GE401- Innovative Product Design & Development I

Subassembly Specification Document

12/09/2011

Team 2 Seydi Afin nl Emirhan Akdemir Cansu Acar Melodi Trkili Onur entre Engin yidoan

Version: 1.0

Contents
Introduction ................................................................................................................................................... 3 Subassembly Descriptions, Functions and Specifications ............................................................................ 3 Arduino Uno ............................................................................................................................................. 3 Physical Specifications ......................................................................................................................... 3 Electrical Specifications:....................................................................................................................... 4 Software Specifications......................................................................................................................... 5 Stepper Motors .......................................................................................................................................... 5 Stepper Motor Drivers .............................................................................................................................. 6 Bill Validator ............................................................................................................................................ 7 Physical Specifications ......................................................................................................................... 7 Electrical Specifications ........................................................................................................................ 7 Software Specifications......................................................................................................................... 7 LCD Display ............................................................................................................................................. 8 Keypad ...................................................................................................................................................... 8 Gas Compressor ........................................................................................................................................ 9 Cooling System Control Card ................................................................................................................. 10 Physical Specifications: ...................................................................................................................... 10 Electrical Specifications:..................................................................................................................... 10 Software Specifications: ..................................................................................................................... 10 UPS ......................................................................................................................................................... 11 Steel Case ................................................................................................................................................ 12 Pasta Tank ............................................................................................................................................... 12 Ingredients Tanks .................................................................................................................................... 13 Bowl Slot ................................................................................................................................................ 13 Helical Mixer for Pasta ........................................................................................................................... 14 5 x Helical Mixers for 5 Ingredients ....................................................................................................... 14 6xGreen and 6xRed LEDs ...................................................................................................................... 15 Subassembly Product Tree .......................................................................................................................... 16 Conclusion .................................................................................................................................................. 17 References ................................................................................................................................................... 18 Appendix A. ................................................................................................................................................ 19

Introduction
In subassembly specification report, the aim is to specify the subassemblies that are required to build MacQuick. Descriptions, functions and specifications of each sub-parts of product are explained. Specifications of product includes electrical specifications (such as operating voltage, output current, torques, power) and physical specification (such as dimensions, operating temperatures, shapes). In addition to them, connections and protocols between subassemblies are clarified throughout report. Block diagram, product tree and software flowchart are also added to report as appendix.

Subassembly Descriptions, Functions and Specifications

Arduino Uno
Arduino Uno is a microcontroller card with the microcontroller ATmega328. It is used as the brain of the MacQuick. It s responsible all the processes except the cooling system that are explained in detailed in the light of the flowchart in Preliminary Design Document of MacQuick. Arduino Uno has 14 Digital input/output pin. It has also 6 analog inputs (Figure 1). The crystal oscillator that is used in it is 16MHz. It has a USB port. The software is installed to the microcontroller via USB port. It has a power jack, ICSP header and a reset button. Further technical specifications are given in the list given below.

Physical Specifications The maximum length and width of the Uno PCB are 6.8cm and 5.3cm respectively. It consists of 4 screw hole to attach the Arduino Uno to a surface. The range that Arduino Uno is functional is between +10C TA +40C.

Figure 1: Arduino Uno Front View

Electrical Specifications: Microcontroller Operating Voltage Input Voltage (recommended) Input Voltage (limits) Digital I/O Pins Analog Input Pins DC Current per I/O Pins DC Current for 3.3V Pin Flash Memory SRAM EEPROM Clock Speed ATmega328 5V 7-12V 6-20V 14 (of which 6 provide PWM output) 6 40mA 50mA 34KB (ATmega328) of which 0.5 KB used by bootloader 2KB(ATmega328) 1KB(ATmega328) 16MHz

Software Specifications Arduino Uno communicates with a computer serially over USB. It uses standard USB COM drivers. The Arduino software includes a serial monitor which allows simple textual data to be sent to the Arduino Uno and this is how the code is installed on the microcontroller.

Arduino Uno can be programmed with the Arduino software. It also has a different programming language. Its language is based on C/C++. On the other hand, it has lots of open source libraries written by Arduino community that enables users to use other programming languages and development environments. Also it is allows the use of any of AVR Libc functions. It is a subset package of standard C library used for Atmel AVR 8-bit RISC microcontrollers. Development environment is also provided by the Arduino community. The open sourced Java based Arduino environment makes us to implement and upload the code to the board. It is multi platform software that runs on Linux, Mac OS X and Windows so there is no need to install any virtual machine to run the software.

Stepper Motors
As described before, stepper motors are used to turn the helical mixers in order to pour the enough amount of pasta into the bowl. Sparkfuns stepper motor is used in MacQuick and its specifications are given below.

COMMON RATING Step angle: Phases: Insulation Resistance: Weight: 1.85 2

DC)

ELECTRICAL SPECIFICATIONS Voltage: Current: 12V 0.33A 34%10 46%20Mh 0.23N.M

DIMENSIONS Height: Width: Depth: 6cm 4cm 4cm

100Mohm(500V Resistance: 0.2Kg Inductance: Holding torque:

Figure 2: Stepper Motor

Stepper Motor Drivers

Even if stepper motors receive the command from Arduino Uno, Arduino Uno can not provide enough current to start the motor movement. For the purpose of providing enough current to the motors while not damaging any other component in the system, Stepper Motor Drivers are used. So they basically provide enough current to the motors. EasyDrivers A3967 will be used in project and this stepper motor driver is designed to control one bipolar stepper motor. It provides 7V-30V and maximum 0.75 amperes for each coil in motor. In the case of emitting more amperes than providing, motor driver can fix ampere in 0.75 amperes by using ampere regulator. A3967 have 13 pins and four pins will be used to control stepper motor. There are two pins (direction, step) which can be assigned to arduino uno; however, we will only use step pin of motor driver because stepper motor will turn in one direction. Specifications are given in table :

Load Supply Voltage: Max Output Current: Logic Supply Voltage Maximum Wake-up Time Dimensions Controller

7V-30V 0.75A 7V 1ms 20x50x3 mm A3967SLBT

Figure 3: Stepper Motor Driver - EasyDrivers A3967

Bill Validator
Bill validator is the component that counts the money that user pays and sends the money is paid signal to the microcontroller. It has a small slot that takes the coin money as input and a locked small case that keeps the paid money inside.

Physical Specifications
Dimensions Coin Diameter Coin Thickness Operating Temperature 102 x 89 x 52 mm 1.5 - 31.5 mm 1.5 - 2.5 mm -20oC up to 70oC

Electrical Specifications It uses 12-24VDC 10% as power supply.

Software Specifications
The NRI G13.mft is able to be taught up to 8 coins/tokens as standard. It uses WinEMP software for downloading complete device and coin configuration. Some of the interfaces that are used are serial s1, serial MDB, ccTalk, USB connectiton.

LCD Display
LCD display is main interface component that is used to show messages to users. It is standard 4x20 LCD that is used with a micro-controller easily. Total credit of the customer, problem messages, informing messages such as the the message shown when the macaroni is ready, are displayed through LCD screen. Messages shown on LCD is determined by Arduino Uno. LCD and Arduino communicate using HD44780 protocol. 5V%20 3mA

Supply Voltage: Supply Current:

Height: Width: Depth:

5cm 9cm 1cm

Operating Temperature: -20C / 70C

Figure 4: LCD

Keypad
Keypad enables user to choose the desired ingredients and keypad directly connects with Arduino Uno. There will be seven buttons in keypad as indicated requirement report. The operating voltage is 5V and Arduino Uno serves as voltage supply for keypad. Data is send serialy from keypad to Arduino Uno and keypad library is used for implementation. Further specifications are given below.

Operation Voltage Operating Temperature Dimensions Number of Output Pins

5V
-20C / 50C

70x120x5 mm 3 (one of pins is serial connection)

Figure 5: The Keypad of MacQuick

Gas Compressor
The pasta and the ingredients will be cooled to the 15 degree Celsius with the traditional vaporcompression refrigeration. Macquick consists of a gas compressor which basically compresses the gas to the pipes to keep the cooling process going. Gas compressor will be controlled by cooling system control card. The operating voltage of compressor will be 220V-240V and the cooling capacity is approximately 250W. All specifications of gas compressor are indicated below;

Supply Voltage Cooling Capacity Displacement Dimensions Cooling Type

220V-240V 250W 9cm3 100.5x113.5x184 mm Static Cooling

Cooling System Control Card

As explained, cooling system will be controlled with a different microcontroller card based on PIC16C58A which will be provided in the refrigeration system itself . It has a temperature sensor and an ADC in it and the controller card sends the command turn on the gas compressor if the current temperature is above 15 degree Celsius and sends turn off command if the currently measured temperature is below 15 degree Celsius. Since this will be taken from a mini refrigerator already coded and designed. So as a subassembly, we are interested in not the specifications of the PIC16C58A in a detailed way but the specification of the complete control card.

Physical Specifications: The length and width of the cooling system control card is 16cm and 14 cm respectively. It consists of 4 screw hole to attach the it to a surface. The range that it is functional is between +10C TA +40C.

Electrical Specifications: Supply Voltage Supply Current Operating Frequency 3 - 6V 1.8 - 3.3 mA 4MHz

Software Specifications: The PIC16C58A in the cooling system control card is preprogrammed and we will not reprogram it again. We may just make some small changes to adjust the critical temperature that it chages the state of the gas compressor from on to of or vice versa.

UPS
Uninterruptible Power Supply (UPS) will be used to supply the system if any power cut situation happens. Also it will prevent the system from the harmonics which means transient ripples that may occur in the input current. In brief, UPS enables system to maintain its durability. The capacity of the UPS is 700VA/490W and it specifications are given below.

Output Output power capacity: Nominal output voltage: Efiiciency at full load: Waveform Type: 420 Watts/700 VA 120V 78%
Stepped approx. to sinewave

Input Nominal Input Voltage: Input Frequency: Cord Length: Maximum input current: 120 V 50/60 Hz3% 1.83 m 12 A

Baterries & Runtime Included battery modules: Typical recharge time: Backup time: Operating temperature: 1 12 hours Given in the figure below 0C / 40C

Physical Height: Width: Depth: Weight: 190 mm 91 mm 310 mm 8 KG

Figure 6: Load vs. Backup Minutes Characteristics of UPS

Steel Case
To prevent any breaking in attempt, the case of the MacQuick will be steel. Steel case can be thought as a rectangular prism with dimensions 180cm(height)x80cm(width)x80cm(depth). Weight of the steel case is about 90kgs. Since all the internal structure will be mounted on steel case,

Pasta Tank
This tank is a part of the internal mechanical structure and it keeps all the pasta inside it. Since MacQuick will not be refilled in the middle of the day, it will be big enough to store enough pasta for one day. It will be a inverted conical shaped tank so that the macaroni will constantly tent to move down where the empty blow is. It will be made of steel which will not give a bad taste to the pasta inside it. The volume of the pasta tank is determined as 58434cm 3 and the amount of pasta to be dropped into bowl is 971cm3 so a full macaroni tank can serve up to 60 bowl of macaroni. The exact sizes of the pasta and the macaroni tanks are given in Figure 5.

Figure 7: a. Pasta Tank - b. Ingredients Tank

Ingredients Tanks
Ingredients tanks are again inverted conical shaped tanks due to the same reason. However, it will be relatively smaller than the pasta tank. It will be made of steel which will not give a bad taste to the pasta inside it. The exact volume and the sizes of the ingredients tanks are given in Figure 5.

Bowl Slot
In the vending process it is expected the user to take a empty bowl from the bowl slot and place into the output box. So we are providing the user the empty bowls in the bowl slot. Bowl slot is a slot near the output slot where the user can take an empty bowl by just applying a small force downwards like in the electric water fountains. Bowl slot is integrated to inside of MacQuick by using screws. Bowl slot will be cylindrical and plastic. User will draw bowl from bowl-slot. There will be approximately 150 bowl in bowl slot. Dimensions of bowl slot are determined in accordance with required number of bowl.

Dimension of bowl (frustum) : top radius 15cm, bottom radius 12cm, height 12cm

Dimension of bowl slot (cylinder) : radius 16cm, height 80cm

Helical Mixer for Pasta

As stated, the mechanical component to drop the pasta and the ingredients will be a helical mixer. By turning it for a specific angle, a specific amount of pasta will be dropped. The exact sizes of the helical mixers are given in Figure 6.

Figure 8: The Model of the Helical Mixer for Ingredient and Pasta

5 x Helical Mixers for 5 Ingredients

The helical mixer to use for ingredients will be smaller ones of the pasta version. Since MacQuick offers 5 different ingredients, there are 5 same sized helical mixers for each ingredients. The exact sizes of the helical mixers are given in Figure 6.

6xGreen and 6xRed LEDs

Since there are 5 ingredients and the macaroni pasta tanks, here are total 12 LEDs in MacQuick. Green LEDs stand for there are enough amount of the ingredient or pasta in the tanks and red LEDs stand for that specific ingredient or pasta has ran out of so that the user know what ingredient s/he can not choose beforehand.

Subassembly Product Tree

1 x x x x x --> MacQuick 1 0 x x x x --> MacQuick Internal Structure 1 0 1 x x x --> MacQuick Internal Structure - Electrical Components 1 0 2 x x x --> MacQuick Internal Structure - Cooling Components 1 0 3 x x x --> MacQuick Internal Structure - Mechanical Components

Conclusion
In previous reports, we mainly focused on whole structures by evaluating requirements of product. After implementing block diagram and software chart, we became to look sub-units of product and with this report we state all specifications and designs of subassemblies of MacQuick. Before documentation of this report, subunits had been analyzed and market researches had been done; hence, subassembly specification report also improve our perspective on the design of the product. Block diagram and product tree added to report as appendix because this report are mainly shaped by evaluating them.

References
1. Arduino Uno. arduino.cc. http://www.arduino.cc/en/Main/ArduinoBoardUno 2. Back UPS-Pro. apc.com. http://www.apc.com/resource/include/techspec_index.cfm?base_sku=BR700G&tab=models 3. EasyDriver Stepper Motor Driver. sparkfun.com. http://www.sparkfun.com/datasheets/Robotics/A3967.pdf 4. Small Refrigeration Compressor. alibaba.com. http://www.alibaba.com/productgs/397489299/small_refrigeration_compressor_GFF86AA_R134a.html?s=p 5. Specification for LCM Module. es.co.th. http://www.es.co.th/Schemetic/PDF/ABC020004B21-BIW-R-01.PDF 6. Step Motor. sparkfun.com. http://www.sparkfun.com/datasheets/Robotics/SM-42BYG01125.pdf 7. PIC16C5X. microchip.com. http://ww1.microchip.com/downloads/en/DeviceDoc/30453b.pdf

Appendix A.