Spring Final Report - Electrical Engineering and Computer Science
Contents
1. Energy keV Next the core of the outer section of the pins was analyzed It was determined that the core of the outer section was primarily a copper nickel alloy for solid solution strengthening Cu 500 400 300 Counts 0 E 5 i e 2 4 6 Energy keV Finally the middle core of the pin where full fractures occur were tested It was determined that there were traces of copper lead and zinc to form a brass core The EDS Spectra diagram can be seen below Counts 1000 4 Cu 800 600 400 e E Pb 200 P Zn Je om PO e 0 0 5 10 15 Energy keV The next form of material analysis involved the use of the scanning electron microscope The following magnified images clearly show the state of the pins before being worn down while being worn down and after being broken Image of banana pin that has not been previously used Image of banana pin that has been worn out and the outer casing has broken Image of worn banana pin zoomed in on fracture of outer casing Fully fractured banana pin Close up of fractured surface 10 0kWV Close up of fractured surface Rx n 9 vc Ns These results confirm the assumption that the pins break due to stre2. enne nnne nn 40 dee 42 1 Introduction 1 1 Project Sponsor The Vanderbilt University School of Engineering VUSE is sponsoring this project Lewis Saettel a manager of VUSE is in charge of programming the locks so that appropriate faculty staff and students can access rooms within Featheringhill and Jacobs Hall VANDERBILT UNIVERSITY V School of Engineering 1 2 Executive Summary Locknetics Ingersoll Rand Schlage locks secure most areas of Featheringhill and Jacobs Hall The Computer Interface Programming CIP module is the device that is used to program the door Lewis Saettel our project sponsor and manager of facilities at Vanderbilt University School of Engineering uses this module daily to grant or remove students and faculty access to the doors in the engineering building Because the locks are reprogrammed on a frequent basis the programming hardware subsequently suffers damage over time After multiple uses the pins of the CIP module break or begin to break in such a way that they are no longer useable About four new modules are purchased yearly totaling over 1000 of programming equipment purchases Various issues were encountered as problems with the existing system The banana pins of the CIP module are unable to withstand stress of the CIP module and bulky cable hanging from the module An additional source of stress arises from the banana pins bein
3. 17 2 5 1 Reader to Host 17 2 5 2 Host Computer to Palmltop cosi bi Eno bua E Re cba Rari te orti e gus 17 2 9 9 Palmtop to GIP MOGUC SES 17 2 5 4 Host Computer to 17 2 9 9 CIP MOGUIE TO LOCK iE EE Er pn Sou bb 17 2 6 eoo Rei Sis eu RE Oei MUR eT Ds 17 2 6 1 Operational Dia Gram sacs IUS SS 18 Proposed tu ees 18 3 1 Wireless RS 232 Connection i orco EEDI iana 19 LET BUSOG ide Eo DEUS DOE 20 SEMI EAN 20 5 m I 21 3 2 Zero InsertloD FOCS PINS ooo EU E VIR an 23 9 9 Redesigning LOCKS 24 Finak SOMIUI OM em ee ieee 24 4 1 Detailed Hardware 24 4 2 Detailed Software Overview eese eene enne 30 4 3 System DIagratJs ma uU dA PME RUD EEUU 34 aea 38 Mc H A 40 Suggestions for Future
4. E ea umm I Ee 1 A E omes i IDF Model Pins Smart Cable The system diagram above shows the IDF model increased degrees of freedom model that was implemented as the final solution In this model the Palmtop device is connected to the newly design CIP module with custom aluminum casing via a cable Next the smart cable that consists of two 18 gauge wires is combined via 1 8 heat shrink tubing This cable is solder connected to the banana pins and threaded through the banana pin handles As seen in the model above the pins connect into the pin slots on the keypad assembly of the lock This model lowers cost places less stress on banana pins can be implemented in a reasonable amount of time and is a simple design as compared to the wireless alternative discussed in the possible solutions section Clamp Attachment Model The clamp attachment model pictured above is an optional add on that was created to program the locks without having to hold the individual banana pins into the slots On the back side there are two screws that allow the model to open for the pins to be 37 clamped in at different depths for a custom snug fit into the lock This machine shop addition provides more stability is adjustable improves electrical contact and is removable if its use is not desired by the lock programmer 5 Testing PCB Design Prior to ordering the P
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6. 15 2 4 1 Module Components The CIP module consists mostly of a DB9 male cable port a printed circuit board with various components an ibutton and two banana pins Below is a picture of the CIP module 2 4 2 Lock Components The lock consists of several discrete components that work together to create a complete system The major parts of the lock are the card reader and circuit the 6 button keypad the system memory circuit board memory and lock control unit The 6 button keypad is used to put the lock in programming mode and also to open the lock This pin thus interfaces with the memory circuit as well as the lock control unit The card reader and its corresponding circuit board reads the data off the card compares it to the database on system memory and then if allowed interfaces with the lock control unit to open the door The memory I O circuit interfaces with the CIP module for data acquisition The lock control unit is responsible locking and unlocking the door 2 4 3 Software Components The software components of the project consist of programs installed on the various pieces of hardware On the host computer the operating system is Windows XP with Service Pack 3 installed Other software on the host computer includes the Locknetics software program which is a database software program based on Microsoft Access that tracks and controls the programming of the doors Also Serial Port Sniffer a program
7. 31 added to a user group a user can still additional access rules by having them added manually LockLink also can set rules to individual locks themselves This includes the smart time function which can dictate how the lock works depending on the time of day This can enable locks to be unlocked for a certain time of day and then only allow card access for a certain time of day The last major function of the LockLink software is the ability to interface directly with the locks in order to send access rules to the locks as well as well receive access logs from the locks This was a function that we used repeatedly when testing our circuit We used the uplink function to send card access rules to the lock to ensure communication was working correctly We also were able to read the credentials from cards into our database by swiping a card through the lock These two combined showed that we were interfacing in a bidirectional manner The version of the software we used during our project was 7 3 5 ExpressPCB ExpressPCB is the free software that we used to layout our custom PCB The software allowed for the layout and easy ordering of custom PCBs The software enabled double sided PCBs as well as ground and power planes A very useful property of the software was its large collection of common components that when placed on the layout represented their size accurately This helped one placing traces on the board as size considerat
8. extremely prevelant and extremely cheap is generally low power while still providing a large range In addition typical RS 232 transmission rates are not as high as what is provided by Bluetooth or infrared As such RF would not provide excess uneeded bandwidth 3 2 Zero Insertion Force Pins Another potential solution was the incorporation of zero insertion force pins This would prevent the pins from breaking due to excessive force Zero insertion force a concept used in the design of IC sockets was invented to avoid problems caused by applying force upon insertion and extraction After extensive searching it does not appear that zero insertion force pins will be able to be found for use with our project The closest application found was that of a zero insertion force compliant pin contact and assembly seen below It describes a compliant pin contact and assembly in which the contact is comprised of two layers each of a different material and coefficient of thermal expansion CTE than the other to enable insertion within an opening in either a cold or hot state to thereby expand and positively engage the opening s walls thereby securely holding the pin in position Representative materials include Invar and aluminum 21 The majority of information found on zero insertion force pins was for use with integrated circuits A normal integrated circuit IC socket requires the IC to be pushed into sprung contacts which the
9. to fit through at the same height as the hole 51 Aluminum Clamp Attachment 30 mm For each circular object the diameter is recorded Banana Pins Dm JL IL IL X Dimension _ 3276 23 5 8mm 48 12 2mm Minimum Panel Thickness is 0 030 0 76mm 52 6 120 3 05 53 Features e Threaded stud enables fast and easy mounting to panels e Solder turret allows wire attachment e Miniature banana plug features gold plated Beryllium Copper for long insertion life and low contact resistance Materials Miniature Banana Plug spring Beryllium Copper Gold Plated Body Brass Gold Plated Hex Nut 4 40 Nut Brass Nickel Plated Ratings Operating Voltage 2500 VDC Current 5 Amperes Max Ordering Information Model 3276 Model 4513 Parts are packaged ten per bag unassembled 54 Installation Instructions How to Trace a Circuit and Design Schematic Place original printed circuit under 5x magnification Identify a single lead of the first component Identify and label all other component leads that share a trace with the lead identified in step two this is a node Check to see if this node has already been labeled If so lead tracing and labeling of this node is not necessary If not labeling and tracing of this node is necessary Hepeat the previous steps for each lead of each component Construct an engineering sketch from this information Use this pap
10. 1 22 NA Randolph amp Rice Printed Circuit Board Custom NA 0 45 0 90 Randolph amp Rice 1 32 1 32 Randolph amp Rice 18 56 18 56 PCB Express 2 18 0 21 0 42 Randolph amp Rice VU Physics 150 00 Machine Shop Wiring 18 Gauge Machine Shop Additions casing clamp pin handles Refer to holes through Design pins Sketches 58 Component Data Sheets 1N4148 Small Signal Diodes FEATURES Silicon Epitaxial Planar Diode Fast switching diodes This diode is also available in other case styles including the 500 123 ik i case with the type designation 14148W the MiniMELF case with the type w designation LL4148 and the SOT23 case with the type designation IMBD4 148 max 50 3 8 MECHANICAL DATA Case 20 35 Glass Case Weight approx 0 13 g Divenis in inches and millimeters MAXIMUM RATINGS AND ELECTRICAL CHARACTERISTICS Ralings si 25 C ambient temperature uniezs gihenwise specined DIXI Rectified Current Average lp 150 mA Half Wave Rectification with Resist Load at Tamp 25 C and f 50 Hz om _ m _ sn eee m Io e _ 1 Valid provided that leads at a distance of 8 mm from case kept at ambient temperature 00 25 59 1N5225 THRU 135267 ZENER DIODES FEATURES 00 35 Silicon Planar Power Zener Diodes Standard Zener voltage tolerance is 596
11. 18 gauge wire to remain exposed on the end designated for banana pin attachment Slide the banana pin handles over the exposed 18 gauge wires otrip a half inch of wire off the ends of the 18 gauge wiring oolder these into the holes drilled into the end of the banana pins machine shop assistance Be careful not to get solder onto the threads of the banana pins 10 Screw the banana pins into the pin handles which have been threaded by the machine shop 1 1 Optional Attach the pin handles into each slot of clamp attachment made by the machine shop at the appropriate depths and fasten the screws into the holes via a Phillips head screwariver 12 The programming equipment is now ready for operation For instructions on how to operate the programming equipment refer to the user s manual 56 Quotes Cost Analysis of Materials Part Type Part Number Quantity 3276 uu 22kQ 25 Watts m 2 2kO 25 Watts 10 25 Watts 1200 25 Watts 1N4148 mE 1N5232 Capacitor Axial Leaded 100V 63V r Vendor 1 94 3 88 Pomona 0 25 0 25 Randolph amp Rice 0 25 0 50 Randolph amp Rice 0 25 0 50 Randolph amp Rice 0 25 0 25 Randolph amp Rice 0 10 0 30 Randolph amp Rice 0 22 0 22 Randolph amp Rice 86 0 86 Randolph amp Rice 57 Heat Shrink Tubing 1 8 BJT Transistor 2N3904 DE9 Male Connector EBY DSO9P 1 22
12. Each iButton has a unique ID number which is detected by the lock when the user taps his or her iButton to it The iButton is unaffected by magnetic fields metal detectors water and most chemicals To store information the iButton is connected into a receptor and software transfers the lock access data to the iButton The iButton is then unsnapped from its receptor and can be touched to each lock The iButton setup information is transferred to the lock s memory This device is seldom used in the engineering building Next the keylock is the traditional way of opening locks and requires a key for entry into the room A master key is provided to the facilities manager and there are individual keys for each door however these are not distributed for use by students or 34 faculty Moving on each door has a distinct five digit code that can be inputted onto the keypad for entry If the code is incorrect the LED light flashes red and if it is correct the LED light flashes green and unlocks the door for about three seconds This is the second most common way that faculty and staff use to gain entry into various rooms within the engineering building The pin connectors labeled in the diagram above serve as the slots for the banana pins of the CIP module to be inserted They are at different depths to compensate for the iButton functionality This depth inconsistency was one of the problems leading to stress and electrical contact problems between the
13. Successful Successful Successful Successful Successful Successful se NO 3 3 3 O4 DA DA DA N N DA Trials were successful if the lock light blinked green when the card was swiped after programming the lock Trials were unsuccessful if the lock light blinked red when the card was swiped after programming the lock This was mainly due to poor electrical contact from the banana pins when programming the lock Notification of this was seen through the Locknetics program alerting the user that the lock was not properly updated Of the fifty trials four trials failed and resulted in an unsuccessfully programmed lock Therefore 9296 of the trials were successful which is a significant improvement from the previous system as described by the project sponsor 39 6 Conclusions There were three goals for this project 1 to minimize the amount of stress on the banana pins when programming the lock module 2 to increase the electrical contact between the banana pins and the lock when programming the lock with the CIP module and 3 to reduce the price of the CIP module All of these were successfully completely by then end of the project The new system allowed for the minimizing of stress on the banana pins by increasing the degrees of freedom through allowing pins to move independently of one another The new system increases the electrical contact between the banana pins firs
14. key card to carry access changes to doors limiting the need to reprogram locks Magnetic Stripe card reader with metal 6 or 12 button PIN pad Manages unlimited number of cards Complete history of last 1000 door events including authorized entry and unauthorized access attempts High security mechanical key override Schlage Everest cylinder Detects and stores event when an emergency override key is used Privacy override available on specifically designated cards 60 000 to 80 000 cycles for minimal routine maintenance utilizing four 4 standard AA batteries Available in cylindrical and mortise locks and exit device trim for the Von Duprin 98 99 series devices Available in a variety of finishes and lever styles Vandlgard clutching lever design Batteries and electronics are positioned on the secure side of door The features of the software of the locks are listed below Integrates with all levels of security from brass keys to biometrics User friendly intuitive software for day to day operations Integrates the Ingersoll Rand online and offline access control systems eliminating the need and inefficiency of having two separate databases Manages an unlimited number of unique PIN codes where card and PIN is required for access Single and multiple workstations with client server can be easily networked to conveniently access a single database Ability to specify gender and ADA when encoding cards Easily integrates with other cam
15. that tracks the activity of the RS 232 port is on the host computer Software on the palmtop device includes a Windows CE operating system Microsoft Activesync and UPLINK exe Microsoft Activesync syncs the program files from the host computer to the palmtop device A Windows CE version of UPLINK exe is used to transmit the programming data for a lock from the palmtop device to an individual lock 16 2 5 Current Interface Definition 2 5 1 Card Reader to Host Computer The computer interfaces with card reader via a USB cable The card reader is used so that manually typing in of the user s social security number and name is not needed The cable used is a standard USB 2 0 cable that comes from the card reader and connects to the USB port of the host computer 2 5 2 Host Computer to Palmtop The host computer connects with the palmtop device by a custom USB cable This is standard connection for most palmtop devices The computer end of the USB cable is a standard size USB interface The palmtop end of the USB cable is custom serial connection Conversion from this custom styled serial port to USB occurs inside the cable and full compatibility is maintained As fitting with the USB standard communication is serial 2 5 3 Palmtop to CIP Module The palmtop device interfaces with the CIP module via a custom RS 232 cable As the palmtop devices serial port is not standard a specialized cable is used to connect to the CIP module This cable co
16. the infrared portion of the electromagnetic spectrum for communication is very common Most remote controls use it to control T Vs DVDs and other electronic devices It has also become popular on palmtops devices including ours For this 20 reason we could once again attempt to reverse engineering the software that is used to send data serially The goal in this case would to purchase an infrared to RS 232 receiver module and configure the software on the palmtop such that data is sent via the infrared port instead of the serial port The problem with this approach remains the fact that reverse engineering proprietary software would be extremely difficult and possibly illegal Another option would be to use a RS 232 to infrared transmission module at the palmtop device and then an infrared to RS 232 receiver module at the CIP module While not as prevelant as the modules for bluetooth one can find the needed components for sale They are however generally cheaper than bluetooth devices of similar kind 3 1 3 Radio Frequency Transmission Yet another solution for wireless data transfer between the CIP module and the lock was to use the radio spectrum to send data Radio Frequency RF transmission is common in several communication applications Using this approach one would have to purchase a RS 232 RF conversion modules as the palmtop does not have an RF transmitter receiver or transceiver However RS 232 RF transmission modules are
17. with B suffix Other tolerances are s i available upon request These diodes are also available in Mini MELF case with i the type designation ZMM5225 ZMM5267 SOT 23 i case with the type designation MMBZ5265 MMBZ5207 and 500 23 case with the types designation MMSz5225 B MM3SzZ5287 t MECHANICAL DATA Dimensions are in inches aad imime Case 00 25 Glass Case Weight approx 0 13 g MAXIMUM RATINGS Rings at 25 C ambient temperature unless otherwise specified uw Zener Current see Table Characterisbics Power Dissipation at Tamp 75 C mW Maximum Junction Temperature GC Storage Temperature Range G T T Thermal Resistance R 300441 CAN Forward Voltage TE V 1 1 Volts HOTES prowided fat leads at a distance of mm from case are kept at ambient ipmpersture domua SEMICONDUCTOR 60 B Zeexracducias FAIRCHILE 243904 MMBT3904 PZT3904 NPN General Purpose Amplifier This device Is designed as a general purpose amplifier and switch The useful dynamic range extends ip 100 mA swicn and to 100 MHz Absolute Maximum Ratings ssia Parameter MOTES ratings are Gade os usce ni ore perafuna of 180
18. CB from Express PCB verification that the circuit design was correct was needed To ensure this the circuit was replicated using a breadboard wiring and the same components specified within the PCB design Wires were soldered into a DB9 connector cable to enable testing of the circuit The process of programming the lock was then performed and a lock was successfully programmed This validated the PCB design layout and allowed the circuit board to be ordered in bulk CIP Module Upgrade In order to verify the effectiveness and efficiency of our system fifty attempts were made to update the lock using the new system At the start of each trial the credentials of a student were read into the database by swiping their Vanderbilt card through the lock The user was granted access to the trial lock on the database within the Locknetics software on the laptop used Then the new system was used to program the lock and the card was swiped afterwards to verify the lock was programmed correctly The results are seen in the table below Number Results Number 8 Successful 9 Failed 38 18 Successful 19 Successful 20 Successful 21 Successful 2 Successful 2 Successful 2 Successful 2 Successful 2 Successful 2 Successful 2 Successful 2 Successful 3 Successful 31 Successful Successful Successful Successful Successful Successful 3 Failed 3 Successful 3 Successful 4 Successful 41 Successful Successful Successful Failed
19. Clear to Send Transmitted Data Received Data 2 cueste aene 1 Received Line Detect DCE Ready t j Received by D TE Device ti from DTE Device Adding a User and Updating Lock Upon opening the LockLink 7 Software you will be prompted for a password After it is entered this is the screen you will see 43 File Facility Groups Users SmarTime Reports Audit Trail Tools ProgramDoors SysOp Help s lt gt XS mw Facility Access Groups Users SmarTime Reports Audit Trail Configuration Program Doors Help To add a user click on the Users button towards the top left You will see the following Screen aD User Access AAN Users T 29 Assign Access SCO View Users By All Users fl Choudhury Ashok AAR Info Credentials A lleer Credential Pnuzccible Credentiale lugbade Morakinyo fi Simakas Ashley Maglard 1 Button Function Normal Access Code dl5333080 23 7z3z u u mlcl i m l Toe eee Delete Filter Update Expiration Date s There may or may not already be users assigned to certain doors Press the add button and you will be prompted with a screen to fill in the name of the user 44 Add a Hew User Last Name Webb First Name Lutald Autolmport ID OK Cancel Help After filling that out press okay and we return to a familiar screen Except this time the user we ad
20. This makes it secure as well as modular The casing also had a space for the DE9 connector and a hole for the wires on the opposite side A picture of the aluminum casing and the whole system is shown below 30 4 2 Detailed Soflware Overview Overview The primary programs used during our project were PSpice LockLink and ExpressPCB PSpice was used for constructing circuit schematics and simulation of circuits LockLink was used to manage card access rules and Express PCB was used to design and order our custom PCB PSpice PSpice Personal Simulation Program with Integrated Circuit Emphasis is an analog circuit and digital Logic simulation software It can be used for simply generating circuit schematics but its main use 15 reliably simulating integrated circuits before going through the expensive manufacturing process Integrated circuits unlike circuits composed of discrete components cannot be breadboarded before actual manufacture As such SPICE programs are used as a way to test them virtually before going through the expensive photolithography process In our project we used PSpice to make an important discovery which determined the trajectory of our project significantly We used PSpice to create a schematic of the CIP circuit and simulate it PSpice has a large library of common components We were able to identify all the components in the CIP circuit and construct it in PSPice PSpice enabled us to perform extensive simula
21. Vanderbilt Locknetics Upgrade Sponsor Vanderbilt University School of Engineering VUSE VUSE Senior Design Project April 22 2009 Justin Gilstrap Akin Olugbade Lutalo Webb Table of Contents N INTFOGUCHION 3 1 4 Project SDODSOE 5 iniu Ld 12 Executive SUMIMANY ice ed 4 1 3 Proe OVEN IC W m 5 1 3 1 Material Analysis of Banana 10 System Overview and 11 2 1 Background dott bie 11 MEME E 11 2 2 System heguiremells R 12 2 2 1 Hardware 13 2 2 2 Software n naa s 13 2 3 System Diagram S uocis Usine 15 2 3 1 Haraware DIagEalTs su iore oer e i aue dte a 15 2 3 2 OoliWatre Diag aM 15 2 4 Major Component Definition eese eese eee e eee 15 2 COMPONE M ES 16 2 4 2 LOCK GOMPONECMIS 16 2 4 3 Software senes 16 2 5 Current Interface
22. ace upwards slightly so that it no longer came in contact with the through hole PCB Construction Once the board was received we began the process of constructing it Using the design file as a guide we soldered the components in their respective places We used rosin core solder This has flux in the core of the solder and makes better solder joints In addition to the components we placed a male DE9 connector that was previously ordered on the board We soldered the pins to the pin holes to complete the DE9 connection Lastly we soldered two 18 gauge wires to wire holes meant to interface with the lock 28 A picture of the constructed PCB is shown below Pin Handles and Wiring We enlisted the machine shop associated with the Vanderbilt Physics Department to help us with several parts of our final hardware design The first of these parts was the custom handles that we now have One problem that the design of the original is that pins were fixed in relation to one another This coupled with the fact that the holes with which the pins interface were not leveled but the pins were led to extra stress being placed on the pins when trying to make a good electrical contact In order to combat this problem we wanted to make the interface with the lock as free as possible To accomplish this we made the pins connected to handles which were in turn connected to two separate wires This allowed for a great deal of freedom The pin handles them
23. ally an improvement Hequirement 6 0 addresses the major concern of the project The existing system required banana pins to be replaced or repaired more than eight times in a school year Therefore Requirement 6 0 to ensure the new system is in fact reducing the stress placed on the banana pins which causes them to break so frequently Lastly Requirement 7 0 was added as an incentive to make the new system more cost effective The project sponsor did not demand this requirement be fulfilled hence the 12 should statement but it would be beneficial to both the sponsor and the school of engineering for the cost of the new system to be less than the existing system 2 2 1 Hardware Requirements oince Requirement 1 0 was vague in its explanation of hardware specifications Requirements 1 1 1 7 were added to better describe the hardware requirement The table below shows these requirements BN Host Computer shall process changes and stores database of access rules 1 1 1 2 Host Computer shall have standard keyboard monitor etc 13 Card Reader shall acquire user information from cards for use to update database on host computer Palmtop Device shall store updated database while going from lock to lock 125 Transmission Medium shall send updated card access rules from the Host Computer to the Palmtop Device 1 6 Transmission Medium shall send the updated card access rules from the Palmtop Device to the Lock Interfacing Module Lock Int
24. ating locks and also thoroughly reduces the time spent repairing banana pins Lastly the Vanderbilt University School of Engineering benefits from the cost effectiveness of the new system Given the current state of the economy saving close to five thousand dollars over the next five years is more meaningful now than ever before 7 Suggestions for Future Work Future projects on this topic would benefit from extensive research in the area of wireless communication A more optimally solution would be to remove the need for cables between the palm top and the lock Some possible methods of wireless communication include RF and IR Another place for future improvement is a more compact design This could be accomplished by reducing the size of the PCB further This would however require 40 better soldering skills than most students gain while at Vanderbilt Practice soldering would be extremely beneficial in reducing board size 4 8 Appendix DB9 and DB25 Female Pin Assignment DB25 Female Sec Data Shield V Received Data Transmitter Signal Timing DCE Source 15 4 v Wr Sec Transmitted Data A oT Receiver Signal Timing Request to Send parem DCE Source 2 Transmitted Data 77 Clear to Send E DCE Ready Local Loopback o3 Signal Ground Received Line 44 877 ow DTE Ready 21 Signal Det ect Ps sa 2 Rem ote Loopback reserve
25. d for testing a w Ring Indicator A Sec Clear to Send reserved for tetin ae WOW P A itm Signal Rate Selector unassigned 1 Sec Reca ved Line 25 Transmitter Signal Timing Signal Detect Y Shield E ID TE Source Sec Request ta Send Test DB Female Recaved Line Signal Daeg Trans mi ted Data 5 7 Clear Send Received Data 3 a E 5 Signal Ground xd Ring Indicatar Shia d t j Received by DCE Device Transmitted from GCE Device 42 9 and DB25 Male Pin Assignment Looting Inte the DTE Device Connector DB25 Male Sec Clear to Send Shield Made Sec ved oa wd 25 Transmitter gna Timing Signal Detect Source lt x ae reserved for testing A Data igna kae Selector ib mere soe Indicator reserved for testing ec 24 Mr lem ote Loopback Received Line soe DTE Ready Signal ect Fi ugnal Ground 1 fie Ser Request to Send 15 Local Loopback a P Ready Nei Ty 17 Clear to Send a 7 Receiver Signal Timing le DCE Source Request to Send LL pp 15 Sec Recei ved Received Data Q8 nd Transmitter Sqnal Timing Transmitted Data DCE Source Shield Sec Transmitted Data DBY Male Shield Signal Ground A 5 Ring Indicator DTE Ready ome
26. ded will be among the names User Access AAN Users ras Assign Access o View User All Users Choudhury Ashok Rea Info Credentials Justin lugbade Morakinyo fi Simakas Ashley Webb Lutala lleer Credenhale Pnezible Credentials Button Add Delete Filter Update Expiration D ate s Next we drag the MagCard from the Possible Credentials box to the User credentials box 45 F User Access AAH Users he X Assign Access SCO View Users Bu All Users An Choudhury Ashok AAR dic A Gilstrap Justin lleer Credenhal lt Poechle Credentale Glugbade Morakinyo Simakas Ashley Webb Lutalo Add MagCard User Active Date Lutala Webb iw Activate Immediately Start Date Wednesday April 22 2009 Label MagCard 1 Misitar Credential e ila Day zl End Date Saturday Januar 01 2005 Access Notes Function Nomaldccess Type MagCard Only m Read Apply Cancel Help We Press the read button and the swip the card of the user we would like to add This takes the credentials from the card and merges it with the user s name When finished press apply When this is done we return to the following screen 46 F User Access Users lt mm Assign Access SOO View U
27. demonstrate that the circuit that we simulated was indeed correct and would work as expected This was done through the process of breadboarding We laid out a version of the circuit on a breadboard with inputs being interfaced with the lock and the RS 232 cable An updating process of a lock was then done through the breadboard to verify the validity of the circuit PCB Design The next step was to design the circuit for custom fabrication This was done using software called ExpressPCB ExpressPCB had a large component library that helped not only because of its size but also because the components were scaled to size That is they took up the same relative size in the software layout as they would on the physical PCB We started at the default PCB size of 3 8x2 5 inches This made it easy to simply layout the circuit without confusion or errors As on the original CIP module circuit we placed traces on both sides of the board This is done when traces would otherwise cross 26 each other and it helps avoid making very convoluted Once this was done went through two additional iterations in order to shrink the size of the PCB down to a reasonable size Pictures of the iterations and the final design are shown below Final Printed Circuit Board Design 1 475x1 4 in After we designed the PCB it was relatively simply to order it due to the integration of the ordering process with the software Forms were filled out regarding shi
28. door and the lock The left side of the pin is the negative terminal for the banana pins and the right side is the positive terminal Finally the door knob is the part of the lock that is rotated downwards for entry into the rooms Lock Block Diagram CIP Module Lock Circuit Keypad Assembly Battery The lock block diagram above is a general representation of the broad components needed to reprogram the locks As can be seen the card reader or card swipe component connects to the numerical keypad The keypad circuit connects to lock circuit located inside the back capsule of the lock Inside the back of the lock is also a source of battery power The lock is powered by four industrial AA batteries and one 3 volt button battery for memory and date time backup The lock circuit is multilayered sends out a signal to unlock lock door and then the LED lights which are a part of the keypad assembly respond to the signal received The only component of the lock block diagram that is not connected to the lock itself is the computer interface programming module This module is inserted into the pin connections located on the keypad assembly and was the main focus of the project Data is transmitted to the CIP module via a handheld PC 35 The pictures below show a real world representation of the lock block diagram as previously discussed Front Interior of Lock 3 i
29. er and pencil sketch to construct a schematic in PSpice How to Test Functionality Obtain each component present in PSpice schematic Configure the components on a breadboard in accordance with the wiring configuration and components in the schematic Connect appropriate wiring to pins via alligator clips Ensure that correct wires are connected to the corresponding DE9 pins Connect the DE9 port to host laptop RS232 cable Test functionality of Locklink program by using the breadboard components as a CIP module and adding and removing a user s access to a sample lock How to Use PCB Express 1 Go to www expresspcb com Download the Free PCB layout software Configure the components and tracing to correspond with the PSpice schematic Make sure to add connections for the DE9 connector and the banana pin wiring on the printed circuit board layout Pay careful attention to the dimensions of the layout and make sure they are within specifications Ensure that there are no ninety degree angles present in the wire traces and that there are no components or traces touching Be sure to leave reasonable space for solder joints How to Construct a Printed Circuit Board 1 Place the appropriate component through the corresponding slot of the printed circuit board refer to final design on PCB Express 55 2 3 6 Bend the wires coming out of the components so that they are adjacent to the board Make sure the com
30. er to export Door n files needed for programming offline Doors Doors Select the Doors that you want to program HCM Doors Start the LackLink Server programming ASI HandEey Doors Close Help We only have the option of pressing the Offline Doors button and so do so This brings up the following screen 48 LockLink Exporter File View File Type Settings Help 5 5 amp Building Building 4 Featheringill H all 4 Jacobs Hall 4 Mechanical DI Door Name Building Name Update Prog Status Select All Clear All Export 3 Close All gt gt Bulliding 3 Door 3 3 54 PM 4 22 2009 We press Select All and then Export Next we press the picture of the CIP module at the top of the screen in order uplink the information It brings up the following prompt Program Lock by Selecting Mame Tour Status After this we press the Re Program Lock by Retrieving Name button Press Okay at the prompt after this and the lock will begin updating 49 Design Sketches Printed Circuit Board 1 475 inches _ 9 Connector 1 4 inches 50 Physical Interface Pin Handles Top View Bottom View 2 5 mm on Casing 26 mm 5 mm Slot on opposite side of casing is a rectangle 30 mm x 10mm for the DE9 connector
31. erfacing Module shall accept new data and places it in the lock 2 2 2 Software Requirements oince Requirement 2 0 was vague in its explanation of software specifications Requirements 2 1 2 8 were added to better describe the software requirement The table below shows these requirements 13 Requirement 2 1 Operating System for Host Computer shall enable control of the host computer 2 2 Database Program shall store and organize the card access rule for each lock 2 3 Database Program shall keep an inventory of all the users that have access to locks 2 4 Palmtop Synchronization Software shall synchronize the database on the Palmtop Device with the database on the Host Computer 2 5 izati 2 6 Palmtop Synchronization Software shall package and send data to the IO Ports on the computer MM Palmtop Operating System shall enable control of the Palmtop Device 2 7 Palmtop Database Software shall organize and store the card access rules on the palmtop device Lock Synchronization Software shall package and send information to IO ports of the Palmtop device intended for the lock 14 2 3 System Diagrams 2 3 1 Hardware Diagram Legend Data bh Transmission Medium 2 3 2 Software Diagram 2 4 Major Component Definition The major components of our project are the CIP module the Locknetics lock software and hardware Each of these components also has various components within them
32. f professor A B Bonds identifying the part in an electronics catalog The component list was as follows Number of Component mE ERN Junction Transistor 2N MEE 24 1200 Diode 1N5232 1 Circuit Simulation The next step in the design process was to simulate the circuit which was sketched To do this PSpice was used to layout our sketched circuit as a PSpice schematic The circuit was then simulated by applying a several inputs to both the RS 232 and two pin side of it There were 4 pins on the RS 232 side that could be asserted or unasserted Thus there were 16 combinations of inputs to apply to it on the RS 232 side This was done and it was noted that the output on the lock interfacing side was either close to Ov or close 5v This enabled us to determine that the output was not some form of RS 232 and was instead closer to the logic levels used in many common electronics TTL This is significant because we originally believed that the CIP module still communicated with the lock using RS 232 levels and hoped that this would allow us to use a wireless RS 232 standard We rejalized that since the lock was using TTL logic levels we could not do this An example of the circuit simulation is given below 25 C1 Lin qo 10k Q2N39 1N4148 9 000V 9 000V 5 000V 2 TX 3 Rx EDOR B CTS Breadboarding Once the simulation was completed the next step was to
33. g the same length but the banana pin slots being inconsistent in depths This requires the user programming the locks to have to maneuver the module in a manner that adds stress to the pins In addition to the stress issues common occurrences are electrical connection problems between the CIP module and the lock due to the poor fit of the pins In many cases this requires multiple attempts to program the locks These problems have made it necessary to produce a method for programming the locks that will alleviate the hassle of frequently reordering CIP modules due to broken pins and save money The final solution that was implemented an entirely new design for the CIP module Circuit analysis was performed which consisted of tracing the original circuit inside the CIP module using a high magnification microscope and lamp The components and their values were identified and ordered Next a PSpice schematic of the existing circuit was formulated and the design was tested for its functionality on an electric breadboard Finally a printed circuit board was ordered and soldered New casing wiring and pin handles were also created with the assistance of a machine shop The new model allowed for the depth of the banana pins to be customized to fit each lock to reduce stress and increase electrical contact It also allowed for the banana pins to be unscrewed via the pin handles for easy replacement Furthermore easy access to the module inside of the alum
34. inum casing was ensured for convenient replacement if needed As stated by our project sponsor an average of four of the old CIP modules were ordered per year in the past Aside from the time and effort required to fix or reorder damage pins with each model costing 250 dollars the cost of ordering new CIP modules over a 5 year period totaled over 5000 The new and improved design costs 28 76 per unit to construct If four were needed to be ordered each year 4424 80 will be saved by Vanderbilt University School of Engineering over a five year period Potential further steps in this project include additional research on wireless communication Possibly Bluetooth or infrared technology could be used to wireless program the locks The locks in the engineering building are offline so programming would still have to be done door by door however a small device could be attached to the lock in order to transmit programming data from a handheld PC to the lock circuitry Additionally a more compact design that would cut down on wire length as well as module size could be implemented 1 3 Project Overview Locknetics Ingersoll Rand Schlage locks secure most areas of Featheringhill and Jacobs Hall There are over one hundred doors that use these particular locks throughout Featheringhill and Jacobs Hall The locks are considered stand alone meaning there is no central point that connects or wires them Therefore they are powered by four indus
35. ions are extremely important when making a PCB Lastly the ordering service was integrated into the software When ready to order one can determine the board type quality and quantity The shipping and billing information 5 entered and the design file is then sent directly to the ExpressPCB servers A screen shot of the software is below 32 ExpressPCBE Untitled File Edit View Component Layout Help I A 0 725 r 0 050 Snap 0 025 33 4 3 System Diagrams External Lock Makeup Card Swipe Green Red LEDs Access Granted or Denied iButton Door Knob The diagram above shows the external components of the Ingersoll Rand locks The card swipe is the main component used for gaining access to rooms in Featheringhill and Jacobs Hall We used this component of the lock to verify whether the CIP module successfully updated credentials to the lock interface and Locklink software The LED lights indicate whether card access iButton access or keypad code entry was granted or denied They also blink and turn different colors depending on the programming stage on the lock that is being utilized The iButton slot enables a device referred to as an iButton to transfer stored information into the lock s memory The iButton is a 16 millimeter computer chip encased in a water tight stainless steel container smaller than a dime The container is attached to a plastic keyfob designed to fit on a keychain
36. k company that is authorized to order parts for these locks in order to get spare parts The ability to program locks is only plausible when there is a CIP module Due to this problem of the miniature banana pins constantly breaking causing the need for more CIP modules it is necessary to produce a method of programming locks that will alleviate the burden of frequently re ordering CIP modules and limiting the number of broken pins 1 3 1 Material Analysis of Banana Pins One of the challenges that need to be addressed with the future solution is that of the feeble banana pins The miniature banana pins on the CIP module must be placed into the lock to be programmed After multiple uses the pins begin to break due to the weight of the CIP module attached to the handheld PC A scanning electron microscope and Energy Dispersive X Ray Spectroscopy were used to get a better understanding of the effects of stress on the pins and the material makeup of the pins Pins in various states were studied A pin that had been exposed to no stress was studied a pin that was worn and beginning to break was studied and a pin that had suffered a fracture from excessive use was studied The pictures below show a CIP module with pins that have not been used The following EDS Spectra diagram shows the material makeup of the outside layer of the banana pins Based on the diagram it has been concluded that the pins are gold plated
37. n grip by friction For an IC with hundreds of pins the total insertion force can be very large tens of newtons leading to a danger of damage to the device or the PCB Also even with relatively small pin counts each extraction is fairly awkward and carries a significant risk of bending pins particularly if the person performing the extraction hasn t had much practice or the board is crowded as can be seen with the unpopular front loading mechanism of the Nintendo Entertainment oystem Low insertion force LIF sockets reduce the issues of insertion and extraction but the lower the insertion force of a conventional socket the less reliable the connection is likely to be With a ZIF socket before the IC is inserted a lever or slider on the side of the socket is moved pushing all the sprung contacts apart so that the IC can be inserted with very little force generally the weight of the IC itself is sufficient with no external downward force required The lever is then moved back allowing the contacts to close and grip the pins of the IC ZIF sockets are much more expensive than standard IC sockets and also tend to take up a larger board area Such a technique has disadvantages that the connector will occupy a large volume since it adds the space of the drawbars and the slide able space thereof Therefore the technique is not useful in the future development of the chips with a high density and large number of pins Further the connecting const
38. ned popularity over the years There are currently three classes of bluetooth with class 3 having the shortest range and consuming the lowest power and class 1 having the longest range and consuming the most power These are seen below Class Maximum Permitted Power Range mW dBm approximate Class 1 100 mW 20 dBm 100 meters Class 2 2 5 mW 4 dBm 10 meters Class3 1 mW 0 dBm 1 meter Class three Bluetooth is what is used in cellular phone headsets that implement Blutetooth Considering the proximity that a person updating a lock would be class three would work well It consumes the least amount of power and thus saves on energy spent There are multiple ways that one could go about implementing via Bluetooh If the palmtop device that is used to uplink data to the lock has a Bluetooth interface which ours does one could transmit data directly from the palmtop to the a Bluetooth to RS 232 module This however would require reverse engineering the proprietary software which is used to send data from the database on the palmtop to the lock While theoretically possible it would require advanced software skills and would possibly be illegal Another option would be to use a RS 232 to Bluetooth transmission module at the palmtop device and then an Bluetooth to RS 232 receiver module at the CIP module Many stand alone RS 232 Bluetooth conversion pairs exists and can be found and purchased failry easily 3 1 2 Infrared The use of
39. nverts the wiring from the custom port to standard RS 232 The standard end of the cable is an RS 232 9 pin female The CIP Module has a 9 pin male connector to which plugs into the female RS 232 port As fitting with the RS 232 standard communication is serial 2 5 4 Host Computer to CIP Module At some times it may be necessary to interface a host computer directly with the CIP module This is the case during testing with a laptop This case requires a specific RS 232 cable his cable fits in the serial port of the computer and has a female connection The CIP module end of the cable also has a female 9 pin port and plugs into the 9pin male RS 232 connection on the CIP module Communication is serial 2 5 5 CIP Module to Lock The CIP module interfaces with the lock via two pins These pins send data from the CIP module to the lock by direct pin connection into two sockets of the lock Communication is serial 2 6 Operational Concept The operational concept is not the most difficult but can be quite tedious First an individual faculty staff or student request access to room in Featheringhill or Jacobs Hall Once approved the Vanderbilt card of the individual is then swiped through a card 17 reader which transmits credentials data of the individual to the host computer through transmission medium i e USB cord The data on the host computer is transferred to a database program within the host computer That data is transfer
40. ponent is as close to the printed circuit board as possible Use rosin core solder and a soldering iron to create solder joints where the wire traces come through the circuit board Make sure the soldering creates a clean connection and does not overlap onto any other slots or traces on the board Hepeat this process for every component on the printed circuit board Strip an 74 off two 18 gauge wires and solder these into the two holes denoted for them on the board Make sure they are long enough to attach to the banana pins outside of the CIP module Lastly attach the DE9 connector to the board This part should snap into place How to Assemble Physical Interface of Module 1 d The aluminum casing and pin clamp attachment were made at the physics machine shop Refer to the design sketches included in the report to have these constructed Place the circuit board into the casing so that the DE9 connector sticks out of its appropriate slot screw the nuts of the DE9 connector in via the outside of the casing so that it is securely built into the casing On the back side of the casing opposite the slot thread both 18 gauge wires through the hole that has been lined with a rubber piece machine shop addition ocrew the top of the casing into place via a phillips head screw driver Heat shrink the wires leaving the casing together with 1 8 heat shrink tubing and a paint stripper providing the heat Allow six inches of the
41. pping billing quantity and board type After the this was all determined the design file was sent directly to the ExpressPCB servers An example of an ordering form is shown below ZI Order Boards Via the Internet Select a double sided board manufacturing service Silk screen and solder masks nat included great option for small quantities and prototyping MiniBoard Service These are the same high quality double sided plated through boards as the Standard Service silkscreen or solder masks The board size must be 3 8 x 2 5 Three boards just 51 C Production Service Production quality double sided boards with plated through holes Including solder masks and top layer silkscreen This is our best value when ordering larger quantities t ProtoPro Service The same tap quality PCBs as our Production Service solder masks and top layer silkscreen included The board size must be 21 square inches or smaller Four boards just 1 9 Back Wee Cancel When we received the board we immediately noted a design error Our inexperience with designing PCBs caused confusion with the nature of two sided boards As such a trace came in contact with a through hole that it was not intended to touch This made the boards ordered invalid A picture of a Zoomed in portion of the board with the error is shown below The error is in the white box This error was corrected by simply moving the tr
42. pus databases Interfaces with leading One Card providers 11 2 2 System Requirements The system requirements are seen in the table below Requirement oystem shall fulfill all hardware specifications oystem shall fulfill all software specifications oystem shall not conflict with pre existing operational concept oystem shall not require more than two trials to update lock oystem shall detect electrical contact within five seconds of banana pin insertion into lock oystem shall reduce the number of broken banana pins from programming by fifty percent oystem should cost 30 percent less than the existing system The first two requirements relate to the hardware and software specifications These are vague but explained in detail later Requirement 3 0 is needed to ensure the project sponsor can still easily use the new system with no additional training This essentially eliminates any transitional period between use of the old and new system to program the locks Because the previous system was unreliable in the number of trials needed to program the locks Requirement 4 0 was added to make certain the new system effectively increased the success rate of programming locks At times the Locknetics program would report that no data was being transmitted to it and this was commonly due to poor electrical contact from the banana pins Requirement 5 0 was added to guarantee the electrical contact of our new system is actu
43. red to a palmtop device through a transmission medium From the palmtop device the data is uploaded onto a syncing program on the palmtop An uploading program is then needed to enable data transfer from the palmtop to the CIP module Using this program the data is sent to the CIP module through a transmission medium The lock is then placed in programming mode via the keypad or a card swipe Data is received by the lock by way of two pins on the CIP module placed in contact with the lock Once the lock receives the data the individual s Vanderbilt card is swiped through the card reader on the lock to verify whether lock was properly programmed The lock light blinks green if access to the individual is granted thus the lock was programmed successfully If unsuccessful the lock light blinks red and the process repeats until the lock is successfully programmed Below is the figure that displays the operational concept in a block diagram 2 6 1 Operational Diagram A S from Host Computer redentials taine ata Uploaded to Palmtop Device Change Request from Vanderbilt Card Database Program Through Through Card Reader on Host Computer Transmission Medium Data Uploaded to Syncing Program on Palmtop Device Data Transferred from Syncing Program to Upload Program Data from Upload Verification by Data Sent from CIP Lock Placed in Program on Palmtop Swiping Vanderbilt Mod
44. ruction of the patent is not good enough to provide a close 22 engagement between the pins and the drawbars There only two engagement points between the pins and the drawbars which will probably result in a poor connection in a short time Also they are known to bend the IC pins at times Therefore they are only used when there is a good reason to do so Large ZIF sockets are commonly mounted on PC motherboards from about the mid 1990s forward These CPU sockets are designed to support a particular range of CPUS allowing computer retailers and consumers to assemble motherboard CPU combinations based on individual budget and requirements CPUs may also be upgraded or replaced during the lifetime of the motherboard socket Personal computers are among the few applications expensive enough to justify elaborate socket systems Smaller ZIF sockets are also commonly used in chip testing and programming equipment 3 3 Re designing Locks An additional solution suggestion was to redesign the circuitry within the lock so that no pins would be required to program each lock This would mean implementing a mini wireless CIP module and installing this on the inside of each lock This way there would be a direct connection from the mini CIP module to the back side of the two pins on the locks Once the lock was put into programming mode it could be reprogrammed without the insertion of pins Mini CIP module would be placed within the lock abo
45. s An example RS 232 linked system can be seen below Details of pin assignments for the standard cables can be seen in the appendix Computer ES Telephone Line Male DB2S Female Interface C able DTE DCE Data Data Terminal Orcutt em inating Equiprm ent Equipr ent The current lock programming system incorporates RS 232 into its design Data is transferred to the CIP module via a cable that conforms with the RS 232 standard Data transfer can happen using a computer s or palmtop s RS 232 serial port to the RS 232 port that exists on the CIP module This allows us to confront the breakage problem by considering several options that involve eliminating the cable between the transmitting device and the CIP module The general premise is to encode the RS 232 data coming from the transmitting device into a wireless standard and then decode that data back to 232 at the module Eliminating the cable would reduce much the rest stress placed on the pins of the CIP module by eliminating the stress caused by the cable on the CIP module Next we will discuss the possible standards which we could use to implement wireless RS 232 19 3 1 1 Bluetooth Another possible solution to the problem was to implment the transmission of data from the data host to the lock via bluetooth Bluetooth was actually actually conceived as a wireless RS 232 solution It is a lower power medium range wireless communication protocol that has gai
46. selves were custom made at the machine shop They were molded from plastic and made to fit our banana pins in terms of threading and pin diameter The pins are simply screwed into the handles due to the custom threading inside of the handles The pins had holes drilled into them bottom of them The 18 gauge wire was placed in these holes The pins were heated up with a high power soldering iron and rosin core solder was placed in the pin hole with the wire and melted to the exposed copper wire that composed the wire This wire was then run through the pin handle and the pin was screwed into the handle This made electrical connection with the pin pin handle and the wire The wires that extended from the pins were connected on the other end to the PCB To make a cleaner design we put the two individual wires inside a heat shrink tubing The heat shrink tubing was made to shrink using a novel idea of a paint stripping tool Pictures of the pin handles and wiring are shown below 29 Aluminum Casing The machine shop helped us develop a custom aluminum casing for our PCB The Aluminum casing was fitted specifically for our board and our needs Some of the requirements that we had for our design was that the case must be strong and light The aluminum casing is both We also wanted to ensure that in the case we needed to access the circuit there would not be a difficult process The aluminum casing has a cover that is secured by only four screws
47. sers By All Users wil Choudhury Ashok Into Credentials A lleer Credeantale Poaecihle Credentials lugbade Morakinyo Simakas Ashley Webb Lutalo M agLard 1 Function Normal Access Code 17345678 9 00000 00 7 l Mia 7 Delete Add Delete Filter Update Expiration D atela Now we want to specify what door the user has access too We do this by clicking on the Assign Access tab The result looks like this 3 User Access VD 922 lt Assign Access JOO View Users By All Users View Access Type Access Types Choudhury Ashok Show All Access Access Profiles Doors Gilstrap Justin Current Access lugbade Morakinyo m Featheringill Hall Simakas Ashley EHS Offline Doors Webb Lutalo testdoar Jacobs Hall Doors 8 testdoore HB Mechanical Offline Doors Testdaor3 Credential Drag We then drag the doors we would like the user to have access to into the Current Access pane We close after this is done This returns us to the main door where 47 we now want to program the doors with the new access rules Click on the program doors button which brings up the following screen Program Doors Click on Button to program only the specified type of Doors Launch the Lack Link Export
48. ss fractures These pins illustrated low cycle fatigue and the limited ductility properties of the pins lead to increased fractures Furthermore this supports the assumption that there is a need for a new method of programming the Locknetics locks that alleviates some of the stress placed on the banana pins of the CIP module 1 4 Proposed Solution by Sponsor In order to save money for VUSE and to reduce possible downtime our sponsor proposed that the CIP module get reverse engineered so that it s data can be transmitted via Bluetooth instead of direct serial data assuming the data from the CIP is typical serial data Then the lock would need a Bluetooth receiver with which to connect to the lock in a permanent way to received the Bluetooth data Bluetooth is built in on the handheld For the purposes of this project it can be assumed that your laptop or a loaner laptop with Bluetooth integrated can be used to develop the computer side of the project and a loaner lock serial cable and CIP module can be used to develop the hardware side of the project 10 2 2 1 System Overview and Description Background Information 2 1 1 Lock Features The lock consists of both hardware and software components The features of the hardware are listed below Built on proven industry leading heavy duty ANSI Grade 1 Schlage lock platform otand alone electronic locking system no hardwiring required Open track 1 or 3 encoding allows the
49. tions to the circuit and determine the expected behavior of the circuit This enabled us to determine that the CIP circuit converted RS 232 logic levels to 5v Ov logic levels and vice versa LockLink LockLink is an access control management software developed by Ingersoll Rand meant to be used with their with their Locknetics Lock system It manages all the locks in the system the users in the system and the access rules The LockLink software allows for the mapping of multiple facilities each which may have multiple buildings The buildings in the facilities may and typically do have multiple doors The management of users in Lock Link is extremely robust In the basic use one can add a user and set an array of access privileges and credentialing Each user can have more than one method of credentialing Magnetic Card Keypad iButton etc as well as a specific kind of access This can be normal access or special privileges such as the ability to access a lock even in the case of a lockdown of a building To simplify the process of setting user access rules LockLink supports user groups This is useful in situations when a certain set of users will have the same access privileges to a large number of doors One first sets the rules for that user group and then any user who must be added to the system who fits the profile for a user group can simply be added to that user group and the access rules will automatically be applied After being
50. tly by allowing each pin to adjust the depth at which it is inserted into the lock and secondly by the additional clamp that increases the stability of the pins once inserted Lastly the system reduced the cost of the CIP module greatly since the circuit board was replicated and purchased separate of buying a complete CIP module The ability to construct the new CIP module system in house greatly reduced the price of the system also Outside of the goals set for the project specific requirements were placed on the project also All system requirements were fulfilled some aspects of the project performing far greater than the required specifications For example it was suggested that the new system cost 30 less than the existing system The existing CIP module cost approximately 250 00 however our new system after subtracting the one time cost of the casing and the adjustable clamp was only 28 76 As seen in the five year cost analysis our new system reduced the cost by far more than 30 when comparing to the existing system In conclusion this project proved to be extremely beneficial to all group members the project sponsor and the Vanderbilt University School of Engineering The project allowed team member to implement theories and practices learned throughout undergraduate education into a practical application project The project sponsor benefited because he now has a new system that reduces the amount of time spent previously on upd
51. trial type AA batteries and one 3 volt button battery for memory and date and time backup The locks are designed with security as the utmost priority and with practicality as its second A database software program which is based on Microsoft Access tracks and controls the programming of the doors A small program called UPLINK EXE is used to bring the programming data of a lock s from the host computer to an individual lock A handheld PC uses Microsoft Activesync to sync the program files from the host computer to the handheld The handheld has a Windows CE version of the UPLINK EXE software that allows one to carry the small handheld unit around to program the individual locks Locks are re programmed on a daily basis and subsequently the handheld and its programming hardware suffer damage over time The programming hardware includes a USB Serial to Hewlett Packard handheld cable and a programming module called a Computer Interface Programmer CIP The CIP module is used to program the door and to read the ibutton credential After multiple uses the pins of the CIP module break or begin to break in such a way that they are no longer useable The pins on the CIP module that touch the lock are miniature banana pins Once the pins break a new CIP module must be purchased The cost of a CIP module is approximately 200 00 to 275 00 each The order time for a CIP can be months since IR Locknetics offers no support for end users One must go to a loc
52. ule to Lock Programming Device Sent to CIP Card Through Pin Contact Module Through Transmission Medium 3 Possible Solutions It was made clear by our sponsor that it is preferred that the project entail a re designing of the CIP module to make use of wireless connection however it is still important to confirm all other possible solutions are explored to assure the most effective and most cost efficient method is selected 18 3 1 Wireless RS 232 Connection The RS 232 standard also known as EIA 232 is a communication standard for serial binary communication between two devices One of these devices is Data Terminal Equipment and the other is the Data Circuit terminating Equipment These are abbreviated as DTE and DCE respectively RS 232 voltage levels for representing binary information is different than that for CMOS or TTL logic A binary 1 is represented by a negative voltage and logic 0 is represented by a positive voltage Voltage levels near zero are invalid Acceptable voltage levels are f plus or minus 3 to 15 volts This wide voltage range compared to typical integrated circuits necessitates the need for logic conversion circuits when interfacing the two There are standard cables and ports associated with the RS 232 standard The most common cables forms are the 25 pin and 9 pin versions Each pin on a connecter has a specific function and this function is standard for 25 and 9 pin male female connector
53. ve 23 Although the outcome of redesigning the locks would be very desirable this option is not very feasible for a few reasons It would it be an extreme hassle and very time consuming to redesign over 100 locks in Featheringhill Hall Additionally by tampering with the circuit design in the locks the warranty with Locknetics would be broken This would mean that if there was ever a defect with the lock it would not be able to be replaced This could become very costly with the locks costing approximately eight hundred dollars each 4 Final Solution 4 1 Detailed Hardware Design Original Circuit Analysis The first step in our hardware design process was to analyze the circuit in the original CIP module The first step in this process was to accurately do a paper and pencil Sketch of the circuit board The challenge came from the two sided property of the board That is there are traces on both the bottom and the top of the circuit board To deal with this problem we used a high magnification microscope with a high powered light that was able to shine through the board This enabled one to view through both sides of the board and make an accurate sketch of the circuit The next step was to identify the components on the board All but one of the components were standard and easily identifiable The last component was identified by unsoldering it from the board viewing the party number listed on it under magnification and with the help o
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