EPS@ISEP | The European Project Semester (EPS) at ISEP

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report [2014/06/25 22:46] – [4.3 Economical] team4report [2014/06/25 23:03] (current) – [8.2 Future Development] team4
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 - open dialogue with employees - open dialogue with employees
 - human rights respect, especially when it is used the labour force from Asian countries (LED supply chain often reaches to this region) - human rights respect, especially when it is used the labour force from Asian countries (LED supply chain often reaches to this region)
-- offering well paid, decent work+- offering well paid, decent work.
  
 ==== 4.4 Life Cycle Analysis ==== ==== 4.4 Life Cycle Analysis ====
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   * Change colors with remote control (radius 10 m);   * Change colors with remote control (radius 10 m);
   * Easy construction to change the LED;   * Easy construction to change the LED;
-  * Include an automatic brightness control system (maximum radius 4,5 m);+  * Include an automatic brightness control system (maximum radius 4 m);
   * Reuse provided components or low cost hardware solutions;   * Reuse provided components or low cost hardware solutions;
   * Use open source and freeware software;   * Use open source and freeware software;
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 Our project has limited financial resources. We have to manage these resources as effective as possible to achieve the best solution. To give you a brief overview, we are showing how our costs are divided during the project.  Our project has limited financial resources. We have to manage these resources as effective as possible to achieve the best solution. To give you a brief overview, we are showing how our costs are divided during the project. 
-Our maximum budget will be 200 euros for the total product costs. Our materials cost was about 50 EUR. Furthermore, we need to add a profit in the price to keep the company running. This profit will be less in comparison to existing companies in the market, because we want to rise our market share and overcome the strong market barriers. In addition to that our price for the product will be between 15-20 € plus a profit margin.  +Our maximum budget is 200 EUR for the total product costs. Our materials cost was about 50 EUR. Furthermore, we need to add a profit in the price to keep the company running. This profit will be less in comparison to existing companies in the market, because we want to rise our market share and overcome the strong market barriers. In addition to that our price for the product will be between 15-20 EUR plus a profit margin.  
-Additionally, we have 5000 € for our marketing advertisement and that will be explained in the marketing budget chapter.+Additionally, we have 5000 EUR for our marketing advertisement and that will be explained in the marketing budget chapter.
  
  
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   - Have to try remote control. For that it is necessary to connect light bulb with a grid and when turning the button of remote control light bulb should change colors (in 10 m)   - Have to try remote control. For that it is necessary to connect light bulb with a grid and when turning the button of remote control light bulb should change colors (in 10 m)
   - Have to try take out  LED and replace it by another LED. Also have to connect light bulb to the grid to see if changed LED is working.   - Have to try take out  LED and replace it by another LED. Also have to connect light bulb to the grid to see if changed LED is working.
-  - Have to connect light bulb to the grid, then move towards to the light bulb, when being at the distance of maximum 4.5 m it should reduce the brightness. Also when moving further than maximum 4,5m from lamp, it should increase the brightness again.+  - Have to connect light bulb to the grid, then move towards to the light bulb, when being at the distance of maximum 4.5 m it should reduce the brightness. Also when moving further than maximum 4 from lamp, it should increase the brightness again.
  
 Besides of technical quality control it is important to pay attention to communication control in terms of teamwork quality. In order to change information and thoughts it is necessary to meet every week, so we can be sure that everyone has same knowledge and information about current situation. Also to make sure if our work is done correctly and in time it is necessary to ask supervisors feedback in the weekly meetings. Also if any problem occurs them we should contact with teachers by e-mail. Besides of technical quality control it is important to pay attention to communication control in terms of teamwork quality. In order to change information and thoughts it is necessary to meet every week, so we can be sure that everyone has same knowledge and information about current situation. Also to make sure if our work is done correctly and in time it is necessary to ask supervisors feedback in the weekly meetings. Also if any problem occurs them we should contact with teachers by e-mail.
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 There are many different LED Lamps with different range of application in the market. Our project is to make unique LED lamp and keep the budget as low as possible. We chose to design a lamp which has an E27 socket, so it can be used everywhere. For remote control Infrared receiver is included, because this method is the cheapest. Also Ultrasonic sensor is added to the lamp. This sensor increases or decreases the brightness of the LED according to your position of the lamp. There are many different LED Lamps with different range of application in the market. Our project is to make unique LED lamp and keep the budget as low as possible. We chose to design a lamp which has an E27 socket, so it can be used everywhere. For remote control Infrared receiver is included, because this method is the cheapest. Also Ultrasonic sensor is added to the lamp. This sensor increases or decreases the brightness of the LED according to your position of the lamp.
-In the remote controller and the LED driver PIC microcontrollers are used. We will control the colours and brightness of the LEDs through PWM modulation with three MOSFETs.+In the remote controller and the LED driver PIC microcontrollers are used. We will control the colours and brightness of the LED through PWM modulation with three MOSFET.
 We will connect the LED to the PCB without soldering analogue LED clip cables, so it is possible to change the LED into new ones without soldering. We will connect the LED to the PCB without soldering analogue LED clip cables, so it is possible to change the LED into new ones without soldering.
 In this chapter is introduced how LED works, Modular LED Lamp design and prototype development which is compatible with actual lamps. There is overview of architecture, components and functionalities, also final results of tested products and some ideas to future development.  In this chapter is introduced how LED works, Modular LED Lamp design and prototype development which is compatible with actual lamps. There is overview of architecture, components and functionalities, also final results of tested products and some ideas to future development. 
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 == 7.3.1 LED driver and panel == == 7.3.1 LED driver and panel ==
    
-In our Modular LED lamp we are using 12V power supply, because it will give enough tension to the system to drive 4 red, 3 blue and 3 green LEDs.  +In our Modular LED lamp we are using 12V power supply, because it will give enough tension to the system to drive 4 red, 3 blue and 3 green LED.  
-We have to include a regulator guarder by a diode to get the right amount of voltage to drive the PIC microcontroller. To the PIC output 3 MOSFETs are connected, one for each colour of LED. It is necessary to control the colour and intensity of the LED with PWM modulation. IR receiver is connected to the PIC microcontroller for the communication between the remote control. Ultrasonic sensor is also connected to the PIC for distance detection. Figure 34 shows our LED driver block diagram, which is simplified version of the schematics in Figure 35 and Figure 36.+We have to include a regulator guarder by a diode to get the right amount of voltage to drive the PIC microcontroller. To the PIC output 3 MOSFET are connected, one for each colour of LED. It is necessary to control the colour and intensity of the LED with PWM modulation. IR receiver is connected to the PIC microcontroller for the communication between the remote control. Ultrasonic sensor is also connected to the PIC for distance detection. Figure 34 shows our LED driver block diagram, which is simplified version of the schematics in Figure 35 and Figure 36.
  
 {{ :untitled_diagram.jpg?direct&200 |}} {{ :untitled_diagram.jpg?direct&200 |}}
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 //Figure 35: LED lamp schematics// //Figure 35: LED lamp schematics//
  
-In Figure 36 there is also schematics for LED panel. As already mentioned with 12V power supply we can connect 4 red, 3 blue and 3 green LEDs to the PCB.+In Figure 36 there is also schematics for LED panel. As already mentioned with 12V power supply we can connect 4 red, 3 blue and 3 green LED to the PCB.
  
 {{ :panel1.jpg?direct&200 |}} {{ :panel1.jpg?direct&200 |}}
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 == 7.3.3 Calculations == == 7.3.3 Calculations ==
  
-To operate the LEDs it is necessary to limit the current to the recommended level to avoid destruction of the device. This way it is possible to adjust the supplied voltage a little and still keep the current within bounds. Therefore resistance calculation has to be done.+To operate the LED it is necessary to limit the current to the recommended level to avoid destruction of the device. This way it is possible to adjust the supplied voltage a little and still keep the current within bounds. Therefore resistance calculation has to be done.
  
  
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 Turns off and on the brightness sensor. Turns off and on the brightness sensor.
  
-==== 7.6 Programming ==== 
  
-The final program we used +In development process occurred some difficulties, for example there was material delay and not much time for improvements for all these functionalities. It means that initial objectives are not fully developed. In this state Modular LED Lamp fits to the E27 socket and has colour changing function, but without remote control, therefore there is a button in lamp surface. Colour changing function have several variations: 
-{{::picprog683.rar|}}+  * 1. Fade through full colour spectrum;  
 +  * 2. Fade through full colour spectrum, 75% intensity, slow; 
 +  * 3. Pastel colours fade, fast;  
 +  * 4. Pastel colour fade, slow;  
 +  * 5. Slow fade Red + Green, 50% to 100%; 
 +  * 6. Slow fade Red + Blue, 50% to 100%; 
 +  * 7. Slow fade Green + Blue, 50% to 100%;  
 +  * 8. Red full intensity, slow fade to off; Green full intensity, slow fade to off; Blue full intensity, slow fade to off; 
 +  * 9. Slow fade of Red to full intensity, slow fade to off; slow fade of Green to full intensity, slow fade to off; slow fade of Blue to full intensity, slow fade to off; 
 +  * 10. Slow fade of Red on, slow fade of Green on, slow fade of Red off, slow fade of Blue on, slow fade of Green off, slow fade of Red on, slow fade of Green off;  
 +  * 11. Slow cycle of fade between rainbow of colour, various combinations of Red, Green and Blue on/off at various intensities; 
 +  * 12. Bright White: Red, Green and Blue combination; 
 +  * 13. Half White: Red, Green and Blue combination; 
 +  * 14. Low White: Red, Green and Blue combination; 
 +  * 15. Full colour spectrum fade; 
 +  * 16. Slower full colour spectrum fade; 
 +  * 17. Slow warm colour spectrum fade; 
 +  * 18. Cool colour spectrum fade; 
 +  * 19. Purple colour fades; 
 +  * 20. Red, Green, Blue cycle at 50mS rate;  
 +  * 21. Red, Green, Blue cycle at 100mS rate; 
 +  * 22. Red, Green, Blue cycle at 200mS rate; 
 +  * 23. Red, Green, Blue cycle at 300mS rate; 
 +  * 24. Red, Green, Blue cycle at 400mS rate; 
 +  * 25. Red, Green, Blue cycle at 0.5S rate; 
 +  * 26. Red, Green, Blue cycle at 1S rate;  
 +  * 27. Triple flash of Green and Blue with delay between flashes. 
 + 
 + 
 +  
 +When the PIC is first powered on after programming, it should start running the first RGB sequence found. It will run a sequence of red-fade out, green-fade out, blue-fade out repeatedly. 
 +Press the Switch to step through all available sequences. When the last sequence has been reached it will go back to the first available sequence. Each time the switch is pressed the RGB LED PWM values are set back to 0 (LED off). 
 +Press and hold switch for about 2 seconds to put the PIC into sleep mode. Once in sleep mode, press the switch for about 2 seconds then release it to wake the PIC from sleep. If the switch button isn't held for two seconds the PIC returns to sleep - this prevents the circuit from being accidentally turned on. 
 +Anytime the PIC is put into sleep mode by holding SW1 switch down, the currently selected sequence is also saved to EEPROM. 
 +For this new solution we also created new electrical scheme which is presented in Figure 54. 
 + 
 +{{ :final_scheme.png?200 |}} 
 +//Figure 54: Final LED Lamp scheme// 
 + 
 +==== 7.6 Programming ====
  
 We are using two PIC12F675 microcontrollers, one of them in the remote control PCB and the other one in the LED driver PCB. We are using two PIC12F675 microcontrollers, one of them in the remote control PCB and the other one in the LED driver PCB.
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 The MPLAB PIC kit 3 allows debugging and programming of PIC® and dsPIC® Flash microcontrollers at a most affordable price point using the powerful graphical user interface of the MPLAB X Integrated Development Environment (IDE). The MPLAB PIC kit 3 is connected to the design engineer's PC using a full speed USB interface and can be connected to the target via an Microchip debug (RJ-11) connector. The MPLAB PIC kit 3 allows debugging and programming of PIC® and dsPIC® Flash microcontrollers at a most affordable price point using the powerful graphical user interface of the MPLAB X Integrated Development Environment (IDE). The MPLAB PIC kit 3 is connected to the design engineer's PC using a full speed USB interface and can be connected to the target via an Microchip debug (RJ-11) connector.
 The connector uses two device I/O pins and the reset line to implement in-circuit debugging and In-Circuit Serial Programming™ [72]. The connector uses two device I/O pins and the reset line to implement in-circuit debugging and In-Circuit Serial Programming™ [72].
 +
 +The final program we used:
 +{{::picprog683.rar|}}
  
  
 ==== 7.7 Light bulb design ==== ==== 7.7 Light bulb design ====
 As our team wanted to create something unique, special light bulb design was made. Light bulb is inspired from nature and has similarity with wood branch.  As our team wanted to create something unique, special light bulb design was made. Light bulb is inspired from nature and has similarity with wood branch. 
-In the design, there is one main tube where three other tubes are coming out. Three tubes are meant for LEDs and one for Ultrasonic sensor to sense movements. Also near to the socket, where goes power supply, there are cuts inside material for cooling. For fixing the electronic parts certain inner design was made as well. Two kinds of hallows were cut into the walls to slide there different PCB-s, we are wiring power supply to the lattice which is in the leg where goes also ultrasonic sensor. For ultrasonic sensor there are 2 round holes, we are placing sensor into the holes and screw it to the tube wall. Tubes have removable covers to make LED changing easier. LED is pressed into the removable covers where LED-shape holes are.+In the design, there is one main tube where three other tubes are coming out. Three tubes are meant for LED and one for Ultrasonic sensor to sense movements. Also near to the socket, where goes power supply, there are cuts inside material for cooling. For fixing the electronic parts certain inner design was made as well. Two kinds of hallows were cut into the walls to slide there different PCB, we are wiring power supply to the lattice which is in the leg where goes also ultrasonic sensor. For ultrasonic sensor there are 2 round holes, we are placing sensor into the holes and screw it to the tube wall. Tubes have removable covers to make LED changing easier. LED is pressed into the removable covers where LED-shape holes are.
 Prototype is made of blue polylactic acid with 3D printer. Prototype is made of blue polylactic acid with 3D printer.
 Figure 56 and Figure 57 are presenting 3D pictures of Modular LED Lamp design and in Figure 58 real printed bulb is shown. Figure 56 and Figure 57 are presenting 3D pictures of Modular LED Lamp design and in Figure 58 real printed bulb is shown.
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 ==== 7.8 Package ==== ==== 7.8 Package ====
  
- For Modular LED Lamp package was design. Package is made of cardboard and there are used 2 colors (black and orange). Black is used in outside and orange inside. Two different colors cardboards are glued together in order to achieve stronger surface. Package is 20*20 cm sized square.  + For Modular LED Lamp package was design. Package is made of cardboard and there are used 2 colors (white and orange). White is used in outside and orange inside. Two different colors cardboards are glued together in order to achieve stronger surface. Package is 20*20 cm sized square.  
-Outside of box are energy label, logo, picture of real lamp, quick response code, bar code and safety instructions. Inside of fox are two illustrative pictures and extra surface for holding lamp.Figure 59 presents box design.+Outside of box are energy label, logo, picture of real lamp, quick response code, bar code and safety instructions. Inside of box there is illustrative picture and extra surface for holding lamp.Figure 59 presents box design.
  
-{{ :photo_3.jpg?200 |}} +{{ :box.jpg?200 |}} 
-Figure 59: Box+//Figure 59: Box//
 ==== 7.9 Tests and Results ==== ==== 7.9 Tests and Results ====
 As it is described in first paragraph certain test have to carry out to be sure if lamp works properly. Tests which are necessary to make are described in the following:  As it is described in first paragraph certain test have to carry out to be sure if lamp works properly. Tests which are necessary to make are described in the following: 
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   * Have to connect light bulb to the grid, then move towards to the light bulb, when being at the distance of maximum 4 m it should reduce the brightness. Also when moving further than maximum 4 m from lamp, it should increase the brightness again.   * Have to connect light bulb to the grid, then move towards to the light bulb, when being at the distance of maximum 4 m it should reduce the brightness. Also when moving further than maximum 4 m from lamp, it should increase the brightness again.
  
-After assembling technical parts, we tried to make previously described tests. First test was successful, Modular LED Lamp fits to E27 socket. For second test it was necessary to try remote control. In figure Figure 60 team member presses the button to control if it is working. Sadly remote control did not work.+After first assembling, we tried to make previously described tests. First test was successful, Modular LED Lamp fits to E27 socket. For second test it was necessary to try remote control. In figure Figure 61 team member is pressing the button to make sure if remote control is working. Sadly remote control did not work.
  
 {{ :testing_remote.png?200 |}} {{ :testing_remote.png?200 |}}
  
-//Figure 60: Testing remote control//+//Figure 61: Testing remote control//
  
-We changed to remote controll to a switch button. We couldn't upload the new program to the PIC12F675 so we had to search and buy a new one. We couldn't find the one which we used originally so we used PIC12F863 in the final product. With this method the led lamp is working correctly. +Third test was about changing the LED which is presented in Figure 62. We were able to change LED, but we don’t know if LED is working. We were not successful making Modular LED Lamp work
- +
 {{ :testing_led.png?200 |}} {{ :testing_led.png?200 |}}
  
-//Figure 61: Inserting LED//+//Figure 62: Inserting LED// 
 + 
 +It means that other tests which needed to have connection to the grid failed. Reason was wrong PCB boards. Probably we made mistake connecting one switch button in the wrong direction. Therefore it poled the circuit to the ground and nothing was working. Solution would be building up a new PCB.  
 +We also made second testing, therefore we drawn new scheme for LED Lamp and changed the features into easy ones. In this case this solution was the best, because we had limited time resource and that way we were able to make lamp at least working. Lamp changes colours and fits to the E27 socket. All the working functions are described in paragraph 7.5 called Functionalities. 
  
  
  
 ==== 7.10 Conclusion ==== ==== 7.10 Conclusion ====
-We chose Modular LED Lamp project, because it sounded interesting (more energy effective lighting) and we had two electrical engineer students in our group. Although, they had knowledge about electricity, there have been still appearing some complications.  +We chose Modular LED Lamp project, because it sounded interesting (energy effective lighting) and we had two electrical engineer students in our group. Although, they had knowledge about electricity, there have been still appearing some complications.  
-First of all, to hand in list of materials, it was necessary to present correct schematics for the LED lamp and remote control. As we didn’t have much experience with LED lamp specialities, completion of schematics and material list was delayed. This led us to the situation that we got materials too late. We had 2 days to assembly product and make the tests. Sadly some problems occurred and prototype didn’t work. . We had to forget about the remote controll and replace it with a single switch button in order to be able to change the colors and different sequences. +First of all, to hand in list of materials, it was necessary to present correct schematics for the LED lamp and remote control. As we didn’t have much experience with LED lamp specialities, completion of schematics and material list was delayed. This led us to the situation that we got materials too late. We had 2 days to assembly product and make the tests. Sadly some problems occurred and prototype didn’t work. Reason was wrong PCB. To solve this situation and present working prototype, we changed the electrical schematics and PCB into easier ones. This change allowed us to see improvements. In current state LED Lamp is able to change colours, there are several colour variations which are described in paragraph 7.5. For changing colours there is button in the lamp, remote control is not used in that kind of solution. Lamp also fits to the E27 socket. 
-In order to have unique product, we made a special design for the light bulb. We created 3D drawings with software called Solid Edge. Our light bulb is inspired by nature and resemble a bit wood branch. Drawings were converted to the suitable version to use a 3D printing option that was by school. The bulb prototype was made of plastic. Also there was made a package. As we are focusing on business clients, it was not necessary to pay so much attention to the packaging. Our package is made of 2 colour cardboard (black and orange) and on the package surfaces are presented all important labels.+In order to have unique product, we made a special design for the light bulb. We created 3D drawings with software called Solid Edge. Our light bulb is inspired by nature and resemble a bit wood branch. Drawings were converted to the suitable version to use a 3D printing option what was provided by school. The bulb prototype is made of plastic. Also there was made a package. As we are focusing to business clients, it was not necessary to pay so much attention to the packaging. Our package is made of 2 colour cardboard (white and orange) and on the package surfaces are presented all important labels. 
  
 ===== 8. Conclusions ===== ===== 8. Conclusions =====
 ==== 8.1 Discussion ==== ==== 8.1 Discussion ====
-From the beginning we have tried to create the most effective team, therefore we used Project management tools like tasks distribution, found several solutions for communication and we set deadlines to ourselves. In our work we want to be precise an always give our best. It is important to hand in deliverables in time, unfortunately there was delay concerning some materials. While we were not able to build prototype we were focused on report, web-page, user manual, packaging, poster, video and bulb design. These parts of deliverables have progressed successfully and what is important, in time. We got materials two days before final assessment, this situation forced us to work faster and more effective. As much as we tried prototype production was not successful, lamp functions did not work. Reason of that problem was PCB which was wrong and also programming. Lack of time didn’t let us to correct these major mistakes.+From the beginning we have tried to create the most effective team, therefore we used Project management tools like tasks distribution, found several solutions for communication and we set deadlines to ourselves. In our work we want to be precise and always give our best. It is important to hand in deliverables in time, but unfortunately there was delay concerning some materials. While we were not able to build prototype we were focused on report, web-page, user manual, packaging, poster, video and bulb design. These parts of deliverables have progressed successfully and what is important, in time. We got materials two days before final assessment, this situation forced us to work faster and more effective. As much as we tried prototype production was not successful, lamp functions did not work. Reason of that problem was PCB which was wrong. Lack of time didn’t let us correct major mistakes, but to solve this problem we drawn new electrical scheme and changed PCB into easy one in order to achieve at least working lamp. This change allowed us to see results. In current state LED Lamp changes colours, but with no help of remote control, there is a button in the lamp which allows changing the colour modes. Also lamp fits to the E27 socket, but other initially set goals need to be improved in future. 
  
 During all the semester we learned a lot about team work and studied lighting specifications in every field. We tried to create the best product we could considering objectives and advice given. During all the semester we learned a lot about team work and studied lighting specifications in every field. We tried to create the best product we could considering objectives and advice given.
 +
  
 This experience gave us definitely advantage in future life. We were able to practice English, we studied lighting specifications, learned sustainability and marketing issues as well as improved our communication and cooperation skills. This experience gave us definitely advantage in future life. We were able to practice English, we studied lighting specifications, learned sustainability and marketing issues as well as improved our communication and cooperation skills.
  
 ==== 8.2 Future Development ====   ==== 8.2 Future Development ====  
-From the beginning we have tried to create the most effective team, therefore we used Project management tools like tasks distribution, found several solutions for communication and we set deadlines to ourselves. In our work we want to be precise an always give our best. It is important to hand in deliverables in time, unfortunately there was delay concerning some materials. While we were not able to build prototype we were focused on report, web-page, user manual, packaging, poster, video and bulb design. These parts of deliverables have progressed successfully and what is important, in time. We got materials two days before final assessment, this situation forced us to work faster and more effective. As much as we tried prototype production was not successful, lamp functions did not work. Reason of that problem was PCB which was wrong and also programming. Lack of time didn’t let us to correct these major mistakes.+As prototype of Modular LED Lamp was not fully successful in testing, new prototype needs to be developed. New PCB and programming improvements has to be done. Nowadays, people want to control everything from their computer and phone. It means an instant access to their devices. Therefore, development considering the remote control could be an option. Instead of using infrared communication between lamp and remote control, we could use Bluetooth or Wi-Fi connection between device and Web application or also design a mobile application for that purpose.  
 +We would like to decrease the size of the lamp. It is necessary to reduce PCB boards and use, for example, other movement detecting sensor in order to achieve smaller bulb dimensions. There are some opportunities for light bulb design development as well. For example, it would be better if there is possibility to move/turn movement detecting sensor. As ultrasound sensor was so big it was very difficult to place it the way that it would move. What is more, different material could be considered, because already used material is sensitive to heat and in high temperatures it could melt. In future design we can use a flexible material. 
  
-During all the semester we learned a lot about team work and studied lighting specifications in every field. We tried to create the best product we could considering objectives and advice given. 
- 
-This experience gave us definitely advantage in future life. We were able to practice English, we studied lighting specifications, learned sustainability and marketing issues as well as improved our communication and cooperation skills. 
  
  ===== Bibliography =====  ===== Bibliography =====

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