Senior Design Project Senior Design Project P06201: Modified Home EntryP06201: Modified Home Entry

Project Sponsor: National Science Project Sponsor: National Science FoundationFoundation

Team Members:Team Members:

Robert Karpowicz (ME) Team LeaderRobert Karpowicz (ME) Team Leader

Brian Long (ME) Chief EngineerBrian Long (ME) Chief Engineer

Jeff Webb (ME)Jeff Webb (ME)

Josh Ribbeck (ME)Josh Ribbeck (ME)

Team Coordinator:Team Coordinator:Dr. Alan NyeDr. Alan Nye

Team Mentors:Team Mentors:Dr. Margaret BaileyDr. Margaret Bailey

Dr. Elizabeth DeBartoloDr. Elizabeth DeBartolo

IntroductionIntroduction Client: Arc of Monroe CountyClient: Arc of Monroe County Sponsor: National Science Foundations (NSF)Sponsor: National Science Foundations (NSF)

– This material is based upon work supported by the National Science This material is based upon work supported by the National Science Foundation under Award No. BES-0527358 Foundation under Award No. BES-0527358

– Any opinions, findings, and conclusions or recommendations expressed Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the in this material are those of the author and do not necessarily reflect the

views of the National Science Foundationviews of the National Science Foundation.. Goal: To create a system to open and close Goal: To create a system to open and close

main doors automatically for residents with main doors automatically for residents with disabilities at assisted living locations.disabilities at assisted living locations.

Locations – Arc of Monroe County Assisted Locations – Arc of Monroe County Assisted Living LocationsLiving Locations– Rush, NY (priority)Rush, NY (priority)– Penfield, NY (if resources allow)Penfield, NY (if resources allow)

Rush Location – Rush Location – View from outsideView from outside

Penfield Location – Penfield Location – View from outsideView from outside

Business AnalysisBusiness Analysis

Primary Stakeholders – Members of the Arc Primary Stakeholders – Members of the Arc of Monroe Countyof Monroe County

Complete goals of project while staying Complete goals of project while staying within the limits of grant ($1500)within the limits of grant ($1500)

Primary Business GoalPrimary Business Goal– Design a working prototype for the Arc residents Design a working prototype for the Arc residents

to use in their assisted living locations. to use in their assisted living locations.

Background ResearchBackground Research

Costs of current commercial systemsCosts of current commercial systems Price Quote from Price Quote from www.privatedoor.comwww.privatedoor.com

– Costs start at $600 (door only)Costs start at $600 (door only)– Additional $600 for actuating lock systemAdditional $600 for actuating lock system

Michigan State performed similar projectMichigan State performed similar project– 2 doors for $10,0002 doors for $10,000

RIT cost approximately $3000 per doorRIT cost approximately $3000 per door

Design ObjectivesDesign Objectives

Design with off-the-shelf componentsDesign with off-the-shelf components– Makes assembly and integration simplisticMakes assembly and integration simplistic– Minimize costsMinimize costs

Modularize design - “Plug and Play” Modularize design - “Plug and Play” – Only connections Only connections

AC powerAC power Door mechanismDoor mechanism Locking mechanismLocking mechanism SensorsSensors

Design Process for Senior Design IDesign Process for Senior Design I1)1) Determine end-user needs with Needs Determine end-user needs with Needs

AssessmentAssessment2)2) Quantify needs with specific goalsQuantify needs with specific goals3)3) Brainstorm concepts to meet goalsBrainstorm concepts to meet goals4)4) Perform feasibility assessments (Pugh Chart)Perform feasibility assessments (Pugh Chart)5)5) Select best conceptSelect best concept6)6) Perform engineering analysisPerform engineering analysis7)7) Select componentsSelect components

Needs Assessment ObjectivesNeeds Assessment Objectives

Door open/close with only single input from userDoor open/close with only single input from user Remote activation by specified users onlyRemote activation by specified users only User input ignored during system operationUser input ignored during system operation Preserve regular door functionPreserve regular door function Door remains open until closed or close on its ownDoor remains open until closed or close on its own Door stopped when object in path detectedDoor stopped when object in path detected High reliabilityHigh reliability Easy maintenanceEasy maintenance

Major Design RequirementsMajor Design RequirementsLine Requirement Source Spec Units

1 Object Detection Customer 5 - 15 Inches

2 Time to Automatic Closing Customer 30 Seconds

3 Activation Force Customer 2 Lbf Maximum

4 Activation Distance Customer 10 Feet Minimum

5 Manual Operation Resistance Customer 5 Lbf Maximum

6 Time to Full OpenAmericans with Disabilities

Act Accessibility Guidelines4 Seconds Minimum

7 Force to Stop DoorAmericans with Disabilities

Act Accessibility Guidelines15 Lbf Maximum

4 Concepts for Door Opening4 Concepts for Door Opening

Linear ActuatorLinear Actuator Motor / GearMotor / Gear Hydraulic RamHydraulic Ram Pulley System Pulley System

Linear Actuator Design Concept SketchLinear 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

Motor / Gear SystemMotor / 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

Hydraulic SystemHydraulic 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

Pulley SystemPulley System

•Pros:Pros:

•CostCost

•Cons:Cons:

•IntegrationIntegration

•ComplicatedComplicated

•Fragile operationFragile operation

•Complicates manual Complicates manual operationoperation

•AestheticsAesthetics

Door Mechanism Pugh ChartDoor Mechanism Pugh Chart

MotorMotorConceptConcept

LinearLinearActuatorActuator

PulleyPulleySystemSystem

HydraulicHydraulicRamRam

CostCost 22 33 11 44

ResistanceResistance 11 33 22 44

Power ConsumptionPower Consumption 22 33 11 44

Torque GeneratedTorque Generated 11 33 44 22

MaintenanceMaintenance 11 22 44 33

IntegrationIntegration 22 11 44 33

AestheticsAesthetics 11 22 44 33

NoiseNoise 22 33 11 44

TotalsTotals 1212 2020 2121 2727

3 Concepts for Lock Actuation3 Concepts for Lock Actuation

Electromagnetic actuationElectromagnetic actuation Rack and pinion with motorRack and pinion with motor Electric solenoidElectric solenoid

1 Concept for System Activation1 Concept for System Activation

Wireless transmitter and receiverWireless transmitter and receiver

Existing Door Frame (Rush Location)Existing Door Frame (Rush Location)

Lock Bypass MechanismLock Bypass Mechanism

The door frame will be modified to allow The door frame will be modified to allow the door to open without moving the the door to open without moving the latch. latch.

A movable piece (shown in red) will be A movable piece (shown in red) will be installed to allow normal operation of the installed to allow normal operation of the door. door.

Electromagnetic UnlockingElectromagnetic Unlocking

•Pros:Pros:

•Ease of maintenanceEase of maintenance

•1 Moving part1 Moving part

•QuietQuiet

•CheapCheap

•Cons:Cons:

•Questionable effectivenessQuestionable effectiveness

Rack and Pinion with Motor UnlockingRack and Pinion with Motor Unlocking

•Pros:Pros:

•Off-the-shelf componentsOff-the-shelf components

•ReliabilityReliability

•Cons:Cons:

•Moving partsMoving parts

•Bulky assemblyBulky assembly

Solenoid UnlockingSolenoid Unlocking

ProsPros– Easy set up, and maintenanceEasy set up, and maintenance– Only 1 moving part.Only 1 moving part.– QuietQuiet– CheapCheap

ConsCons– Reliability (continuous duty)Reliability (continuous duty)

Latch Mechanism Pugh ChartLatch Mechanism Pugh Chart

ElectromagnetElectromagnet Rack & PinionRack & Pinion SolenoidSolenoid

CostCost 22 33 11

ReliabilityReliability 33 11 22

SizeSize 22 33 11

Life ExpectancyLife Expectancy 33 11 22

AestheticsAesthetics 22 33 11

Power ConsumptionPower Consumption 33 11 22

IntegrationIntegration 22 33 11

TotalsTotals 1717 1515 1010

Engineering Analysis and SynthesisEngineering Analysis and Synthesis

Motor selectionMotor selection Design of door lock bypassDesign of door lock bypass Use of sensorsUse of sensors Logic controllerLogic controller Logic and wiring diagramsLogic and wiring diagrams Transmitter / receiverTransmitter / receiver Electrical accessoriesElectrical accessories

IR Sensors

Electromagnets

ElectromagneticClutch

Box Containing:-Motor -Receiver-Stamp-Electrical Components

Clutch

Locking Mechanism

Actuation and Unlocking SystemsActuation and Unlocking Systems

Parallax Logic Stamp Parallax Logic Stamp for programmingfor programming

Rolling code Rolling code transmitter / receiver transmitter / receiver – Similar to garage doorSimilar to garage door– SecuritySecurity– About 1 trillion possible About 1 trillion possible

codescodes

Motor SelectionMotor Selection

Motor usedMotor used– 90 VDC90 VDC– 250 in-lbf max 250 in-lbf max – 3.2 RPM max3.2 RPM max

DC Motor ControllerDC Motor Controller– Powers motor onlyPowers motor only– Speed adjustabilitySpeed adjustability– Fused control protectionFused control protection– Surge suppressionSurge suppression

Motor VerificationMotor Verification

Working Model simulationWorking Model simulation

Force

MotorHinge

Motor VerificationMotor Verification InputsInputs

– Motor speed: 3.2 RPM (19.2 Motor speed: 3.2 RPM (19.2 º/s)º/s)– Resistance: 5 lbfResistance: 5 lbf

OutputOutput

ElectromagnetsElectromagnets

Force to overcome door seal = 8 lbfForce to overcome door seal = 8 lbf Motor output = 6 lbf maxMotor output = 6 lbf max Electromagnets installedElectromagnets installed

– One for each directionOne for each direction– Provides additional forceProvides additional force

Push Electromagnet

Pull Electromagnet

Magnetic Plate

ELECTROMAGNETICELECTROMAGNETICSLIP CLUTCHSLIP CLUTCH

Disconnects drive when system not in Disconnects drive when system not in operationoperation– Allows for low resistance to manual operationAllows for low resistance to manual operation

Slip if torque exceeds 250 in-lbf torqueSlip if torque exceeds 250 in-lbf torque Protects motor from overloadProtects motor from overload

– Clutch slips at max motor torqueClutch slips at max motor torque

Link FEA AnalysisLink FEA Analysis

Finite Element Analysis12” Bar Linkage1500 lbf Tensile LoadFerric Stainless Steel (25ksi Yield)Factor of Safety: 1.59

Motor PositionMotor Position A digital encoder used to A digital encoder used to

monitor door position during monitor door position during operationoperation– Determines when door Determines when door

opened/closedopened/closed– Determines when door manually Determines when door manually

stopped/movedstopped/moved

Design of the Door lock BypassDesign of the Door lock Bypass

Solenoid (1” Stroke) to clear door latchSolenoid (1” Stroke) to clear door latch 4 lbf lift capacity4 lbf lift capacity Custom brackets machined from 303 stainlessCustom brackets machined from 303 stainless

– Ease of machinabilityEase of machinability– Corrosion resistantCorrosion resistant– High strengthHigh strength

Lock bypass in the open position Lock bypass in the closed position

Fixed Plate FEA AnalysisFixed Plate FEA Analysis

Finite Element AnalysisConstrained by 4 Mounting Holes1000 lbf Load Applied to Surface AFerric Stainless Steel (25ksi Yield)Factor of Safety: 1.25

Surface A

Object DetectionObject Detection

Infrared analog distance Infrared analog distance sensors sensors

Range of 10 to 80 cmRange of 10 to 80 cm A-D converter to change A-D converter to change

analog signal to digitalanalog signal to digital Sensor arrangement – as Sensor arrangement – as

shownshown– Outside - 3 across the span Outside - 3 across the span

of the door and 2 feet up of the door and 2 feet up from the floorfrom the floor

– Inside – 2 across the span of Inside – 2 across the span of the door and 2 feet from the the door and 2 feet from the floorfloor

Location of sensors – Front of door

Location of sensors –Back of door

Electrical AnalysisElectrical AnalysisComponent

Voltage(DC unless noted)

Resistance(Ohms)

Current(Amps)

Power(Watts)

Wireless Receiver 120 VAC -- -- --DC Motor ** 90 112.5 0.8 72Stamp 9 0.322Solenoid 24 52.4 0.458 11.0Clutch - SO42 24 51.2 0.469 11.3Electromagnet 24 102.9 0.233 5.6

1.48 27.8

Mode 124VDC Supply

Amps Watts

Solenoid 0.458 11.0Electromagnet 0.233 5.6

0.691 16.6

Mode 224VDC Supply

Amps Watts

Solenoid 0.458 11.0Clutch 0.469 11.3

0.927 22.2

**Powered by Separate Motor Controller

Input Voltage (AC) Output Voltage (DC) Amps Watts100 - 240 24 1.3 30

Selected DC Power Supply (McMaster # 7009K75)

Wiring Wiring DiagramDiagram

120 VAC Source

120 VAC – 24 VDCTransformer

Relay

Solenoid+ -

Relay

ElectromagneticClutch+ -

Encoder+ -

Out

Voltage Regulator

OutIn

DC Motor+ -

Relay Relay

A/D Converter

Infrared Sensor

Transmitter Receiver

Signal

+ - +-

Out

9 VDC Battery

24 VDC

9 VDC

A/D Converter

Infrared Sensor

A/D Converter

Infrared Sensor

A/D Converter

Infrared Sensor

A/D Converter

Infrared Sensor

120 VAC – 90 VDCDC Motor Controller

Relay

Electromagnet+ -

Item Component Supplier Part # Qty. Price Per Total Price

1 DC Gearmotor Grainger 4Z723 1 $238.75 $238.75

2 DC Speed Controller Grainger 4Z527 1 $75.75 $75.75

3 Wireless Trasmitter McMaster Carr 8129A81 2 $23.88 $47.76

4 Wireless Receiver McMaster Carr 8129A57 1 $33.66 $33.66

5 Solenoid - 24VDC McMaster Carr 70155K6 1 $12.80 $12.80

6 Basic Stamp Kit Parallax 228802 1 $99.00 $99.00

7 Slip Clutch Minarik Electric SO42 1 $179.00 $179.00

8 Electromagnet McMaster Carr 5698K216 2 $49.75 $99.50

9 DC Power Supply McMaster Carr 7009K75 1 $109.00 $109.00

10 IR Sensor / Cable Parallax 805-00005-605-00003 5 $13.95 $69.75

11 A/D Convertor Parallax ADC0831 5 $6.00 $30.00

12 Encoder Bourns Inc. ECW1J-B24-AC0024 1 $2.74 $2.74

13 Drive Link ** Custom -- 1 $20.00 $20.00

14 Driven Link ** Custom -- 1 $20.00 $20.00

15 Door Hinge ** Custom -- 1 $8.00 $8.00

16 Door Latch ** Custom -- 1 $70.00 $70.00

17 Fixed Plate ** Custom -- 1 $50.00 $50.00

18 Magnetic Block ** Custom -- 1 $45.53 $45.53

19 Electromagnet Block ** Custom -- 1 $49.75 $49.75

20 Transition Shaft ** Custom -- 1 $3.00 $3.00

21 Misc Electrical Components Various -- 1 $75.00 $75.00

** Approximate Price for Raw 303 Stainless $1,338.99

Modified Home EntryBill of Materials

Senior Design 2 Project Plan Senior Design 2 Project Plan (tentative)(tentative)

1)1) Order parts after Thanksgiving holiday Order parts after Thanksgiving holiday

2)2) Plan installation and test procedurePlan installation and test procedure

3)3) Parts acquired before winter recessParts acquired before winter recess

4)4) Start test assembly in the new yearStart test assembly in the new year

5)5) Install at Arc location in JanuaryInstall at Arc location in January

6)6) Troubleshoot during remainder of quarterTroubleshoot during remainder of quarter

SummarySummary

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

IR Sensors

Electromagnets

ElectromagneticClutch

Box Containing:-Motor -Receiver-Stamp-Electrical Components

Clutch

Locking Mechanism

Questions?Questions?