Background Initial Design Approaches Meeting Outcomes. Final Design Approaches Plan for next semester. FM Approvals

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1 Class II Division 2 Occupancy Sensor Presented on November 28, 2012 by: James Fisher Michael Gazda Russell Gee JoAnne Hitchcock Gledi Progonati Christopher Zannoni Dr. Sung Yeul Park (ECE) Dr. George Lykotrafitis (ME) Senior Design

2 Background Agenda Initial Design Approaches Meeting Outcomes FM Approvals Sensor Switch Final Design Approaches Plan for next semester Testing of design Gantt chart and team member roles

3 Background What are occupancy sensors? Why?

4 Occupancy Sensor Technology Sensor Power (Low Voltage<200 mw) Line Voltage Relay and Power Supply for Sensor Control Signal Sensor Manual Switch

5 Class 2 Division II Safety This device must work in a Class 2 Div. II environment Metal dusts, carbon dusts, flour and grain dusts abnormally present Warehouses/Storage areas Intrinsic Safety Limits energy in device, removing possibility of ignition Composed of passive components that store little or no energy Temperature limitations

6 Initial Design Approaches Using original requirements

7 Both Sensor and Relay Enclosed Dust-Tight Conduit Line Voltage Relay and Power Supply for Sensor Power to Luminary Dust-Tight Enclosure Control Signal Sensor Power Sensor Window made out of IR transmissible material

8 Wired Solution with Connector (Assumes IS sensor)

9 Wireless Solution (Assumes IS sensor)

10 Research=More Questions Our research led to many unanswered questions about requirements What are the testing methods? Which, of the many, requirements are relevant to our project? What are the component and design restrictions? We contacted a NRTL FM Approvals offered to help Answered many questions Provided expert opinions Helped finalize our approach

11 FM Approvals Background OSHA approved testing/certification company Parent company: FM Global In business since 1835 Make the regulations that drive industry standards Acts as disinterested, 3 rd party observer where design process is concerned Qualified to test for IS (intrinsic safety), dustignition proof, explosion-proof, etc. ECE Senior Design

12 FM Approvals Meeting Explained the testing process: Duration Approach Various tests depending on desired certification: Crush, exclusion (purge/pressurize), flammability, rigidity, torque, mould stress, hot and cold impact, intrinsic safety Will be explained later in presentation General requirements to pass tests ECE Senior Design

13 FM Approvals Meeting We explained the initial designs Received feedback What would/wouldn t pass testing Discussed possible solutions and provided specs. Enclose the sensor using dust ignition proof standard Or make sensor intrinsically safe using provided standard Changes needed from initial product to completed, passable design ECE Senior Design

14 Sensor Switch Meeting Gave us two options Enclose the sensor Find a 1mm thick Fresnel lens for PIR sensor window Make sensor intrinsically safe Professor Park advised us to do this option ECE Senior Design

15 Design Process Brainstorm Evaluate Advisement Sensor Switch Meeting FM Approvals Meeting Advisor s Recommendation Finalize Create ECE Senior Design

16 Final Design Approach Dust-ignition proof box enclosing relay according to the FM3616 standard Intrinsically safe sensor according to FM3610 which refers you to ANSI/ISA and ANSI/ISA standards 16

17 Dust Circulation Testing We will build an apparatus to determine whether the enclosure is dust tight. Create vacuum within enclosure Circulate talcum powder within chamber

18 Impact Testing 2.7 J impact test for Class II 1kg test mass, falling from height 270mm Steel hemisphere 25mm diameter as impact point Unit assembled, mounted on concrete with mass over 20kg (Drop test not necessary- not portable)

19 Thermal Endurance Non-metallic elements which dustprotection is dependent must undergo thermal endurance testing Heat: 4 weeks at (90±5)% humidity, (20±2)K above maximum service temperature Cold: 24hr, 5 to 10K below minimum service temperature

20 Circuit Design and Testing Determine how circuit works Recently acquired blueprints Work with Sensor Switch engineers Analyze components for IS Redesign PSpice analysis PCB Design and Prototype Practical tests ECE Senior Design

21 Timeline-Past September Initial Hazardous Environment Research-found required specs Meeting with Sponsor (9/19) October Requested Blueprints Website Design Projects specifications Project Statement Website finished NEC research 1500p doc Found 12 specs relating to project Contacted FM Approvals Enclosure design Project specs redefined Setup meeting with FM approvals Wireless and Wired research November Final Written Proposal FM Approvals meeting Project redefined Sensor Switch meeting Project Redefined Test equipment researched Blueprints received Final Presentation 21

22 Timeline-Future Figure out circuit w/ss Initial Enclosure Design Finalize Enclosure design Build Test Equipment Analyze components for IS Redesign Circuit Prototype Circuit PCB design Test Circuit Test Enclosure 1 December January Febuary March April WinterBreak

23 Individual Tasks & Roles Russell Design and Build Test Equipment Gledi PCB Design and Help with Test Equipment JoAnne Circuit Design and Circuit Testing Mike & James Designing, Prototyping, Testing of Relay Enclosure Chris Team Management and Circuit Testing 23

24 Budget Cost of Project Complexity of regulations hindered design progress. $13,000 Impractical to make a detailed budget in 12 hours. However most money spent will go towards testing equipment. 24

25 Questions?