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Consisting Of: Glenn Trost and Paul Hansen

Thursday May 24, 2012
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Table Of Contents
Cover Page 1
Table of Contents 2
Executive Summary 3
Prototype Diagram 5
Service Manual 6
Results 10
Bill of Materials 12
Conclusion 16










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Executive Summary-
For our project we were tasked with designing the electrical system for a prototype car.
We needed to create a keyless entry, seatbelt sensor, motor system, car horn, windshield wipers,
directional signals, brake system, a rear obstruction sensor and a subsystem enhancement. For
the enhancement we were given a list of add-ons that we could make to make our product better.
Not only did we have to create these systems, most of them needed to be integrated into other
systems so they work together (such as the three input key being needed to start the motors). For
this assignment we were required to build each system, integrate them together as requested and
debug and make it all of it work together when we were evaluated on the due date.
In our time spent we were able to create the desired systems, integrate them and have
them run efficiently and with the simplest design. This design was optimal because it was easy to
produce, easy to debug and had a quality wiring job that made replacing burnt out components a
breeze. With the neatness of the circuit in addition to the simplicity of the systems our product
would undoubtedly be the preferred solution. Once we completed the initial builds of the system
we went back to test each subsystem and did a thorough debugging, fixing problems with the
motors, horn and other subsystem. While did this we spent large amounts of time cleaning up the
wiring, and looking for ways to make circuits simpler and more efficient. For our subsystem
enhancement we created a radio tuner, which can cycle through ten radio stations and would be a
very positive addition to our system. Most people who drive tend to use their radio more than
their wipers and headlights so a radio station tuner would be something that the majority of car
buyers will be looking for.
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Subsystem
Name
Points
Earned
Maximum
Points
Possible
Motors 20 20
Brakes 15 15
Wipers 10 10
Headlights 11 20
Rear View 20 20
Horn 10 10
Turn
Signals 13 15
Keyless
Entry 10 10
Seatbelt
Sensor 10 10
Radio
Tuner 16 20
Neatness 20 20
Total 155 170

Cost of Subsystems
Subsystem
Total
Cost
Motors 5.3
Radio 4.26
Brakes 2.72
Seatbelt
Sensor 2.45
Horn 1
Headlights 2.1
Turn
Signals 4.08
Keyless
Entry 2.94
Wipers 50.5
Rear
Obstruction
Senor 1.11
Total 76.46
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For the production of this product, the carbon footprint is pretty minimal. We didnt have
to transport it so we created 4480 kilograms of CO2 in the manufacturing and 1540 kilograms of
CO2 in disposal for a total of 6030 kilograms of CO2. This figure might be high because we are
unsure if any of the parts are recyclable, because if they are the projected number will be even
lower.
Prototype Design:
This prototype layout will be intuitive and easy to use for multiple reasons. The first
reason would be that the wiring is extremely neat. There are no flyovers every wire is as close to
the board as possible and wires going across the board go under and pop back up on the other
side where they fit into their component. This is very helpful to the user and saves a lot of time
that would have been spent looking for a specific input or output or trying to find where a
specific wire goes if it becomes unplugged. The second factor that this layout is optimal would
be that all of the integrated circuits can be easily replaced. There is nothing over them, next to or
overlapping them and even a novice could pull one out and replace it with a replacement part.
This is a breath of fresh air compared to other prototypes, where if you needed to replace a
component you couldnt because of all of the wires and other parts overlapping or neighboring it.
The third and final reason our layout is that all of the input switches and output indicators are
clearly labeled in their respective key. This speeds up operation time and makes sure the
technology incompetent users dont accidentally push the wrong button. With these three factors
working together it can easily be seen that our prototype is extremely user friendly and can be
easily handled by the average person.

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Service Manual:
Wipers:
This is by far the easiest and most expensive component of the entire project. We used a
Board of Education, a switch and a servo motor. We had the board of education running our
wiper program (as shown below) with the input of the servo hooked to the specified port. We
then hooked one end of the switch to Vcc and hooked it in series with the red wire of the servo
motor. We then connected the black wire to ground to complete the circuit. This way when we
flipped the switch on, it completed the circuit and the wiper (aka the servo) turned back and
forth. Here is the specific program we used:
' {$STAMP BS2}
OUTPUT 12 'connected to servo motor
OUT12=0 'start with the control line low.
n VAR Byte 'byte size variable (0-255) used in the for loop
' this loop rotates the servo motor fully clockwise.
loop: ' line label so program can return here .
FOR n = 1 TO 15 ' repeats loop 15 times to send 15 pulses to the servo
PULSOUT 12, 500 ' sends a high pulse to the serco with a duration
'of 500 x 2 us = 1ms. pulses of this
'width will drive the servo to fully clockwise
PAUSE 20 ' servo requires 20 ms betweenb pulses
NEXT
DEBUG CLS, "Serco position:fully clockwise" 'cls clears the screen
FOR n = 1 TO 15 ' repeats loop 15 times to send 15 pulses to the servo
PULSOUT 12, 750 ' sends a high pulse to the serco with a duration
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'of 750 x 2 us = 1..5ms. pulses of this
'width will drive the servo to the midpoint
PAUSE 20 ' servo requires 20 ms between pulses
DEBUG CLS, "servo position: Midpoint"
'This loop rotates the servo motor to the fully counterclockwise position.
FOR n = 1 TO 15 ' repeats loop 15 times to send 15 pulses to the servo
PULSOUT 12, 1000 ' sends a high pulse to the servo with a duration
' of 1000 x 2 us = 2000 ms. Pulses of this width
' will drive the servo fully counter clockwise.
PAUSE 20 ' servo requires 20 ms between pulses
NEXT
DEBUG CLS," servo position fully counterclockwise"
GOTO loop
Headlights:
For this system we started out with a triple input NOR gate. This wasnt our preferred
chip, however the cabinet didnt have triple input OR gates. We then took a output from the
switch of the wiper, a switch designed specifically for the headlights and a phototransistor
hooked up to 5V. These three made up the inputs of the headlights. We then took the output, and
put it into three other NOR inputs to invert it into a Triple input OR gate without using an
inverter. We then took the output of that and hooked it in series with the red wire of the AC
power supplier and hooked the black wire into ground. With this setup when any input goes high
the chip will output high turning on the AC power supply and lighting up the light bulb.
Radio Station Selector:
For this we used the model that we used in class. This model consisted of a 74LS93
hooked up as a MOD 10 counter, a 74LS47 Decoder, a 4116RCF 470 Ohm resistor chip and a
FND507 seven segment display. To simplify it, we hooked up a push button on the board instead
of using the one on the trainer. We then hooked up the pushbutton to the counter, whose output
was hooked up to the 74LS47 decoder, whose outputs went through the 470 Ohm resistor chip
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and into the seven segment display. This way when the pushbutton was pushed, it would cycle
through the ten stations on the display.
Horn:
This subsystem was relatively simple, but it took us a long time to get working properly.
We just took a AND gate and an OR gate and a pushbutton. We had the output of the backup
sensor and the output of the pushbutton, put them in the OR gate whose output went into the
AND gate. While in the AND gate it is combined with the Clock signal to output a frequency if
the horn or the Distance sensor go off. We took the output of the AND gate and ran it through
the speaker with the other part of the speaker going to ground.
Seatbelt Sensor:
This was another simple design that was built around the H2A1 photo interrupter. We
simply hooked up the photo interrupter as shown in the lab packet with the red led hooked up in
series with the output of the receiver. This way when something blocks the photo interrupter the
current flow stops turning off the LED and signaling that the seatbelt is buckled.
Rear Obstruction Sensor:
This system was another of the many simple systems used in our prototype that makes
our design easy. We used the sensor attached to the wooden chassis and hooked the red wire to a
comparator and potentiometer in series to 5V and the black wire to ground. We used the
comparator and potentiometer to regulate the distance that it senses and tuned it to 10 cm. We
then hooked up the output of the sensor into the brakes, motors and horn.
Three Switch Keyless Entry:
For this we used two D flip flops and based our design of the model in lab 8. If you press
D then CLK the Q output will put out a constant high. We hooked two together to make it a three
switch entry and hooked the outputs (Q and Q NOT) to LEDs. For extra security we hooked up
the Q output to an AND gate with the input of the motors, so if the wrong sequence is entered the
motors wont start.

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Brakes:
This was another system that we made simple for ease of use. We hooked up a
pushbutton and put in a RED LED that would light when it was pressed. We then took the output
and inverted it and put it in an AND gate with the Q output with the input for the motors. With
this setup when the motors are running and we push the brakes the red led comes on and the
motors stop.
Turn Signals:
For the turn signals we ended up using a more complex design. We had three push
buttons (one for left, one for right and the third for reset) hooked up to flip flops that would give
a high Q when their button was pushed. These Q outputs were hooked up to AND gates with the
clock signal, and then put into LEDs. When both buttons were pressed the flip flops reset each
other and it causes the red LED to light. This can then be shut off by pressing the reset
pushbutton.
Motor:
This is by far the most complex system out of the whole project. We used the motor
design from the dual motor control lab. We then took this model and integrated the Three switch
keyless entry, the brakes and the backup sensor so it wouldnt work unless the conditions of the
other systems were met. We then hooked the motors up to two switches so they would go
forward or reverse.






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Results:
Our testing went well but not as well as we hoped. Our phototransistor for our headlights
had been working fine the night before, but for some reason stopped working on our testing day.
Although we tried to debug it, we didnt have enough time to fix the problem before we had to
test so we lost the majority of the points that we didnt get there. Another problem was that our
turn signal and horn were hooked up to run on the same frequency. This was detrimental because
for optimal performance the turn signals and the horn needed to be hooked up at different
frequencies to receive full credit so we ended losing points there as well. The third place we lost
points was on the radio tuner, where when you pushed the channel selector button it occasionally
jumped multiple stations when it should have only changed one. We could have fixed this by
running it through a Schmitt inverter which would have cleaned up the signal and made sure it
only changed one channel at a time. Those were the only places that we lost points and overall
we did very well on the testing phase.

















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Names Paul Hansen Glenn Trost__________________________________________Point Total (170 max) ____155____

1. Keyless Entry: Motor Activated & Green LED On (5) __5_____

Motor Lockout & Yellow LED On (5) ___5____
Keyless Entry Total (10) __10_____

2. Seatbelt Sensor: Red LED On if "Buckle" Not Inserted (10) ___10____
Seatbelt Total (10) ____10___

3. Horn: High Pitched Sound when Button Pressed (5) ____5___

Sounds when Rear Obstacle Detected (5) __5_____
Horn Total (10) ____10___

4. Headlights: On when Toggle On (5) ___5____

On when Ambient Light Level is Low (10) __1____

On when Wiper is On (5) __5_____
Headlight Total (20) __11____

5. Windshield Wiper: Rotates Back and Forth When Toggle On (10) _10_____
Wiper Total (10) ____10___

6. Directional Signal: Left Green LED Blinks at Low Rate only if Left Switch Pressed (5) __5____

Right Green LED Blinks at Low Rate only if Right Switch Pressed (5) __5_____

Red LED Blinks at Low Rate if both Left and Right Switches Pressed (5) __3____

Signal Total (15) ___13___

7. Motor: Off Anytime Switches are in the Neutral Position (working motor) (5) _5_____

Spins Forward with Switches in Forward Position & Activated (5) __5_____

Spins Backward Switches in Forward Position & Yellow Backup Light on (10) _10____

Motor Total (20) ___20____

8. Brake: Red LED On when Brake Button Pressed (5) __5_____

Motors Off when Pressed (Forward & Reverse) (10) ___10___
Brake Total (15) __15____

9. Rear Obstruction
Sensor: Red Brake LED on when Object < 10cm (Forward or Reverse) (5) ___5____

Horn on only if Motor in Reverse and Object < 10cm (5) __5_____

Motor Goes Off only if in Reverse when Object < 10cm (10) ___10____
Rear Obstruction Total (20) _20_____

10. Subsystem Name of Subsystem(s) ______Radio Tuner__________________________
Enhancement: Comments:
Subsystem Enhancement Total (20) ___16___


11. Circuit Neatness: Good Layout, Well Labeled, Neat Wiring Circuit Neatness Total (20)
___20___

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Bill Of Materials
Part Name Vendor
Part
Number Quantity
Unit
Price
Totals
Per Part
Dual D-type pos.-
edge-triggered
flip-flops
TI 74LS74 4 0.38 1.52
Quad 2-input
positive-OR gates
TI 74LS32 2 0.38 0.76
Quad Differential
Comparator TI LM339n 1 0.11 0.11
Quad 2-input
positive-NAND
Schmitt triggers
TI 74LS14 2 0.4 0.8
Quadruple 2-Input
Positive-AND
Gates
TI 74LS08 3 0.37 1.11
Triple 3-input
positive-NOR gates
TI 74LS27 1 0.41 0.41
4-Bit Binary
Counters
TI 74Ls93 1 1.9 1.9
BCD-to-Seven-
Segment
Decoders/Drivers
TI 74LS47 1 1.15 1.15
Quadruple Half-H
Drivers
TI SN75441 1 0.75 0.75
Single, Current-
Limited, Power-
Distribution Switch TI PS2051 3 0.6 1.8
Hex inverter
buffers
TI 74ls06 1 0.55 0.55
470 Resistor Chip Digi Key 4116RCF 1 0.76 0.76
Push button parallax

7 0.1 0.7
7 Segment Display Futurlec i7208D 1 0.35 0.35
Green LED Parallax

3 0.5 1.5
Red LED Parallax

3 0.5 1.5
Yellow LED Parallax

1 0.5 0.5
100k
Potentiometer

1 1.5 1.5
Photo-transisitor Parallax

1 1.49 1.49
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Photo- Interrupter Parallax H21A 1 1.5 1.5
Diode Parallax

3 0.2 0.6
2k Resistor Parallax

2 0.15 0.3
470 Resistor Parallax

14 0.15 2.1
1k Resistor Parallax

3 0.2 0.6
10k Resistor Parallax

7 0.2 1.4
.14 Pf capacitor Parallax

2 0.15 0.3
Basic Stamp Parallax

1 50 50
switch Digi Key

1 0.5 0.5

76.46




Subsystems

Motors

Quadruple Half-H
Drivers

SN75441 1 0.75 0.75
Hex Inverter
Buffers

74LS06 1 0.55 0.55
Single, Current-
Limited, Power-
Distribution Switch

Ps2501 3 0.6 1.8
470 Ohm Resistor

6 0.15 0.9
10k Resistor

5 0.2 1
.14uf

2 0.15 0.3

Total
Cost 5.3
Radio

470 Resistor Chip Digi Key 4116RCF 1 0.76 0.76
BCD-to-Seven-
Segment
Decoders/Drivers TI 74LS47 1 1.15 1.15
4-Bit Binary
Counters TI SN74LS93 1 1.9 1.9
7 Segment Display Futurlec i7208D 1 0.35 0.35
Push button parallax

1 0.1 0.1

Total
Cost 4.26
Brakes

Red LED Parallax

1 0.5 0.5
Quadruple 2-Input
Positive-AND
TI 74LS08 1 0.37 0.37
14

Gates
Quad 2-input
positive-NAND
Schmitt triggers
TI 74LS14 2 0.4 0.8
470 Ohm Resistor

1 0.15 0.15
10k Resistor

1 0.2 0.2
Diodes Parallax

3 0.2 0.6
Push button parallax

1 0.1 0.1

Total
Cost 2.72

Seatbelt Sensor

Red LED Parallax

1 0.5 0.5
Photo- Interrupter Parallax H21A 1 1.5 1.5
2k Resistor Parallax

1 0.15 0.15
470 Resistor Parallax

2 0.15 0.3

Total 2.45

Horn

Quadruple 2-Input
Positive-AND
Gates
TI 74LS08 1 0.37 0.37
Quad 2-input
positive-OR gates
TI 74LS32 1 0.38 0.38
Push button parallax

1 0.1 0.1
470 Resistor Parallax

1 0.15 0.15

Total 1
Headlights
Triple 3-input
positive-NOR gates
TI 74LS27 1 0.41 0.41
Photo-transisitor Parallax

1 1.49 1.49
1k Resistor Parallax

1 0.2 0.2

Total 2.1
Turn Signals

Dual D-type pos.-
edge-triggered
flip-flops
TI 74LS74 2 0.38 0.76
Quad 2-input
positive-NAND
Schmitt triggers
TI 74LS14 1 0.4 0.4
Quadruple 2-Input
Positive-AND
Gates
TI 74LS08 1 0.37 0.37
Push button parallax

3 0.1 0.3
1k Resistor Parallax

3 0.2 0.6
15

470 Resistor Parallax

1 0.15 0.15
Green LED Parallax

2 0.5 1
Red LED Parallax

1 0.5 0.5

Total 4.08
Keyless Entry

Dual D-type pos.-
edge-triggered
flip-flops
TI 74LS74 2 0.38 0.76
Quad 2-input
positive-OR gates
TI 74LS32 1 0.38 0.38
Green LED Parallax

2 0.5 1
Yellow LED Parallax

1 0.5 0.5
1k Resistor Parallax

1 0.2 0.2
Push button parallax

1 0.1 0.1

Total 2.94
Wipers

Basic Stamp Parallax

1 50 50
switch Digi Key

1 0.5 0.5

Total 50.5
Rear Obstruction
Sensor

Quad Differential
Comparator TI LM339n 1 0.11 0.11
100k
Potentiometer Digi Key

1 1 1

Total 1.11









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Conclusion:
Overall our design is very strong. It is simple, easy to fix and it is easy for someone who
isnt technically gifted to operate. This is the optimal solution to the problem because it is very
user friendly and is more catered more towards the average customer. With that we included the
radio station selector because the average driver listens to the radio and by including it we make
our system even more desirable to the average driver.
However even with all of our success we did have some shortcomings. For one we had a
lot of trouble keeping everything working at the same time, with problems arising and more
problems taking their place when they were fixed. We could have improved on this if we were
given another chance, by spending more time debugging and giving extra care not to mess up
any of the working systems. By having more time to test and debug we would have been able to
improve our score on this project.
Overall our cost was good for the time we had to create this project. We made things
simple and tried to use as few chips as possible when creating the circuit. A few major areas
where we could have saved money would be for one the wipers; we would have been able to
save fifty dollars of our total cost if we were able to circumvent the use of the stamp for turning
the wipers. Another area we could have saved would have been the turn signals, where we could
have used a greatly simplified version of it, but had a disagreement about it and ended up using a
more complex version that holds the signal but uses three more chips. The final way we could
have reduced the cost would have been by utilizing our space better. If we had the time to
reorganize everything to fit better we could have saved a board a few chips and a lot of wire.
However with the constraints we were under we didnt have time to do this.
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For the sustainability analysis we used 4480 kilograms of CO2 in the manufacturing and
1540 kilograms of CO2 in disposal for a total of 6030 kilograms of CO2 over its entire life. As
stated previously if we had the time we could have cut out a board which would have greatly
decreased the impact of the lifecycle of this product.
The Restriction of Hazardous Substances Directive or RoHS is a directive created by the
European Union to restrict the presence of hazardous substances in an array of products. The six
substances that were restricted were Lead, Mercury, Cadmium, Hexavalent chromium,
Polybrominated biphenyls (PBB) and Polybrominated diphenyl (PBDE) ether. Below is a table
of the compliance of each specific subsystem:
Motors Compliant
Turn
Signals Compliant
Brakes Compliant
Keyless
Entry Compliant
Wipers Compliant
Seatbelt
Sensor Compliant
Headlights Compliant
Radio
Tuner Compliant
Rear View Compliant Horn Compliant

Overall since all of the components we purchased came from a supplier that complies with
RoHS we were able to create a system that fully complies and has no issues with these
restrictions. This is beneficial for marketing in other countries and also should enforce your
decision that our product is the optimal choice for your company.