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
Slide 2
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)
Slide 3
Rush Location View from outside
Slide 4
Penfield Location View from outside
Slide 5
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.
Slide 6
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
Slide 7
Slide 8
Slide 9
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
Slide 10
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
Slide 11
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
Slide 12
Major Design Requirements
Slide 13
4 Concepts for Door Opening Linear Actuator Motor / Gear
Hydraulic Ram Pulley System
Slide 14
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
Slide 15
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
Slide 16
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
Door Mechanism Pugh Chart
MotorConceptLinearActuatorPulleySystemHydraulicRam Cost2314
Resistance1324 Power Consumption 2314 Torque Generated 1342
Maintenance1243 Integration2143 Aesthetics1243 Noise2314
Totals12202127
Slide 19
3 Concepts for Lock Actuation Electromagnetic actuation Rack
and pinion with motor Electric solenoid 1 Concept for System
Activation Wireless transmitter and receiver
Slide 20
Existing Door Frame (Rush Location)
Slide 21
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.
Slide 22
Electromagnetic Unlocking Pros:Pros: Ease of maintenanceEase of
maintenance 1 Moving part1 Moving part QuietQuiet CheapCheap
Cons:Cons: Questionable effectivenessQuestionable
effectiveness
Slide 23
Rack and Pinion with Motor Unlocking Pros:Pros: Off-the-shelf
componentsOff-the-shelf components ReliabilityReliability
Cons:Cons: Moving partsMoving parts Bulky assemblyBulky
assembly
Slide 24
Solenoid Unlocking Pros Easy set up, and maintenance Only 1
moving part. Quiet Cheap Cons Reliability (continuous duty)
Engineering Analysis and Synthesis Motor selection Design of
door lock bypass Use of sensors Logic controller Logic and wiring
diagrams Transmitter / receiver Electrical accessories
Actuation and Unlocking Systems Parallax Logic Stamp for
programming Rolling code transmitter / receiver Similar to garage
door Security About 1 trillion possible codes
Slide 29
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
Slide 30
Motor Verification Working Model simulation Force
MotorHinge
Slide 31
Motor Verification Inputs Motor speed: 3.2 RPM (19.2 /s)
Resistance: 5 lbf Output
Slide 32
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
Slide 33
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
Slide 34
Link FEA Analysis Finite Element Analysis 12 Bar Linkage 1500
lbf Tensile Load Ferric Stainless Steel (25ksi Yield) Factor of
Safety: 1.59
Slide 35
Motor Position A digital encoder used to monitor door position
during operation Determines when door opened/closed Determines when
door manually stopped/moved
Slide 36
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
Slide 37
Lock bypass in the open positionLock bypass in the closed
position
Slide 38
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
Slide 39
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
Slide 40
Location of sensors Front of door Location of sensors Back of
door
Slide 41
Slide 42
Electrical Analysis **Powered by Separate Motor Controller
Selected DC Power Supply (McMaster # 7009K75)
Slide 43
Wiring Diagram
Slide 44
Slide 45
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
Slide 46
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.