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Senior Design Project P06201: Modified Home Entry Project Sponsor: National Science Foundation Team Members: Robert Karpowicz (ME) Team Leader Brian Long (ME) Chief Engineer Jeff Webb (ME) Josh Ribbeck (ME) Team Coordinator: Dr. Alan Nye Team Mentors: Dr. Margaret Bailey Dr. Elizabeth DeBartolo

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Introduction Client: Arc of Monroe County Sponsor: National Science Foundations (NSF) This material is based upon work supported by the National Science Foundation under Award No. BES-0527358 Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation. Goal: To create a system to open and close main doors automatically for residents with disabilities at assisted living locations. Locations Arc of Monroe County Assisted Living Locations Rush, NY (priority) Penfield, NY (if resources allow)

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Rush Location View from outside

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Penfield Location View from outside

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Business Analysis Primary Stakeholders Members of the Arc of Monroe County Complete goals of project while staying within the limits of grant ($1500) Primary Business Goal Design a working prototype for the Arc residents to use in their assisted living locations.

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Background Research Costs of current commercial systems Price Quote from www.privatedoor.com www.privatedoor.com Costs start at $600 (door only) Additional $600 for actuating lock system Michigan State performed similar project 2 doors for $10,000 RIT cost approximately $3000 per door

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Design Objectives Design with off-the-shelf components Makes assembly and integration simplistic Minimize costs Modularize design - Plug and Play Only connections AC power Door mechanism Locking mechanism Sensors

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Design Process for Senior Design I 1)Determine end-user needs with Needs Assessment 2)Quantify needs with specific goals 3)Brainstorm concepts to meet goals 4)Perform feasibility assessments (Pugh Chart) 5)Select best concept 6)Perform engineering analysis 7)Select components

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Needs Assessment Objectives Door open/close with only single input from user Remote activation by specified users only User input ignored during system operation Preserve regular door function Door remains open until closed or close on its own Door stopped when object in path detected High reliability Easy maintenance

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Major Design Requirements

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4 Concepts for Door Opening Linear Actuator Motor / Gear Hydraulic Ram Pulley System

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Linear Actuator Design Concept Sketch Pros:Pros: Complete electrical controlComplete electrical control Low resistance to manual operationLow resistance to manual operation Simple integrationSimple integration Low maintenanceLow maintenance Cons:Cons: Long travelLong travel CostCost

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Motor / Gear System Pros:Pros: Off-the-shelf componentsOff-the-shelf components Ease of integrationEase of integration Low costLow cost Quiet operationQuiet operation Low maintenanceLow maintenance Cons:Cons: High resistanceHigh resistance

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Hydraulic System Pros:Pros: Off-the-shelf componentsOff-the-shelf components Simple designSimple design Cons:Cons: NoiseNoise High power consumptionHigh power consumption CostCost High maintenanceHigh maintenance

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Pulley System Pros:Pros: CostCost Cons:Cons: IntegrationIntegration ComplicatedComplicated Fragile operationFragile operation Complicates manual operationComplicates manual operation AestheticsAesthetics

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Door Mechanism Pugh Chart MotorConceptLinearActuatorPulleySystemHydraulicRam Cost2314 Resistance1324 Power Consumption 2314 Torque Generated 1342 Maintenance1243 Integration2143 Aesthetics1243 Noise2314 Totals12202127

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3 Concepts for Lock Actuation Electromagnetic actuation Rack and pinion with motor Electric solenoid 1 Concept for System Activation Wireless transmitter and receiver

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Existing Door Frame (Rush Location)

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Lock Bypass Mechanism The door frame will be modified to allow the door to open without moving the latch. A movable piece (shown in red) will be installed to allow normal operation of the door.

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Electromagnetic Unlocking Pros:Pros: Ease of maintenanceEase of maintenance 1 Moving part1 Moving part QuietQuiet CheapCheap Cons:Cons: Questionable effectivenessQuestionable effectiveness

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Rack and Pinion with Motor Unlocking Pros:Pros: Off-the-shelf componentsOff-the-shelf components ReliabilityReliability Cons:Cons: Moving partsMoving parts Bulky assemblyBulky assembly

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Solenoid Unlocking Pros Easy set up, and maintenance Only 1 moving part. Quiet Cheap Cons Reliability (continuous duty)

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Latch Mechanism Pugh Chart Electromagnet Rack & Pinion Solenoid Cost231 Reliability312 Size231 Life Expectancy 312 Aesthetics231 Power Consumption 312 Integration231 Totals171510

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Engineering Analysis and Synthesis Motor selection Design of door lock bypass Use of sensors Logic controller Logic and wiring diagrams Transmitter / receiver Electrical accessories

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IR Sensors Electromagnets Electromagnetic Clutch Box Containing: -Motor -Receiver -Stamp -Electrical Components Clutch Locking Mechanism

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Actuation and Unlocking Systems Parallax Logic Stamp for programming Rolling code transmitter / receiver Similar to garage door Security About 1 trillion possible codes

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Motor Selection Motor used 90 VDC 250 in-lbf max 3.2 RPM max DC Motor Controller Powers motor only Speed adjustability Fused control protection Surge suppression

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Motor Verification Working Model simulation Force MotorHinge

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Motor Verification Inputs Motor speed: 3.2 RPM (19.2 /s) Resistance: 5 lbf Output

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Electromagnets Force to overcome door seal = 8 lbf Motor output = 6 lbf max Electromagnets installed One for each direction Provides additional force Push Electromagnet Pull Electromagnet Magnetic Plate

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ELECTROMAGNETIC SLIP CLUTCH Disconnects drive when system not in operation Allows for low resistance to manual operation Slip if torque exceeds 250 in-lbf torque Protects motor from overload Clutch slips at max motor torque

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Link FEA Analysis Finite Element Analysis 12 Bar Linkage 1500 lbf Tensile Load Ferric Stainless Steel (25ksi Yield) Factor of Safety: 1.59

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Motor Position A digital encoder used to monitor door position during operation Determines when door opened/closed Determines when door manually stopped/moved

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Design of the Door lock Bypass Solenoid (1 Stroke) to clear door latch 4 lbf lift capacity Custom brackets machined from 303 stainless Ease of machinability Corrosion resistant High strength

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Lock bypass in the open positionLock bypass in the closed position

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Fixed Plate FEA Analysis Finite Element Analysis Constrained by 4 Mounting Holes 1000 lbf Load Applied to Surface A Ferric Stainless Steel (25ksi Yield) Factor of Safety: 1.25 Surface A

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Object Detection Infrared analog distance sensors Range of 10 to 80 cm A-D converter to change analog signal to digital Sensor arrangement as shown Outside - 3 across the span of the door and 2 feet up from the floor Inside 2 across the span of the door and 2 feet from the floor

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Location of sensors Front of door Location of sensors Back of door

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Electrical Analysis **Powered by Separate Motor Controller Selected DC Power Supply (McMaster # 7009K75)

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Wiring Diagram

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Senior Design 2 Project Plan (tentative) 1)Order parts after Thanksgiving holiday 2)Plan installation and test procedure 3)Parts acquired before winter recess 4)Start test assembly in the new year 5)Install at Arc location in January 6)Troubleshoot during remainder of quarter

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Summary This project provides a unique opportunity to improve the quality of life for the inhabitants of the Arc of Monroe Countys assisted living locations.

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IR Sensors Electromagnets Electromagnetic Clutch Box Containing: -Motor -Receiver -Stamp -Electrical Components Clutch Locking Mechanism Questions?