GE401- Innovative Product Design & Development I

Preliminary Design Document

12/07/2011

Team 2 Seydi Afin nl Emirhan Akdemir Cansu Acar Melodi Trkili Onur entre Engin yidoan

Version: 1.0

Contents
Introduction .................................................................................................................................................. 3 Block Diagram ............................................................................................................................................... 3 Description of Main Blocks and Their Relationships..................................................................................... 3 Descriptions of Subassemblies...................................................................................................................... 5 Arduino Uno .............................................................................................................................................. 5 Stepper Motors ......................................................................................................................................... 5 Stepper Motor Drivers .............................................................................................................................. 5 Gas Compressor ........................................................................................................................................ 5 Cooling System Control Card .................................................................................................................... 5 UPS ............................................................................................................................................................ 6 Steel Case .................................................................................................................................................. 6 Pasta Tank ................................................................................................................................................. 6 Ingredients Tanks ...................................................................................................................................... 6 Bowl Slot ................................................................................................................................................... 6 Helical Mixer for Pasta .............................................................................................................................. 6 5 x Helical Mixers for 5 Ingredients .......................................................................................................... 6 Product Tree ................................................................................................................................................. 7 Interfaces ...................................................................................................................................................... 9 Bill Validator .............................................................................................................................................. 9 LCD Display................................................................................................................................................ 9 Keypad .................................................................................................................................................... 10 LEDs ......................................................................................................................................................... 10 Output Slot .............................................................................................................................................. 11 Bowl Slot ................................................................................................................................................. 11 Software Structures .................................................................................................................................... 11 Conclusion ................................................................................................................................................... 12 References .................................................................................................................................................. 13 Appendix A. ................................................................................................................................................. 14 Appendix B. ................................................................................................................................................. 15

Introduction
The aim of this report is basically to describe the main blocks of the MacQuick and the relationships and interfaces between these blocks. It will be supported with the block diagram and the software flowchart to illustrate the functioning of the product which also gives a more clear understanding of the relationships between blocks. (See Appendix A,B)The product tree will be given in the document which clearly indicates the needed components to build the product completely and their quantity. In product tree, unique codes will be assigned to each component to prevent any confusion in the process of building the product. So the preliminary design document of MacQuick is also a guide in the process of assembling and turning a number of components to a functioning MacQuick.

Block Diagram
Since in Preliminary Design Document it is aimed to define the components of MacQuick and the relationships between them, it is a good idea to give the block diagram of MacQuick beforehand. So that, the reader can easily follow the information provided in the report. The block diagram is provided in Appendix A.

Description of Main Blocks and Their Relationships

There exixts basically 4 main blocks in the system. First main block can be titled as the user interface block which consists of bill validator and keypad. Second block includes Arduino Uno and can be named as the brain of the system. Main operations of the system; in particular, filling the bowl with pasta and macaroni, is done in the third block. Last block is the cooling system.

First block basically consists of the user interface components of MacQuick and considers the whole user interface components as one main block. The most important components of this main block are bill validator and keypad. These components are used to take inputs into the system. In detail, bill validator gets the money from the customer, counts it, sends a warning to the customer if the money taken is not sufficient. Likewise, keypad enables customer to specify his/her ingredient choices. Ultimately, these components are used a kind of interface between the customer and the machine, take the required inputs from the customer and send the appropriate information accordingly to the Arduino Uno.

Second block consists Ardunio Uno. This block can be defined as the brain of the MacQuick. Arduino Uno takes the data sent from bill validator and keypad, it assess this data and determines the road map of the system. For instance, according to the data taken from keypad, it determines which ingredients are desired by the customer. Then, in order to activate the motors that are used to pour the related ingredients into the bowl, it sends required information to the drivers of the aforesaid motors one by one. When the preparation process of the macaroni is over, Arduino Uno also inform the customer through the LCD.

Third block consists of stepper motors and motor drivers. As mentioned above, Arduino determines which stepper motor will be activated. Since Arduino cannot provide sufficient current to the motors, motor drivers are used the control the stepper motors. When a stepper motor is activated, it starts to turn the helical mixers which is stick to the motor with a gear. As this helical mixers turns, ingredients in the ingredient tank are pushed and they are poured into the bowl consequently.

Cooling system can be referred as the last main block and it consists of a gas compressor, temperature sensor and a control card. Its main function is to measure the internal temperature of the machine using the sensor and maintain the distance at a constant degree specified by the owner of the machine.

Descriptions of Subassemblies
The descriptions of the subassemblies which are the parts of user interface are provided in the Interfaces title. So here, the rest of the subassemblies will be explained under separate sub topics as follows. Arduino Uno Arduino Uno is a microcontroller card with the microcontroller ATmega328. It is used as the brain of the MacQuick. It s responsible all the processes except cooling control that are explained in detailed in the light of the flowchart in Preliminary Design Document of MacQuick. Stepper Motors Stepper motors are the motors that you can easily control how many degrees it will turn. This is important in our application since it is planned to control the amount of pasta and ingredients with the number of turns of the helical mixers. Stepper Motor Drivers Even if stepper motors receive the command from Arduino Uno, Arduino Uno can not provide enough current to start the motor movement. For the purpose of providing enough current to the motors while not damaging any other component in the system, Stepper Motor Drivers are used. So they basically provide enough current to the motors. Gas Compressor The pasta and the ingredients will be cooled to the 15 degree Celsius with the traditional vaporcompression refrigeration. It consists of a gas compressor basically compresses the gas to the pipes to keep the cooling process going. Cooling System Control Card As explained, cooling system will be controlled with a different microcontroller which will be provided in the refrigeration system itself . It has a temperature sensor and an ADC in it and the controller card sends the command turn on the gas compressor if the current temperature is above 15 degree Celsius and sends turn off command if the currently measured temperature is below 15 degree Celsius.

UPS Uninterruptible Power Supply (UPS) will be used to supply the system if any power cut situation happens. Also it will prevent the system from the harmonics which means transient ripples that may occur in the input current. In brief, UPS enables system to maintain its durability. Steel Case To prevent any breaking in attempt, the case of the MacQuick will be steel. Pasta Tank This tank is a part of the internal mechanical structure and it keeps all the pasta inside it. Since MacQuick will not be refilled in the middle of the day, it will be big enough to store enough pasta for one day. It will be a inverted conical shaped tank so that the macaroni will constantly tent to move down where the empty blow is. Ingredients Tanks Ingredients tanks are again inverted conical tanks due to the same reason. However, it will be relatively smaller than the pasta tank. Bowl Slot In the vending process it is expected the user to take a empty bowl from the bowl slot and place into the output box. So we are providing the user the empty bowls in the bowl slot. Bowl slot is a slot near the output slot where the user can take an empty bowl by just applying a small force downwards like in the electric water fountains. It can Helical Mixer for Pasta As stated, the mechanical component to drop the pasta and the ingredients will be a helical mixer. By turning it for a specific angle, a specific amount of pasta will be dropped. 5 x Helical Mixers for 5 Ingredients The helical mixer to use for ingredients will be smaller ones of the pasta version. Since MacQuick offers 5 different ingredients, there are 5 same sized helical mixers for each ingredients.

Product Tree
According to VFood component numeration system all components of MacQuick numerated as follows: 1 x x x x x --> MacQuick 1 0 x x x x --> MacQuick Internal Structure 1 0 1 x x x --> MacQuick Internal Structure - Electrical Components 1 0 2 x x x --> MacQuick Internal Structure - Cooling Components 1 0 3 x x x --> MacQuick Internal Structure - Mechanical Components

Bill of Material
Table 1: Bill of Material for MacQuick except Cooling Unit Assembly Stock Number 100000 Stock Number 101001 101002 101003 101004 101005 101006 101007 101008 102000 103001 103002 103003 103004 103005 103006 Drawing no 100000 - BOM Assembly Part Description MacQuick Assembly Part Description MacQuick Part Describtion Arduino Uno LCD Keypad Bill Validator Stepper Motor Motor Driver Adapter LED Cooling unit Steel Case Pasta Tank Ingredient Tank Bowl Slot Helical Mixer for Pasta Helical Mixer for Ingredients Prepared by Emirhan Akdemir Date 12.08.2011

Number Used 1 1 1 1 6 6 1 12 1 1 1 5 1 1 5 Checked by Seydi Afin nl

Table 2: Bill of Material For Cooling Unit of MacQuick Assembly Stock Number 102000 Stock Number 102001 102002 102003 Drawing no 102000 - BOM Assembly Part Description Cooling Unit Assembly Part Description Cooling unit Part Describtion Gas Compressor Control Card ADC Block Prepared by Emirhan Akdemir Date 12.08.2011

Number Used 1 1 1 Checked by Seydi Afin nl

Interfaces
This section includes all user interface components specifications. There are 5 different of user interface components in MacQuick: Bill Validator The first interface component is bill validator which is used by customers to give an input to the machine. G-13.mft is used as bill validator.Bill validator is the component that counts the money that user pays and sends the money is paid signal to the microcontroller. It has a small slot that takes the coin money as input and a locked small case that keeps the paid money inside.

Figure 1: Bill Validator

LCD Display LCD display is main interface component that is used to show messages to users. It is standard 4x20 LCD that is used with a micro-controller easily. Total credit of the customer, problem messages, informing messages such as the the message shown when the macaroni is ready, are displayed through LCD screen.

Figure 2: LCD

Keypad Keypad is another main interface component that is used to take inputs from users. It simply consists of several number of hard buttons. Customer chooses ingredients by pressing the related buttons on keypad. If an ingredient button pressed inadvertently by a customer, this can be easily compensated by pressing the Clear button. After the ingredients are chosen, the customer presses the Give me my Macaroni button and the process of preparing the macaroni starts.

Figure 3: Keypad

LEDs LEDs are placed to show current status of all ingredient stocks including macaroni stock. All these LED need to be labeled accordingly. For each ingredient, there exist two LEDs, red and green one. Green one indicates that the specific ingredient exists in stocks and available for customers, whereas red one indicates that the ingredient has ran out of stock.

Figure 4: LEDs

Output Slot Main output interface of MacQuick is this output slot. It is the place that MacQuick fills the bowl that is placed. In order to avoid unwanted situations, this slot has a sensor that monitors the bowl before the macaroni filling process's beginning. It needs to be big enough for bowl. Also it has a grate that is placed at the bottom of this component. User puts the bowl to this slot and wait for the machine to complete the macaroni making process and takes the bowl with a macaroni from there. Bowl Slot This slot simply has bowls on it and the only thing user should do is taking bowl on it. Further information is provided under Descriptions of Subassemblies topic.

Software Structures
The main software related component of system is Arduino UNO board. Its language is based on C/C++. On the other hand, it has lots of open source libraries written by Arduino community that enables users to use other programming languages and development environments. Also it is allows the use of any of AVR Libc functions. It is a subset package of standard C library used for Atmel AVR 8-bit RISC microcontrollers. Development environment is also provided by the Arduino community. The open sourced Java based Arduino environment makes us to implement and upload the code to the board. It is multi platform software that runs on Linux, Mac OS X and Windows so there is no need to install any virtual machine to run the software.

The software flowchart that will be implemented is provided. (See Appendix B) The software flowchart of MacQuick is explained. The complete vending process is given step by step in following.

1.

When the ingredients are filled and the MacQuick is plugged in the machine starts. When it is filled, the amount of ingredients is set to full.

2.

First, ingredients in each slot are checked. If there is a missing ingredient, the status is set to missing and a specific LED is turned to red. If not, it writes Ready to LCD.

3.

And start to wait for someone to come and pay for the macaroni. When the sufficient amount of money is paid it moves to step 4 given below. MacQuick starts to wait user to push the specific ingredient button or done button which means the user finished to choose ingredients and s/he wants the macaroni. If ingredient button is pushed, the ingredient is displayed in LCD. Increase the counter of the ingredient. And if user wants any more ingredients, s/he just presses the button of it and the same process repeats. If user pushes Give me my macaroni button, program moves to the step 6

4.

5.

6. 7.

Presence sensor checks whether there is an empty bowl is placed into the output box or not. If not wait until the bowl is placed. If it is placed, the macaroni preparation process begins. Write Preparing in LCD until the preparing process is completed. When it is done the process is repeated from the beginning. And again checks ingredients.

Conclusion
In Preliminary Design Document the main blocks and subassemblies are described and their relationships are explained. The block diagram of the MacQuick is provided in the Appendix A because it gives a general overview to the all the components and their connections which is the main discussion of this report. The software flowchart and the explanation of the vending process step by step also gave a further illustration of the blocks and their relationships. The product tree is also created. First the whole product, MacQuick is divided into 3 parts whcih are Electrical Components, Cooling System and Mechanical System then the subassemblies are listed under these blocks. Each subassembly is given a unique number and this creates a common language that everybody will understand in the light of our product tree.

References
1. Arduino Uno. arduino.cc. http://www.arduino.cc/en/Main/ArduinoBoardUno 2. Back UPS-Pro. apc.com. http://www.apc.com/resource/include/techspec_index.cfm?base_sku=BR700G&tab=models 3. EasyDriver Stepper Motor Driver. sparkfun .com. http://www.sparkfun.com/datasheets/Robotics/A3967.pdf 4. Small Refrigeration Compressor. alibaba.com. http://www.alibaba.com/productgs/397489299/small_refrigeration_compressor_GFF86AA_R134a.html?s=p 5. Specification for LCM Module. es.co.th. http://www.es.co.th/Schemetic/PDF/ABC020004B21-BIW-R-01.PDF 6. Step Motor. sparkfun.com. http://www.sparkfun.com/datasheets/Robotics/SM-42BYG01125.pdf 7. PIC16C5X. microchip.com. http://ww1.microchip.com/downloads/en/DeviceDoc/30453b.pdf

Appendix A.

Appendix B.