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: Team Mentors:
Dr. Alan Nye Dr. Margaret Bailey
Dr. Elizabeth DeBartolo
 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)
Rush Location –
View from outside
Penfield Location –
View from outside
 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.
 Background Research
 Costs of current commercial systems
 Price Quote from 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
 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
 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
 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
 Major Design Requirements
Line 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

Americans with Disabilities
6 Time to Full Open 4 Seconds Minimum
Act Accessibility Guidelines
Americans with Disabilities
7 Force to Stop Door 15 Lbf Maximum
Act Accessibility Guidelines
 4 Concepts for Door Opening
 Linear Actuator
 Motor / Gear
 Hydraulic Ram
 Pulley System
 Linear Actuator Design Concept Sketch

•Pros: •Cons:
•Complete electrical control •Long travel
•Low resistance to manual operation •Cost
•Simple integration
•Low maintenance
 Motor / Gear System

•Pros: •Cons:
•Off-the-shelf components •High resistance
•Ease of integration
•Low cost
•Quiet operation
•Low maintenance
Hydraulic System

•Pros:
•Off-the-shelf components
•Simple design

•Cons:
•Noise
•High power consumption
•Cost
•High maintenance
Pulley System

•Pros:
•Cost

•Cons:
•Integration
•Complicated
•Fragile operation
•Complicates manual
operation
•Aesthetics
 Door Mechanism Pugh Chart

Motor Linear Pulley Hydraulic

Concept Actuator System Ram

Cost 2 3 1 4

Resistance 1 3 2 4

Power Consumption 2 3 1 4

Torque Generated 1 3 4 2

Maintenance 1 2 4 3

Integration 2 1 4 3

Aesthetics 1 2 4 3
Noise 2 3 1 4

Totals 12 20 21 27
 3 Concepts for Lock Actuation
 Electromagnetic actuation
 Rack and pinion with motor
 Electric solenoid

1 Concept for System Activation

 Wireless transmitter and receiver
Existing Door Frame (Rush Location)
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.
 Electromagnetic Unlocking

•Pros:
•Ease of maintenance
•Cons:
•1 Moving part
•Questionable effectiveness
•Quiet
•Cheap
 Rack and Pinion with Motor Unlocking

•Pros: •Cons:

•Off-the-shelf components •Moving parts

•Reliability •Bulky assembly

 Solenoid Unlocking
 Pros
– Easy set up, and maintenance
– Only 1 moving part.
– Quiet
– Cheap
 Cons
– Reliability (continuous duty)
 Latch Mechanism Pugh Chart

Electromagnet Rack & Pinion Solenoid

Cost 2 3 1
Reliability 3 1 2
Size 2 3 1
Life Expectancy 3 1 2
Aesthetics 2 3 1
Power Consumption 3 1 2
Integration 2 3 1
Totals 17 15 10
Engineering Analysis and Synthesis

 Motor selection
 Design of door lock bypass
 Use of sensors
 Logic controller
 Logic and wiring diagrams
 Transmitter / receiver
 Electrical accessories
Box Electromagnets
Containing:
-Motor
-Receiver
-Stamp Locking Mechanism
-Electrical
Components
IR Sensors

Electromagnetic
Clutch Clutch
 Actuation and Unlocking Systems
 Parallax Logic Stamp
for programming

 Rolling code
transmitter / receiver
– Similar to garage door
– Security
– About 1 trillion possible
codes
 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
 Motor Verification
Working Model simulation

Force

Hinge Motor
 Motor Verification
 Inputs
– Motor speed: 3.2 RPM (19.2 º/s)
– Resistance: 5 lbf
 Output
 Electromagnets
Push Electromagnet

Pull Electromagnet

Magnetic Plate

 Force to overcome door seal = 8 lbf

 Motor output = 6 lbf max
 Electromagnets installed
– One for each direction
– Provides additional force
 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
 Link FEA Analysis

Finite Element Analysis

12” Bar Linkage
1500 lbf Tensile Load
Ferric Stainless Steel (25ksi Yield)
Factor of Safety: 1.59
 Motor Position
 A digital encoder used to
monitor door position during
operation
– Determines when door
opened/closed
– Determines when door manually
stopped/moved
 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
Lock bypass in the open position Lock bypass in the closed position
Fixed Plate FEA Analysis
Surface A

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
 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
Location of sensors – Front Location of sensors –Back of
of door door
 Electrical Analysis
Voltage Resistance Current Power
Component
(DC unless noted) (Ohms) (Amps) (Watts)
Wireless Receiver 120 VAC -- -- --
DC Motor ** 90 112.5 0.8 72
Stamp 9 0.322
Solenoid 24 52.4 0.458 11.0
Clutch - SO42 24 51.2 0.469 11.3
Electromagnet 24 102.9 0.233 5.6
1.48 27.8

Mode 1 Mode 2
Amps Watts Amps Watts
24VDC Supply 24VDC Supply
Solenoid 0.458 11.0 Solenoid 0.458 11.0
Electromagnet 0.233 5.6 Clutch 0.469 11.3
0.691 16.6 0.927 22.2

Selected DC Power Supply (McMaster # 7009K75)

Input Voltage (AC) Output Voltage (DC) Amps Watts
100 - 240 24 1.3 30
**Powered by Separate Motor Controller
 A/D Converter A/D Converter

Wiring Infrared Sensor Infrared Sensor

Diagram
A/D Converter A/D Converter A/D Converter

Infrared Sensor Infrared Sensor Infrared Sensor

DC Motor
+ - Solenoid
Relay Relay + -
Electromagnetic Relay
+ Clutch -
Relay

Out
Encoder
+ -

Electromagnet
+ -
Signal 120 VAC – 90 VDC Relay
Out DC Motor Controller
Transmitter Receiver
+ - - +
In Out
24 VDC
120 VAC Voltage Regulator
9 VDC Battery
Source
9 VDC
120 VAC – 24 VDC
Transformer
 Modified Home Entry
Bill of Materials
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
 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
 Summary
 This project provides a unique opportunity to
improve the quality of life for the inhabitants
of the Arc of Monroe County’s assisted living
locations.
Box Electromagnets
Containing:
-Motor
-Receiver
-Stamp Locking Mechanism
-Electrical
Components
IR Sensors

Electromagnetic
Clutch Clutch

Questions?