Class II Division 2 Occupancy SensorClass II Division 2 Occupancy Sensor
James FisherJames Fisher
Michael GazdaMichael Gazda
Presented on November 28, 2012 by:Presented on November 28, 2012 by:
Michael GazdaMichael Gazda
Russell GeeRussell Gee
JoAnne HitchcockJoAnne Hitchcock
Gledi ProgonatiGledi Progonati
Christopher ZannoniChristopher Zannoni
Dr. Sung Yeul Park (ECE) Dr. George Lykotrafitis (ME)Dr. Sung Yeul Park (ECE) Dr. George Lykotrafitis (ME)
Senior Design 2012Senior Design 2012--20132013
AgendaAgenda Background
Initial Design Approaches
Meeting Outcomes
FM Approvals
Sensor Switch Sensor Switch
Final Design Approaches
Plan for next semester
Testing of design
Gantt chart and team member roles
ECE Senior Design 2012ECE Senior Design 2012--20132013
Background
What are occupancy sensors?
Why?
ECE Senior Design 2012ECE Senior Design 2012--20132013
Occupancy Sensor Technology
Relay and
Power Supply
for SensorSensor
Line
Voltage
Sensor Power
(Low Voltage
Class 2 Division II Safety
This device must work in a Class 2 Div. II environment Metal dusts, carbon dusts, flour and grain dusts abnormally present
Warehouses/Storage areas Warehouses/Storage areas
Intrinsic Safety Limits energy in device, removing possibility of ignition
Composed of passive components that store little or no energy
Temperature limitations
ECE Senior Design 2012ECE Senior Design 2012--20132013
Initial Design Approaches Using original requirements
ECE Senior Design 2012ECE Senior Design 2012--20132013
Both Sensor and Relay Enclosed
Relay and
Power Supply
for Sensor
Control
Line
VoltagePower to
Luminary
Dust-Tight Conduit
Sensor
Dust-Tight Enclosure
Window made out of IR transmissible material
Sensor
Power
Control
Signal
ECE Senior Design 2012ECE Senior Design 2012--20132013
Wired Solution with Connector (Assumes IS sensor)
ECE Senior Design 2012ECE Senior Design 2012--20132013
Wireless Solution(Assumes IS sensor)
ECE Senior Design 2012ECE Senior Design 2012--20132013
Research=More Questions
Our research led to many unanswered questions about requirements What are the testing methods?
Which, of the many, requirements are relevant to our project?our project?
What are the component and design restrictions?
We contacted a NRTL FM Approvals offered to help
Answered many questions
Provided expert opinions
Helped finalize our approach
ECE Senior Design 2012ECE Senior Design 2012--20132013
FM Approvals Background
OSHA approved testing/certification company Parent company: FM Global
In business since 1835
Make the regulations that drive industry Make the regulations that drive industry standards
Acts as disinterested, 3rd party observer where design process is concerned
Qualified to test for IS (intrinsic safety), dust-ignition proof, explosion-proof, etc.
11ECE Senior Design 2012ECE Senior Design 2012--20132013
FM Approvals Meeting
Explained the testing process:
Duration
Approach
Various tests depending on desired Various tests depending on desired certification:
Crush, exclusion (purge/pressurize), flammability, rigidity, torque, mould stress, hot and cold impact, intrinsic safety
Will be explained later in presentation
General requirements to pass tests
12ECE Senior Design 2012ECE Senior Design 2012--20132013
FM Approvals Meeting
We explained the initial designs Received feedback
What would/wouldnt pass testing
Discussed possible solutions and provided specs.specs. Enclose the sensor using dust ignition proof standard
Or make sensor intrinsically safe using provided standard
Changes needed from initial product to completed, passable design
13ECE Senior Design 2012ECE Senior Design 2012--20132013
Sensor Switch Meeting
Gave us two options
Enclose the sensor
Find a 1mm thick Fresnel lens for PIR sensor window
Make sensor intrinsically safe
Professor Park advised us to do this option
14ECE Senior Design 2012ECE Senior Design 2012--20132013
Design Process
Brainstorm
Evaluate
Advisement
Sensor Switch Meeting Sensor Switch Meeting
FM Approvals Meeting
Advisors Recommendation
Finalize
Create
15ECE Senior Design 2012ECE Senior Design 2012--20132013
Final Design Approach
Dust-ignition proof box enclosing relay according to the FM3616 standard
16ECE Senior Design 2012ECE Senior Design 2012--20132013
Intrinsically safe sensor according toFM3610 which refers you to ANSI/ISA60079-0 and ANSI/ISA60079-11 standards
Dust Circulation Testing
We will build an apparatus to determine whether the enclosure is dust tight.is dust tight.
Create vacuum within enclosure
Circulate talcum powder within chamber
ECE Senior Design 2012ECE Senior Design 2012--20132013
Impact Testing
2.7 J impact test for Class II
1kg test mass, falling from height 270mm
Steel hemisphere 25mm diameter as Steel hemisphere 25mm diameter as impact point
Unit assembled, mounted on concrete with mass over 20kg
(Drop test not necessary- not portable)
ECE Senior Design 2012ECE Senior Design 2012--20132013
Thermal Endurance
Non-metallic elements which dust-protection is dependent must undergo thermal endurance testing
Heat: 4 weeks at (905)% humidity, Heat: 4 weeks at (905)% humidity, (202)K above maximum service temperature
Cold: 24hr, 5 to 10K below minimum service temperature
ECE Senior Design 2012ECE Senior Design 2012--20132013
Circuit Design and Testing
Determine how circuit works
Recently acquired blueprints
Work with Sensor Switch engineers
Analyze components for IS Analyze components for IS
Redesign
PSpice analysis
PCB Design and Prototype
Practical tests
20ECE Senior Design 2012ECE Senior Design 2012--20132013
Timeline-Past
Initial Hazardous Environment Research-found required specsMeeting with Sponsor (9/19)Requested BlueprintsWebsite DesignProject Statement
September
Projects specificationsWebsite finishedNEC research 1500p doc
October
21
NEC research 1500p docFound 12 specs relating to projectContacted FM ApprovalsEnclosure designProject specs redefinedSetup meeting with FM approvalsWireless and Wired research
Final Written ProposalFM Approvals meeting Project redefinedSensor Switch meetingProject RedefinedTest equipment researchedBlueprints received Final Presentation
November
Timeline-FutureDecember January Febuary March April
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Figure out circuit
w/SS Winter Break
Initial Enclosure
Design
Finalize Enclosure
design
22
Build Test
Equipment
Analyze
components for IS
Redesign Circuit
Prototype Circuit
PCB design
Test Circuit
Test Enclosure
Individual Tasks & Roles
Russell Design and Build Test Equipment
Gledi PCB Design and Help with Test Equipment
JoAnne JoAnne Circuit Design and Circuit Testing
Mike & James Designing, Prototyping, Testing of Relay
Enclosure
Chris Team Management and Circuit Testing
23ECE Senior Design 2012ECE Senior Design 2012--20132013
Budget
Complexity of regulations hindered design progress.
$13,000Cost of Project
design progress.
Impractical to make a detailed budget in 12 hours.
However most money spent will go towards testing equipment.
24
Questions?Questions?Questions?Questions?
ECE Senior Design 2012ECE Senior Design 2012--20132013
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