White Paper - Capstone Experience - Texas A&M University

“Merging the past with the present”
SPONSORED BY:
FACULTY ADVISOR: PROFESSOR GEORGE WRIGHT
RHYVLE TECHNOLOGIES
TAIWO ADEBIYI
WILLIAM KOONCE
BRADLEY SANDERS
BRAD WOODARD
OCTOBER 15, 2007

| 10/15/2007
CLASSIC COMFORT
“Merging the past with the present”
INTRODUCTION
Background
Throughout the years, building, customizing, and maintaining classic cars has remained a
popular hobby for people of all ages. Some go to great lengths and invest innumerous amounts of
time and money into their automobile. Over many years, technology has obviously advanced. The
wiring in cars today has greatly improved. Many of these classic car enthusiasts have always
wanted the more modern features that are currently limited to cars of today. What is to keep us
from going back and updating these features in the cars from the past that people love so dearly
Painless Performance approached us with this exact problem. They desired a device which would
interface with their wiring harness and allow for an array of modern features to be added.
Objective
In this project, Rhyvle Technologies will design a device that will utilize both hardware and
software to bring the classic car into the present. The device will attach in-line with the wiring harness
produced by Painless Performance and allow for features such as headlight and radio delay, daytime
drive lights, dome light dimming, as well as adding a kill switch to the car. Painless Performance does not
want these new features to cost a fortune and are adamant that the production cost be as low as
possible. The price needs to be low enough to be profitable for the company, but affordable for their
customers.
Justification
Painless Performance started out by simply selling the wiring harness and has built their
company from this product. Seventeen years later they have a 43,000 square foot facility manufacturing
over five hundred different products for show cars. Painless Performance feels that there is a need in
the market for a product such as this, and who better to know this market than Painless. The people
that love classic cars really do want their vehicles to look like an original classic but they also want some
of the new electronic features that are available in most modern cars today. Our product will bring these
desired features to the classic car industry while maintaining an affordable price.
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| 10/15/2007
CLASSIC COMFORT
“Merging the past with the present”
PROJECT DESIGN
Problem Statement
Rhyvle Technologies will provide a module which will attach to the current wiring harness
produced by Painless Performance; allowing control of certain electrical systems in the car.
Functional Requirements
Our biggest concern with creating the Classic Comfort module is keeping our costs down. We
would like our final prototype to be approximately $150 and a final manufacturing cost of $100. The
size of the module should be small enough to allow for it to be easily mounted under the dash of a
classic car and be hidden from the consumer.
The module must be able to interface with the ignition circuit in order to have an easy access kill
switch. When the kill switch is activated, the car will not start. This feature was requested by Painless in
order to lower the amount of car thefts on their customers.
The radio delay will allow for operation of the radio even after the engine of the car has been
turned off. The radio will stay on after the car’s engine has been turned off until the driver-side door
has been opened. At this point the system will turn the radio off.
The headlight delay will keep the headlights on for a desired period of time after the car has
been shut off. This feature is triggered once the engine has been shut off and unlike the radio delay
opening or closing the door has no effect on its timing.
The dome light dimming process will occur when the engine is off. When any door is opened
the dome light will simply come on. When the door is closed the dome light will fade out over a short
time period specified by the user. When the engine is running the dome light will operate normally with
no dimming.
Daytime driving lights will be another feature which will be added on the vehicle. Whenever the
engine is turned on the headlights will be turned on automatically. The rear taillights and the
illumination in the dash board will not be turned on while the user is driving the car. The taillights and
the dash board will turn on when the user turns their car lights on for nighttime driving. If the user
simply wants to turn the daytime drive lights off then they can simply switch their lights to the on
position, if not already, and then turn them off normally. This will send a signal to our device to turn the
daytime driving lights off until the engine is shutoff.
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CLASSIC COMFORT
“Merging the past with the present”
A dual seven segment display with a three button interface will be included to allow for the user
to change different setting such as the dimming time of the dome light, the delay time of the radio and
headlights, as well as turning on and off the daytime driving lights.
Overview Diagram
This diagram depicts the overall functionality of our product. It will interface directly with the
current wiring harness in the automobile and draw power from the battery. The device will intercept
signals sent through the wiring harness to the ignition, radio, dome light, and headlights. It will then
output the correction to these signals allowing for the defined user controls.
Figure 1. Conceptual Design
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CLASSIC COMFORT
“Merging the past with the present”
Functional Block Diagram
This functional block diagram depicts how the Classic Comfort device will intercept different
signals being sent through the automobile and output its own desired signals and controls to the proper
location.
Figure 2. Functional Block Diagram
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CLASSIC COMFORT
“Merging the past with the present”
The functional layout of our system is centered on the PIC18F microcontroller. The
microprocessor will be powered using the existing car battery through a 12V to 5V filter circuit. This
filter circuit will be designed to filter any fluctuations or noise that may appear on the microprocessor
power line.
Next we have the ignition switch, door switch, and headlight switch which are connected
through current detection circuits to the microprocessor. These current detection circuits will allow the
microprocessor to detect the status of these switches, whether on or off, and process that signal
according to the software implemented in the microprocessor.
The modern functions we will be implementing in our product will include a dome light delay,
headlight delay, radio delay, and daytime running headlights. A kill switch will also be added in our
design that will provide basic user security. The dome light delay will be controlled by the status of the
ignition and door switches as seen by the microprocessor. Based on the status of these switches, the
microprocessor will determine the proper action to take and its output will be connected to an
accessory power circuit which will act as a line-driver to power the dome light delay circuit. Similarly,
the radio delay, headlight delay, and daytime running headlights will also be controlled by the status of
one or more of these switches.
A dual seven segment display and a three button user interface will allow the user the
functionality of adjusting the delay settings of a particular function or turning a feature on or off.
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CLASSIC COMFORT
“Merging the past with the present”
WORK PLAN
In this section we identify the work that needs to be done. We take a look at the project overall and
identify the main phases which will be associated with the project. By taking these phases and breaking
them down further into activates, tasks, and even subtasks, every aspect of the project can be
identified. The WBS for our project is divided into six phases. Figure 3 shows the phase level of the
Classic Comfort project. The phases for the completion of our project include Research, Hardware
Design, Software Design, Testing, Fabrication, and Documentation.
Figure 3. Work Breakdown Structure
Research
Research will be conducted at the beginning of the project. It will be conducted mostly in
current limiting circuits, noise filtering, Painless wiring harnesses, microcontrollers, dual seven segment
displays, and size constraints.
Hardware Design
The basic hardware design of our product will include connection to most existing wiring
harnesses in classic cars and also full integration with Painless Performance wiring harnesses. Our design
will contain regulated power from the existing car battery connected through a protection circuit to the
microprocessor and dual seven segment display. We will also implement three current detections
circuits that will be connect to the headlight, door, and ignition switches to obtain the status of these
switches to be input to the microprocessor. The output of the microprocessor will then be connected
through an amplification circuit, to a particular function, i.e. headlight delay, radio delay, etc. which will
drive the function according to switch status and software design of the microprocessor.
Software Design
The software code will be written to command the microcontroller to perform various tasks.
Software codes will monitor the voltages and control timing and levels of voltage output from the
device. It is important that the software be robust, extensible, fault-tolerant, secure, and maintenance
must be easy. These goals will be met in the software design.
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CLASSIC COMFORT
“Merging the past with the present”
Testing
Testing will be performed throughout the timeline of this project to ensure success. Each
individual component will be tested at various levels. Desktop testing of individual component will be
done in order to ensure that each component operates properly. There will then be a breadboard test
for the overall system to insure that our device performs to specifications. Finally there will be a
prototype test which will ensure the entire functionally of the device. This will allow us the opportunity
to make sure our Classic Comfort product works according to our requirements.
All impedance components will be tested in order to ensure proper voltage drop. Amplifiers will
be tested to ensure proper operation. The signal conditioning circuit will be tested to ensure they
convert the voltages and currents properly as well as protect the microcontroller.
Software will be tested to ensure it performs to specifications; it will be tested for robustness,
extensibility, fault-tolerance, and ease of maintenance. The software must be able to perform under low
resources and also allow for future modifications without having to change the entire software system
design. It must be able to recover from errors and have the ability to also be reset by the user. This
system must be easy to maintenance as well as update.
We will also stress test the entire system making sure that all of the separate components can
work at the same time without destroying our prototype. Overall our system must perform optimally in
the expected conditions of an everyday car.
Fabrication
Fabrication will be performed after each of the prototype PCBs are created. Once each board is
populated, we will test the hardware and software on each of the boards according to the test plan. We
will also need to create an enclosure for our device to assist in keeping hazardous objects outside of our
device. The enclosure will include a place for a dual seven segment display, three buttons for user
control, a place for incoming and outgoing cables to connect to the wiring harness, and a reset button to
default the device to its factory default settings.
Documentation
Our documentation will cover two major areas, the final technical report and the user’s manual.
The final technical report will consist of all major information that Painless will want from us as well as
all technical documentation that will cover our costs, parts list, major troubles we incurred, etc. The final
technical report will include the final set of schematics that will detail how the Classic Comfort device
was designed. It will also include the final source code that show the exact code used in programming
the PIC18F microcontroller. The report will also include the final PCB layout of our board mapping out
each individual component which was used. Our test plan and the results from the final testing will be
documented as well in our final technical report. In the user’s manual we will include information for the
user so they will know how to install the classic comfort device. It will also include information on how
to properly utilize the three button user interface in order to change each individual setting.
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CLASSIC COMFORT
“Merging the past with the present”
MILESTONES
A milestone is a terminal event that marks the completion of a work package or phase. It helps
signify key events in a project and also may indicate direction of travel since key decisions made at
milestones may alter the route through the project plan. Throughout the lifetime of our project, there
will be significant events that will be used to report the project progress. These milestones will be used
by the project stakeholders to identify the completion of the tasks. Milestones will also be used by
Rhyvle Technologies to identify readiness to begin a new phase or group of tasks.
Completion of Research
Research will be conducted for each component involved in the Classic Comport project.
Completion and Approval of Hardware Design
Layout of hardware components and connections will be completed and presented to the
project advisor for approval.
Completion and Approval of Software Design
Flow chart developed by the software engineer will be presented to the project advisor. The
flow chart will be assessed by the advisor.
Completion of Proto-board Mock-up
A working proto-board mock-up of the system will be completed which will allow for testing to
be done.
Acceptance of PCB Design
A PCB layout will be designed and sent out to be manufactured for the final prototype.
Completion and Approval of Test Plan
Documentation of how individual components as well as the overall system testing will be
presented to the advisor for approval.
Completion and Acceptance of Final Documentation
The documentation will include any and all documented work, charts, graphs, schematics, etc.
required throughout the entire process of our product.
Completion and Acceptance of Prototype
A working prototype will be demonstrated and delivered to our stakeholders and assessed to
ensure the performance of required specification.
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CLASSIC COMFORT
“Merging the past with the present”
DELIVERABLES
A project deliverable is defined as an item that has value to our stakeholders. The stakeholders
in the Classic Comfort project include our sponsor and contact Mr. Overholser of Painless Performance
and our project technical advisor Professor George Wright. Deliverables will be presented to the project
stakeholders throughout the lifetime of the project development. The deliverables will be used to assess
the progress of the project.
Weekly Status Reports
Weekly status reports will be presented to our stakeholders providing them with up to date
information on how the project is progressing throughout the semester.
Detailed Parts List
This list will contain the parts that will be used to populate our PCB board for our prototype.
Circuit Schematic
This circuit schematic will detail the circuit layout of the Classic Comfort device.
PCB Layout
Shows the layout of the PCB, including the parts and where they will be connected.
Software Flow Chart
This will describe the process that will be performed by the microcontroller.
Source Code
This is the implementation of the algorithm, written in the C programming language, which will
run on a PIC microcontroller.
Test Plan / Test Report
This is the documented test plan in order to fully test the system and results.
User’s Manual
The user manual will provide basic installation instructions and diagrams as well as a
troubleshooting guide for the customer.
Functional Prototype
This will be our final working prototype that we will present to our stakeholders for approval.
Final Technical Report
The final technical report will detail the entire project as a whole and be the basis of the ENTC
420 experience.
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| 10/15/2007
CLASSIC COMFORT
“Merging the past with the present”
RESOURCES
Expenses
Figure 4 shows a short list of approximate costs which will be incurred during the development
of our product. These values represent estimations which were made to the best of our knowledge and
simply show that the project can be completed in a cost effective manner. The values have been
estimated for a time period of eighteen weeks.
Item Description Tally Estimated Cost
Labor 4 x $30 x 20hr/wk x 18wks $54,000
Work Space $1200 x 4.5 mos (18wks) $5,400
PCB $120 x 3 $360
Code Warrior License $1,900
Wiring Harnesses $400 x 2 $800
Microcontroller Development Kit $250
Miscellaneous Parts $250
Oscilloscope $2,000
Multimeter $100
Function Generator $300
Estimated Total $65,360
Figure 4. Expenses
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| 10/15/2007
CLASSIC COMFORT
“Merging the past with the present”
ENVIRONMENTAL ANALYSIS
Socio-Cultural Forces
In American culture, restoring and working on cars is both prevalent and socially endorsed.
There would be very little cultural resistance to our product, since it simply allows the restorer of the
classic car the ability to add modern features to their vehicle.
Competitive Forces
Most companies that work with automotive electronics deal with one of two aspects: add-ons
for current cars, or wiring harnesses for older cars. Since our product is a hybrid of the two, allowing an
older wiring harness to work with new functionality, we could avoid direct competition with the
established dealers. The aftermarket car parts business is a market area where competition is fierce. It
can be safely assumed that shortly after introduction into the market, a competitor would be trying to
release a similar product. Thus, it is imperative to capture market share quickly.
Economic Forces
Currently, the price of an entire wiring harness can run, at the low end, approximately $250, and
can rise steadily as the cars become older, more complex, or both. Our product price range is between
$75 and $150. The product we are producing will increase the quality and add features to this wiring
harness adding value to their investment. Since our product costs so little and adds such great features,
those who would already be considering spending several hundred dollars on a wiring harness would
find making the investment and purchasing our product as well, an attractive proposition.
Political Forces
At the moment, there are no strong opponents of aftermarket car parts, since the parts are safe
and have caused little to no injury.
Legal and Regulatory Forces
Our product would have to be tested and approved so that it can be shown that there are no
product defects that could cause harm to the consumer. The main federal agency that would be
involved in this process would be the Consumer Product Safety Commission. While there are few direct
regulatory forces, a company’s name attached to a certain product lends credence to its quality. A
company could quickly lose the trust and business of a customer if it was to put out an unsafe product.
Technological Forces
The technology to create our product is available and has been for some time. The product is
not hard to create; it simply has not been made.
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CLASSIC COMFORT
“Merging the past with the present”
SWOT ANALYSIS
This is a tool used to help describe the strengths, weaknesses, opportunities and threats of our
project. It is done by objectively looking at the project and seeing what internal and external factors can
cause the project to become favorable or unfavorable in achieving the goal of finishing the project.
Figure 5. SWOT Analysis
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CLASSIC COMFORT
“Merging the past with the present”
Counter the threat of imitation by gaining market share early on to become the segment front
runner.
Match the opportunity to create add-ons with the base product to create more products that
can be introduced into the product family.
Use the fact that certain sets of vehicles need certain boxes to break the customer data base
into narrower groups so that marketing to them will be more precise and future products can be
matched with the customers’ needs.
TEAM QUALIFICATIONS
Hierarchical Chart
Rhyvle Technologies is composed of four main team members consisting of a project manager,
hardware engineer, software engineer, and application engineer. A marketing advisor is also utilized
from time to time in order to help out with different aspects of the project. Bradley Sanders is the
project manager and is responsible for ensuring that the project finishes on time and under budget.
William Koonce is the hardware engineer for Rhyvle Technologies making him in charge of hardware
design, PCS layout, and technical schematics. Taiwo Adebiyi is the software engineer who’s
responsibilities range from microcontroller, software, and overall general computer expertise. Bradley
Woodard is Rhyle Technologies applications engineer making him responsible for things such as parts,
testing, and overall system integration. Miguel Abugattas is the marketing advisor for Rhyvle
Technologies. His duties include providing business research and marketing strategies for the team.
Bradley Sanders
Project Manager
William Koonce
Hardware Eng.
Taiwo Adebiyi
Software Eng.
Bradley Woodard
Application Eng.
Miguel Abugattas
Marketing Advisor
Figure 6. Rhyvle Technologies Hierarchy
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CLASSIC COMFORT
“Merging the past with the present”
Bradley Sanders – Project Manager
Mr. Sanders has many years of experience in programming as well as networking. His experience
includes advanced software development, data structures, object oriented programming, graphical user
interface development, web development, database programming, and hardware programming. He also
received a CCNA in 2002 from Cisco Systems. His programming experience consists of Assembly
Language, C/C++, Java, Basic, VB.net, and SQL. His work experience includes materials manager for Eimo
Inc., PC technician for Universal Computer Systems/Reynolds and Reynolds, and is currently contracting
as a programmer and working with CAS insurance as a project manager. At CAS he is in charge of six
programmers for a rewrite of an insurance claims system.
William Koonce – Hardware Engineer
Mr. Koonce is a veteran of the United States Navy where he has over three years of experience
as a weapons system electronics technician. He has also been trained in advanced circuit repair,
soldering, and advanced cable fabrication and repair. While in the Navy, he was responsible for the
maintenance and repair of electronic equipment down to component level. He was also employed at
AT&T Broadband in Plano, TX where he was trained in broadband line equipment repair up to and
including cable repair, line amplifier replacement and repair, and extensive downstream and upstream
troubleshooting techniques.
Taiwo Adebiyi – Software Engineer
Mr. Adebiyi has five years of experience in both high and low level software programming. He is
highly skilled in computer languages such as Java, C/C++, Assembly Language, and Perl. He is
experienced in data structures, graphical user interface development, database programming, network
programming, web development and programming for the PowerPC microcontroller. He is also
experienced in both Windows and Linux environments as well as being A+ certified. His work experience
includes, network administration, building and testing Compaq/HP servers, technician for Yahoo
Business Services, and PC technician for Universal Computer Systems/Reynolds and Reynolds.
Bradley Woodard – Application Engineer
Mr. Woodard has been working in the electronic shop for the chemistry department at Texas
A&M University for over three years. He is the current IEEE-Tech Parts store manager and has an
extensive knowledge of both passive and active components. He previously has assisted in fabricating
and testing various stand alone high-voltage power supplies and system controls for the Chemistry
department.
Miguel Abugattas – Embedded Business Member
Mr. Abugattas is a marketing specialist and Finance major at Texas A&M University. He is
currently director of account management for The Edge magazine at Mays Business School. His duties
include managing and directing all ad sales for The Edge.
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