest MTest amp amp amp amp 5 Schedule timel Text 6 5 Schedule timel Text amp amp Schedule timel Text amp amp Schedule timel Text amp XL D2 DateValue DateAdd DateInterval Month AddNumberOfMonths MTest amp amp Schedule timel Text amp amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 6 End If Case 6 If Schedule June Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths MTest amp amp Schedule timel Text amp amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 7
29. MODE 1 SetOutputPWM2 SINGLE OUT PWM MODE 1 Fd SetOutputPWM3 SINGLE OUT MODE 1 Reset duty cycle for PWMs XLV pwml dc C INITIAL pwm2 dc C INITIAL pwm3 dc C INITIAL pwm4_dc W INITIAL pwm5 dc W INITIAL Set Duty Clcle for PWMs SetDCPWM4 pwm4_dc SetDCPWM1 pwml dc SetDCPWM2 pwm2 dc SetDCPWM3 pwm3 dc SetDCPWM5 pwm5 dc else 1 power_status 1 power_status 0 PORTDbits RD7 1 ClosePWM1 ClosePWM2 ClosePWM3 ClosePWM4 ClosePWM5 break case WHITE_UP WHITE UP PORTDbits RD6 1 if pwm5 dc gt DC MAX else pwm5_dc pwm5_dc W CHANGE SetDCPWM5 pwm5_dc break case WHITE_DOWN WHITE DOWN PORTDbits RD6 1 if pwm5 dc lt DC MIN else Lu pwmb5 dc pwm5 dc CHANGE SetDCPWM5 pwm5 dc White PWM Red PWM Green PWM Blue PWM Extra PWM XLVI break case RED_UP RED UP PORTDbits RD5 1 if pwml dc gt DC MAX else pwml dc pwml dc CHANGE SetDCPWM1 pwml dc RED_DOWN RED DOWN PORTDbits RD5 1 if pwml dc lt DC MIN else pwml dc pwml dc CHANGE SetDCPWM1 pwml dc break case GREEN_UP GREEN UP PORTDbits RD4 1 if pwm2_dc gt DC_MAX else pwm2 dc pwm2 dc C
30. Me B71 End If IN 0 Enabled System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col System Drawing Col Then True If NumberOfLamps 1 Then 1 1 1 End If IN l Enabled True If NumberOfLamps 2 Then 1 1 N_2 Enabled 1 End If True If NumberOfLamps gt 3 Then 1 N_3 Enabled Me B1 True lor lor lor lor lor Lor 1 1 lor 1 lor Transparen Transparen Transparen lor Gray lor Gray lor Gray lor Gray lor Gray lor Gray lor Gray lor Gray lor Gray IN O BackColor System Drawing Color White IN O ForeColor System Drawing Color Black IN l BackColor System Drawing Color White IN l ForeColor System Drawing Color Black IN 2 BackColor System Drawing Color White IN 2 ForeColor System Drawing Color Black IN 3 BackColor System Drawing Color White cb cb ct cr XXI Me BTN_3 ForeColor End If System Drawing Color Black If NumberOfLamps gt
31. PCB Design After all research was done on all of the different components that attached to processor and the Zigbee chip a printed circuit board was created Since the Zigbee is an RF transceiver a lot of things had to be considered when laying out the board The MRF24J40 Datasheet mentions everything that should be considered in the designing of a RF board The datasheet also provided a suggested layout for the Zigbee chip so the design that was approached was to follow Microchips design as closely as possible The final layout is shown below in Figure 3 LEDmote REMOTE Figure Remote Control PCB Design 3 6 3 Control Lamp 3 6 3 1 Power Supply The power supply for the lamp was designed a lot differently than in the remote control The lamps were designed to be plugged into a 120V 60Hz or 240V 50Hz wall socket So the first step was to send the voltage through a switch mode power supply which would cut the voltage down to 12V DC The 23 power supply that was chosen was a ETS120400UTC P5P SZ made by CUI Inc From the datasheet it was found that this power supply could handle currents of up to 50A This was a little over kill because currently the LED array draws little less than 25A It was chosen a little high in case more LEDs were needed in the future which would ultimately draw more current This power supply would then output 12V as stated above which would be used to drive the 12V LED array But another step down in v
32. Setup Preset1BtnName Text Preset2Name Setup Preset2BtnName Text Preset3Name Setup Preset3BtnName Text Me BTN_PRESET1 Text Strings Left Preset1Name 9 Me BTN PRESET2 Text Strings Left Preset2Name 9 Me BTN PRESET3 Text Strings Left Preset3Name 9 Me Refresh End If End Sub D SETUP OPERATION Preset 1 Button Text Preset 1 Name Field gt 1 Ww Preset 2 Button Text wa Field D Preset 3 Button Text Preset 3 Name Field 4 Hide Setup Screne Ww Figure 19 Setup Operation Flow Diagram and Code 4 5 2 1 2 3 6 SCHEDULE BUTTON The schedule button was one of the most complicated functions in the entire program The large variability of the recurrence and time frames created the complication The flow diagram in Figure 20 shows the flow of the schedule program along with the code for the schedule setting operation and the timer elapsed event handling The recurrence is found in Appendix 10 4 4 54 Private Sub BTN_SCHEDULE_Click ByVal sender As System Object ByVal As System EventArgs Handles BTN SCHEDULE Click Schedule ShowDialog If Schedule DialogResult Windows Forms DialogResult OK Then If Schedule Preset1 Checked True Then ScheduleSetting Preset 1 Elself Schedule Preset2 Checked True Then ScheduleSetting Preset 2 Elself Schedule Preset3 Checked True Then ScheduleSetting Preset 3 Else ScheduleSetting Disabled End If I
33. amp Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 10 End If Case 10 If Schedule chk10 Checked True Then DateValue DateAdd DateInterval Month AddNumberOfMonths mo Now amp amp Schedule timel Text amp D2 amp Schedule AMPM1 Text AddNumberOfDays D2 D2 DateAdd DateInterval Day EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 11 End If Case 11 If Schedule chkll Checked True Then Now amp amp Schedule timel Text amp D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 12 End If Case 12 If Schedule chk12 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths 5 amp Schedule timel Text 6 Schedule AMPM1 Text AddNumberOfDays D2 D2 DateAdd DateInterval Day EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 13 End If Case 13 If Schedule chk13 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text 6 mo amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop Tr
34. assumed that the Zigbee protocol stack could have been loaded onto the PIC18F87J10 Although it was assumed that the MC13192 would be able to work with the PIC18F87J10 it was hard to find support for doing this Then around January another chip made by Microchip was released The Zigbee Chip that was selected was the MRF24J40 There was a lot more support for this chip and Microchip has its own Zigbee Protocol Stack specifically designed for PIC18F Microcontrollers The support for loading the stack onto a PIC18F processor can be found in the AN965 Microchip Stack for the ZigBee Protocol Datasheet This chip was selected because microchip fully supports this Zigbee chip with the PIC18F87J10 This Zigbee chip was designed to connect through the SPI port on the PIC18F87J10 and was also designed to send out a clock output for the PIC18F87J10 to use 3 3 3 5 Remote Control PCB Design After all research was done on all of the different components that attached to processor and the Zigbee chip a printed circuit board was created Since the Zigbee is an RF transceiver a lot of things had to be considered when laying out the board The MRF24J40 Datasheet mentions everything that should be considered in the designing of a RF board The datasheet also provided a suggested layout for the Zigbee chip so the design that was approached was to follow Microchips design as closely as possible The final layout is shown below in Figure 3 LEDmote
35. at the time that we researched 12 it It was found to be able to connect to a large variety of microcontrollers through a SPI connection which the PIC18F87J10 supports So at the time it was assumed that the Zigbee protocol stack could have been loaded onto the PIC18F87J10 Although it was assumed that the MC13192 would be able to work with the PIC18F87J10 it was hard to find support for doing this Then around January another chip made by Microchip was released The Zigbee Chip that was selected was the MRF24J40 There was a lot more support for this chip and Microchip has its own Zigbee Protocol Stack specifically designed for PIC18F Microcontrollers The support for loading the stack onto a PIC18F processor can be found in the AN965 Microchip Stack for the ZigBee Protocol Datasheet This chip was selected because microchip fully supports this Zigbee chip with the PIC18F87J10 This Zigbee chip was designed to connect through the SPI port on the PIC18F87J10 and was also designed to send out a clock output for the PIC18F87J10 to use 3 4 2 5 Remote Control PCB Design After all research was done on all of the different components that attached to processor and the Zigbee chip a printed circuit board was created Since the Zigbee is an RF transceiver a lot of things had to be considered when laying out the board The MRF24J40 Datasheet mentions everything that should be considered in the designing of a RF board The datasheet also prov
36. change colors brightness and how to turn the lighting system on and off In software the user was able to easily identify functionality from the PC program available The software followed conventional programming standards Harmony is qualified in the following sentence by Gayle Ermer an associate professor at Calvin College The design should be pleasing to use attractive and promote healthy relationships This norm also known as integrity was seen in the aesthetic value of the design which was fun flexible intriguing and easy to use The final design norm stewardship was seen in the use of LED lights as opposed to incandescent bulbs The use of LED lights minimized power consumption and removed detrimental effects on the environment that occur from excessive energy consumption Such detrimental effects include global warming from the burning of fossil fuels and environmental damage resulting from other power generation units such as hydroelectric dams which interfere with natural water forms In addition LEDs do not have the toxic materials of lead and mercury that incandescent and fluorescent bulbs use nor does a user need to be concerned with the possible dangers associated with broken glass from damaged bulbs of this type The use of wireless technology minimized the need for wiring between light modules and so reduced the overall system cost Although the initial installation costs were greater ultimately the long term costs wer
37. circuit board was designed much in the same way as the remote control circuit board With the development kit that was purchase for the LMX9830 some of the software that came with the kit provided the prints for the four layers of the development kit These prints were replicated as close as possible just like the PIC18F87J10 and the MRF24J40 were before Also a bit of concern was created by the use of two RF modules on one board The solution that was proposed by the team was to put the two RF modules as far away as possible From Figure 5 it can be seen that the Bluetooth was populated near the top left and the MRF24J40 located at the bottom middle of the board 10 Figure 5 Lamp Base 3 3 5 Secondary Lamps The secondary lamps do not need any more explaining because they are basically just a striped down Control Lamp The secondary lamps do not need a Bluetooth unit because these lamps just rely on the Zigbee modules to communicate to the rest of the lamp network Complications Two One Display Display 3 4 Limited by Development Boards Also see Section 4 3 Lamps Lamp Original Design 3 4 1 Overview Remote Control Button Array 1 PIC18F87110 Control Lamp Secondary Lam LMX9830 MRF241J40 SPI PIC18F87H0 PIC18F87H0 SPI 24140 Amplifier LED Array Computer Program Figure 2 Original Design Block Diagram 3 4 2 Remote Control The remote control was designed t
38. coordinator received a transmission from the remote control and it had the device ID of EP_LIGHT the Coordinator Program would process the command This was done in the switch statement that started like this switch params APSDE_DATA_indication DstEndpoint case EP_ZDO case EP_LIGHT Once the program recognized that it was supposed to perform the command it had just received it began to process what it had to do The program went through a couple more steps to collect the data and then entered another switch statement that deciphered what code it has just received and needed to perform data APLGet switch data case POWER WriteUSART POWER MESSAGE_INDICATION 1 TxBuffer TxDatat SUCCESS break The first line shown above uses the APLGet function to pull the data off of the Zigbee Transciever and then set it to a variable data The variable data was then processed into a switch statement to decode each instruction In the first case shown above it could be seen that the Coordinator Program immediately takes the data received and puts it on the UART transmit register for it to be relayed to the PWM Program using the WriteUSART function The next line simply changed the LED on the development board to alert the users that it had successfully received and transmitted the message to the other processor The seventh line shown above sent a message back to the remote control let
39. each language It was considered whether or not the language was adequate to fulfill the desired functions of software for this project The software needed to interface with a Bluetooth card The capability to create a graphical user interface GUI that is transparent to the user was also required It had to be capable of creating applications compatible with Windows because that was the OS we intended to install our prototype software on Without adequate software no matter how familiar the team was with the language certain functions could not be created Another criterion was an adequate support system to answer all programming queries In summary the criteria were previous experience functional Bluetooth interface capacity to create transparent GUI ability to create windows compatible applications and an adequate support system 45 4 5 2 1 1 2 Alternatives There were three alternatives considered for software programming language The alternatives were Java C and Basic Java is an object oriented programming language developed by Sun Microsystems It was designed to be executed on multiple operating systems It was also designed for using computer networks C is a high level programming language originally developed by Bell Labs Basic stands for Beginner s All purpose Symbolic Instruction Code and originated at Dartmouth College It was created as a programming language for the non technical user 4 5 2 1 1 3 Decisio
40. foreseeable drawback to the motion detector system is that in some modern day detector systems the lighting systems shut down if a person stays relatively motionless in a room for an extended period of time For this reason the team believes Innotec should explore the use of heat detectors as an alternative to motion detectors to use with the LEDmote system 8 2 Reflections Many lessons were learned by team LEDmote throughout the design process These lessons involved scheduling design steps and documentation Scheduling is a delicate process for the experienced for the relatively inexperienced team LEDmote scheduling became even more of a test Table 21 in section 6 2 display this scheduling difficulty clearly The actual hours spent over the course of the semester over shot the estimations by 276 6 hours a 20 over shoot In retrospect the team should have rearranged the design process and allowed for more design and debugging time In the schedule plan hardware design was limited to the beginning of the semester All hardware was to be completed at the beginning of the semester before any work on the software was done This structure eventually led to the inevitable problems that occurred in the original design A better a 44 Vishay i Fairchild Semiconductor Fairchild Semiconductor 87 strategy would have been to order development kits at the very beginning of the semester get the software working gain a familiar understand
41. how many steps the colors would change With the color change set to 100 there were 10 different steps for each individual color The two constants after these changed definitions were used for the UART and allowed it to check if data was ready to be received or not 4 5 2 24 2 USART Initialization This function is similar to the USART Initialization in the Coordinator Program Although this UART has to primarily receive transmissions from the Coordinator Program so it is set up differently Also this function must be set up for two UARTS one for the Coordinator Program and one to communicate with the Bluetooth module It starts out the same as the UART function in the Coordinator Program with the setup of the Baud rate for the first UART XSTAlbits SYNC 0 XSTAlbits BRGH 0 BAUDCON1bits BRG16 SPBRG1 0x07 0 67 The SPBRG value for this one is different because it was discovered that the HPC Board uses a 10Mhz oscillator Table 11 below was found in the PIC18F87J10 Datasheet Again a value for the SPBRG1 had to be chosen so that the baud rate would be 19200 Table 11 Baud Rates SYNC 0 BRGH 0 BRG16 0 BAUD Fosc 10 000 MHz RATE Actual 5 SPBRG K Rate Error value K decimal 0 3 1 2 1 202 16 129 2 4 2 404 16 64 9 6 9 766 1 73 15 19 2 19 531 1 73 7 57 6 52 083 9 58 2 115 2 78 125 32 18 1 Now the baud rates for the two programs were se
42. lighting system The functions and user operation are explained in detail in the LEDmote PC Console Version 1 0 User 135 6 Veldkamp 48 4 5 2 1 2 3 GUI Architecture OPEN a KEX D PROGRAM USER USER FORM ess AND N A CREDIT SUB DIALOG ROUTINES 2 CONTROL FORM MINIMIZE BUTTON HELP BUTTON MANUAL BUTTON PRESET BUTTONS SETUP SCHEDULE BUTTON BUTTON SETUP SCHEDULE HELP Save Array Into DIALOG DIALOG CLOSE BUTTON LAMP LAMP BUTTONS CONTROLS lt gt 4 PRESET BUTTON OPERATION LAMP CONTROLS OPERATION LAMP OPERATION p CANCEL BUTTON OK BUTTON EXIT COMMAND OK BUTTON SETUP OPERATION SCHEDULE OPERATION Figure 15 Overall System Software Flow Diagram The GUI software interface consisted of five user forms and layouts When the user double clicks the executable file the interface opens into the credit dialog screen Throughout the duration of this screen a number of actions are performed in the system The breakdown of these actions is shown in Figure 15 The entire system can be broken down into process flow diagrams All of the variables were stored in a large array This array contained all the information for each indivi
43. maintaining appearance Tighter Specs on Parts Temperature 10degC 65degC 10degC 70degC Tighter Specs on Parts Frequency 40Hz 70Hz 47Hz 63Hz Tighter Specs on Parts Common voltage 5 VDC 5 12vDC More Light Output Common current 5A max 1 58A Lower Power Consumption White voltage 25V max 12V Fit to New Design White current per LED 400mA max 157mA Lower Power Consumption RGB voltage 25V max 12V Fit to New Design RGB current 500mA max 57 5mA H Lower Power continuous Consumption Operating System Windows XP Windows XP PC Wireless Protocol Bluetooth Bluetooth PC Operating distance 10 meters 10 meters 30 feet 30 feet Remote Operating distance 10 meters 10 meters 30 feet 30 feet Remote Wireless Protocol Zigbee Zigbee Remote Functions On Off Color On Off Color Intensity Intensity Some of the major changes to electrical characteristics occurred in the power consumption Most notable was the change in the number of LEDs to use which went from 4 white and 6 tri colors to 10 white and 8 tri color LEDs However the power consumption went from an estimated 25W to 23W which ties directly into our design goal of making an efficient and low power lamp E Osram Tri color LED Datasheet CUI Inc Power Supply Datasheet CUI Inc Power Supply Datasheet 7 CUI Inc Power Supply Datasheet CUI Inc Power Supply Datasheet CUI Inc Power Supply Datasheet 10 Osram Golden Dragon Datasheet H
44. not limit the user to any distance from a light but at the same time it was designed for limited operability of the lights 3 3 3 1 Power Supply The remote control was designed to use 2 AA batteries which would produce a 4 5 V output onto the board This was a little high because the processor and Zigbee module were specified to run at 3 3 V To knock down the voltage to a tolerable level for the processor to handle a REG103GA 3 3 linear voltage regulator was used The datasheet for this regulator states that this voltage regulator can take an input of up to 15 V This was nice to know because it can handle the input from the batteries On an added note the voltage regulator can also handle an input of 12 V which the Lamp Modules run off of This voltage regulator is also rated at 500 mA this is well above the current that the main processor and the Zigbee processor ever pull 3 3 3 2 Button Array In creating a button array for the prototype the team aimed to create an intuitive user interface A power button served as an on off switch for the display lamp Other buttons consisted of three sets of two buttons to increase or decrease the amount of red green and blue coloration added to the emitted light from the lamps Finally the remote control had increment and decrement buttons for the RGB LEDs and for all the white LEDs simultaneously The buttons that were chosen were from ITT Industries and had the characteristics of normally op
45. of a UART The PIC18F87J10 was a very good processor for this project and it was decided that it could be used in the remote control and the Lamps The button inputs were designed to directly input into 11 different I O Ports on the processor 3 6 2 4 Zigbee Chip Originally the Freescale Semiconductor MC13192 was used This Zigbee chip seemed to be the best chip that we could use at the time that we researched 22 it It was found to be able to connect to a large variety of microcontrollers through a SPI connection which the PIC18F87J10 supports So at the time it was assumed that the Zigbee protocol stack could have been loaded onto the PIC18F87J10 Although it was assumed that the MC13192 would be able to work with the PIC18F87J10 it was hard to find support for doing this Then around January another chip made by Microchip was released The Zigbee Chip that was selected was the MRF24J40 There was a lot more support for this chip and Microchip has its own Zigbee Protocol Stack specifically designed for PIC18F Microcontrollers The support for loading the stack onto a PIC18F processor can be found in the AN965 Microchip Stack for the ZigBee Protocol Datasheet This chip was selected because microchip fully supports this Zigbee chip with the PIC18F87J10 This Zigbee chip was designed to connect through the SPI port on the PIC18F87J10 and was also designed to send out a clock output for the PIC18F87J10 to use 3 6 2 5 Remote Control
46. old He attended Gateway Primary and High Schools located in Harare Zimbabwe before immigrating with his parents to the United Kingdom In 2002 he chose to continue his education at Calvin College after discovering his interest in learning about the country of his birth and hearing a call from God He hopes to use his skills to one day work in International Development back on his home continent Chris currently works for Apex Controls in Hudsonville Michigan and will work for them as a fulltime Controls Engineer once he graduates in May 2007 Dan Prince was born in Shelby Michigan and was raised in New Era Michigan He went to New Era Christian School for his education from Preschool to the eighth grade His high school education took place at Western Michigan Christian High School in Muskegon Following his senior year of high school he moved to Grand Rapids and began his freshman year at Calvin College starting in the engineering program At the conclusion of his second year at Calvin he chose an electrical and computer engineering concentration because of a growing affinity towards computers and electronics He is now in his fourth year at Calvin and will graduate in May of 2007 with a bachelor s degree of science in engineering He currently works for GE Aerospace and is planning to attend graduate school at the University of Michigan in the Fall of 2007 Ryan Truer was born and raised in Grand Rapids Michigan He attended Sylvan Christian
47. projected first year sales are 34 000 units a conservative 0007 of industry market share Table 17 The income statement for the initial year Table 18 of production was created using the financial analysis in the previous sections The marginal revenues of the products are 10 5 and 54 5 for the desk lamp and conference room respectively The launch expense is amortized over an adjusted three years The selling expense was calculated with a 100 000 base 0 70 per unit sold for sales person salary and advertising expenses The maintenance and insurance costs are rough estimates The warranty expense assumes a 4 claim rate on the products sold The cost of the replaced products was calculated into this warranty expense The first year of production show a net loss of 291 240 22 which is typical for an initial product launch 75 Table 18 First Year Projected Income Statement LEDmote PRODUCT LAUNCH INCOME STATEMENT FIRST YEAR STATEMENT Number of Units 30 000 00 10 59 Sales Price Per Unit 89 17 Desk Lamp Revenue 2 675 046 15 COGS 2 391 691 20 Desk Lamp Net Income 283 354 95 CONFERENCE ROOM Marginal Revenue Number of Units 4 000 00 54 39 Sales Price Per Unit 200 11 Conference Room Revenue 800 456 30 COGS 365 098 61 Conference Room Net Income 435 357 69 OV ERHEAD EXPENSES Launch Amortization Expense 938 692 40 Selling Expense 123 800 00 Maintenance Expense 25 000 00 Insura
48. so increasing its cost Table 4 1 Lamp Module Alternatives Decision Matrix o E o 2 Weights out of 10 Lamp Module Alternatives Individual Lamp Modules 29 8 7 3 5 AllLamp ModulesatOnce 9 7 7 Scheduler Control 5 3 287 7 166 4 2 2 Lighting Decisions While the actual market product LEDs will be provided by Innotec the team felt it was necessary for the remote control decision matrix and subsequent control decisions to examine the alternatives for LED lighting given the project requirements The decision matrix shown in Table 5 7 weighs the different lighting techniques of the Red Green Blue RGB LEDs and white LEDs More specifically it raises the question of how many different colors the remote control will offer and what range of dimming capabilities it can provide Both of these options deal with how the remote control will increase the color or brightness level This issue was not a problem for the remote because it has three different color buttons each controlling one of the three colors in the RGB LED It then sends out an up or down signal of the specific color pressed The two different alternatives were weighted closely in the end because no significant additional design was needed to add more colors The processor received a signal through the wireless transmitting device to increase the color by a certain increment for each button pressed Table 4 2
49. use a mains voltage supply from a building s electrical system However the system should function normally if an alternative supply such as a generator or battery were to be used provided that such alternative supplies met the remaining electrical requirements Each lamp must be provided with a 12VDC minimum common voltage to ensure proper operation In the original design and in production this is provided by connecting a mains supply through a switch mode power supply mounted directly to the lamp PCB In the secondary design and the prototype the DC voltage was provided by Agilent E3620A and Hewlett Packard E3611A power supplies 4 The Design 4 1 Design Overview The design strategy used in the past semester was focused on getting a working prototype for Innotec to build upon when the project is continued by their engineers 4 2 Design Decisions 4 21 Lamp Module Decision The decision matrix shown in Table 5 8 discusses the different alternatives on how the remote controls multiple lamps The team decided that the remote would regulate all the lamp modules at the same time Allowing the remote control to individually manipulate different lamps in the area was too complicated to fit into a single remote while still providing an ease of use to the consumer The alternative was to create a lighting schedule with the remote control This alternative did not stand up to other alternatives adding unnecessary complexity to the remote control and
50. 0 program in the lamp base This program was designed specifically to receive the signals coming from the remote control Zigbee processor The third program called LEDmote PWM was written and programmed onto the original processor the PIC18F87J10 and its main task was to receive the commands from the Zigbee coordinator and then adjust the pulse width modulation PWM of the LEDs accordingly These three programs will be described more specifically in the following sections 4 5 2 2 1 Constants Defined Through All Programs Some variables needed to be defined from one program to another These variables were sent and received as instructions from the two Zigbee processors and through the Zigbee Coordinator and the 37 may be helpful to refer to Appendix 10 5 and follow the programs through while reading this section 57 PWM processor A different hex number was assigned to each of the different button instructions The commands that were assigned to each of the buttons are shown below in Table 9 Table 9 Button Command Functions POWER 0x01 WHITE UP 0x02 WHITE DOWN 0x03 RED UP 0x04 RED_DOWN 0x05 GREEN_UP 0x06 GREEN DOWN 0x07 BLUE_UP 0x08 BLUE_DOWN 0x09 COLOR_UP COLOR DOWN These constants can be found at the very beginning of every program that was written The constants were set using the define code for example to define the Power instruction defi
51. 00 0 00400 0 00330 0 00400 0 00400 0 06125 1 22840 1 01260 0 32200 0 71000 1 48632 9 78075 Total Master Component Costs PRICE 0 480 0 044 1 040 1 040 0 278 0 059 0 023 0 028 0 023 0 214 0 017 0 007 0 011 0 009 0 428 0 009 0 004 0 005 0 005 0 035 0 004 0 003 0 004 0 004 0 123 1 228 1 013 0 322 0 710 1 486 9 781 49 072 10 3 LED Array Worst Case Component Analysis A COMPONENT DEFINITIONS ASSUMPTIONS AND REQUIREMENTS 1 VOLTAGES 2 LED i SOURCE 12V ii REGULATED VRegulated FORWARD VOLTAGE Vewhite VrRea V VrGreen 22V 3 8V 12 VRegulatedMax 3 2V VFWhiteMax 1V VrFRedMax 24V VEGreenMax 3 9 VEBlueMax 41V ii MIN MAX CURRENT AT 80 DUTY CYCLE IERed 20mA IEGreen 20mA IEBlue 20mA iii MAX P CONSUMPTION Ep white 2 3W MaxP EDRed 80mW MaxPr gpGreen 85mW MaxPr 85mW IFWhiteMax 700mA IFRedMax 35mA IEGreenMax 29mA IFBlueMax 25mA MAX JUNCTION TEMPERATURE Tired 125C 125C Tipiue 110C 3 TRANSISTORS i RDS ON Rdson 1 120 Rdson T2 4 1 50 114V VRegulatedMin 2 8 VrWhiteMin 3 1 VeRedMin 1 839 VFGreenMin 3 0 VFBlueMin 3 0 100mA VII ii VGS MAX MIN
52. 2 T8 T4 MICROCHIP C1 C2 C9 D1 L1 C44 C40 C41 C42 C43 C3 C4 C6 C10 C11 C45 C13 C8 C12 C14 C46 C5 C7 C47 OSC1 MRF24J40 R2 16 15 12 14 OSC2 PRODUCT DESC Voltage Regulator Pow er Supply Connector Connector Connector Transistor Transistor Microcontroller Capacitor Capacitor Capacitor Diode Inductor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Crystal Oscilator Zigbee Chip Resistor Resistor Inductor Inductor Inductor Oscillator DESCRIPTION IC STP DN SW VOLT REG 3 3V 16DIP Trans Table Top 12VDC 4A E Star Conn Pow er Jack 2 1X5 5MM Hi Cur CONN HEADER 5POS 7 92MM R A Conn Mod Jack 6 6 R A PCB 50AU MOSFET N CHAN 20V 3A SSOT3 MOSFET N CH 100V 0 4A SOT 223 IC PIC MCU FLASH 32KX16 64TQFP CAP ELECT 100UF 16V VS SMD CAP ELECT 330UF 6 3 VS SMD CAP CER 10UF 6 3V X5R 0603 DIODE SCHOTTKY 40V 1A SOD123 INDUCTOR MULTILA Y ER 330UH 1210 CAP CER 3PF 50V COG 0402 CAP CER 5PF 50V COG 0603 CAP CER 20PF 50V 5 COG 0603 CAP CER 27PF 50V 5 COG 0603 CAP CER 47PF 50V 5 COG 0603 CAP CER 10000PF 16V 10 X7R 0603 CAP CER 1UF 16V Y5V 0603 CER 180PF 50V 5 0603 CAP CER 2 2UF 10V Y5V 0603 CAP CERAMIC 7PF 50V 0603 CRYSTAL 20 000MHZ 18PF FUND SVD IC TXRX IEEE ZIGBEE 2 4GHZ 40QFN RES 0 0 OHM 1 10W 5 SMD RES 10K OHM 1 10W 5 0603 SMD INDUCTOR MULTILAY ER 4 7NH 0603 INDUCTOR MULTILAY ER 5 6NH 0603 IND
53. 22 Figure 8 Prototype Amplifier 24 Fig re 9 Rmin Calculation er e tue b n ERE EE eae ees 24 Fig ure 10 Rmax CalculatiOn etr ie ette Ee tard vec edet ex 24 Figure 1 1 MOSFET TranslStOE eet eee eS ie ated eee A Gee We 25 Figure 12 Display lamp utes te ete tede tete nr t o e eth a 26 Figure 13 Software Architectures nnan reete eb tetti 28 Fig re 1 GUI EayOut tente ettet tc ete 29 Figure 15 Overall System Software Flow 30 Figure 16 System Array 31 Figure 17 Credit Dialog Form Process 31 Figure 18 Mode Buttons Operation and 34 Figure 19 Setup Operation Flow Diagram and Code 35 Figure 20 Schedule Operation Flow 36 Figure 21 Lamp Controls Operation Flow Diagram 38 Figure 22 Corporate Operating System Market Share 53 Figure 23 Bread boarded components of Prototype Remote 66 vi Table of Tables Table T TEME 3 Table 2 Prototype Requirements 6 Table 3 Electrical Characteristics Requirements 6 Table 4 1 Lamp Mo
54. 5 000 00 1 5 000 00 TOTAL COST 1 877 384 79 The capital requirements for the launch of this product are shown in Table 12 The capital requirements were high due to various factors such as the production line build The equipment needed to support the LEDmote manufacturing line was quoted at 1 5 million dollars This did not included the engineering line design time of 250 000 The breakdown of the prototype cost 2 384 79 is shown in Table 13 Given the launch costs they will be amortized over a three year adjusted span The annual amortization expense is shown in Table 14 72 Table 13 Prototype Costs Description Price Microchip Zigbee Protocol 270 00 New ark Parts 12 19 Digi Key Parts 30 67 Mouser Parts 31 34 Stencils Unlimited 344 00 Mouser Parts 15 62 Arrow 291 15 Microchip Part 20 07 Microchip Part 29 75 Digi Key Parts 425 00 Advanced Circuits 390 00 Sunstone Circuits 525 00 GRAND PROJECT TOTAL 2 384 79 SPONSORSHIPS Calvin College 5 300 00 Sunstone 350 00 Advanced Circuits 390 00 Total Sponsoships 1 040 00 External Project Expense 1 344 79 Table 14 Product Launch Annual Amortization Schedule ist Year 50 938 692 40 2nd Year 30 563 215 44 3rd Year 20 375 476 96 5 1 4 2 Core operations The product will be assembled and packaged through in house operations Sales will not be conducted directly with customers instead product will b
55. 6R90 LFS D6R30 LFS D6R60 LFS D6R40 LFS D6R50 LFS D6R00 LFS 555165 1 PIC18F66J10T l PT 1599 ESGYBAT GJMt1555C1HR30BB01D GRM 1885C1HR50CZ01D GRM1885C1H200JA01D GRM1885C1H270JA01D GRM1665C1H470JA01D GRM188R71C103KA01D GRM188F51C104ZA01D GRM1885C1H181JA01D GRM188F51A225ZE01D GQM 885C1H7ROCBO1D ABM8 20 000MHZ B2 T MRF24J40 VML CRCWO06030000Z0TA CRCW06031 OKOJNEA MLG1608B4N7S MLG1608B5N6D MLG1608B10NJ SG 3030JC 32 7680 555165 1 TL2575 33IN ECE V1CA101P GRM188R60J106ME57D 1N5819HW 7 F NLV32T 331J PF MANUFA CTURER MPD ITT Industries ITT Industries ITT Industries ITT Industries ITT Industries ITT Industries Tyco Electronics AMP Microchip Hammond Manufacturing Murata Murata Murata Murata Murata Murata Murata Murata Murata Murata Abracon Corporation Microchip Technology Vishay Dale Vishay Dale TDK Corporation TDK Corporation TDK Corporation Epson Electronics Tyco Blectronics AMP Texas Instruments Panasonic ECG Panasonic ECG Murata Diodes Inc TDK Corporation Total Component Costs TOTAL UNIT BULK PRICE BULK PRICE 0 022 0 009 0 009 0 009 0 009 0 007 0 007 0 013 0 021 0 241 1 131 3 590 0 003 0 003 0 043 0 043 0 043 1 48632 22 352 10 2 3 Base Bill of Materials Slave Processor amp Power Zigbee 3 ale 0 uiu REFERENCE CONN1 CONN2 CONNS T1 T
56. 8 Fory 0 10 sw Write PresetlArray x amp textdelimiter Next y 0 Next x 0 0 08 10 sw Write Preset2Array x amp textdelimiter Next y 0 Next x 0 8 10 sw Write Preset3Array x amp textdelimiter Next y 0 56 Next x 0 sw Close End Sub 4 5 2 1 2 3 10 LAMP CONTROLS The lamp controls was the heart of the program operation These set of controls provided the user with the ability to actually control each lamp through various settings The controls operation flow diagram is shown in Figure 21 LAMP CONTROLS OPERATION WHITE BLACK OUT COLOR BLACK OUT COLOR COLOR RAINBOW PANEL do Output Wintensity Signal to Current Lamp Output Wintensity 0 to Current Lamp Output Set Wfade 1 CIntensity O to COLOR PANEL EN p Ww Set Cfade 1 et Rainbow Current Lamp SCRENE Send RGB Values to Current Lamp D Figure 21 Lamp Controls Operation Flow Diagram 4 5 2 2 PIC Programs The LEDmote project needed three different types of programs written for the two different types of microcontrollers One program called LEDmote Zigbee Remote Control was written and programmed onto the remote control processor the PIC18F4620 which controlled one Zigbee node The next program called LEDmote Zigbee Coordinator was written for and programmed onto the PIC18F462
57. A brief section of calling the different function prototypes was found after the defining of variables and then the main function which was the real program that runs everything Even though the main function has been called some more initialization needs to be done A function named Hardwarelnit was Called to run which was used to initiate the pins to input and output and also enabled other registers that configure the processor to do specific operations 4 5 2 2 2 2 Hardware Initialization In the Hardwarelnit function the DemoRFD began by setting the processor in order to talk to the Zigbee processor chip This essentially means that it was setting the pin directions for the Serial Port Interface The next section looks at how this function sets up the processor to deal with interrupts 4 5 2 2 2 3 Interrupt Initialization Step 1 requires that the interrupt flag bit be cleared This is done by the line INTCONbits RBIF 0 59 The first part of this line INTCONbits refers to the register INTCON short for the first Interrupt Control Register This register was filled with bits and flags that were used to specify which type of interrupt were to be used and also flags that were checked to see if an interrupt had occurred The second part of the line RBIF refers to a flag bit used for interrupts RBIF is a flag bit that is set to 1 if a change in PORT RB4 7 has occurred For example if RB4 is pushed input RB4 changes from 1 to 0 and
58. AB tries to simulate what the processor would be doing Both of these debuggers were very useful in programming the processors Another nice feature that MPLAB supports is the use of Breakpoints These can be set anywhere in program and would pause the debugger so that you can then start stepping through the program The last feature used in testing the PIC programs was the Watch Window This window allowed the user to select any variable or port on the processor and see what value it is currently at 8 Conclusion 8 1 Recommendations 8 1 1 Bluetooth The team was able to get the Bluetooth dongle kits working together Unfortunately given time constraints the Bluetooth was not connected to the final prototype The microprocessor was operational until just days before the senior design night The team feels that another couple weeks that Bluetooth would have been implemented and fully operational The PC software was Bluetooth ready The utilization of the Bluetooth framework library made the connection process with visual basic seamless Unfortunately given no hardware to communicate with this PC functionality was not implemented In retrospect the team feels that they should have started the development kit prototype a couple weeks earlier in order to implement Bluetooth 8 1 2 Working PCBs The team recommends the addition of a 10MHz oscillator to clock the microprocessors on all the PCBs This allows the processors to run at a faster rate and so
59. End Sub Save New Master Lamp Criteria Private Sub Check Criteria End Sub Map all variables to MAIN and Load the MAIN Screen Private Sub Create User Interface LEDmoteControl Show XVI LEDmoteControl Setup Screne Me Hide End Sub End Class 10 4 2 Schedule Screen Scheduler Setting General C DISABLED PRESET 1 C PRESET Time 02 00 PM PRESET3 Enable Recurrence Recurrence C Daily Recur every 1 A week s on Weekly Sunday Wednesday Monday Thursday Tuesday Friday sols Saturday C Monthly OK Cancel Imports System Windows Forms Public Class Schedule Private Sub Form Load MsgBox Test End Sub Private Sub OK_Button_Click ByVal sender System Object ByVal System EventArgs Handles OK_Button Click Me DialogResult System Windows Forms DialogResult OK End Sub Private Sub Cancel Button Click ByVal sender As System Object ByVal e As System EventArgs Handles Cancel_Button Click Me DialogResult System Windows Forms DialogResult Cancel End Sub Private Sub Disabled_CheckedChanged ByVal sender As System Object ByVal e As System EventArgs Handles Disabled CheckedChanged If Disabled Checked True Then Me GeneralGroup Visible False Me RecurrenceGroup Visible False Else Me GeneralGroup Visible True End If End Sub Private Sub Presetl CheckedChanged ByVal s
60. End Sub End Class System Windows Forms DialogResult Cancel ByVal e As System EventArgs ByVal e As System EventArgs XIX 10 4 4 LEDmote Screen LEDmote MANUAL 2 PRESET 1 4 d SETUP 9 MINIMIZE 4 HELP dk EXIT ALL LAMPS BLACK OUT BLACK OUT FADE EFFECT FADE EFFECT RAINBOW EFFECT Imports System IO Public Class LEDmoteControl Inherits System Windows Forms Form Public Sub Setup Screne CurrentMode MANUAL NewMode MANUAL CurrentLamp ALL LAMPS NewLamp ALL LAMPS WhiteIntensity Text WhiteBar Value 100 50 amp Me BTN_PRESET1 Text PresetlName Me BTN_PRESET2 Text Preset2Name Me BTN_PRESET3 Text Preset3Name Change Mode Show Number Of Lamps End Sub Private Sub Show Number Of Lamps Me BTN_0 Enabled False Me BTN_1 Enabled False Me BTN_2 Enabled False Me BTN_3 Enabled False Me BTN_4 Enabled False Me BTN_5 Enabled False Me BTN_6 Enabled False Me BTN 7 Enabled False Me BTN_9 Enabled False Me BTN 0 BackColor Me BTN_1 BackColor Me BTN_2 BackColor Me BTN_3 BackColor Me BTN_4 BackColor Me BTN_5 BackColor Me BTN_6 BackColor Me BTN_7 BackColor Me BTN_9 BackColor Me BTN 0 ForeColor Me BTN_1 ForeColor Me BTN_2 ForeColor Me BTN_3 ForeColor Me BTN_4 ForeColor Me BTN_5 ForeColor Me BTN_6 ForeColor Me BTN_7 ForeColor Me BTN_9 ForeColor If NumberOfLamps gt 0 Me B71 Me B71
61. F transceiver a lot of things had to be considered when laying out the board The MRF24J40 Datasheet mentions everything that should be considered in the designing of a RF board The datasheet also provided a suggested layout for the Zigbee chip so the design that was approached was to follow Microchips design as closely as possible The final layout is shown below in Figure 3 LEDmote REMOTE Figure Remote Control PCB Design 3 5 3 Control Lamp 3 5 3 1 Power Supply The power supply for the lamp was designed a lot differently than in the remote control The lamps were designed to be plugged into a 120V 60Hz or 240V 50Hz wall socket So the first step was to send the voltage through a switch mode power supply which would cut the voltage down to 12V DC The 18 power supply that was chosen was a ETS120400UTC P5P SZ made by CUI Inc From the datasheet it was found that this power supply could handle currents of up to 50A This was a little over kill because currently the LED array draws little less than 25A It was chosen a little high in case more LEDs were needed in the future which would ultimately draw more current This power supply would then output 12V as stated above which would be used to drive the 12V LED array But another step down in voltage was needed before it could be run to the microprocessors which ran at 3 3V To make this step down the same voltage regulator that was used in the remote control was again used
62. FWhite PLEDWhite 171 W MaxCalePp Epwhite VFWhiteMin MaxCurrenty Ep white ppwhite 2 062 W _ Epwhite MaxCalcPr Epwhite PMarginy EDWhite ene ite 3 TRANSISTOR i CURRENT AND MARGIN VEWhiteMin Ros 44 1 Ros 44Tolerancd 4 MaxDutyCyclewpite 5 MaxCurrenty 2 494 CurrentMargin T 16 864 C GREEN LED CIRCUIT CALCULATIONS 1 RESISTORS i OHM Source FGreen Electr Rj gcajc7 440 Q FGreen Ry gMax 7 8 Ry Tolerance gMax7 446420 R1 gMin R1 8 1 Ri 437 580 ii CURRENT 2 VFGreenMin MaxDutyCycleg een 1 8 MaxCurrentp 8 16 29mA iii POWER g 8 8 0 117W MARGINS PRatingp 87 8 PMargittg 8 PMarging 87 53 086 2 LED i CURRENT amp MARGIN VEGreenMin Rig MaxCurrenty EDGreen 21 719mA IEGreenMax MaxCurrentr CurrentMarginy EDGreen IEGreenMax EDGreen 13 122 ii POWER AND
63. HANGI SetDCPWM2 pwm2 dc case GREEN_DOWN GREEN DOWN PORTDbits RD4 1 1 pwm2 dc lt DC MIN else pwm2 dc pwm2 dc G CHANGE SetDCPWM2 pwm2 dc break case BLUE_UP BLUE UP PORTDbits RD3 1 if pwm3 dc gt DC MAX else XLVII pwm3 dc pwm3 dc CHANGI SetDCPWM3 pwm3 dc Lu break case BLUE_DOWN BLUE DOWN PORTDbits RD3 1 if pwm3 dc lt DC MIN T else pwm3 dc pwm3 dc B CHANGE SetDCPWM3 pwm3 dc break case COLOR_UP COLOR UP PORTDbits RD2 1 if pwml_dc gt DC_MAX if pwm2 dc gt DC MAX if pwm3 dc DC MAX else pwm3 dc pwm3 dc B CHANGI SetDCPWM3 pwm3 dc Gl break case COLOR_DOWN COLOR DOWN PORTDbits RD2 1 if pwm3 dc lt DC MIN else pwm3 dc pwm3 dc B CHANGE SetDCPWM3 pwm3 dc default break if PowerFlag bits Power 1 XLVIII PowerFlag bits Power 0 if power_status power_status 1 Set up the Period for the PWMs period Ox0F 1 period Sets the period for PMW1 Jur OpenPWM2 period OpenPWM3 period OpenPWM4 period OpenPWM5 period Extra Setup for Special PWM Registers ECCP1 ECCP2 ECCP3 SetOutputPWM1 SINGLE_OUT output_mode SetOutputPWM2 SINGLE OUT output mode SetOutputPWM3 SI
64. IC18F87H0 PIC18F87H0 SPI 24140 Amplifier LED Array Computer Program Figure 2 Original Design Block Diagram 3 5 2 Remote Control The remote control was designed to allow the users to communicate to any 16 light in the room from any position he she is standing The remote control is nice feature to have with this lighting system because it does not limit the user to any distance from a light but at the same time it was designed for limited operability of the lights 3 5 2 1 Power Supply The remote control was designed to use 2 AA batteries which would produce a 4 5 V output onto the board This was a little high because the processor and Zigbee module were specified to run at 3 3 V To knock down the voltage to a tolerable level for the processor to handle a REG103GA 3 3 linear voltage regulator was used The datasheet for this regulator states that this voltage regulator can take an input of up to 15 V This was nice to know because it can handle the input from the batteries On an added note the voltage regulator can also handle an input of 12 V which the Lamp Modules run off of This voltage regulator is also rated at 500 mA this is well above the current that the main processor and the Zigbee processor ever pull 3 5 2 2 Button Array In creating a button array for the prototype the team aimed to create an intuitive user interface A power button served as an on off switch for the display
65. IRF510 G Gate Source Figure 11 MOSFET Transistor 4 5 1 3 2 Display Lamp The display lamp came with a mounted switch as an example of the wall mounted switch as described in Section 4 2 7 The LED Array PCB was mounted in an orientation such that white light reflected effectively off the white paper backing of the display lamp and also off of the diamond plated steel used to shield observers from direct eye contact with the white LEDs Additionally two semicircular sheets of plastic were inserted in the steel plating to distinguish the color LED operation from the white LEDs The display lamp in operation can be seen in Figure 12 44 Figure 12 Display Lamp 4 5 2 Software Solution 4 5 2 1 PCSoftware As discussed in the Business Plan section the operating system used for the design of the software was Windows XP The prototype was designed on Windows XP SP2 4 5 2 1 1 Programming Language 4 5 2 1 1 1 Criteria Selecting an appropriate software programming language was vital to time expenses and functionality If an unfamiliar language was selected then more time must be spent in familiarization with the language If a tedious language was selected more time must be spent in programming the intricacies of the language Therefore one heavily weighted criterion was how familiar the team was with the language This was measured as the amount of previous experience team members had with
66. M 1 10W 5 0603 SMD RES 3 30K OHM 1 10W 1 0603 SMD RES 10 0K OHM 1 10W 1 0603 SMD INDUCTOR 3 9NH 450MA 0603 LED 1 5V BLUE WTR CLR 1210 SMD LED 1 5V RED WTR CLR 1210 SMD IC REG ULTRA LDO 150MA SOT 23 5 IC SRL EE 64K 1 8V 8TSSOP OSC 32 768KHZ 5 23PPM SMD MODULE BLUETOOTH SRL PORT 60BGA PART NUMBER TAS 4025A GRM188R71H103KA01D TACL105K010XTA TACL225M016XTA GQM1885C1H101JB01D GRM188R71C104KA01D GRM1885C1H4R7CZ01D GRM188F51A225ZE01D GRM1885C1H120JA01D GQM1 885C1 H8R2CB01D GRM1885C1H221JA01D GRM188R71H222KA01D GRM1885C1 H390JA01D GRM188F51C104ZA01D GQM1 885C1H7ROCB01D GRM188R71H102KA01D CRCW06031KOOFKEA RCO0603FR 07523RL RCO0603FR 07130RL CRCW06031KOOFKEA CRCW06031 00KF5EA RCO603JR 070RL CRCWO06033K30FKEA CRCW060310KOFKEA LQG18HN3N9S00D SML DSP1210USBC TR SML DSP1210SIC TR LP39851M5 2 8TR NOPB AT24C64A 10TE 1 8 SG 3030JC 32 7680KB3 LMX9830SMX MANUFA CTURER TEW MuRata AVX Corporation AVX Corporation MuRata MuRata MuRata MuRata MuRata MuRata MuRata MuRata MuRata MuRata MuRata MuRata Vishay Dale Yageo Co Yageo Co Vishay Dale Vishay Dale Yageo Co Vishay Dale Vishay Dale MuRata Lumex Opto Lumex Opto National Semiconductor Atmel Epson Hectronics National Semiconductor UNIT BULK TOTAL BULK PRICE 0 48000 0 00882 1 04000 1 04000 0 27800 0 01476 0 01134 0 02754 0 01134 0 21400 0 01656 0 00666 0 01134 0 00882 0 21400 0 00936 0 00400 0 00480 0 00480 0 007
67. MARGIN PLEDGreen FGreen PLEDGreen 94mW MaxCalcPr gpGreen m GreenMin MaxCur rent ED Greer MaxCalcPp EDGreen 65 158mW gpGreen MaxCalcH PMarginy reen PMargin LEDGreen 23 343 3 TRANSISTOR i CURRENT AND MARGIN Vi V M F M MaxCurrentp CMS 8 MaxCurrenty 130 317mA 4 2 CurrentMargin Idp 4 CurrentMargin 67 421 D BIUE LED CIRCUIT CALCULATIONS 1 RESISTORS i OHM Vsource VEBlue 16 4100 FBlue 16 16 1 Ro 16Tolerance Ro 16 416 129 Ro 16Min Ro 16 1 Ro 16Tolerance Ro 16Min 407 880 ii CURRENT VEBlueMin 165 MaxDutyCycle pjye Ro 16 16 17 476mA iii POWER MaxPro 16 16 MaxCurrentpg a MaxPgo 167 0 126 W XI MARGINS 16 16 PMargin Bing 16 PRatingpo 16 2 LED i CURRENT amp MARGIN VEBlueMin Ro 16 MaxCurrenty 23 301mA MaxCurrentr EDBlu e IFBlueMax MaxCurrenty CurrentMarginr EDBlue CurrentMargin gpp ue 6 796 ii POWER AND MARGIN PLEDBlue lFBlue PLEDBlue 76mW MaxCalcPr MaxCu
68. N SCHEDULE Click Schedule ShowDialog If Schedule DialogResult Windows Forms DialogResult OK Then If Schedule Presetl Checked True Then ScheduleSetting Preset 1 Elself Schedule Preset2 Checked True Then ScheduleSetting Preset 2 ElseIf Schedule Preset3 Checked True Then ScheduleSetting Preset 3 Else ScheduleSetting Disabled End If If Schedule Disabled Checked False Then If Schedule RecurrenceEnabled Checked False Then Recurrence None Else If Schedule Yearly Checked True Then Recurrence Yearly ElseIf Schedule Weekly Checked True Then Recurrence Weekly ElseIf Schedule Monthly Checked True Then Recurrence Monthly Else Recurrence Daily XXIX End If End If Call SetTimerLength End If End If End Sub Private Sub ScheduleTimer Elapsed ByVal sender As Object ByVal e As System Timers ElapsedEventArgs Handles ScheduleTimer Elapsed If TimerLength 0 Then Perform Timer Operation and Reset TimerLength If ScheduleSetting Preset 1 Then NewMode Preset1Name Call ElseIf ScheduleSetting Preset 2 Then NewMode Preset2Name Call Change Mode ElseIf ScheduleSetting Preset 3 Then NewMode Preset3Name Call Change Mode End If If Recurrence None Then Else Call SetTimerLength End If End If TimerLength TimerLength 1 End Sub Private Sub SetTimerLength Dim D1 D2 DTest As Date Dim DayOfWeek DayOfMonth MonthOfY
69. NGLE OUT output mode E Reset duty cycle for PWMs pwml dc C INITIAL pwm2 dc C INITIAL pwm3 dc C INITIAL pwm4_dc W INITIAL pwm5 dc W INITIAL Set Duty Clcle for PWMs SetDCPWMA pwm4 dc White PWM SetDCPWM1 pwml dc Red PWM SetDCPWM2 pwm2 dc Green PWM SetDCPWM3 pwm3 dc Blue PWM SetDCPWM5 pwm5 dc Extra PWM else if power_status 1 power_status 0 ClosePWM1 ClosePWM2 ClosePWM3 ClosePWMA ClosePWM5 end power flag if XLIX end while end main pragma code pragma interrupt InterruptHandlerHigh void InterruptHandlerHigh 0001 POWER FLAG 1 INTCON3bits INT3IF 6 Resent Flag Bits to 0 INTCONbits INTOIF 0 INTCON3bits INT1IF 0 INTCON3bits INT2IF 0 INTCON3bits INT3IF 0 PowerFlag bits Power 1 if INTCONbits RBIF INTCONbits RBIF 0 fi PowerFlag bit Power 1 INTCONbits GIEH 1 77 void USARTInit void Synchronous USART Setup TXSTA1 SYNC RCSTA1 SPEN 5 1 5 INTCON3bits INT2IF amp INTCON3bits INT1IF amp INTCONbits INTOIF Set Power Flag 5 Asynchronous USART Setup 5 1 1 Set BAUD Rate TXSTAlbits BRGH 0 BAUDCON1bits BRG16 0 SPBRG1 0x07 TXSTAlbi
70. NewLamp 4 Byte Integer CType CType CurrentArray NewLamp 5 Byte Integer End If The code above took the values stored for the selected lamp and displayed them in the lamp controls Later in the code the background color of the buttons was adjusted to show which lamp had been selected 4 5 2 1 2 3 4 MODE BUTTONS The PC Control Console V1 0 has four mode buttons Manual Preset 1 Preset 2 Preset 3 When the manual button or preset buttons were pressed the following code was executed Private Sub MANUAL Click ByVal sender As System Object ByVal As System EventArgs Handles BTN MANUAL Click NewMode MANUAL Call Change_Mode End Sub The system contained two global variables and NewMode When a mode button was pressed the NewMode variable was changed to the desired mode The operation structure and code are displayed below in Figure 18 52 Private Sub Change_Mode Select Case CurrentMode Case CurrentArray Case Preset2Array CurrentArray Case Preset3Name Preset3Array CurrentArray Case Else End Select Select Case NewMode Case PresetiName Me BTN_PRESET1 Enabled False Me BTN_PRESET2 Enabled True Me BTN_PRESET3 Enabled True Me BTN_MANUAL Enabled True CurrentArray 1 Case Preset2Name Me BTN_PRESET1 Enabled True Me BTN_PRESET2 Enabled False Me BTN_PRESET3 Enabled True Me BTN_MANUAL
71. OME BEFORE TAXES 358 998 85 Income Tax 143 599 54 NET INCOME 215 399 31 6 Project Management 6 1 Team Management The team was organized with no designated leader but with a top rocks system to ensure accountability Such a system is used by Innotec and other companies It works by having each member work on a small daily task which they list on a whiteboard At each top rocks meeting the individuals are asked how they have progressed on their task and if incomplete what they need to get it done The team helped each other out a lot during the project with the result that while one person may have been focusing on a large aspect of the project they were often supported at various times by one or more other team members 78 6 1 1 Chris Kreft During the first semester Chris was responsible for researching and selecting from the amplifier alternatives He was also responsible for deciding on how centralized or distributed the power and control systems would be and the layout for the remote control He was also responsible for writing sections of the PPFS During the second semester Chris initially did research on switch mode power supplies Ultimately however the team decided that due to time constraints they would purchase rather than build a power supply Chris checked over the layout of the control lamp base layout before printing and worked with Dustin and Dan to solder parts to the boards Chris also worked on the PIC micr
72. Osram Tri color LED Datasheet 27 3 7 Production Design Requirements The prototype built by Team LEDmote is designed to lead into a production phase implemented by Innotec 3 7 1 Requirements Please refer to the LEDmote PC Control Console User Manual to determine production requirements for the PC 3 7 2 Electrical Requirements Some flexibility was allowed in the production design electrical requirements to adjust the intensity of the LEDs However it was assumed that once a base current had been chosen little deviation would occur from this set current so that all intensity adjustments were implemented through the PWM instructions of the MCU As can be seen in Table 3 the prototype common current was set at 1 58A although this can be adjusted up to a maximum of 5A depending on the product s unique requirements The voltage across the LEDs should not exceed 25V 3 7 3 LED Enclosure Requirements While building the prototype Team LEDmote did not study in depth the casing and reflective elements of a production system There are many varieties of lamp fixtures that could potentially be designed to house the LEDs of each lamp module In the case of room lighting such fixtures should be used to distribute and diffuse the light evenly throughout a room In both the room lighting case and the direct lighting case for example in the use of the system in a desk lamp direct exposure of the eyes to the LEDs should be avoided From i
73. PC user interface The semester was completed with setup for design night and completion of the final report 6 2 Schedule The team set a very aggressive schedule as advised by the team mentor at Innotec This aggressive schedule was set up around a few key events The Milestones Microsoft Project file is shown in Section 10 1 The milestones began with February due dates for the design of the hardware This included design of the circuits and layout of PCBs The hardware design went a little behind schedule delaying the team a week After finishing preliminary hardware design the team moved on to software design This was planned to fill the void between ordering and receiving hardware The hardware was received in time for spring break so much of that week was spent soldering and testing Unfortunately we were unable to get working hardware by March 30 as set in the schedule After a few extra weeks of debugging beyond March 30 it was decided that the team would move to the backup plan and work on getting a prototype working on development kits At this point the team shifted its major focus to the development of working software As shown in the Milestones schedule the plan was to have a working and tested prototype a full two weeks before the final presentation of the project These two weeks would then be dedicated to rounding out the project and finalizing the documentation aspects of the project Unfortunately setbacks caused t
74. RBIF would then be set to a 1 RBIF was then checked on every clock and if was set to 1 the processor would check a register at location 0x08 to see what it should Step 2 requires that PORTB pull ups be enabled This is done by the line INTCON2bits RBPU 0 The first part of the line INCON2bits refers to another register that controlled the interrupts The second part RBPU refers to the bit of that register that enabled the pull ups for PORT B This is important because it allowed the processor to correctly read the signals coming into the chip Step 3 requires that PORT is set to an input This be done by the line TRISBbits TRISB4 1 TRIS is the command for any PIC processor that sets the direction of any PORT on the processor TRISBbits refers to struct that was set up in the header file of the processor and this struct refers to the TRIS of PORT B The second part of this line TRISB4 refers to the specific bit of this struct This line of code set RB4 to an input because it was set to a 1 likewise if it were set to 0 the PORT would then become an output This concludes the Hardwarelnit function but there are two more steps that must be considered to set up the interrupts that should be discussed here Step 4 sets PORTB to be of high priority This can done by the line RCONbits IPEN 1 This is used more commonly when there are more than one kind of interrupt driven processes in the program This pr
75. School from pre school to eighth grade and after that obtained a high school education at Grand Rapids Christian High School After high school he chose to attend Calvin College for a pre architecture degree After a year he switched into the electrical and computer engineering program Ryan is currently in his fifth year at Calvin and plans to graduate in May 2007 He currently serves as an intern at Beta Integrated Concepts and also grades and lab assists for a microelectronics class He plans to work for Alticor after graduation Dustin Veldkamp was born and raised in southwest Minnesota He brought business background education and experience to the group He graduates in May 2007 from Calvin College with degrees in Business and Engineering Dustin worked with Tom Veenstra and was the team s main liaison with the company He plans to work for Gentex once he graduates Figure 1 Team LEDmote 1 5 Engineering 339 and 340 Engineering 339 and 340 are classes offered by Calvin College in the Fall and Spring respectively of each year The classes are collectively called Senior Design and are a unique opportunity for Calvin engineering students to get hands on experience with a real engineering project under the supervision of four engineering professors one from each of the four engineering concentrations offered at Calvin While working on their projects the team members also receive instruction in using Christian design norms to i
76. Sides 7 252 Individual Buttons 7 269 Scroll Wheel like iPOD 7 243 4 2 4 Amplifier Decision In researching the amplifier alternatives and in discussions with Mr Veenstra the team determined that an ideal solution could be reached by using a combination of the first and third alternatives i e using a high power transistor to output the necessary current together with PWM to vary the brightness S All About Circuits PWM power controller 2003 lt http www allaboutcircuits com vol_6 chpt_6 9 html gt 31 Table 4 4 Amplifier Decision Matrix 2 5 E o a s 219 55 8 2 o 5 SON gt lt Weights out of 10 ______ Switch Alternatives High power transistor 8 7 289 Operational 8 5 209 Amplifier DCP Pulse Modulation 8 9 10 357 4 2 5 Power Decision Similarly to the decision matrix for the control system the power system decision matrix showed very little difference between the two options A centralized system is probably more cost effective than a distributed system because it minimizes the number of power supplies The team chose to use distributed power supplies on each of the lamp modules since a centralized power supply would require the technicians who installed the lighting system to do additional wiring beyond that which the room already contains By using a system that has both distributed power and distributed control the overall lighting system has ma
77. Sw itches Red Sw itches Green Switches White Sw itches Connector Microcontroller Enclosure Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Crystal Oscilator Zigbee Chip Resistor Resistor Inductor Inductor Inductor Oscillator Connector Voltage Regulator Capacitor Capacitor Capacitor Diode Inductor DESCRIPTION Holds AA Batteries for remote Color Brightness Pow er On Off Switch Blue Switches for Blue coloration Red Sw itches for Red coloration Grn Sw itches for Grn coloration White Brightness Conn Mod Jack 6 6 R A PCB 50AU IC PIC MCU FLASH 32KX16 64TQFP CASE STY BAT GRY 6 7 x 3 3 x 1 33 CAP CER 3PF 50V COG 0402 CAP CER 5PF 50V COG 0603 20PF 50V 5 COG 0603 CER 27PF 50V 5 COG 0603 CAP CER 47PF 50V 5 COG 0603 CAP CER 10000PF 16V 10 X7R 0603 CER 1UF 16V Y5V 0603 CAP CER 180PF 50V 5 0603 CAP CER 2 2UF 10V Y5V 0603 CAP CERAMIC 7PF 50V 0603 CRYSTAL 20 000MHZ 18PF FUND SMD IC TXRX IEEE ZIGBEE 2 4GHZ 40QFN RES 0 0 OHM 1 10W 5 SMD RES 10K OHM 1 10W 5 0603 SMD INDUCTOR MULTILAY ER 4 7NH 0603 INDUCTOR MULTILA Y ER 5 6NH 0603 INDUCTOR MULTILA Y ER 10NH 0603 OSC 32 768KHZ 54 23PPM SMD Conn Mod Jack 6 6 R A PCB 50AU IC STP DN SW VOLT REG 3 3V 16DIP CAP ELECT 100UF 16V VS SMD CAP ELECT 330UF 6 3V VS SMD CAP CER 10UF 6 3V X5R 0603 DIODE SCHOTTKY 40V 1A SOD123 INDUCTOR MULTILA Y ER 330UH 1210 PART NUMBER BC3AAW D
78. Truth Table White White Red Red Green Green Blue Blue Color Color power Up Down Up Down Up Down Up Down Up Down Y1 X2 1 3 2 1 2 2 2 3 Y2 X4 Y3 X1 Y3 X2 Y3 X3 Y3 X3 A 1 0 1 0 1 0 1 0 1 0 1 B 0 1 1 0 0 1 1 0 0 1 1 0 0 0 1 1 1 1 0 0 0 0 D 0 0 0 0 0 0 0 1 1 1 1 7 1 5 2 Testing Once the encoder was thought to be hooked up correctly and checked over a few times some simple tests were performed to ensure the correct operation of the encoder was run Some wires were connected to output pins 16 to 19 and were then connected to an oscilloscope A power supply was then turned on and set to 3 3 volts with a max current set just above the typical current ratings for the chip Each button was then pushed and the outputs were monitored on 4 different channels to check the outputs according to the table Everything was verified to be working correctly and the outputs were right around 3 3V when active The 3 3 V posed a problem however Through testing the microcontroller in another section it was found that the inputs were active low meaning that signals are only recognized if the inputs are pulled to ground This was a problem since the processor would not recognize the outputs from the encoder correctly if at all 7 1 6 Inverter 7 1 6 1 Hook Up To solve this problem the outputs would have to be inverted Since an inverter chi
79. UCTOR MULTILAY ER 10NH 0603 OSC 32 768KHZ 5 23PPM SMD PART NUMBER TL2575 33IN ETS120400UTC P5P SZ PJ 002AH SMT DF22L 5P 7 92DS 555165 1 FDN339AN FDT461N PIC18F66J10T VPT ECE V1CA101P ECE V0JA331P GRM188R60J106ME57D 1N5819HW 7 F NLV32T 331J PF GJM1555C1HR30BB01D GRM1885C1HR50CZ01D GRM1885C1H200JA01D GRM1885C1H270JA01D GRM1665C1H470JA01D GRM188R71C103KA01D GRM188F51C104ZA01D GRM1885C1H181JA01D GRM188F51A225ZE01D GQM1885C1H7ROCB01D ABM8 20 000MHZ B2 T MRF24J40 l ML CRCWO06030000ZO0TA CRCW060310KOJNEA MLG1608B4N7S MLG1608B5N6D MLG1608B10NJ SG 3030JC 32 7680KB3 UNIT BULK TOTAL BULK MANUFACTURER PRICE Texas Instruments 0 750 CUI Inc 16 996 CUI Inc 0 360 Hirose Electronic Ltd 0 480 Tyco Hectronics AMP 0 457 Fairchild Semiconductor 0 175 Fairchild Semiconductor 0 273 Microchip 2 960 Panasonic ECG 0 106 Panasonic ECG 0 106 Murata 0 120 Diodes Inc 0 234 TDK Corporation 0 077 Murata 0 022 Murata 0 009 Murata 0 009 Murata 0 009 Murata 0 009 Murata 0 007 Murata 0 007 Murata 0 013 Murata 0 021 Murata 0 214 Abracon Corporation 1 131 Microchip Technology 3 590 Vishay Dale 0 003 Vishay Dale 0 003 TDK Corporation 0 043 TDK Corporation 0 043 TDK Corporation 0 043 Epson Hectronics 1 48632 Total Slave Component Costs PRICE 0 750 16 996 0 360 0 480 0 457 0 175 0 819 2 960 0 106 0 106 0 120 0 234 0 077 0 022 0 035 0 018 0 035 0 009
80. al main function and not in the hardware initialization The only code that was in the function was 68 TRISD 0x00 This code allowed PORT D to become outputs which would be later used for outputs as test LEDs Now that everything was initialized the main function could resume 4 5 2 2 4 4 main Function The first thing that the main function did was turn one of the LEDs on so that the user would know that the program was running whenever the LED lit up This was done by the line PORTD 0x01 The next thing that the program did was set the power_status variable to 0 This let the program know that the power of the lights was off Later it would be seen that this bit was toggled back and forth depending if the lights are on or off Next the program went into a while loop that allowed the program to continually check if any new receptions had come from the Coordinator Program The first few lines dealt with getting the information from the UART char inputstr 1 opcode 0x00 getslUSART inputstr 1 opcode inputstr 0 The first line created a character array for the data that was pulled off of the reception register and stored in positions in the inputstr array The gets1USART function probably was one of the most important functions of the program It was originally written by microchip and found in some of the example code that came with the MPLAB C18 Compiler It also was also referenced in the MPLAB C18 Library doc
81. ant to look for any low priority interrupts that are enabled At this point almost all of the initializations had been taken care of The only remaining initialization was the function call of Zigbeelnit which talked to the Zigbee chip through the recently set up SPI port set up in the Hardwarelnit function This was an important initialization but is not talked about in this report because it was assumed that Microchip was initializing the Zigbee correctly and therefore was not researched Here the processor could now be considered initialized and the main program can be talked about 4 5 2 2 2 4 main Function The majority of this function was done by Microchip who provided the demo program The interrupts were enabled and then a while loop was started early on in the function The while loop allowed the program to continually repeat itself and see if any new changes had occurred since the last run through Right after the while statement the watchdog timer was cleared This was important because if it was not cleared the processor would notice that it reached a certain value and would halt the program because it thought there was a problem After that was cleared the main portion of the program began The processor went into one big switch statement and checked the value of currentPrimitive This variable was defined by the Zigbee Stack and it was decided that it should not be modified The variable was assigned different values based on
82. ault Industrial Consultant for Engr 340 Dwight Schrute Innotec Corporation Microchip Corporation Advanced Circuits Sunstone Circuits Murata Electronics TEW 88 9 Bibliography CUI Inc Digikey 6 July 2006 29 2007 lt http www cui com pdffiles ETS120400UTC P5P SZ pdf gt Fairchild Semiconductor Fairchild P N FDS8926A 2007 Fairchildsemi com 8 2007 http www fairchildsemi com pf FD FDS8926A html Fairchild P N FDS6570A 2007 Fairchildsemi com 8 May 2007 http www fairchildsemi com pf FD FDS6570A html Fairchild P N MM74C922 2007 Fairchildsemi com 8 May 2007 http www fairchildsemi com pf MM MM74C922 html Mouser Electronics Product Finder 2007 Mouser com 8 May 2007 http www mouser com search refine aspx Ntt 512 MM74CO4N gt Microchip Technologies Inc MRF24J40 Datasheet 8 December 2006 Microchip com Mrach 2007 lt http ww1 microchip com downloads en DeviceDoc 39776a pdf gt PIC18F67J10 2007 Microchip com 8 May 2007 lt http www microchip com stellent idcplg IdcService SS_GET_PAGE amp nodeld 1335 amp dDocName en02 0089 gt Microchip Technology Inc PICDEM HPC Explorer Board 2007 Microchip com 8 May 2007 http www microchip com stellent idcplg IdcService SS PAGE amp nodeld 1406 amp dDocNamezen52 0448 Microchip Technology Inc 965 Microchip Stack for the Zigbee Protocol 2007 Microchip com March 2007 lt http
83. ceesesssaeeeeecsseseseseaeeeeeessessesssaeeesens 59 Table 24 Project Forecast i he ertet te Ae 61 Table 25 Actual HOUMS 62 Table 26 Comparison able i is ate es 62 27 63 Table 28 Initial PCB Test 64 Table 29 Encoder Chip Truth 65 vii 1 Introduction 1 1 The Project Team LEDmote designed and prototyped a wirelessly controlled lighting system using multicolor LED lights This lighting system was designed with flexibility in mind so that it can be marketed in a variety of applications including conference room theater and home lighting Wireless control was designed to be available through a remote control device and also via computer software which could be loaded either onto a wireless compatible laptop brought into a room or onto a wirelessly compatible local desktop computer located in the room The lighting system provided a range of color options to the user and provided a variety of settings for light intensity The lighting system can be implemented by using a number of light fixtures distributed throughout a room 1 2 Innotec Project LEDmote was supported by Innotec Corporation located in Zeeland MI Innotec is a growing company that designs and builds automated systems for the automobile industr
84. cles define INITIAL 500 define R INITIAL 500 define G INITIAL 700 define B INITIAL 300 These values could be set from a range of to 900 depending on the initial condition that was wanted With the settings shown above the white LEDs were set to half power and the mixture of the red green and blue that was chosen would turn the lamp a nice shade of green Next a set of minimum and maximum constants were defined define DC MAX 900 define DC MIN 75 The values were set based on a few tests performed on the pulse width modulation outputs When the duty cycle was constantly turned up the pulse would roll over back to zero creating an malfunction in the operation of the light The light would roll over close to a duty cycle of 1000 so a maximum value was set to 900 so that it would not create a problem The minimum was set to 75 also to prevent a malfunction when turning the LEDs down However it was found that when the duty cycle was turned all the way down it would not malfunction and simply just bottom out This could have been excluded but was left in case of a future error The last set of constants defined were define W CHANGE T5 define CHANGE 100 define G CHANGE 100 define B CHANGE 100 This set of constants would ultimately determine how many different colors the light could produce With the defined period talked about above it allowed the duty cycle to be set from 0 to 1000 The change constants define
85. d the optimal values and tolerances for the resistors This analysis can be seen in Appendix 10 3 Figure 4 LED Array 3 4 3 5 Lamp Base PCB The lamp base printed circuit board was designed much in the same way as the remote control circuit board With the development kit that was purchase for the LMX9830 some of the software that came with the kit provided the prints for the four layers of the development kit These prints were replicated as close as possible just like the PIC18F87J10 and the MRF24J40 were before Also a bit of concern was created by the use of two RF modules on one board The solution that was proposed by the team was to put the two RF modules as far away as possible From Figure 5 it can be seen that the Bluetooth was populated near the top left and the MRF24J40 located at the bottom middle of the board 15 Figure 5 Lamp Base 3 4 4 Secondary Lamps The secondary lamps do not need any more explaining because they are basically just a striped down Control Lamp The secondary lamps do not need a Bluetooth unit because these lamps just rely on the Zigbee modules to communicate to the rest of the lamp network Complications PCB of Non Remote working 3 5 No Connection to main MCU Also see Section 4 3 Device PCB of Original Design Remote Device 3 5 1 Overview Remote Control Button Array 1 PIC18F87110 Control Lamp Secondary Lam LMX9830 MRF241J40 SPI P
86. d the communication from itself to the PWM program The UART was selected as the best option for this operation In order to use the UART it had to be initialized properly A function was written specifically to initiate the UART for the proper settings that were needed This function was called right at the beginning of the main function and right before the Hardwarelnit function was called In order to set up the UART the PIC18F4620 Datasheet was referenced On page 211 there are specific directions on what registers and bits had to be set to perform an asynchronous transmission The first step that had to be taken was to setup the Baud Rate of the UART This could be configured using the table on pg 207 shown below in Table 10 Table 10 Baud Rates SYNC 0 BRGH 1 BRG16 0 BAUD Fosc 4 000 MHz RATE Actual SPBRG 96 K Rate value K decimal 0 3 1 2 1 202 16 207 2 4 2 404 16 103 9 6 9 615 16 25 19 2 19 231 16 12 57 6 62 500 8 51 3 115 2 125 000 8 51 1 This table gives a listing of all the different clocks that the processor could be run at and what were the proper settings for the desired baud rate The first bit of information that was determined was the oscillator frequency on the PICDEM Z board This was found by inspection of the board to be 4 00MHz The desired baud rate that the UART was to be set to was 19200 and in order to get this baud
87. des For added flexibility the user could also change the settings of individual lamps as well Permitting that there was adequate time for design the software would also include a lighting schedule With the lighting schedule feature the user could select what color and brightness the lights would be at any time of the day The lights would then automatically turn to these presets at the appropriate times 3 1 2 2 PIC program for Lamp Base The Lamp Base PIC MCU software was intended to manage the incoming signals from both the Bluetooth and Zigbee transceivers decode them and change the duty cycle of the pulse width to the appropriate setting 3 1 2 3 PIC program for Remote Control The Remote Control PIC MCU software was intended to receive the button inputs and send out a wireless message that corresponds to the button pressed 3 2 Design Norms Throughout the design process the team was concerned with how the design of the system correlated with Christian values One way to do this was to identify the design norms that could apply to the project Design norms are general principles that give an ethical guideline for a project and ensure that technology is truly in service of God and society The design norms chosen for this project were transparency harmony and stewardship Transparency appeared in the project in both hardware and software In the hardware the remote control was user friendly allowing a user to easily identify how to
88. directly input into 11 different I O Ports on the processor 3 5 2 4 Zigbee Chip Originally the Freescale Semiconductor MC13192 was used This Zigbee chip seemed to be the best chip that we could use at the time that we researched 17 it It was found to be able to connect to a large variety of microcontrollers through a SPI connection which the PIC18F87J10 supports So at the time it was assumed that the Zigbee protocol stack could have been loaded onto the PIC18F87J10 Although it was assumed that the MC13192 would be able to work with the PIC18F87J10 it was hard to find support for doing this Then around January another chip made by Microchip was released The Zigbee Chip that was selected was the MRF24J40 There was a lot more support for this chip and Microchip has its own Zigbee Protocol Stack specifically designed for PIC18F Microcontrollers The support for loading the stack onto a PIC18F processor can be found in the AN965 Microchip Stack for the ZigBee Protocol Datasheet This chip was selected because microchip fully supports this Zigbee chip with the PIC18F87J10 This Zigbee chip was designed to connect through the SPI port on the PIC18F87J10 and was also designed to send out a clock output for the PIC18F87J10 to use 3 5 2 5 Remote Control PCB Design After all research was done on all of the different components that attached to processor and the Zigbee chip a printed circuit board was created Since the Zigbee is an R
89. dual lamp The breakdown of the array components are listed below in Figure 16 49 System Array Settings Current irray Lamp Variable Variable Lamp Name White Intensity Color Intensity Red Green Blue White Fade Color Fade White Blackout Color Blackout 10 Rainbow Effect Q O0 1 Figure 16 System Array Settings Each function and control in Figure 15 was broken down into the sections below to explain their function and codes 4 5 2 1 2 3 1 CREDIT DIALOG CREDIT DIALOG LOAD Load Criteria From Data txt File into Array User Select Master Lamp From Devices Search For Bluetooth Devices Master Lamp Found Load current information from all lamps into array Setup all variables for control screen Hide Credit Load Control Dialog Screen Form Figure 17 Credit Dialog Form Process Flow 50 During the credit dialog process flow the program began by loading the data txt file into the system array An excerpt from the data txt file is pasted below OH 18 0 255 128H 0 False False False False False O 18 0 255 128 0 False False F alse False False O 18 0 255 128 0 False False The system array was set up as the storage structure for the lamp settings and values The was used as the delimiter separating the variables Once this file was
90. dule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 1 End If Case Else D2 Now EndLoop True End Select Loop Case Else D2 Schedule Datel Value amp amp Schedule timel Text amp End Select TimerLength DateDiff DateInterval Minute D2 End Sub Private Sub BTN HELP Click ByVal sender As System Object Help Show End Sub End Class 10 5 PIC PWM Program p18f87310 h lt pwm h gt lt stdio h gt lt usart h gt include include include include CONSTANTS ByVal e As System EventArgs AddNumberOfMonths MTest AddNumberOfMonths MTest amp Schedule AMPM1 Text amp amp 5 Schedule timel Text amp amp Schedule timel Text amp Handles BTN_HELP Click XLII define CLOCK_FREQ define BAUD_RATE define SPBRG_VAL define POWER define WHITE_UP define WHITE DOWN define RED UP define RED DOWN define GREEN UP define GREEN DOWN define BLUE UP define BLUE DOWN define COLOR UP define COLOR DOWN define W define C define DC MAX define DC MIN define W CHANGE define R CHANGE define G CHANGE define B CHANGE define ConsoleIsPutReady define ConsoleIsGetReady typedef unsigned char BYTE APPLICATION VARIABLI union struct ES unsigned Power unsigned None 10000000 19200
91. dule Alternatives Decision Matrix sees 10 Table 4 2 Lighting Alternatives Decision 11 Table 4 3 Button Alternatives Decision 12 Table 4 4 Amplifier Decision 12 Table 4 5 Power Decision 13 Table 4 6 Control Decision Matrix 14 Table 4 7 Wall Switch Decision 14 Table 4 8 Programming Language Decision Matrix sesenta 27 Table 12 Button Command 5 39 Table 13 Rates tree eoe teres 45 Table 14 Baud nete ee t ect to et eee eee EE Le sine 49 Table 15 Product Launch Costs iier cet eode eere ce bert eet Pneu eee ound 53 16 lt e RT et Pd egi e rasta E ree Woes ENS 54 Table 17 Product Launch Annual Amortization Schedule 54 Table 18 Desk Lamp Cost Analysis 55 Table 19 Conference Room Cost Analysis 56 Table 20 Annual Sales Projections 56 Table 21 First Year Projected Income Statement 57 Table 22 Second Year Projected Income Statement 58 Table 23 Third Year Projected Income StatEMeNt ccccccccccsssesssececece
92. e False Me GroupWeekly Visible False Me GroupYearly Visible False End If End Sub Private Sub Weekly CheckedChanged ByVal sender As System Object Handles Weekly CheckedChanged If Weekly Checked True Then Me GroupMonthly Visible False Me GroupWeekly Visible True Me GroupYearly Visible False End If End Sub Private Sub Monthly CheckedChanged ByVal sender As System EventArgs Handles Monthly CheckedChanged If Monthly Checked True Then Me GroupMonthly Visible True Me GroupWeekly Visible False Me GroupYearly Visible False End If End Sub Private Sub Yearly CheckedChanged ByVal sender As System Object Handles Yearly CheckedChanged If Yearly Checked True Then System Object ByVal e As System EventArgs ByVal e As System EventArgs As ByVal e ByVal e As System EventArgs XVIII End End Sub End Class Me Me Me GroupMonthly Visible False GroupWeekly Visible False GroupYearly Visible True 10 4 3 Setup Screen MAIN MENU BUTTON NAMES PRESET 1 PRESET 1 PRESET 2 PRESET 2 PRESET 3 PRESET 3 Imports System Windows Forms Public Class Setup Private Sub OK_Button_Click ByVal sender System Object Handles OK_Button Click Me DialogResult End Sub Private Sub Cancel_Button_Click ByVal sender As System Object System Windows Forms DialogResult OK Handles Cancel Button Click Me DialogResult Me Close
93. e MCU of 10MHz Therefore the MCU was unable to function properly and did not acknowledge itself when contacted by the ICD2 programmer In EC mode the 2 5MHz crystal can be run but only thing is that few of the peripherals may run very slow 25 This quote from Microchip support and data from the Microchip data sheet lead the team to believe that correct connection to the chip was not attainable while receiving a 2 5MHz clock from the Zigbee module The chip ran properly as detected from the clock division output This output provided a frequency output clock which was successfully determined through views on an oscilloscope All VCC inputs were receiving proper voltages and all GND inputs were grounded However when addressed by the program the chip did not respond with an identification code as the chip on the development board did Microchip Technology Inc 2 Support Response 4 6 2007 4 09 AM Microchip Support 6 Microchip Technologies Inc 39 4 4 2 Lamp Base Complications The Lamp Base also had the same issues that were designed into the remote board Also the lamp base had a short underneath the Bluetooth chip This chip was a 60 pin Ball grid array BGA measuring 6mm by 9mm leaving very little room for error As the soldering paste melted beneath the chip it was determined that a solder bridge was formed across pins that are connected to power and ground This caused the board to not power up properly and tests s
94. e distributed through various industrial and commercial suppliers Using national and international commercial and building suppliers will provide visibility for the product line Outsourcing for complex parts such as the PCB board will allow for lower launch costs along with low productions costs 5 1 5 Financial Projections 5 1 5 1 Market Price Research Market research was conducted on current market LED desk lamps and conference room lighting products The research included various suppliers in order to diversify and obtain a realistic market price for the LEDmote products The average retail price of LED desk lamps is 133 75 with a standard deviation of 69 73 LEDmote Marketing Plan Since the desk lamp is a high volume product the analysis assumes a 50 retailer markup from the production price The manufacturing sale price is 89 17 and will be used for the remaining financial analysis 73 The average retail price of conference lights is 360 21 with a standard deviation of 97 21 LEDmote Marketing Plan The conference lights are a specialty product with a typical retailer markup around 80 The manufacturing sale price is 200 11 and will be used in the remaining financial analysis 5 1 5 2 Production Cost Analysis The desk lamp production cost breakdown is shown in Table 15 below The lamp fixture itself contains LEDs material and miscellaneous components Team LEDmote is not designing the fixture itself so the material component
95. e minimized Also since LED and wireless technology are fairly recent developments their relative costs as compared to alternatives are anticipated to decrease over time 3 3 Project Requirements 3 3 1 Prototype Requirements The original prototype called for one remote one PC connection and two lamps One of the lamps was to contain both a Zigbee and Bluetooth wireless transceiver and the other would contain a Zigbee transceiver alone This was to demonstrate the functions of the prototype which include a Bluetooth transfer repeated to both lamps a Zigbee transfer repeated to both lamps a Bluetooth transfer that changes only one lamp functional demonstration of a remote and functional demonstration of software on a PC Table 2 Prototype Requirements Check Original Final Design Prototype One One Remote Remote Control Control Zigbee Zigbee Connectio Connectio n n One PC Incomplet Connectio e Reason for Change See Section 4 3 Original Design n Bluetooth 3 3 2 Overview Connectio Remote Control Secondary Lam n 1 PIC18F87H0 MRF24J40 SPI SPI MRF24J40 PIC18F87110 Amplifier Computer Program LEDArray Figure 2 Original Design Block Diagram 3 3 3 Remote Control The remote control was designed to allow the users to communicate to any light in the room from any position he she is standing The remote control is a nice feature to have with this lighting system because it does
96. ear As Integer Dim Today As Boolean Dim EndLoop As Boolean Dim AddNumberOfMonths AddNumberOfWeeks AddNumberOfDays As Integer 21 Now DTest DateString 5 6 Schedule timel Text amp 6 Schedule AMPM1 Text If DateDiff DateInterval Minute D1 DTest 0 Then Today False Else Today True End If Select Case Recurrence Case Daily If Today False Then D2 DateValue DateAdd DateInterval Day 1 Now amp amp Schedule timel Text amp amp Schedule AMPM1 Text Else D2 DateString amp amp Schedule timel Text amp amp Schedule AMPM1 Text End If Case Weekly AddNumberOfWeeks 0 XXX AddNumberOfDays 0 EndLoop False DayOfWeek Weekday Now FirstDayOfWeek Sunday If Today False Then If DayOfWeek 7 Then DayOfWeek 1 AddNumberOfWeeks Schedule NumericWeek Value 1 End If DayOfWeek DayOfWeek 1 AddNumberOfDays AddNumberOfDays 1 End If Do While EndLoop False Select Case DayOfWeek Case 1 If Schedule Sunday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp amp Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfWeek 2 End If Case 2 If Schedule Monday Checked True Then D2 DateValue DateAdd DateInterval WeekOfYear AddNumberOfWeeks Now amp amp Schedule timel Text amp
97. ed to send a transmission once the transmission register was full This completed the initialization of the UART and allowed for the processor to send data to the Pulse Width Modulation Processor 4 5 2 2 3 2 Hardware Initialization The hardware initialization of the Coordinator Program contained a lot of the same steps as the Remote Control Program did It started out again with all of the predefined initialization of the SPI ports for the Zigbee Daughter Card making sure that the two processors were able to communicate The next thing that was initialized was PORT A bit 0 This was set to an output so that the program would allow the user to see an LED on the development board to flash when it received a transmission This was done by the line TRISA 0 0 This was about all that had to be initialized on the hardware side of things There was no additional interrupt initialization apart from Zigbee because this program was only used to receive the signals from the remote control and relay those to the PWM Processor 4 5 2 2 3 3 Function Once everything was initialized properly the main function of the program could begin Once again lot of this program was left from the demo program that it was based on The whole first part of the 65 main function consisted of setting up a Zigbee network Once the network was set up the Coordinator Program could start looking for messages from the other devices in the network If the
98. eferenced for sending messages can be found on page 21 in the AN965 document In this report only the applicable sections of how to send a transmission will be included the rest can be found better described in the AN965 document The code began with an if statement to check if the processor was not busy and made sure that the Zigbee receiver was not busy by calling function ZigBeeReady Another if statement was then added under the first to check what instruction should be sent out More specifically this if statement checked to see which flag the interrupt routine had set See Section 4 5 2 2 2 5 Once a Flag had been recognized the processor started the routine of sending out a message The first step of the routine was to clear the interrupt flag The example below shows how this was done if PowerFlag bits Power PowerFlag bits Power FALSE As discussed above this example shows that the power flag was set to TRUE so it would go to this operation The next line reset the power flag to FALSE so that on the next time around in the while loop it would not continuously perform this transmission The next important piece of code that was modified was TxBuffer POWER This line of code sent the constant defined at the very beginning of the program and stored it in the TxBuffer This buffer was a stack that contained all of the instructions for the Zigbee module to send out Once this was done the transmissi
99. en single pole single through buttons which can be found on the SPST Momentary Key Switches Datasheet This allows us to connect the 3 3V line to one side of the push button and the other side to the processor and when pushed the button would allow 3 3V to trigger the processor 3 3 3 3 Processor The processor that was chosen was the PIC18F87J10 made by microchip This processor was chosen above other ones mainly because of its five pulse width modulation outputs its two UART port modules and it ran on a common 3 3V input As the search began for the processor it was hard to find one with that many pwm outputs and two UART ports When the project first began the team was under the impression that two UARTs would be needed to connect to the Bluetooth module and the Zigbee module This however changed along the way because it was found out that the Zigbee uses a Serial Port instead of a UART The PIC18F87J10 was a very good processor for this project and it was decided that it could be used in the remote control and the Lamps The button inputs were designed to directly input into 11 different I O Ports on the processor 3 3 3 4 Zigbee Chip Originally the Freescale Semiconductor MC13192 was used This Zigbee chip seemed to be the best chip that we could use at the time that we researched it It was found to be able to connect to a large variety of microcontrollers through a SPI connection which the PIC18F87J10 supports So at the time it was
100. ender As System Object ByVal e As System EventArgs Handles Presetl CheckedChanged If Presetl Checked True Then Me GeneralGroup Visible True Me RecurrenceEnabled Checked False Else XVII Me GeneralGroup Visible False End If End Sub Private Sub Preset2_CheckedChanged ByVal sender As System Object ByVal e As System EventArgs Handles Preset2 CheckedChanged If Preset2 Checked True Then Me GeneralGroup Visible True Me RecurrenceEnabled Checked False Else Me GeneralGroup Visible False End If End Sub Private Sub Preset3_CheckedChanged ByVal sender As System Object ByVal e As System EventArgs Handles Preset3 CheckedChanged If Preset3 Checked True Then Me GeneralGroup Visible True Me RecurrenceEnabled Checked False Else Me GeneralGroup Visible False End If End Sub Private Sub RecurrenceEnabled_CheckedChanged ByVal sender As System Object ByVal As System EventArgs Handles RecurrenceEnabled CheckedChanged If RecurrenceEnabled Checked True Then Me RecurrenceGroup Visible True Me Daily Checked True Me GroupMonthly Visible False Me GroupWeekly Visible False Me GroupYearly Visible False Me Datel Visible False Me lblDate Visible False Else Me RecurrenceGroup Visible False Me Datel Visible True Me lblDate Visible True End If End Sub Private Sub Daily CheckedChanged ByVal sender As System Object Handles Daily CheckedChanged If Daily Checked True Then Me GroupMonthly Visibl
101. er residential and institutional consumer industries 5 1 2 3 Potential customers The commercial and industrial sectors are the primary potential customers of the LEDmote product family The series of products will be designed and priced mainly for use in conference rooms and offices The price of the product will limit its use in residential settings though residential applications are not out of the question The software will be designed for a windows based systems Currently 9396 of corporate operating systems are running Microsoft Windows based systems42 Figure 22 Standard and Poors Corporation Standard amp Poor s industry surveys Standard and Poors Corporation New York July 1997 1 Net Applications Operating System Market Share November 2006 lt http marketshare hitslink com report aspx qprid 2 gt 71 84 95 Windows 5 46 Windows 2000 4 10 OS 1 90 Windows 98 1 29 Macintel 0 31 Windows 136 Other Figure 22 Corporate Operating System Market Share 5 1 3 Marketing Strategy See supportive LEDmote MARKETING PLAN 5 1 4 Operations 5 1 4 1 Capital Requirements Table 12 Product Launch Costs Part Name Price Unit Quantity Unit Price Prototype Materials 2 384 79 1 2 384 79 Engineering Design Time 100 00 1200 120 000 00 Engineering Line Design 5 250 000 00 1 250 000 00 Productioon Line Build 1 500 000 00 1 1 500 000 00 Patent Fees
102. erial Port with another unit the two Bluetooth units can transmit whatever data that is needed 3 6 3 3 Amplifier Circuit An amplifier circuit was needed because the PIC18F87J10 outputs 3 3V and the LEDs run on 12V This would not allow the LEDs to light up properly because they would never get to the right voltage level In order to drive the LEDs a N Channel MOSFET transistor was designed to step up the voltage The transistors that were chosen were FDN339AN transistors made by Fairchild Semiconductor The datasheet that went along with these transistors states that they can handle 20V and up to 3A These transistors had to be rated high enough to handle the 2 3A draw from LEDs 3 6 3 4 LED Array The LED Array PCB can be seen in Figure 4 Using a set of four high power MOSFET transistors the current driven through each pair of LED s can be controlled By pulse width modulating the base of each transistor the intensity of each color can be adjusted The prototype array contains 8 RGB LEDs used to demonstrate color changes and ten white LEDs The white LEDs are not mounted to the board in Figure 4 due to heat dissipation requirements In 24 order to quickly dissipate heat the white LEDs must be mounted to a specialized heat sink surface If mounted to the PCB the base of the PCB will likely melt The white LEDs were mounted directly to the display lamp metal casing to allow heat dissipation The white LEDs are connected to the pads show
103. essor embedded into it With its own processor in it the Bluetooth protocol stack does not have to be loaded onto the PIC18F87J10 like the Zigbee Stack does Even though the price of this Bluetooth module was slightly higher because of the built in processor it paid off because it would only be used in one lamp which would prevent the lighting system to be too expensive The Bluetooth module would connect to the microprocessor using a UART interface The datasheet of the LMX9830 gives explicit directions on how the UART is set up The UART in the LMX9830 supports a four wire connection which operates better because it uses two recognition lines But the LMX9830 can also connect to a two wire UART microprocessor which the PIC18F87J10 only supports this information can be found in the LMX9830 Software Users Guide It requires that the Clear To Send CTS input to be pulled ground This will allow the two processors to properly talk to one another This Bluetooth module was used because it creates a Serial Port with another Bluetooth unit Once it is connected as a Serial Port with another unit the two Bluetooth units can transmit whatever data that is needed 3 4 3 3 Amplifier Circuit An amplifier circuit was needed because the PIC18F87J10 outputs 3 3V and the LEDs run on 12V This would not allow the LEDs to light up properly because they would never get to the right voltage level In order to drive the LEDs a N Channel MOSFET transistor wa
104. etween the Zigbee controller and the Bluetooth controller and also manage the lights The original plan was that a master lamp would contain both Bluetooth and Zigbee wireless controllers whereas all secondary lamps would contain only Zigbee wireless controllers 3 1 1 2 Bluetooth The Bluetooth protocol was chosen for its functionality and marketability Bluetooth is functional because the wireless signals transmitted by a Bluetooth transceiver are not fixed to one frequency The signals hop around on varying frequencies at very high speeds to prevent interference with other signals This allows the lighting system to utilize two 2 4GHz wireless protocols The Zigbee protocol will be fixed to one frequency while the Bluetooth protocol will hop around avoiding interference with Zigbee Bluetooth is marketable simply because it is common in many devices already on the shelf Most new computers and laptops have a Bluetooth transceiver and many handheld devices do as well If a customer s device did not have Bluetooth it would be easy to purchase a USB plug in module that could communicate with this lighting system If the Zigbee protocol were to be used as the sole wireless transmission method most customers would have no method of connecting to the lamps except by the remote control This would resulted in limited control of the lamp system 3 1 1 3 Zigbee The Zigbee protocol was chosen to give the project increased flexibility and f
105. f Schedule Disabled Checked False Then If Schedule RecurrenceEnabled Checked False Then Recurrence None Else If Schedule Yearly Checked True Then Recurrence Yearly Elself Schedule Weekly Checked True Then Recurrence Weekly Elself Schedule Monthly Checked True Then Recurrence Monthly Else Recurrence Daily End If End If Call SetTimerLength End If End If End Sub Timer Elapsed Event Private Sub ScheduleTimer_Elapsed ByVal sender As Object ByVal e As System Timers ElapsedEventArgs Handles ScheduleTimer Elapsed If TimerLength 0 Then Perform Timer Operation and Reset TimerLength If ScheduleSetting Preset 1 Then NewMode Call Change_Mode Elself ScheduleSetting Preset 2 Then NewMode Preset2Name Call Change_Mode Elself ScheduleSetting Preset 3 Then NewMode Preset3Name Call Change_Mode End If If Recurrence None Then Else Call SetTimerLength End If End If TimerLength TimerLength 1 End Sub OPERATION SCHEDULE SETTING ELECTED a TIMER T MINUTE INTERVALS GB SET TIMER LENGTH NOW TO SCHEDULED EVENT TIMER ELAPSED d RUN SCHEDULE ETTING EVENT RECUR DISABLED DISABLE TIMER Zh d RECUR ENABLED Figure 20 Schedule Operation Flow Diagram 4 5 2 1 2 3 7 MINIMIZE BUTTON The minimize button performs the minimize command
106. f Schedule chk18 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp AddNumberOfDays D2 EndLoop True D2 DateAdd DateInterval Day Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 19 End If Case 19 True Then If Schedule chk19 Checked XXXVI amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text Else If Schedule chk22 Checked Else amp Schedule timel Text 6 D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 20 End If If Schedule chk20 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 21 End If If Schedule chk21 Checked True Then Now amp amp Schedule timel Text amp D2 DateValue DateAdd DateInterval Month AddNumberOfMonths D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 22 End If True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp
107. fDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 27 End True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 28 End If Case 28 If Schedule chk28 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp AddNumberOfDays D2 EndLoop True D2 DateAdd DateInterval Day AddNumberOfDays AddNumberOfDays 1 DatePart DateInterval Month Now DayOfMonth 1 AddNumberOfMonths Schedule NumericUpDownl Value 1 2 Then Else DayOfMonth 29 XXXVIII End If End If Case 29 If Schedule chk29 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now 5 amp Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 30 End If Case 30 If Schedule chk30 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 If DatePart DateI
108. fMonth 1 AddNumberOfDays AddNumberOfDays 1 End If Do While EndLoop False Select Case DayOfMonth amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text Case 1 Schedule chkl Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 2 End If Case 2 If Schedule chk2 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 3 End If Case 3 If Schedule chk3 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 4 End If Now Now Now amp amp amp amp Schedule timel Text amp amp Schedule timel Text amp amp Schedule timel Text amp XXXIII Case 4 If Schedule chk4 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths 5 amp Schedule timel Text amp amp Schedule AMPM1 Text AddNumberOfDays D2 D2 DateAdd DateInterval Day EndLoop True Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 5 End If
109. gh the price of this Bluetooth module was slightly higher because of the built in processor it paid off because it would only be used in one lamp which would prevent the lighting system to be too expensive The Bluetooth module would connect to the microprocessor using a UART interface The datasheet of the LMX9830 gives explicit directions on how the UART is set up The UART in the LMX9830 supports a four wire connection which operates better because it uses two recognition lines But the LMX9830 can also connect to a two wire UART microprocessor which the PIC18F87J10 only supports this information can be found in the LMX9830 Software Users Guide It requires that the Clear To Send CTS input to be pulled ground This will allow the two processors to properly talk to one another This Bluetooth module was used because it creates a Serial Port with another Bluetooth unit Once it is connected as a Serial Port with another unit the two Bluetooth units can transmit whatever data that is needed 3 3 4 3 Amplifier Circuit An amplifier circuit was needed because the PIC18F87J10 outputs 3 3V and the LEDs run on 12V This would not allow the LEDs to light up properly because they would never get to the right voltage level In order to drive the LEDs a N Channel MOSFET transistor was designed to step up the voltage The transistors that were chosen were FDN339AN transistors made by Fairchild Semiconductor The datasheet that went along with these
110. had to be done for the PWM 1 2 and 3 because they were specified as special outputs for the processor The function that set up these special PWM outputs was SetOutputPWMx Lastly the duty cycle had to be set in order for the pulse width modulation to work SetDCPWMx was the function that was responsible for this This function received the duty cycle that was specified and overwrote the old one After this function was called the PWM outputs were operating If the power_status equalled 1 the program recognized that the light was on and then would go into the else statement The first step of this statement reset the power_status variable to zero The else statement then proceeded to close the PWM outputs by calling another function from the MPLAB C18 Library the ClosePWMx This function did all the operations needed to stop the outputs of the pulse width modulation Now if the opcode equalled RED_UP the program entered a different case statement as shown below Case RED_UP if pwml_dc gt DC MAX The first thing that this case statement did was check to see if the duty cycle was already maxed out If it was the program simply exited the case statement and did not change the duty cycle If it was less than the specified DC MAX constant then the program would proceed to increase the duty cycle It did this by adding the change constant to the dc pwmx variable and then called on the SetDCPWMx function again which overwrote
111. he 3 3V line to one side of the push button and the other side to the processor and when pushed the button would allow 3 3V to trigger the processor 4 3 2 3 Processor The processor that was chosen was the PIC18F87J10 made by microchip This processor was chosen above other ones mainly because of its five pulse width modulation outputs its two UART port modules and it ran on a common 3 3V input As the search began for the processor it was hard to find one with that many pwm outputs and two UART ports When the project first began the team was under the impression that two UARTs would be needed to connect to the Bluetooth module and the Zigbee module This however changed along the way because it was found out that the Zigbee uses a Serial Port instead of a UART The PIC18F87J10 was a very good processor for this project and it was decided that it could be used in the remote control and the Lamps The button inputs were designed to directly input into 11 different I O Ports on the processor 4 3 2 4 Zigbee Chip Originally the Freescale Semiconductor MC13192 was used This Zigbee chip seemed to be the best chip that we could use at the time that we researched it It was found to be able to connect to a large variety of microcontrollers through a SPI connection which the PIC18F87J10 supports So at the time it was assumed that the Zigbee protocol stack could have been loaded onto the PIC18F87J10 Although it was assumed that the MC13192 would be ab
112. he schematics in Eagle of all the PCBs He then designed the four layer board for the Lamp Base After the PCBs were ordered he began looking into how the PIC processors were programmed When the boards came back after the rest of the team had finished soldering the boards Ryan began to debug the boards with Dan and tried to figure out what was wrong with them When those were determined not worth trying to fix he began searching for a second option and decided to purchase the PICDEM Z development kit in order to get the prototype working After this decision was made Ryan began to start writing all of the code for the PIC Processors During this time he helped out various team members with some of the hardware issues 6 1 4 Dustin Veldkamp During the first semester Dustin researched the business plan along with the LED array Dustin created a worst case analysis for the components for the LED array Parts were ordered using the values determined by the worst case analysis It was Dustin s responsibility to create the schematics for the LED array and remote circuit He also designed and ordered the printed circuit boards for both schematics After the PCBs were laid out Dustin spent his time researching the business plan for the project Following the receipt of parts Dustin began soldering and assembling all the circuits boards at 79 Innotec Next Dustin began researching the PC software Once the software protocol was chosen he designed the
113. hkRainbow Checked Curren PictureBoxl BackColor 0 4 Byte Else lblCurrentLamp Text LAMP WhiteBar Value CurrentArr WhiteIntensity Text Whi chkBlackOutWhite Checked chkBlackOutColor Checked LAMPS ay 0 1 teBar Value 100 50 amp CurrentArray 0 8 CurrentArray 0 9 entArray 0 6 entArray 0 7 tArray 0 10 Integer CType CType CurrentArray 0 amp NewLamp 1 ay NewLamp 1 teBar Value 100 50 amp CurrentArray NewLamp 8 CurrentArray NewLamp 9 5 Byte System Drawing Color FromArgb CType CurrentArray 0 Integer Byte Integer XXVI chkFadeWhite Checked CurrentArray NewLamp 6 chkFadeColor Checked CurrentArray NewLamp 7 chkRainbow Checked CurrentArray NewLamp 10 PictureBoxl BackColor System Drawing Color FromArgb CType CType CurrentArray NewLamp 3 Byte Integer CType CType CurrentArray NewLamp 4 Byte Integer CType CType CurrentArray NewLamp 5 Byte Integer End If Select Case CurrentLamp Case ALL LAMPS BTN all BackColor Color White Case 0 BTN 0 Color White Case 1 _1 Color White Case 2 BTN 2 BackColor Color White Case 3 BTN_3 BackColor Color White Case 4 BIN_4 BackColor Color White Case 5 BTN 5 BackColor Color White Case 6
114. hose two weeks to be used in trouble shooting and problem analysis so the schedule was not followed completely 6 2 1 Task Specification The team was able to determine an estimate for the hours spent on Senior Design this semester from the Microsoft Project file Milestones Section 10 1 The estimated hours are shown in the project forecast Table 21 The estimated hours were determined by multiplying the number of weeks before a task by 80 hours for each week 20 hours per team member a week This gives a total estimate of 1120 hours for the 14 weeks of the semester Table 21 Project Forecast Milestone Start Date Weeks Milestones Estimated Hours 2 9 2007 2 Schematic Layout 160 2 16 2007 1 Circuit Board Layout 80 2 23 2007 0 5 Order Boards 40 3 30 2007 3 Working Tested Hardware 240 4 13 2007 2 Working Tested Software 160 4 20 2007 3 Working Tested Prototype 240 5 5 2007 2 Senior Design Banquet 160 5 7 2007 0 5 Project Review 40 Totals 14 1120 Actual hours were kept on a timesheet by each team member throughout the year Every hour spent on senior design was recorded as well as what task was worked on during that time 80 Table 22 Actual Hours Milestone Task Chris Dustin Total 1 Design Review 5 5 38 5 1 Remote Design 13 0 30 5 1 Power Supply 12 55 17 5 1 Bluetooth Design 5 12 81 5 1 Zigbee Design 0 0 70 45 1 LED Array Lamp Design 0 57 1 57 1 1 Microcontroller Desig
115. howed that this weak power signal was insufficient to supply the microcontroller 4 4 3 Complications Conclusion Because of the previously mentioned complications the original plan had to be put aside in favor of the secondary plan The secondary plan was then implemented because it implemented the use of key hardware predesigned and prefabricated in the form of development kits 4 5 Final Prototype The final prototype had three modules to it the remote control control lamp and a computer program The prototype block diagram can be seen below in Figure 6 The red blocks represent the portions that were added to the design and the orange blocks represent the parts that were just modified or swapped out for different components The following sections lay out the decisions hardware and software of the final prototype Remote Control Control Lamp PIC18F4620 24140 Figure 6 Prototype Block Diagram 4 5 1 Hardware Solution 4 5 1 1 Development Kits In implementing hardware the team chose to use two different development kits provided by Microchip The first was the HPC Explorer board which included a PIC18F8722 convenient connectors for programming and I O LEDs a 10MHz crystal and several buttons The team used the HPC board as a central controller that could take Zigbee communicated inputs from the remote control as well as 40 Bluetooth communicated inputs from the PC while outp
116. hown from left to right across the top of Figure 4 are connected in series to two white LEDs Given the variability of the resistors and LEDs a worst case analysis was performed on this circuit to find the optimal values and tolerances for the resistors This analysis can be seen in Appendix 10 3 Figure 4 LED Array 3 5 3 5 Lamp Base PCB The lamp base printed circuit board was designed much in the same way as the remote control circuit board With the development kit that was purchase for the LMX9830 some of the software that came with the kit provided the prints for the four layers of the development kit These prints were replicated as close as possible just like the PIC18F87J10 and the MRF24J40 were before Also a bit of concern was created by the use of two RF modules on one board The solution that was proposed by the team was to put the two RF modules as far away as possible From Figure 5 it can be seen that the Bluetooth was populated near the top left and the MRF24J40 located at the bottom middle of the board 20 Figure 5 Lamp Base 3 5 4 Secondary Lamps The secondary lamps do not need any more explaining because they are basically just a striped down Control Lamp The secondary lamps do not need a Bluetooth unit because these lamps just rely on the Zigbee modules to communicate to the rest of the lamp network Complications PCB of Non Lamp working 3 6 Short on the Board Also
117. ice of this Bluetooth module was slightly higher because of the built in processor it paid off because it would only be used in one lamp which would prevent the lighting system to be too expensive The Bluetooth module would connect to the microprocessor using a UART interface The datasheet of the LMX9830 gives explicit directions on how the UART is set up The UART in the LMX9830 supports a four wire connection which operates better because it uses two recognition lines But the LMX9830 can also connect to a two wire UART microprocessor which the PIC18F87J10 only supports this information can be found in the LMX9830 Software Users Guide It requires that the Clear To Send CTS input to be pulled ground This will allow the two processors to properly talk to one another This Bluetooth module was used because it creates a Serial Port with another Bluetooth unit Once it is connected as a Serial Port with another unit the two Bluetooth units can transmit whatever data that is needed 4 3 3 3 Amplifier Circuit An amplifier circuit was needed because the PIC18F87J10 outputs 3 3V and the LEDs run on 12V This would not allow the LEDs to light up properly because they would never get to the right voltage level In order to drive the LEDs a N Channel MOSFET transistor was designed to step up the voltage The transistors that were chosen were FDN339AN transistors made by Fairchild Semiconductor The datasheet that went along with these transi
118. ided a suggested layout for the Zigbee chip so the design that was approached was to follow Microchips design as closely as possible The final layout is shown below in Figure 3 LEDmote REMOTE Figure Remote Control PCB Design 3 4 3 Control Lamp 3 4 3 1 Power Supply The power supply for the lamp was designed a lot differently than in the remote control The lamps were designed to be plugged into a 120V 60Hz or 240V 50Hz wall socket So the first step was to send the voltage through a switch mode power supply which would cut the voltage down to 12V DC The 13 power supply that was chosen was a ETS120400UTC P5P SZ made by CUI Inc From the datasheet it was found that this power supply could handle currents of up to 50A This was a little over kill because currently the LED array draws little less than 25A It was chosen a little high in case more LEDs were needed in the future which would ultimately draw more current This power supply would then output 12V as stated above which would be used to drive the 12V LED array But another step down in voltage was needed before it could be run to the microprocessors which ran at 3 3V To make this step down the same voltage regulator that was used in the remote control was again used 3 4 3 2 Bluetooth Module The Bluetooth module that was chosen was the LMX9830 Bluetooth Serial Port Module made by National Semiconductor This Bluetooth module was chosen because it has its own proc
119. if statement This input looked very similar to the defined value of POWER 0000 0001 in binary only inverted That is because the processor was pulled high and recognized a change when an input was pulled to ground shows 0 These input codes were generated from the encoder inverter hardware circuit described in Section 4 5 1 2 2 and 4 5 1 2 3 the port was different than this one it would go onto the next line if RB7 1 6 RB6 INT 1 6 RB5 INT 0 6 INT 1 WhiteFlag bits WhiteUp TRUE The processor went through the rest of the if statements to see if any one of the opcodes could be detected If one was detected the processor would go into that if statement and perform the next line For the above example WhiteFlag bits WhiteUp TRUE If this line was called it would set the WhiteUp bit of the WhiteFlag which would ultimately run the transmission if statement in the main At the very end of this interrupt function three more steps had to be performed before the processor could leave this function The three lines of code were INTCONbits RBIE 0 LATB PORTB INTCONbits RBIF 0 The first line disabled the interrupts on change of the PORTB This needed to be done because otherwise the processor might start another interrupt of the same kind before it had finished processing the first one The second line used the LATB register which cleared any mismatch that might have occurred betwee
120. in the specific processor So PORTBbits was the variable that was assigned to the entire register that refers to the input output PORT 58 RB4 refers to the bit 4 of that register which correlates to the input output RB4 pin This was repeated for RB5 RB6 and RB7 The next section was designated for a structs setup These made it easier to understand the program because it allowed the defining of one type of variable and then separating that type of variable into different sections For example the white flag variable was written as Static union struct unsigned WhiteUp s 17 unsigned WhiteDown 1 unsigned None 56 bits unsigned char Value WhiteFlag This takes an 8 bit variable and assigns it name of WhiteFlag It then allows that variable to be broken up into its different bits such as WhiteUp When this variable is later called it can be assigned all at once by writing WhiteFlag Value 0x00 This code set all of the bits to zero A convenient feature of this code format is the capability to assign each bit in the variable an individual value while leaving the rest of the bits unchanged To do this one would simply write WhiteFlag bits WhiteUp 1 This creation of a struct was used for each of the different variables that were needed RedFlag GreenFlag BlueFlag and ColorFlag The use of these variables will be seen later where they were used to keep track of interrupts if one occurred
121. ing of how the development kits are laid out and then move on to design of hardware A strategy such as this would have given the team enough time to get more of the components working and possibly a little time to order PCBs near the end of the semester Since hardware design time was stretched out other aspects of the schedule suffered Hardware debugging and software design time were shortened to accommodate the extra design time With less time to debug the PCBs a quick decision had to be made to abandon them and switch to development kits in order to achieve a working prototype This chain reaction made way for the development kit prototype that the semester ended with instead of a working design laid out on PCBs Another problem encountered during the semester was a lack of proper documentation Documentation of every aspect of the design process is a critical Improper documentation caused the team to do multiple orders for parts which in turn delayed fabrication Improper documentation also caused more time at the end of the semester to be devoted to the report If decisions and design strategies were recorded during the process of design then less time would be consumed recalling this information 8 3 Acknowledgements Dr Steven VanderLeest Professor Engineering Chair Calvin College Dr Randall Brouwer Professor of Engineering Calvin College Tom Veenstra Head of Lighting R amp D Innotec Kyle Israels LED Lighting Innotec Tim Theri
122. is means that lamps would have to be within 10 meters 33 feet of each other to ensure a connected network and with less interference lamps could be spaced up to 50 meters 164 feet apart 82 7 1 4 Remote Testing a piece of hardware requires small steps and checks on key points Several important features must be verified before any software can be loaded on the system The sequence of tests was laid out in Table 25 This was used for both the remote and lamp base PCBs Table 25 Initial PCB Test Procedure Test Part being tested Successful Result Power Test Power Jack Voltage Touch the lead of an 4 5V 12V is shown on Regulator Oscilloscope to the hot the jack and 3 3V is lead on the power jack shown on the output of and voltage regulator the voltage regulator Clock Test Zigbee chip Touch the lead of Bluetooth 15MHz Bluetooth chip Osciloscope to the Zigbee 20MHz clock input pins MCU 20MHz RF Output Test RF Lines Touch the lead of an A frequency of 2 4GHz Oscilloscope the isshown on the RF lines inputs of the two RF antennas MCU Communication MCU Plug in ICD2 Verify that the MCU is Test programmer recognized in software Hello World MCU Run Hello World Verify that the Correct demonstration program output pins show a on the MCU voltage UART Test MCU Run UART test software Verify that the UART on the MCU pins show the correct sequence SPI Test MCU Run SPI test
123. l Lamp 4 3 3 1 Power Supply The power supply for the lamp was designed a lot differently than in the remote control The lamps were designed to be plugged into a 120V 60Hz or 240V 50Hz wall socket So the first step was to send the voltage through a switch mode power supply which would cut the voltage down to 12V DC The power supply that was chosen was a ETS120400UTC P5P SZ made by CUI Inc From the datasheet it was found that this power supply could handle currents of up to 50A This was a little over kill because 18 Microchip Technology Inc P Microchip Technologies Inc CUI Inc 36 currently the LED array draws a little less than 25 It was chosen little high in case more LEDs were needed in the future which would ultimately draw more current This power supply would then output 12V as stated above which would be used to drive the 12V LED array But another step down in voltage was needed before it could be run to the microprocessors which ran at 3 3V To make this step down the same voltage regulator that was used in the remote control was again used 4 3 3 2 Bluetooth Module The Bluetooth module that was chosen was the LMX9830 Bluetooth Serial Port Module made by National Semiconductor This Bluetooth module was chosen because it has its own processor embedded into it With its own processor in it the Bluetooth protocol stack does not have to be loaded onto the PIC18F87J10 like the Zigbee Stack does Even though the pr
124. lamp Other buttons consisted of three sets of two buttons to increase or decrease the amount of red green and blue coloration added to the emitted light from the lamps Finally the remote control had increment and decrement buttons for the RGB LEDs and for all the white LEDs simultaneously The buttons that were chosen were from ITT Industries and had the characteristics of normally open single pole single through buttons which can be found on the SPST Momentary Key Switches Datasheet This allows us to connect the 3 3V line to one side of the push button and the other side to the processor and when pushed the button would allow 3 3V to trigger the processor 3 5 2 3 Processor The processor that was chosen was the PIC18F87J10 made by microchip This processor was chosen above other ones mainly because of its five pulse width modulation outputs its two UART port modules and it ran on a common 3 3V input As the search began for the processor it was hard to find one with that many pwm outputs and two UART ports When the project first began the team was under the impression that two UARTs would be needed to connect to the Bluetooth module and the Zigbee module This however changed along the way because it was found out that the Zigbee uses a Serial Port instead of a UART The PIC18F87J10 was a very good processor for this project and it was decided that it could be used in the remote control and the Lamps The button inputs were designed to
125. le to work with the PIC18F87J10 it was hard to find support for doing this Texas Instruments Incorporated 17 ITT Industries 35 Then around January another chip made by Microchip was released The Zigbee Chip that was selected was the MRF24J40 There was a lot more support for this chip and Microchip has its own Zigbee Protocol Stack specifically designed for PIC18F Microcontrollers The support for loading the stack onto PIC18F processor can be found the AN965 Microchip Stack for the ZigBee Protocol Datasheet This chip was selected because microchip fully supports this Zigbee chip with the PIC18F87J10 This Zigbee chip was designed to connect through the SPI port on the PIC18F87J10 and was also designed to send out a clock output for the PIC18F87J10 to use 4 3 2 5 Remote Control PCB Design After all research was done on all of the different components that attached to processor and the Zigbee chip a printed circuit board was created Since the Zigbee is an RF transceiver a lot of things had to be considered when laying out the board MRF24J40 Datasheet mentions everything that should be considered in the designing of a RF board The datasheet also provided a suggested layout for the Zigbee chip so the design that was approached was to follow Microchips design as closely as possible The final layout is shown below in Figure 3 225 516 Figure 3 Remote Control PCB Design 4 3 3 Contro
126. lized 4 224 4 2 7 Switch Decision Wall mounted switches controlled the power feed to all lamp modules This provided a basic functionality in the event of failure or absence of wireless devices such as the remote control laptop or in room computer The manual switching functionality was deemed essential for emergency cases However other functions of the lamp modules such as variable brightness and color were not built into the wall switches Adding these features to a wall mounted switch decreased the need for a wireless controller such as a remote or laptop Thus the associated flexibility was reduced The software and remote provided an on off function for the lamp modules without the use of wall mounted switches 33 Table 4 7 Wall Switch Decision Matrix flexibility of overall design user friendliness Weights out of 10 Switch with all features 4 3 Original Design 4 3 1 Overview Remote Control Control Lamp Secondary Lamp mr 1 PIC18F87H0 MRF24140 SPI MRF24140 PIC18F87H0 Computer Program Figure 2 Original Design Block Diagram 4 3 2 Remote Control The remote control was designed to allow the users to communicate to any light in the room from any position he she is standing The remote control is a nice feature to have with this lighting system because it does not limit the user to any distance from a light but at the same time it was designed for limited operability of the lights 34
127. loaded into the array the credit dialog activates a search for local Bluetooth devices in the computers area A list of Bluetooth devices was compiled and compared to the stored master lamp name If no device was found that matches the master lamp name or no master lamp has been previously designated a list of potential devices was displayed to the user Once the master lamp was found and or chosen the program retrieved information from all the lamps The lamps current settings were downloaded into the array and variables such as the number of lamps were set Finally the credit dialog screen was hidden and the control form was loaded 4 5 2 1 2 3 2 CONTROL FORM The control form took the variables and array set by the credit dialog and displayed these variables to the user via the interface shown in Figure 14 The entire code for this interface could be found in the electronic documents submitted with this report LEDmoteControl txt The control form had a group of buttons that performed their specified events These events and their actions are laid out in Figure 16 4 5 2 1 2 3 3 LAMP BUTTONS The PC Control Console V1 0 has ten lamp buttons Lamps 1 9 When any of these buttons were pressed the following code was executed Private Sub BTN all Click ByVal sender As System Object ByVal As System EventArgs Handles BTN all Click NewLamp ALL LAMPS Call Change Lamp End Sub The system contains two global variables
128. n The decision matrix in Table 4 8 shows Visual Basic as the superior programming language choice for software development The major factor in making this decision was that the team had more collective experience in coding Visual Basic This included having two year intern work experience with Visual Basic software Other factors that supported this decision were the extensive support structure available on MSDN Microsoft Developer Network MSDN has extensive resources in developing software with specific applications for windows developing GUI and interfacing to Bluetooth Java has a wide variety of applications and all the required capabilities However the team s unfamiliarity with the language and its unknown complexities ruled Java out as an acceptable alternative Although the team has had two classes on C the experience and ease of use of Visual Basic ruled out the use of C Table 4 8 Programming Language Decision Matrix to Interface Bluetooth Development Development System HP GUI Windows Java 8 C 8 Basic 9 Programming Language Wikipedia 7 December 2006 lt http en wikipedia org wiki Java_ 28programming_language 29 gt 33 Wikipedia 7 December 2006 lt http en wikipedia org wiki C 2B 2B gt BASIC Wikipedia 7 December 2006 lt http en wikipedia org wiki BASIC gt 3 MSDN 7 December 2006 lt http msdn2 micros
129. n 0 18 5 19 5 1 Scheduling 0 0 15 6 2 PCB Design 36 5 28 152 5 3 Order Parts 30 28 5 98 4 Drill Solder PCBs 22 3129 80 4 Amplifier Circuit 9 5 0 19 5 5 PIC Software 40 0 210 5 PC Software 0 67 5 67 5 6 Miscellaneous Testing and Debug 10 0 82 7 Final Report 28 5 51 6 168 1 7 Design Night and Prep 20 5 8 61 5 8 Meetings Conference Calls 9 4 24 9 Class 18 15 5 68 85 9 Presentations 17 1 5 34 Totals 271 335 2 1396 6 These hours were then funneled into 20 different tasks which were each assigned a milestone The 8 milestones are shown in Table 22 With this method the team could compare the actual hours to the estimated for each milestone Table 23 Comparison Table Estimate Difference 1 330 65 144 186 65 2 72 805 3 36 62 4 216 1165 5 144 1335 6 216 134 7 144 856 8 Project Review 36 12 9 Totals 1120 276 6 Table 23 shows the variation between the estimated and actual hours The estimate column uses 90 of each milestone s hours for the estimate and 10 is left over for the overhead hours row Class and 81 Presentations CEAC fall under overhead The most significant value from the task breakdown is the comparison of total actual hours to total estimated hours Team LEDmote spent 276 6 hours more than it estimated for the semester Many of this extra spending was generated from an extended hardware design time that was predicted to end with board layo
130. n PORT B and the reading of the processor value The third line reset the interrupt on change flag back to zero so that the processor could do other things the next time around the while loop and so that it could detect another interrupt in the future 4 5 2 2 3 LEDmote Zigbee Coordinator Program This program like the RFD was based entirely on the Demo program that came with the PICDEM Z Development Kit The program was called DemoCoordinator and it was capable of setting up a Zigbee network and then being able to send a couple commands across the network The demo program was rewritten to incorporate the commands that were needed to control the lighting system This program was only needed because of how the prototype was designed This processor was used only to receive the commands from the other Zigbee module the remote control and relay the 63 messages to the PWM Program If the final design was successful the PWM program would not only control the lights but also be able to send and receive messages from the other Zigbee modules Since this program was only designed to relay messages from the remote control to the PWM program there was no need to add in any other variables or constants that were needed in the Remote Control program The only constants that were defined in this program were the button opcodes as were found in the remote control program and later in the PWM program 4 5 2 2 3 1 UART Initialization This program require
131. n at the top of the board Current passes through four current controlling resistors before passing through the LEDs The white LEDs are paired in series so each of the first five pads shown from left to right across the top of Figure 4 are connected in series to two white LEDs Given the variability of the resistors and LEDs a worst case analysis was performed on this circuit to find the optimal values and tolerances for the resistors This analysis can be seen in Appendix 10 3 Figure 4 LED Array 3 6 3 5 Lamp Base PCB The lamp base printed circuit board was designed much in the same way as the remote control circuit board With the development kit that was purchase for the LMX9830 some of the software that came with the kit provided the prints for the four layers of the development kit These prints were replicated as close as possible just like the PIC18F87J10 and the MRF24J40 were before Also a bit of concern was created by the use of two RF modules on one board The solution that was proposed by the team was to put the two RF modules as far away as possible From Figure 5 it can be seen that the Bluetooth was populated near the top left and the MRF24J40 located at the bottom middle of the board 25 Figure 5 Lamp Base 3 6 4 Secondary Lamps The secondary lamps do not need any more explaining because they are basically just a striped down Control Lamp The secondary lamps do not need a Bluetooth unit because
132. nce 10 000 00 Warranty Expenses 106 620 61 Total Expenses 1 204 113 00 NET INCOME BEFORE TAXES 485 400 36 Income Tax 194 160 14 NET INCOM E 291 240 22 The second year income statement Table 19 was created using the financial analysis from the research and projections in the previous sections The number of units sold increased from the previous due to product exposure and advertising The projected second year sales are 68 000 units still a conservative 00105 of industry market share Table 17 The sale price of the units was decreased by 5 to account for inflation and keep the product competitive The marginal revenue percentage of the desk lamp is 696 The marginal revenue percentage of the conference room is 5296 The second installment of the launch amortized expense is reflected along with a selling expense calculated with a set 100 000 base fee 0 60 per unit sold for sales person salary and advertising expenses The warranty expense assumes a 496 claim rate on the products sold The cost of the replaced products was calculated into this warranty expense Additionally the company begins to expense R amp D to cover the development of new products in order to remain competitive The product line will produce a net profit of 3 329 58 in its second year 76 Table 19 Second Year Projected Income Statement LEDmote PRODUCT LAUNCH INCOME STATEMENT FIRST YEAR STATEMENT DESK LAMP Marginal Revenue Numbe
133. ncrement and decrement buttons for the RGB LEDs and for all the white LEDs simultaneously The buttons that were chosen were from ITT Industries and had the characteristics of normally open single pole single through buttons which can be found on the SPST Momentary Key Switches Datasheet This allows us to connect the 3 3V line to one side of the push button and the other side to the processor and when pushed the button would allow 3 3V to trigger the processor 3 4 2 3 Processor The processor that was chosen was the PIC18F87J10 made by microchip This processor was chosen above other ones mainly because of its five pulse width modulation outputs its two UART port modules and it ran on a common 3 3V input As the search began for the processor it was hard to find one with that many pwm outputs and two UART ports When the project first began the team was under the impression that two UARTs would be needed to connect to the Bluetooth module and the Zigbee module This however changed along the way because it was found out that the Zigbee uses a Serial Port instead of a UART The PIC18F87J10 was a very good processor for this project and it was decided that it could be used in the remote control and the Lamps The button inputs were designed to directly input into 11 different I O Ports on the processor 3 4 2 4 Zigbee Chip Originally the Freescale Semiconductor MC13192 was used This Zigbee chip seemed to be the best chip that we could use
134. ne POWER 0x01 These were the only constants that could be found consistently from one program to another 4 5 2 2 2 LEDmote Zigbee Remote Control Program This program was based on one of the demo programs that came with the Zigbee Development Kit The demo program was called DemoRFD which was written to configure the processor as an end user device It included all of the initial setup of the Zigbee network and also had some code embedded inside it to output simple commands To write the Remote Control Program for this project the DemoRFD program was modified to send out the code that was specific for our remote control 4 5 2 2 2 1 Constants and Variables Defined in RFD In addition to the button opcode instructions as described above the RFD program also had defined constants After the opcodes were defined the input ports were assigned to an interrupt constant The PIC allowed PORT B to be assigned as interrupts This means that if the processor was set up correctly it would recognize a change on PORT B and set a flag bit in one of the registers This would then halt the program By assigning a constant to these inputs a more intuitive representation of the interrupt handler routine was possible An example of how these were set is define INT PORTBbits RBA PORTBbits RB4 was found in the header file for the PIC18F4620 that was provided by Microchip The header file of each processor provides a struct breakdown of each register
135. nfluence their design career development and job seeking ethics and team building 2 Terms Table 1 Terms ENGR Engineering FFD _Full Function Device Zigbee FPGA Field Programmable Gate Array GUI _Graphical User Interface IEEE Institute of Electrical and Electronics Engineers 1 0 Input Output LED Light Emitting Diode MCU Microcontroller Unit MOSFET Metal Oxide Semiconductor Field Effect Transistor 5 _Operating System PC Personal Computer PCB _Printed Circuit Board PIC Microcontroller Developed by Microchip Technology PPFS Project Proposal and Feasibility Study PWM Pulse Width Modulation RFD Restricted Function Device Zigbee RGB _Red Green Blue SPI _Serial Port Interface UART Universal Asynchronous Receiver Transmitter USB _Universal Serial Bus VAC _Volts Alternating Current VDC Volts Direct Current 3 Project Scope In an engineering project it is critical to accurately spell out the scope of the project This both sets the expectations for the group and keeps the group united with one common focus With guidance provided by the scope the team made key decisions steering the progress of the project throughout the course of the semester During each major decision the project requirements were consulted to determine which path was most directed towards the requirements 3 1 The Challenge 3 1 1 Scope of Hardware 3 1 1 1 MCU The PIC Microcontroller Unit MCU in the lamp base was meant to coordinate b
136. nformal tests run on the prototype lamp the team determined that a user should not to look directly at white LEDs running with a current greater than 500mAP At this current repeated exposure to the intensity of the light could cause some health risks and in the short term will likely cause some discomfort to the user The team did not determine a maximum current for the RGB LEDs as all tested currents did not approach an intensity that caused any measure of discomfort 3 7 4 Lamp Spacing Requirements Test runs on the prototype indicated that the lamp s light even when reflected was clearly visible from distances of over 300ft In production design of room lamps the team recommends that the LEDs be directed downward in multiple directions through a transparent diffuser The team recommends that lamps be spaced no more than 30ft apart to provide adequate lighting to the room However the lamps may be spaced at distances of up to 250ft direct line of sight if necessary Spacing of lamps is limited only by the range of travel of Zigbee electromagnetic waves and the interference they encounter Refer to Section 7 1 3 for documentation on testing of Zigbee communication in various environments The current system can implement up to 180 separate Zigbee equipped modules OSRAM OSRAM 14 Microchip Technology Inc 28 The system requires that each lamp module be connected to a supply source It is assumed that most production systems will
137. nterval Month Now 4 Or 6 Or 9 Or 11 Then DayOfMonth 1 AddNumberOfMonths Schedule NumericUpDownl Value 1 Else DayOfMonth 31 End If End If Case 31 If Schedule chk31 Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp amp Schedule timel Text amp amp Schedule AMPM1 Text D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True Else AddNumberOfDays AddNumberOfDays 1 AddNumberOfMonths Schedule NumericUpDownl Value 1 DayOfMonth 1 End If Case Else D2 Now EndLoop True End Select Loop Case Yearly DayOfMonth DatePart DateInterval Day Now EndLoop False MonthOfYear DatePart DateInterval Month Now Dim MTest As Date AddNumberOfMonths 0 MTest DatePart DateInterval Month Now amp amp Schedule NumericYearly Value amp amp DatePart DateInterval Year Now amp amp Schedule timel Text amp amp Schedule AMPM1 Text XXXIX If DateDiff DateInterval Minute D1 MTest lt 0 Then AddNumberOfMonths AddNumberOfMonths 1 If MonthOfYear 12 Then MonthOfYear 1 Else MonthOfYear MonthOfYear 1 End If End If Do While EndLoop False Select Case MonthOfYear Case 1 If Schedule January Checked True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule AMPM1 Text EndLoop True Else AddNumberOfMonths AddNumberOfMonths 1 MonthOfYear 2 End If Case 2 If Schedule
138. o allow the users to communicate to any 11 light in the room from any position he she is standing The remote control is nice feature to have with this lighting system because it does not limit the user to any distance from a light but at the same time it was designed for limited operability of the lights 3 4 2 1 Power Supply The remote control was designed to use 2 AA batteries which would produce a 4 5 V output onto the board This was a little high because the processor and Zigbee module were specified to run at 3 3 V To knock down the voltage to a tolerable level for the processor to handle a REG103GA 3 3 linear voltage regulator was used The datasheet for this regulator states that this voltage regulator can take an input of up to 15 V This was nice to know because it can handle the input from the batteries On an added note the voltage regulator can also handle an input of 12 V which the Lamp Modules run off of This voltage regulator is also rated at 500 mA this is well above the current that the main processor and the Zigbee processor ever pull 3 4 2 2 Button Array In creating a button array for the prototype the team aimed to create an intuitive user interface A power button served as an on off switch for the display lamp Other buttons consisted of three sets of two buttons to increase or decrease the amount of red green and blue coloration added to the emitted light from the lamps Finally the remote control had i
139. oft com en us default aspx gt 46 4 5 2 1 2 Software Design 4 5 2 1 2 1 Software Architecture The software architecture shown in Figure 13 was the hierarchy leading from the user interface to the Bluetooth module Windows API Bluetooth Driver Bluetooth Hardware Figure 13 Software Architecture The GUI received input and displayed output directly to the user When receiving an input from the user the GUI transfered it through a Windows API to the Bluetooth Driver and directed the Bluetooth hardware to send the desired instruction The instruction was decoded in the hardware by the controller and pulses were sent to LEDs When a command was received by the controller from the remote it relays onto other Zigbee devices and relayed back through Bluetooth transmission to the laptop controller When received by the Bluetooth hardware on the laptop the signal percolated back up the hierarchy and was reflected in the GUI by a change in either the color selected or white LED intensity setting 47 4 5 2 1 2 2 GUI Layout LEDmote MANUAL 9 PRESET 1 9 9 SETUP MINIMIZE HELP ALL LAMPS WHITE COLOR BLACK OUT BLACK OUT FADE EFFECT FADE EFFECT RAINBOW EFFECT Figure 14 GUI Layout The concept of the GUI is illustrated in Figure 1Figure 14 All features of the GUI are subject to change The GUI will vary greatly depending on the environment and size of the
140. ogram contains the Zigbee Interrupts and the PORT B interrupts both of which are equally important and should be set to the same priority RCONbits is another register associated with the setup of interrupts While IPEN stands for the bit position that corresponds to the enabling of high and low interrupts If set to 1 PORTB was initialized as high priority If the bit was set to 0 PORTB would be set to low priority If PORT B was set to low priority and a change was recognized the interrupt flag for this change would be set If the Zigbee interrupt was set to high priority and was also flagged then the processor would automatically give precedence to the Zigbee interrupt even though it occurred later Step 5 requires that all the interrupts to be enabled This step actually took place outside of the hardware initialization and in the main function because it was important to make sure that the processor did not start looking for interrupts before all other initializations were configured correctly To do this the code below was written 60 INTCONbits GIEH 1 Once again INTCONbits refers to the interrupt control register talked about earlier Although this time GIEH was used to set a different bit in that register to 1 GIEH stands for Global Interrupt Enable High which means that the processor would now start looking for any high priority interrupts that were enabled GIEL is not used here but this bit would be used if it were import
141. oltage was needed before it could be run to the microprocessors which ran at 3 3V To make this step down the same voltage regulator that was used in the remote control was again used 3 6 3 2 Bluetooth Module The Bluetooth module that was chosen was the LMX9830 Bluetooth Serial Port Module made by National Semiconductor This Bluetooth module was chosen because it has its own processor embedded into it With its own processor in it the Bluetooth protocol stack does not have to be loaded onto the PIC18F87J10 like the Zigbee Stack does Even though the price of this Bluetooth module was slightly higher because of the built in processor it paid off because it would only be used in one lamp which would prevent the lighting system to be too expensive The Bluetooth module would connect to the microprocessor using a UART interface The datasheet of the LMX9830 gives explicit directions on how the UART is set up The UART in the LMX9830 supports a four wire connection which operates better because it uses two recognition lines But the LMX9830 can also connect to a two wire UART microprocessor which the PIC18F87J10 only supports this information can be found in the LMX9830 Software Users Guide It requires that the Clear To Send CTS input to be pulled ground This will allow the two processors to properly talk to one another This Bluetooth module was used because it creates a Serial Port with another Bluetooth unit Once it is connected as a S
142. on the control form window This button provides the ability for the user to hide the program window and open it up again simply by clicking on it in the windows task bar 55 Private Sub BTN_MINIMIZE_Click ByVal sender As System Object ByVal As System EventArgs Handles BTN_MINIMIZE Click Me WindowState FormWindowState Minimized End Sub 4 5 2 1 2 3 8 HELP BUTTON The help button opened a help dialog screen This screen provided the user with a guide on how to operate the program 4 5 2 1 2 3 9 EXIT BUTTON The exit button performed two operations First all of the array and global variable information was stored into the data txt file Second the program was exited completely Private Sub EXIT Click ByVal sender As System Object ByVal e As System EventArgs Handles EXIT Click Call Save Data End End Sub The save data subroutine is show below It utilizes a series of for statements along with the write command to create the data txt file Private Sub Save Data Dim x y As Integer Dim textdelimiter As String Create an instance of StreamWriter to read from a file Dim sw As StreamWriter New StreamWriter System AppDomain CurrentDomain BaseDirectory amp data txt textdelimiter sw Write UserName amp textdelimiter sw Write PresetName amp textdelimiter sw Write Preset2Name amp textdelimiter sw Write Preset3Name amp textdelimiter sw Write MasterLampName amp textdelimiter Forx 0To
143. on was sent followed by a few more instructions sent on every transmission that dealt with the destination of the message and the security of the message More details about the other steps in send the message are found in the AN965 document An if statement identical to this one was then written for the rest of the interrupt flags that would be detected This brings us to the end of the modified code and to the end of the main function 4 5 2 2 2 5 Interrupt Service Routine The Interrupt Service Routine could be found below the main function and controlled all the operations if an interrupt occurred This function is called Void UserInterruptHandler void The first task of this function was to determine if an interrupt had occurred so an if statement referring to INTCONbits RBIF was checked written if INTCONbits RBIF 1 38 Microchip Technology Inc 39 Microchip Technology Inc 62 As mentioned above in Section 4 5 2 2 2 3 the RBIF was normally set to 0 and if a change was seen on the input PORTB4 7 the flag of that register was set The next step of the interrupt function was to check and record which input caused the flag This was necessary because any one of the four inputs could set off this one flag So another if statement was written which looks like this if RB7 INT 1 6 RB6 INT 1 6 RB5 INT 1 6 PowerFlag bits Power TRUE The processor compared the PORT B register to this
144. oprocessor and wrote a Hello World test program in assembly code laying a foundation for Ryan s software work Chris designed built and tested the PCBs for the button array and the amplifier in the secondary plan Chris was also responsible for ordering parts researching parts for the LED array working with Dustin on the initial LED array hardware testing two presentations and helping write up the final report 6 1 2 Dan Prince During the first semester Dan researched wireless protocols After the team determined that the Zigbee protocol would be used it was Dan s responsibility to create a schematic for the Zigbee transceiver and surrounding circuitry After the PCBs were laid out Dan spent his time ordering parts until this task was completed Following the receipt of parts Dan began researching and learning PIC microcontroller programming and software Next Dan began testing and debugging PCBs This was followed by Zigbee protocol research and setup of Zigbee transfers using PIC software While continuing experiments with Zigbee Dan worked on the amplifier circuit and button circuit The semester was completed with setup for design night and completion of the final report 6 1 3 Ryan Truer During the first semester Ryan started to research different Bluetooth Modules and the overall set up of a Bluetooth device He was then assigned to pick out a Bluetooth Module that was used for the project After that was done Ryan began to make t
145. overcomes the complications detailed in Section 4 3 The team also recommends that soldering of components be done by a professional electrician or by machine so that more accurate soldering connections can be made 8 13 Lamp Base Transistors Team LEDmote only determined late in the prototype development stage of the project that an amplifying circuit of some kind would be needed It had not been forseen that the output voltage from the processor would be insufficient to power the LEDs directly and it was not until the testing stage that this problem arose In designing an amplifier circuit the team chose the most readily available transistors the VN88AFs that would function effectively for the design However the VN88AFs were rated much higher than necessary particularly in the area of drain source voltage which has a maximum value of 80V In a production system a lower rated and cheaper transistor would be more appropriate One difficulty in finding an appropriate transistor was that the output voltage from the microprocessor was 3 3V The transistors were thus required to have a gate source voltage of about 33 Vishay 86 3 3V However many transistor datasheets do not state the gate source voltage rating for their transistor In production the team has researched several possible MOSFETs that could be used to provide better amplifier efficiency These include the Vishay Siliconix Si2312BDS Fairchild FDS6570A and Fairchild 2
146. p was already being used for the encoder chip it was decided that the same chip could be used for the outputs The chip included six individual inverters embedded inside so another 8 pins were used for the outputs 7 1 6 2 Testing Once again the circuit had to be tested to ensure the operation of the encoder chip The power was then turned on again set to the right voltage and current limiting levels and then plugged into the proto board Once again the oscilloscopes were set up to read the four output channels and the buttons were pressed again The outputs began as expected out and became inverted Then a button was pressed and held down and the low levels went high and the high levels all went low This phase also operated correctly The button that was pressed was then released and a problem was noticed The lines did not return to their idle state In order to make sure that the chip was still operating a 84 probe was attached to the Output Enable input which was also being run through the inverter chip This line was operating correctly so we knew that the chip was still working It was concluded that the inputs could recognize an active high input but could not recognize an active low input In order to correct this pull down resistors were attached to the inputs of the inverter chip The circuit was powered up once again and tested the same way as above This time everything was functioning correctly Below in Figure 23 is a picture
147. pendix 10 3 Figure 4 LED Array 4 3 3 5 Lamp Base PCB The lamp base printed circuit board was designed much in the same way as the remote control circuit board With the development kit that was purchase for the LMX9830 some of the software that came with the kit provided the prints for the four layers of the development kit These prints were replicated as close as possible just like the PIC18F87J10 and the MRF24J40 were before Also a bit of concern was created by the use of two RF modules on one board The solution that was proposed by the team was to put the two RF modules as far away as possible From Figure 5 it can be seen that the Bluetooth was populated near the top left and the MRF24J40 located at the bottom middle of the board 38 Figure 5 Lamp Base 4 3 4 Secondary Lamps The secondary lamps do not need any more explaining because they are basically just a striped down Control Lamp The secondary lamps do not need a Bluetooth unit because these lamps just rely on the Zigbee modules to communicate to the rest of the lamp network 4 4 Complications The original plan had some significant complications caused both by the design and fabrication of the PCBs 4 41 Remote Complications In the Remote Control Circuit the MCU received an oscillating external signal from the Zigbee transceiver clock The Zigbee transceiver outputs a clock signal with a frequency of 2 5MHz which is below the minimum input clock rate for th
148. perational as long as it is within 30 feet of any lamp The computer must be within 30 feet of the master lamp in order to be operable The lamps will output 500 lumens which is equivalent to a 60 watt light bulb Taking these factors into consideration will determine the number of lamps needed per room Providing all these features at the market price of the average product on the market today is a great business opportunity 5 1 22 Industry Environment 5 1 2 1 Overview of the industry The commercial lighting fixture industry manufactures electric lighting fixtures for commercial industrial and institutional customers About 80 percent of industry output in 1997 was used for commercial and institutional purposes This characterized the market for the LEDmote family of products As of 1997 about 320 companies competed in the commercial lighting fixture industry Of these only a handful of companies have achieved over 400 million dollars in sales each The demand in I With such a high market demand and a diverse group of suppliers the market entry should not be difficult the US lamp industry is in the area of 6 5 billion units a year tota 5 1 2 2 Projected position for the future The first product release will involve conference room lighting and desk lighting The circuitry is being designed to accommodate other applications with as little adjustment as possible This provides the opportunity to bring the wireless LED lighting concept to oth
149. price aspect is an estimate based on Innotec s input The lamp controls pricing section consists of the Bluetooth and FPGA device along with various other minor components A miscellaneous components section is included to account for parts that have not yet been accounted for Finally labor shipping packaging is included into the price giving a total cost of 72 98 per unit sold Table 15 Desk Lamp Cost Analysis Part Name Price Unit Quantity Per Unit Unit Price LAMP FIXTURE Components Table 18 18 67 1 00 18 67 Material 7 50 1 00 7 50 TOTAL LED FIXTURE EXPENSE 26 17 LAMP CONTROLS Components Table 20 5 49 07 1 00 49 07 TOTAL LAMP EXPENSE 49 07 TYPICAL NUMBER OF COMPONENTS PER UNIT Lamp Fixture 26 17 1 00 26 17 Labor 12 00 0 04 0 48 Packaging 1 50 1 00 1 50 Shipping 250 1 00 2 50 Lamp Controls 49 07 1 00 49 07 TOTAL COST OF GOODS SOLD 79 72 The conference lighting production cost breakdown is shown in Table 16 below The lamp fixture itself contains LED material and miscellaneous components Team LEDmote is not designing the fixture itself so the material component price aspect is an estimate based on Innotec s input It is higher than the desk lamp given the built in aesthetics that will be required and the size of the conference room lamp fixtures The lamp controls pricing section consists of the Zigbee transceiver FPGA device minor components and one fourth of the Bluetooth module cos
150. r G CurrentArray i 5 ColorDialogl Color B PictureBoxl BackColor System Drawing Color FromArgb CType CurrentArray 0 3 Byte Integer CType CurrentArray 0 4 Byte Integer CType CType CurrentArray 0 5 Byte Integer Next Else CurrentArray CurrentLamp 3 ColorDialogl Color R CurrentArray CurrentLamp 4 ColorDialogl Color G CurrentArray CurrentLamp 5 ColorDialogl Color B PictureBoxl BackColor System Drawing Color FromArgb CType CurrentArray CurrentLamp 3 Byte Integer CType CType CurrentArray CurrentLamp 4 Byte Integer CType CType CurrentArray CurrentLamp 5 Byte Integer End If End Sub Private Sub BTN MANUAL Click ByVal sender As System Object ByVal e As System EventArgs Handles BTN MANUAL Click NewMode MANUAL Call Change Mode End Sub Private Sub PRESET1 Click ByVal sender As System Object ByVal As System EventArgs Handles BTN_PRESET1 Click NewMode Preset1Name Call Change Mode End Sub Private Sub BTN PRESET2 Click ByVal sender As System Object ByVal e As System EventArgs Handles BTN PRESET2 Click NewMode Preset2Name Call Change Mode End Sub Private Sub BTN PRESET3 Click ByVal sender As System Object ByVal e As System EventArgs Handles BTN PRESET3 Click NewMode Preset3Name Call Change Mode End Sub Private Sub all Click ByVal sender As System Object ByVal e As System EventArgs Handles all Click
151. r of Units 60000 5 9 Sales Price Per Unit 84 71 Desk Lamp Revenue 5 082 587 69 COGS 4 783 382 40 Desk Lamp Net Income 299 205 29 CONFERENCE ROOM Marginal Revenue Number of Units 8000 52 096 Sales Price Per Unit 190 11 Conference Room Revenue 1 520 866 96 COGS 730 197 22 Conference Room Net Income 790 669 74 OV ERHEAD EXPENSES 213 241 21 132 069 09 Warranty Expenses R amp D Expenses Launch Amortization Expense 563 215 44 Selling Expense 140 800 00 Maintenance Expense 25 000 00 Insurance 10 000 00 Total Expenses 1 084 325 74 NET INCOME BEFORE TAXES 5 549 29 Income Tax 2 219 72 NET INCOME 3 329 58 The third year income statement Table 20 was created using the financial analysis from the research and projections in the previous sections The number of units sold increased from the previous terms due to product exposure and advertising The projected second year sales are 91 000 units still a conservative 0016996 industry market share The sale price of the units is decreased by 1096 from the original price to account for inflation and to keep the product competitive Additionally the cost of goods sold was decreased by 5 to account for improvements in production efficiency and decrease in component costs The marginal revenue percentage of the desk lamp is 5 596 The marginal revenue percentage of the conference room is 5296 The final la
152. rate the SPBRG value had to be set to 12 So the follow code was written to do this 0 XSTAbits SYNC 1 XSTAbits BRGH BAUDCONbits BRG16 0 30 Microchip Technology Inc 64 SPBRG 0 0 The first line shown above sets the UART to asynchronous mode by clearing the Synchronous bit in the TXSTA register The second line allowed the use of a second register to help define the baud rate more clearly The last line shown above finally set the Baud Rate Register to a decimal value of 12 which told the processor to use a 19200 Baud Rate After the baud rate had been set a few more steps needed to be performed before the UART was fully operational First the serial port had to be enabled and to do this the line of code shown below was used RCSTAbits SPEN 1 This enabled the physical input and output of the UART to communicate The next operation that must be performed was the choice of nine bit mode or eight bit mode Nine bit mode allowed a ninth bit to be sent to check for errors in the transmissions For this project it was decided just to use the standard eight bit mode so the code below was added RCSTAbits RX9 0 The last setting that needs to be set is TXSTAbits TXEN 1 This allowed the UART module in the PIC18F4620 to allow transmissions If this was not set to high the processor would never send out a transmission However if set high the processor would recognize that it need
153. reamReader System AppDomain CurrentDomain BaseDirectory amp Data txt Dim readcontents textdelimiter As String of the file is reached readcontents sr ReadToEnd Read and display the lines from the file until the end XV textdelimiter Dim splitout Split readcontents textdelimiter sr Close UserName splitout 0 splitout 1 Preset2Name splitout 2 Preset3Name splitout 3 MasterLampName splitout 4 For i 5 To 103 For x 0 To 8 For y 0 To 10 PresetlArray x y splitout i 1 1 1 Next 0 Next x 0 Next For i 104 To 202 For x 0 To 8 For y 0 To 10 Preset2Array x y splitout i i i 1 Next 0 Next x 0 Next For i 203 To 301 For x 0 To 8 For y 0 To 10 Preset3Array x y splitout i 1 1 Next 0 Next x 0 Next End Sub Search For Master Lamp and retrieve individual Lamp Info Private Sub Master_Lamp_Search Dim i As Integer NumberOfLamps 7 For 1 0 8 Current White Intensity on Each Lamp CurrentArray i 1 0 Current Color Intensity on Each Lamp CurrentArray i 2 0 Current Red Intensity on Each Lamp CurrentArray i 3 0 Current Green Intensity on Each Lamp CurrentArray i 4 O Current Blue Intensity on Each Lamp CurrentArray i 5 0 CurrentArray i 6 False CurrentArray i 7 False CurrentArray i 8 False CurrentArray i 9 False CurrentArray i 10 False Next
154. riority peripheral interrupts TCONbits GIEL 1 Set RBO 1 RB2 to INPUTS PORTB 0x00 TRISB LATB 0x00 Bluetooth Inquiry Command void BT_Inquiry_CMD void WritelUSART 0x02 LII Wri Wri Wri Wri Wri Wri Wri Wri Wri tel tel tel tel tel tel tel tel tel recurn SA SA SA SA SA SA SA SA SA 0x52 0x00 0x03 0x00 0x55 0 0 0 00 0 00 0 03 2 2 M Ne Ne Ne Ne Ne Ne 89 lt LII
155. rrenty EDBlue 1 EDBlue 69 903mW ae MaxCalcPLEpBiue arg EDBlue LEDBlue PMargin LEDBlue 17 761 3 TRANSISTOR 1 CURRENT AND MARGIN J VsourceMax x VEBlueMin MaxCurrentp3 MaxDutyCycle ae Ro 16 3 139 806mA 4 x MaxCurrenty4 CurrentMargin 4 1472 4 CurrentMargin 65 049 RED LED CIRCUIT CALCULATIONS 1 RESISTORS i OHM Vsource VERed R17 24Calc 2009 XII 24Max 7 17 24 1 R17 24Toleranc 7 24 903 992 24Min R17 24 1 17 24 R17 24Min 494 010 CURRENT _ VERedMin MaxCurrentp 7 24 gt og R47 24 7 247 16 187mA POWER MaxPa 7 547 24 MaxCurrentg 7 24 17 245 0 131 W MARGINS PRatingg 17 247 17 24 17 24 2 LED i CURRENT amp MARGIN i VERedMin MaxCurreny 17 24 MaxCurrenty d 21 583mA IFRedMax CurrentMarginy IFRedMax CurrentMarginy 38 334 ii POWER AND MARGIN Pr gpRed VFRed lFRed PLEDReq 40mW MaxCalcPp VERedMin
156. s designed to step up the voltage The transistors that were chosen were FDN339AN transistors made by Fairchild Semiconductor The datasheet that went along with these transistors states that they can handle 20V and up to 3A These transistors had to be rated high enough to handle the 2 3A draw from LEDs 3 4 3 4 LED Array The LED Array PCB can be seen in Figure 4 Using a set of four high power MOSFET transistors the current driven through each pair of LED s can be controlled By pulse width modulating the base of each transistor the intensity of each color can be adjusted The prototype array contains 8 RGB LEDs used to demonstrate color changes and ten white LEDs The white LEDs are not mounted to the board in Figure 4 due to heat dissipation requirements In 14 order to quickly dissipate heat the white LEDs must be mounted to a specialized heat sink surface If mounted to the PCB the base of the PCB will likely melt The white LEDs were mounted directly to the display lamp metal casing to allow heat dissipation The white LEDs are connected to the pads shown at the top of the board Current passes through four current controlling resistors before passing through the LEDs The white LEDs are paired in series so each of the first five pads shown from left to right across the top of Figure 4 are connected in series to two white LEDs Given the variability of the resistors and LEDs a worst case analysis was performed on this circuit to fin
157. sType part amp ExactDS Starts gt 90 10 Appendices 10 1 Microsoft Milestones Project File e Task Name Duration Start 1 E Milestones 67 days Fri 2 9 07 2 Schematic Layout 1 day Fri 2 9 07 uit Board L 1 day Fri 2 4 6 07 4 Order Boards Fri 2 23 07 5 E Working Tested Hardware 1 day Fri 3 30 07 5 Working Tested Software 1 day Fri 443 07 Vorking Tested Prototype 1 day Fri 4 20 07 8 E Senior Design Banquet 1 day Sat 5 5 07 3 Project Review by Professors 5 days Mon 5 7 07 Finish Fri 5 11 07 Fri 2 8 07 Fri 2 4 6 07 Fri 2 23 07 Fri 3 30 07 Fri 4 3 07 Fri 4 20 07 Sat 5 5 07 Fri 5 11 07 February 1 1 April 1 1 24 241 248 225 34 341 325 4 48 415 4 22 4 28 58 5H3 ls 29 216 223 3 30 1 420 55 10 2 Bill of Materials 10 2 1 LED Array Bill of Materials QTY 16 16 20 10 REFERENCE R1 R2 R4 R5 R6 R7 R9 R10 R11 R12 R13 R14 R15 R16 R45 R46 R47 R48 R49 R50 R51 R52 R53 R54 R55 R56 R57 R58 R59 R60 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 LED1 LED2 LEDS LED4 LEDS LED6 LED7 LED8 LED9 LED10 LED11 LED12 LED13 LED14 LED15 LED16 LED17 LED18 L1 PRODUCT NAME
158. se the processor recognized a change to a low voltage from a default high voltage while the encoder output a higher voltage upon a button push input The MM74CO4N inverter chip was chosen as it was readily available and appeared to function effectively The team discovered that the inverter worked most effectively when the output from the encoder was tied to a pull down resistor so that the current reaching the inverter was low In the prototype these pull down resistors had a value of 10MO 4 5 1 2 4 PIC18F4620 In the prototype of our design the PIC18F4620 was used as part of the PICDEM Z development kit The original design called for the PIC18F87J10 processor but the 4620 came pre installed in the development kit and so the team chose to do some research on this processor and use it instead of the 87J10 in the remote control The 4620 on the development kit came with the hardware necessary to take inputs and then output to the Zigbee daughter 4 5 1 3 Lamp Base 4 5 1 3 1 Amplifier The amplifier circuit was designed to amplify the signal from the microprocessor to the LEDs Since the processor only outputs a voltage of 3 3V and the LEDs required a higher voltage to operate correctly selecting the correct amplifier circuitry proved important Fairchild Semiconductor n Fairchild Semiconductor Microchip Technology Inc 30 Microchip Technology Inc 31 Microchip Technology Inc 42 Figure 8 Protot
159. see Section 4 3 Original Base PCB of Design Lamp Base 3 6 1 Overview Remote Control Button Array 1 PIC18F87110 Control Lamp Secondary Lam LMX9830 24140 5 1 PIC18F87H0 PIC18F87H0 SPI 24140 Amplifier LED Array Computer Program Figure 2 Original Design Block Diagram 3 6 2 Remote Control The remote control was designed to allow the users to communicate to any 21 light in the room from any position he she is standing The remote control is nice feature to have with this lighting system because it does not limit the user to any distance from a light but at the same time it was designed for limited operability of the lights 3 6 2 1 Power Supply The remote control was designed to use 2 AA batteries which would produce a 4 5 V output onto the board This was a little high because the processor and Zigbee module were specified to run at 3 3 V To knock down the voltage to a tolerable level for the processor to handle a REG103GA 3 3 linear voltage regulator was used The datasheet for this regulator states that this voltage regulator can take an input of up to 15 V This was nice to know because it can handle the input from the batteries On an added note the voltage regulator can also handle an input of 12 V which the Lamp Modules run off of This voltage regulator is also rated at 500 mA this is well above the current that the main processor and the Zigbee processor ever pull
160. software Verify that the SPI pins on the MCU show the correct sequence The remote PCB passed all the power tests but did not pass all the clock tests The MCU did not have a 20MHz clock input it was only a 2 5MHz clock signal Also the RF Output Test and MCU Communication Test did not pass probably caused by the earlier failure of the Clock Test 7 1 5 Encoder 7 1 5 1 Hook Up The encoder chip MM74C922 was first placed down on the Proto Board Ground and V wires were then attached to pins 10 and 20 respectively These wires were not hooked up yet however A 10 uF capacitor was connected to the key bounce mask pin 7 in order for the chip to pull off any de bouncing from the buttons Another 1 uF capacitor was connected to the Oscillator Input pin 6 which was specified to be 1 10 the size of the key bounce capacitor An inverter chip 74 04 was connected between the Data Available output pin 13 and Output Enable pin 15 which is an active low input This was done so that when the chip sends out a signal notifying that the data is ready to send the chip also 83 gets activated to send out that data If this was not done the encoder would be constantly sending out the data to the microprocessor Next the 11 buttons had to be connected to inputs 1 4 and 1 4 This was done according to the truth table and given to us from the datasheet of the encoder chip shown in Table 26 below Table 26 Encoder Chip
161. stors states that they can handle 20V and up to These transistors had to be rated high enough to handle the 2 3A draw from LEDs 4 3 3 4 LED Array The LED Array PCB can be seen in Figure 4 Using a set of four high power MOSFET transistors the current driven through each pair of LED s can be controlled By pulse width modulating the base of each transistor the intensity of each color can be adjusted The prototype array contains 8 RGB LEDs used to demonstrate color changes and ten white LEDs The white LEDs are not mounted to the board in Figure 4 due to heat dissipation requirements In order to quickly dissipate heat the white LEDs must be mounted to a specialized heat sink surface If mounted to the PCB the base of the PCB will likely melt National Semiconductor Co National Semiconductor Co i Fairchild Semiconductor 37 The white LEDs were mounted directly to the display lamp metal casing to allow heat dissipation The white LEDs are connected to the pads shown at the top of the board Current passes through four current controlling resistors before passing through the LEDs The white LEDs are paired in series so each of the first five pads shown from left to right across the top of Figure 4 are connected in series to two white LEDs Given the variability of the resistors and LEDs a worst case analysis was performed on this circuit to find the optimal values and tolerances for the resistors This analysis can be seen in Ap
162. t A miscellaneous components section is included to take into account for parts that we did not account for in the design We are assuming that the typical conference room will have one remote one mother lamp with dual wireless technologies i e Zigbee and Bluetooth and three slave lamps Therefore the single unit cost includes one fourth of the remote and Bluetooth module Finally labor shipping packaging and one forth remote cost are included into the price giving a total cost of 76 29 74 Table 16 Conference Room Cost Analysis Part Name Price Unit Quantity Per Unit Unit Price LAMP FIXTURE Components Table 18 31 96 1 00 31 96 Material 15 00 1 00 15 00 TOTAL LED FIXTURE EXPENSE 46 96 LAMP CONTROLS Master Components Table 19 5 49 07 0 25 12 27 Slave Components Table19 30 64 0 75 22 98 TOTAL LAMP EXPENSE 35 25 REMOTE COSTS Components 22 35 1 00 22 35 TOTAL REMOTE EXPENSE 22 35 TYPICAL NUMBER OF COMPONENTS PER UNIT Remote 22 35 0 25 5 59 Lamp Fixture 46 96 1 00 46 96 Labor 12 00 0 04 0 48 Packaging 1 00 1 00 1 00 Shipping 2 00 1 00 2 00 Lamp Controls 35 25 1 00 35 25 TOTAL COST OF GOODS SOLD 5 91 27 5 1 5 3 Projected Income Statements Table 17 Annual Sales Projections Year1 Year 2 Year 3 Desk Lamp 30 000 60 000 80 000 Conference Room 4 000 8 000 11 000 The annual sale projections are derived from the market research in the LEDmote marketing plan The
163. t this was the most intuitive layout This layout can be seen in Figure 7 The team chose to use small round buttons for the prototype to minimize space requirements on the remote control Red Green and Blue buttons were selected to correspond to the red blue and green color increases White buttons were designated to represent increases and decreases in white color Black buttons were designated to represent increases and decreases in all three colors A yellow button was selected as a power button 41 4 5 1 2 2 Encoder The team chose to use MM74C922 encoder chip after realizing that a compatibility issue had arisen The remote control needed to have 11 input buttons to the PIC18F4620 processor but the processor only had 4 inputs The encoder s main function was to serve as a matrix so that the correct signals would be passed to the processor The selected encoder also had an inbuilt debouncer which circumvented the difficulties the team had previously experienced with bouncing The encoder datasheet showed a simple design for asynchrous data entry onto a bus providing a very similar circuit to our needs This circuit included an oscillator function using a capacitor connected to ground and an inverter set up on the Data Available pin to set up the Output Enable pin so that the encoder signals could be read by the processor 4 5 1 2 3 Inverter The team found it necessary to include an inverter chip in the remote control design becau
164. t to be the same and could communicate properly once data was sent The rest of the UART was set up in the next few lines RCSTAlbits SPEN 1 RCSTAlbits RX9 0 RCSTAlbits CREN 1 The serial port was enabled on the first line shown above This line of code refered to the RCSTA1 register The 1 the name allowed the processor to distinguish between the two different UARTs in the processor The next line of code above set this UART to eight bit mode and the line under that was the most important CREN stands for Continuous Reception This allowed the processor to always look for data in the UART receive register as opposed to setting it to single reception where the UART would have to be reset after every reception The next step in the function was to set up the second UART for the Bluetooth module communication The baud rate was set up identically because the Bluetooth module also used a baud rate 19200 The rest of the UART was set up the same way except that the transmitter had to be enabled as well This was done by the line TXSTA2bits TXEN 1 After this was set both the UARTs in this processor were set up and fully capable of communicating to the other two processors 4 5 2 243 Hardware Initialization The hardware initialization function was then called in the main program to initiate any other application necessary settings For this program the initialization was very short because PWM were set up in the actu
165. textdelimiter For x 0 To 8 For y 0 To 10 Sw Write PresetlArray x y 5 textdelimiter Next 0 Next x 0 For x 0 To 8 For y 0 To 10 sw Write Preset2Array x amp textdelimiter Next 0 Next x 0 For x 0 To 8 For y 0 To 10 sw Write Preset3Array x amp textdelimiter Next y 0 sw Close End Sub Private Sub BTN_MINIMIZE_Click ByVal sender As System Object ByVal e As System EventArgs Handles BTN_MINIMIZE Click Me WindowState FormWindowState Minimized End Sub Private Sub WhiteBar_Scroll ByVal sender As System Object ByVal e As System EventArgs Handles WhiteBar Scroll WhiteIntensity Text WhiteBar Value 100 50 amp 5 If CurrentLamp ALL LAMPS Then CurrentArray 0 1 WhiteBar Value 1 1 WhiteBar Value CurrentArray 2 1 WhiteBar Value CurrentArray 3 1 WhiteBar Value CurrentArray 4 1 WhiteBar Value CurrentArray 5 1 WhiteBar Value CurrentArray 6 1 WhiteBar Value CurrentArray 7 1 WhiteBar Value XXIII CurrentArray 8 1 WhiteBar Value Else CurrentArray CurrentLamp 1 WhiteBar Value End If End Sub Private Sub btnColorPanel_Click ByVal sender As System Object ByVal As System EventArgs Handles btnColorPanel Click Dim i As Integer ColorDialogl ShowDialog If CurrentLamp ALL LAMPS Then For 0 8 CurrentArray i 3 ColorDialogl Color R CurrentArray i 4 ColorDialogl Colo
166. that displays the circuit connections of the button array encoder and inverter This will then be connected to the Remote Control Processor to test if the inputs are being decoded correctly in the software Figure 23 Bread boarded components of Prototype Remote Control 7 2 Software Testing 7 2 1 PC Software The software went through extensive testing even though the final version did not have full Bluetooth functionality Each mode was tested to be sure they would retain the values The scheduler was tested in every recurrence scenario Each setup option was tested along with the color panel Everything proved to be fully functional Through the testing process some glitches were discovered in the scheduling code that was immediately remedied 7 2 2 PIC program To test the programs for the processors MPLAB provides a very useful debugging tool incorporated into it After some code had been written the processor would be programmed normally and the program would be checked from a hardware aspect If these tests did not work the program would then be test using one of the debuggers inside MPLAB The first debugger that would be used is the programmed debug on the processor itself In this debug mode the user is able to step through the program and see 85 if it is following the correct path that it should be following The second debugger is called MPLAB SIM which is a debugger that does not use the processor itself but instead MPL
167. the known progress or step of the program that needed to be performed After that step was performed currentPrimitive then incremented the proper instruction so the switch statement would do the next instruction in the list on the next run through The whole first part of this function dealt with how the Zigbee RFD connected to the network The next task of this function was to receive and transmit application specific instructions from one Zigbee module to another For this project the program only needed to send transmissions to the Zigbee Coordinator so the section on how the DemoRFD program sent messages was the most informative section of the entire DemoRFD program supplied by Microchip It can be found in the section below of the code KKK KKK KKK KKK KKK KK KKK KKK KK KKK KKK KKK KKK KKK KKK KK KKK KKK KKK KK Place all processes that can send messages here Be sur to call ZigBeeBlockTX when currentPrimitive is set to APSDE_DATA_request KKK KKK KKK KKK KKK KKK KK KKK KKK KKK KKK KEK KKK KKK KK KKK KKK KKK KKK KK The next step was to write the code that actually sent the wireless transmission to the other Zigbee Coordinator Some research was done and the code found in the AN965 Microchip Stack for the 61 Zigbee Protocol document was used This document usefully explained how the demo programs and gave more specifics on important instructions used to control transmissions The section that was r
168. the last duty cycle with the new increased one This same sort of operation was done for the rest of the UP opcodes and also for the DOWN opcodes by subtracting the CHANGE constants for the duty cycles After the proper case statement had been performed the program waited for another UART transmission to be received 5 Business Plan 5 1 1 Business Opportunity There are many lighting products currently available in commercial industry A corporation has thousands of lamps to choose from in order to meet their needs In order to enter an industry with hundreds of established suppliers you must offer a product that is unique to the industry The product that team LEDmote was aiming to develop did this in several ways LEDmote used new LED technology in its lamp modules providing customers with high clarity pure white light at a very low power The LED cells lasted longer and burned cooler than regular lighting methods in the current market greatly improving efficiency Team LEDmote s project incorporated multicolor accenting effects and a wireless 70 control system giving customers more freedom and more control over their lighting environment from their computer or remote control Mood lighting is easily accessible for conference rooms depending on the presentation The conference room lighting system will be packaged as an easily expandable 4 lamp system with a remote control The number of lamps will depend on the room size The remote will be o
169. these lamps just rely on the Zigbee modules to communicate to the rest of the lamp network Complications PC PC Software Software 3 6 5 Electrical Requirements In the Project Proposal and Feasibility Study that the team put together in the fall of 2006 there was a list of project requirements that would determine the degree of success of the project at the end of spring 2007 These requirements are listed in Table 3 below Table 3 Electrical Characteristics Requirements Check Description Original Final Prototype Reason for Change Requirement Attribute 18 More Light Output 10 More Light Output 6 8 More Light Output Number of total LEDs per lamp White LEDs per lamp RGB LEDs per lamp Max intensity white LEDs 800 lumens 500 lumens Requires Less Light Max intensity RGB LEDs TBD 180 lumens Changed to Accent Lighting Max current per white LED 500mA Increased Tolerances Osram Golden Dragon Datasheet 4 Osram Tri color LED Datasheet 1 Osram Golden Dragon Datasheet 26 Description Original Final Prototype Reason for Change Requirement Attribute Max current per RGB LED 50mA 70 Increased Tolerances Lamp total power 25W 23W Lower Power consumption Consumption Estimated number of colors 256 256 Dimming variability Continuous 16 Segments Simplifies Design while Continuous operating Voltage 90VAC 250VAC 100VAC 240VAC still
170. ting it know that the message was received properly Once done with the message handling the case statement was broken and waited for another transmission to be received 4 5 2 2 4 LEDmote PWM Program This program was written for the main purpose of controlling the outputs of the LEDs It communicated through a UART connection to the Zigbee Coordinator chip which relayed the signals from the remote control At the beginning of the project it was decided that this program would control all the light modulation and Zigbee communications But due to some problems discussed earlier it was decided that this program would only do the PWM outputs 4 5 2 2 4 1 Constants and Variables Defined in PWM Program The PWM Program has extra Constants defined that the other two programs lack because of the pulse width modulation handling The program started out the same way defining the opcode instructions which were just the same as the other two programs The next defined constant was used to set the period for the pulse width modulation this was shown below 66 define PERIOD_INITIAL OxFF The initial period was set to OxFF because this was the largest period that it could be set to This allowed for the maximum amount of adjustment of the LED brightness If it were really small the LEDs would flicker so fast that a large change in the duty cycle would not be seen by the naked eye The next set of constants define the initial conditions for the duty cy
171. transistors states that they can handle 20V and up to 3A These transistors had to be rated high enough to handle the 2 3A draw from LEDs 3 3 4 4 LED Array The LED Array PCB can be seen in Figure 4 Using a set of four high power MOSFET transistors the current driven through each pair of LED s can be controlled By pulse width modulating the base of each transistor the intensity of each color can be adjusted The prototype array contains 8 RGB LEDs used to demonstrate color changes and ten white LEDs The white LEDs are not mounted to the board in Figure 4 due to heat dissipation requirements In order to quickly dissipate heat the white LEDs must be mounted to a specialized heat sink surface If mounted to the PCB the base of the PCB will likely melt The white LEDs were mounted directly to the display lamp metal casing to allow heat dissipation The white LEDs are connected to the pads shown at the top of the board Current passes through four current controlling resistors before passing through the LEDs The white LEDs are paired in series so each of the first five pads shown from left to right across the top of Figure 4 are connected in series to two white LEDs Given the variability of the resistors and LEDs a worst case analysis was performed on this circuit to find the optimal values and tolerances for the resistors This analysis can be seen in Appendix 10 3 Figure 4 LED Array 3 3 4 5 Lamp Base PCB The lamp base printed
172. ts ura t ees 6 3 4 Production Design Requirements 8 341 PCRequirements n ert e eoe voran Eee uen eo e ein EER vtri ete ioa 8 3 4 2 Electrical Requirements iT e A edens 8 3 4 3 LED Enclosure Requirements 8 3 4 4 Lamp Spacing 8 AREA DIIN e a 9 4 1 ee aac acd hen ete eet eee RE 9 4 2 Design DECISIONS ete ce e e OU ERN 9 4 2 1 kamp Module Decision ertet rt 9 4 22 Lighting DECISIONS Si erret et tente et deett te ene et Rte 10 4 2 3 Button Decision ok ns ite LO ek eee Ed UY eie mies 11 4 2 4 Amplifier 12 425 POWER DECISION ahi A een 13 4 2 6 System 15 13 42 7 Switch Decision tae ei ere EE ERR Poele rias 14 4 3 eet tdt teet id etude a 15 4 3 1 EE 15 4 3 2 Remote Control cetera eet ees o 15 433 Control Lamp Tere e eiie 17 4 3 4 20 4 4 Complication Sesso
173. ts 3 3V and the LEDs run on 12V This would not allow the LEDs to light up properly because they would never get to the right voltage level In order to drive the LEDs a N Channel MOSFET transistor was designed to step up the voltage The transistors that were chosen were FDN339AN transistors made by Fairchild Semiconductor The datasheet that went along with these transistors states that they can handle 20V and up to 3A These transistors had to be rated high enough to handle the 2 3A draw from LEDs 3 5 3 4 LED Array The LED Array PCB can be seen in Figure 4 Using a set of four high power MOSFET transistors the current driven through each pair of LED s can be controlled By pulse width modulating the base of each transistor the intensity of each color can be adjusted The prototype array contains 8 RGB LEDs used to demonstrate color changes and ten white LEDs The white LEDs are not mounted to the board in Figure 4 due to heat dissipation requirements In 19 order to quickly dissipate heat the white LEDs must be mounted to a specialized heat sink surface If mounted to the PCB the base of the PCB will likely melt The white LEDs were mounted directly to the display lamp metal casing to allow heat dissipation The white LEDs are connected to the pads shown at the top of the board Current passes through four current controlling resistors before passing through the LEDs The white LEDs are paired in series so each of the first five pads s
174. ts SYNC RCSTAlbits SPEN lt gt RCSTAlbits RX9 0 RCSTAlbits CREN RCSTAlbits SPEN 1 TRISCDbits IRISCO 0 TRISCHits TRISCT 1 5 1 0x24 5 1 0x20 5 1 0x90 SPBRG SPBRG_VAL BAUDCON1 0x40 u void HardwareInit void CCP2CONbits CCP2M2 0 V f I Inturrupt Configuration Section Set to Asynchronous Set Serial Bit Nine Eight bit mode Enable Reception Serial Port ENABLE bit Sets RC6 to INPUT for TX USART1 Sets RC7 to OUTPUT for RX USART1 Enables TXEN and BRGH HIGH Enables TXEN and BRGH LOW Enables Serial Port amp Continous Receive Enable REceive Operation is Idle Set Up Timerd TMROH 0 clear timer TMROL 0 clear timer TOCON 0x82 set up timerO prescaler 1 8 Set Flag Bits to 0 PowerFlag Value 0x00 Disable Global Interrupts INTCONbits GIEH 0 INTCONbits GIEL 0 Enable Priority Levels RCONbits IPEN 1 INTERRUPT ENABLE BITS INTCONbits RBIE 1 Interrupt On Change Enable bit RB7 4 INTCON2bits RBPU 0 Disables all PORTB Pull ups INTERRUPT PRIORITY BITS INTCONZbits RBIP 1 Interrupt on Change Clear RBO 1 RB2 FLAGS INTCONbits RBIF 0 Enables all HIGH priority inturrupts NTCONbits GIEH 1 N Enables all LOW p
175. ue Else AddNumberOfDays AddNumberOfDays 1 DayOfMonth 14 End If Case 14 If Schedule chk14 Checked True Then XXXV amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text amp Schedule AMPM1 Text D2 D2 DateAdd DateInterval Day AddNumberOfDays DayOfMonth 15 End If If Schedule chk3 Checked True Then D2 Now amp D2 DateAdd DateInterval Day AddNumberOfDays DayOfMonth 16 End If If Schedule chk16 Checked Else If Schedule chk17 Checked Else Now amp amp Schedule timel Text amp DateValue DateAdd DateInterval Month AddNumberOfMonths AddNumberOfDays D2 EndLoop True AddNumberOfDays 1 on DateValue DateAdd DateInterval Month AddNumberOfMonths amp Schedule timel Text amp AddNumberOfDays D2 EndLoop True AddNumberOfDays 1 True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 17 End If True Then D2 DateValue DateAdd DateInterval Month AddNumberOfMonths Now amp amp Schedule timel Text amp D2 DateAdd DateInterval Day AddNumberOfDays D2 EndLoop True AddNumberOfDays AddNumberOfDays 1 DayOfMonth 18 End If Case 18 I
176. ument The first variable sent to this function was inputstr which told the function where to store the data The second variable sent to the function told it how much data it should copy into the array For this case the Coordinator Program was only sending it one Byte of instruction so only one Byte had to be stored into the inputstr array The last line of code listed above set the opcode variable to whatever data is stored in the first position of the inputstr This was the Data received from the UART The next step was to decipher what opcode was received from the UART This was done by loading the opcode value into a switch statement switch opcode case POWER if power status power status 1 power status 0 Break 69 Above is the general switch statement of how the program worked and how the PWMs was used If the opcode equaled the POWER constant then it would go into the case statement shown above The first thing that this case statement did was check if the light was on or off If equal to zero the program would set the power_status variable to 1 and then proceed to turn the LEDs on The program turned on the LEDs by using three functions that were also found in the MPLAP C18 Library document First the PWM outputs were initialized by calling the OpenPWMx command This would set up all the need hardware for the PWM to be outputted It also set the period of the PWMs Second some special initialization
177. unch expense amortized along with a selling expense was calculated with a 100 000 base 0 50 per unit sold for sales person salary and advertising expenses The warranty expense assumed a 3 claim rate on the products sold The claim rate is decreasing due to more efficient processes and decrease PPM The cost of the replaced products is calculated into this warranty expense The company continues the R amp D expense to cover the development of new products in order to remain competitive The product line produces a net profit of 77 177 132 25 in the third year The third year final statement reflects closely the sustainable income from this product line into the future years Table 20 Third Year Projected Income Statement LEDmote PRODUCT LAUNCH INCOME STATEMENT THIRD YEAR STATEMENT DESK LAMP Marginal Revenue Number of Units 80000 5 6 Sales Price Per Unit 80 25 Desk Lamp Revenue 6 420 110 77 COGS 6 058 951 04 Desk Lamp Net Income 361 159 73 CONFERENCE ROOM Marginal Revenue Number of Units 11000 51 9 Sales Price Per Unit 180 10 Conference Room Revenue 1 981 129 33 COGS 953 820 12 Conference Room Net Income 1 027 309 21 OV ERHEAD EXPENSES Launch Amortization Expense 375 476 96 Selling Expense 145 500 00 Maintenance Expense 25 000 00 Insurance 10 000 00 Warranty Expenses 221 455 93 R amp D Expense 252 037 20 Total Expenses 1 029 470 09 NET INC
178. unctionality The Zigbee protocol has the added functionality of creating networks of transceivers Within a Zigbee network when a signal is sent from one transceiver it is repeated to the entire array This means that a remote could send a signal to one lamp and this signal would be sent to all lamps in the network This is flexible because the remote can make its original communication with any lamp t is functional because networks can be used for an entire room or an entire office building The lone requirement is that the distance between lamps can be no greater than 10 meters 33 feet 3 1 1 4 Supporting Hardware The supporting hardware of the system consists of an array of buttons on the remote to function as inputs an array of tri color LEDs to provide colored light an array of white LEDs to provide working light and transistors at every pulse width output to give the LEDs adequate voltage The hardware also includes an encoder chip which functions both as a button debouncer and a transition stage from our 11 input button to our 4 interrupt ports on the development boards 3 1 2 Scope of Software 3 1 2 1 PCSoftware The Personal Computer PC software was intended to give a user more control and functionality over lamp arrays The original design was meant for the user to be able to select a color out of a choice of over 1 000 colors The user could also have chosen brightness for both white and multi colored light from a list of 12 sha
179. ut but instead continued on through the entire semester 7 Testing and Verification Testing and verification was used in every aspect of the design to check that each part of the design was working and to determine the tolerances of the device 7 4 Hardware Testing 711 MCU The MCU testing was mostly performed using LEDs on the HPC Explorer board and monitoring the PWM outputs 7 1 2 Bluetooth See section 8 1 1 7 1 3 Zigbee After confirming that a signal was being sent from one Zigbee module to another the team began to run tests on the range to determine the actual tolerances Table 24 shows the results Table 24 Zigbee Test Results Range in meters feet Obstacles Wireless Interference Open Air 200 250 656 820 _ Engineering 50 60 164 197 Wi Fi Building Johnny s 20 25 66 82 Brick Walls Wi Fi a b g Cafe 10 12 33 39 Concrete Walls and Wi Fi a b g Wood Doors Library 10 12 33 39 Steel Bookshelves Wi Fi The office environment is mix between the Engineering Building and the Library environments The Engineering Building has open bays with very few walls or obstructions It does however have interference from Wi Fi The Library environment has rows of steel bookshelves and interference from Wi Fi A typical office building might have steel and padded cubicles within rooms of plaster walls and may also have Wi Fi interference Th
180. utting a signal to light up the specified LEDs The second development kit was the PICDEM Z two of which were used in the secondary design The PICDEM Z board is a recent design by Microchip created specifically for testing communication through Zigbee One of the boards was used as a basis for the remote control while the other was used to communicate with the HPC board via UART hardwired connections The PICDEM Z has a PIC18LF4620 processor a MRF24J40 transceiver daughter card and many similar features to the HPC board 4 5 1 2 Remote Control The prototype remote control was made up of bread boarded components A remote control PCB was designed and populated for demonstration Unfortunately it only had partial functionality so the team decided it should not be used The likely cause of malfunction was the difficulties in soldering the parts to the board resulting in some components not making a clean electrical connection to the rest of the circuit 4 Figure 7 Prototype Remote Control PCB Layout 4 5 1 2 1 Button Array The power button was placed at the upper left corner of the remote as it lay in the user s hand standard position for an on off switch in many remote controllers The increment buttons for the red green and blue colors were placed above the decrement buttons The increment buttons for the all color and white were placed on the right side while the decrement was placed on the left The team felt tha
181. ximum flexibility Lamp modules could be designed not just as individual lighting units in rooms but could be used almost anywhere in a room for example as a desk lamp Table 4 5 Power Decision Matrix c T gt 5 2 8 323 2 on 9 o _ Weights out of 10 2 A 10 9 2 Switch Alternatives 32 Distributed 247 Centralized 245 4 2 6 System Decision The decision matrix analysis shows that the pros and cons of each system were nearly balanced The distributed control alternative provides the greatest amount of flexibility but the cost of installing a control in every fixture was cost inefficient The centralized control option had the advantage of minimizing the necessary number of system processors and therefore reducing cost However centralized control reduces the flexibility of the project by forcing physical wiring to be installed between the control circuitry and the lamp modules This seemed somewhat counter intuitive to the team s objective of creating a wireless lighting system Hence despite distributed control only marginally beating out centralized control the team chose a distributed control system for their design Table 4 6 Control Decision Matrix 2 T gt 2 o 5 m DL Weights out of 10 10 Switch Alternatives Distributed 8 232 Centra
182. y Innotec and its six satellite companies currently employ about 450 people The company chiefly operates in the West Michigan area but has recently expanded globally opening manufacturing plants in Hungary China and Mexico They are branching out into other industries especially in the LED industry Innotec wanted to build a lighting system based on the prototype lamp module design created by team LEDmote This lighting system would then be sold at profit on the market Innotec supplied funding for the prototype and assistance in providing requirements and project objectives In addition Innotec allowed Team LEDmote to use their soldering facilities and resources in project development Our project has provided them with a design analysis report a prototype and a business analysis which they can use to potentially develop into a final product 1 3 Mentor Tom Veenstra an employee of Innotec was the mentor for this project Mr Veenstra is a graduate of the Calvin College Engineering program with a concentration in electrical engineering He currently leads R amp D in the Innotec lighting division He was instrumental in providing requirements and advice for the design team He was the team s chief liaison with Innotec 1 4 The LEDmote Team Team LEDmote was comprised of Chris Kreft Dan Prince Ryan Truer and Dustin Veldkamp Chris Kreft was born in Philadelphia Pennsylvania to Zimbabwean parents who returned home when he was two years
183. ype Amplifier PCB The amplifier circuit consisted of 4 inputs from the PIC18F87J10 processor resistors transistors and output pins The transistors were used as the actual amplifiers that allow for adjustments in the LEDs The resistance of the gate resistors was required to be greater than Rmin in order to limit the output current of the Microcontroller The calculation of Rmin is seen in Figure 9 Vowm 33V 184 Rain R Figure 9 Rmin Calculation With a MOSFET transistor shown in Figure 11 the gate and source together was modeled as a capacitor This created an RC circuit which dampened the PWM if the RC time constant was low enough To ensure that this did not occur the RC time constant was set to be a factor of 10 less than the period of the PWM The following equations calculated Rmax as a result of these considerations 1024 Tpwm Rmax 204 0 10 C Figure 10 Rmax Calculation Considerations for the transistors in the design of the Amplifier Circuit were such that they must handle the drain to source voltage so that the transistors were not destroyed by overly high currents The resistors are rated at 10kO a value assigned because it was between Rmin and Rmax Also the 43 transistors must be activated by a 3 3V gate to source voltage because this was what the chip driving the amplifier was able to produce Drain Connected to Drain NN
184. ystem EventArgs System EventArgs Handles Handles Handles Handles Handles Handles Handles Handles Handles BTN 0 BTN 1 BTN 2 BTN 3 BTN 4 BTN 5 BTN 6 BTN 7 BTN 9 Click Click Click Click Click Click Click Click Click XXV Preset3Array Case Else End Select Select Case NewMode Case Me BTN_PRESET1 Me BTN_PRESET2 Me BTN PRESET3 CurrentArray Enabled False Enabled True Enabled True Me BTN MANUAL Enabled True CurrentArray Case Preset2Name Me BTN_PRESET1 Me BTN PRESET2 Me BTN PRESET3 PresetlArray Enabled True Enabled False Enabled True Me BTN MANUAL Enabled True CurrentArray Case Preset3Name Me BTN_PRESET1 Me BTN_PRESET2 Me BTN PRESET3 Preset2Array Enabled True Enabled True Enabled False Me BTN MANUAL Enabled True CurrentArray Preset3Array Case MANUAL Me BTN_PRESET1 Enabled True Me BTN_PRESET2 Enabled True Me BTN_PRESET3 Enabled True Me BTN_MANUAL Enabled False End Select CurrentMode NewMode NewLamp ALL LAMPS Call Change_Lamp Me Refresh End Sub Private Sub Change Lamp If NewLamp ALL LAMPS Then lblCurrentLamp Text ALL WhiteBar Value CurrentArr WhiteIntensity Text Whi chkBlackOutWhite Checked chkBlackOutColor Checked chkFadeWhite Checked Curr chkFadeColor Checked Curr c

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