Packaging Specifications and Design - Design Project

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					ECE 477                     Digital Systems Senior Design Project                     Rev 8/09

                Homework 4: Packaging Specifications and Design

Team Code Name: ___POSitron_________________________________ Group No. _7____
Team Member Completing This Homework: __Jacob_Wyant_________________________
E-mail Address of Team Member: _______jwyant_ @


                Excellent – among the best papers submitted for this assignment. Very few
                corrections needed for version submitted in Final Report.
                Very good – all requirements aptly met. Minor additions/corrections needed for
                version submitted in Final Report.
                Good – all requirements considered and addressed. Several noteworthy
                additions/corrections needed for version submitted in Final Report.
                Average – all requirements basically met, but some revisions in content should
                be made for the version submitted in the Final Report.
                Marginal – all requirements met at a nominal level. Significant revisions in
                content should be made for the version submitted in the Final Report.
                Below the passing threshold – major revisions required to meet report
                requirements at a nominal level. Revise and resubmit.
* Resubmissions are due within one week of the date of return, and will be awarded a score of
“6” provided all report requirements have been met at a nominal level.

ECE 477                       Digital Systems Senior Design Project                        Rev 8/09

1.0    Introduction
       POSitron is a point of sale system that allows a customer to easily purchase any product
normally sold in a convenience store with greater efficiency and receive the ordered goods at a
specific pick-up point. A wooden box with a slanted top will act as the kiosk's frame. It will
hold a touch-screen, keyboard, Atom board, power strip, and power adapter for the Atom. The
top will be slanted so that the touch screen will be accessible to users of varying heights and the
keyboard will protrude from the box in front of the screen on a horizontal surface to allow for
comfortable typing.
       The other portion of the project which will need packaging is an inventory management
system containing four hoppers for dispensing products, a conveyor belt for transporting those
goods to the pick-up location, and a slanted portion similar to what one might see at the end of
check-out lines at grocery stores to serve as a reservoir for products waiting to be bagged by the
customer. This will be of modular construction with the four hoppers, conveyor belt, and
distribution area making up the 6 different separate sections to simplify transportation of the
project and to allow each part to be constructed and tested independently.

Commercial Product Packaging

       An ATM and a DVD rental kiosk are two products that share similarities in functionality
with the POSitron. Both of these items are used to control a complex inventory and
communicate with central databases via the internet just as the POSitron does. However, the
items those machines dispense are contained inside the same packaging as the electronics
responsible for user interaction and inventory management, whereas ours will not have the
burden of also needing to contain the products since they will be kept in a separate dispensing
area. Since all three items' packaging have essentially the same goal of securing valuables while
allowing the customer to easily interface with a simple display, we can use similar ideas for our

ECE 477                       Digital Systems Senior Design Project                        Rev 8/09

2.1    Product #1

       The packaging our project will most be like is that of a DVD rental kiosk for a simple yet
stylish look. These kiosks are made to be sturdy in order to protect not only the goods within,
but the electronics used for customer interaction as well. It is this same concept of solid and
secure, yet appealing and memorable, that we would like to bring to our project. We will
accomplish this with a solid wood casing to protect the LCD screen, touch panel, and computer
because it is strong enough to endure misuse and theft attempts, yet inexpensive enough to fit
within the boundaries of our project‟s budget. It also allows us to easily create a slanted portion
to hold a screen at an angle similar to most DVD rental kiosks for the purpose of allowing easier

       The disadvantage of this design, however, is that since these forms of kiosks are meant to
be an all-in-one package to conserve space and be easily setup in any location they are extremely
restricted in space and the type of product they can provide. The POSitron, on the other hand, is
expandable with the possibility of additional conveyor belts being added to the existing system.
Although such an expansion would put the POSitron at more of a disadvantage in terms of size,
DVD rental kiosks such as the one pictured above measuring about 3‟x3‟ whereas the POSitron
5‟x2-½„ without the kiosk which is about 2‟x1-½‟.

ECE 477                       Digital Systems Senior Design Project                        Rev 8/09

2.2    Product #2

       Many of the same advantages and disadvantages can also be seen in an ATM. An ATM's
packaging is also very solid to protect its components and the money within, and it has an
appearance easily recognizable by customers; both of which are aspects we incorporate in our
design. One feature it has that a DVD-rental kiosk does not is a small keypad attached to the
device near the screen. Similarly, the POSitron will be using a physical keyboard for ease of use
to the customers. This will allow them to search the inventory, enter usernames, and type

       The differences are also much the same as with DVD-rental kiosk in that the POSitron is
designed for its flexibility in types and amounts of products in can provide while an ATM has a
fixed size cash box to draw from.        This again means that the POSitron will be larger in
dimension and not as simple to mass produce.

3.0    Project Packaging Specifications

       The POSitron kiosk shall be constructed from planks and boards readily available to our
teammate Ben Horst through his connections in the woodworking industry. Access to the right
tools for the job and ample supplies will contribute significantly to the strength of the end

       The kiosk will be constructed using 1x1 poplar boards for the skeleton and fiberboard
paneling for the skin. It will use ¼” paneling to cover the bezel and a 12”x9” piece of lexan to

ECE 477                        Digital Systems Senior Design Project                      Rev 8/09

protect the LCD screen. Additionally, thin holes in the kiosk will be cut out of the back to allow
for excess heat to escape. This will prevent the Atom board and monitor from overheating and
possibly getting damaged.

       The inventory management system will be supported by a ¾” maple veneer plywood
plank. ¼” MDF panels will be used for the dispenser front panels with 3/8” poplar dowel rods as
uprights to contain the products. This will all be constructed using 1 1/2” screws, 1” screws,
super glue and wood glue.

PCB Footprint Layout

       The PCB we will be using will go along with our inventory management system which
has no size restriction and readily available power. Therefore, the limiting factor on our design
choices is cost with availability and size kept in close consideration. For our two multiplexers
(model 74HC/HCT4051) we chose the through-hole model because they cost less than surface
mount multiplexers and are more easily accessible, although they take up slightly more space.
Our transformer, the T-1150, was chosen from a large number of possibilities that would meet
our power needs because it was the most affordable and has the smallest dimensions of those
considered. The port to connect the microcontroller with the Atom board will be RJ45 in order
to connect with a CAT-5 cable. Finally, the model MC9S12NE64 80-pin Freescale
microcontroller was chosen over the 112 pin model because we found documentation that
explains how to best connect that model to the RJ45 jack necessary for ethernet communication.
The total area of this board should be about 18 in2 (3”x6”).

4.0    Summary

       Like with ATMs and DVD rental kiosks, our project will be of sturdy design with special
attention put on ease of use for the customer. This will be accomplished with the assistance of
experienced carpenters with the right tools, and result in a product which is both mobile and
sturdy enough to protect the valuable electronics within. The PCB board contained within will
be cost effective with a high focus on reliability.

ECE 477                    Digital Systems Senior Design Project                Rev 8/09

                                    List of References

[1]   “Automated teller machine.” [Online]. Available:

[2]   “Redbox.” [Online]. Available:

[3]   “How Redbox Works.” [Online]. Available:

[4]   “MASSCOOL FD08025S1M4 80mm Case Fan - Retail.” [Online]. Available:

[5]   “Lexan GRA0112001000 Sheet Stock.” [Online]. Available:

[6]   “Datasheet - T-1150 - "U" INTERFACE TRANSFORMER.” [Online]. Available:

[7]   “MC9S12NE64 Data Sheet.” [Online]. Available:

[8]   “MC9S12NE64 Data Sheet.” [Online]. Available:

ECE 477       Digital Systems Senior Design Project     Rev 8/09

          Appendix A: Project Packaging Illustrations

                    Above: full view of kiosk

                   Above: side view of kiosk

ECE 477   Digital Systems Senior Design Project    Rev 8/09

                Above: top view of kiosk

                 Above: Conveyor Belt

          Above: front view of the conveyor belt

ECE 477       Digital Systems Senior Design Project        Rev 8/09

               Above: top view of the conveyor belt

          Above: hoppers for dispensing various products

                   Above: side view of hoppers

ECE 477                      Digital Systems Senior Design Project                          Rev 8/09

                                Above: top view of single hopper

          Above: the reservoir, serving as the final destination for the desired products

ECE 477   Digital Systems Senior Design Project   Rev 8/09

           Above: front view of the reservoir

            Above: top view of the reservoir

ECE 477                     Digital Systems Senior Design Project                 Rev 8/09

                        Appendix B: Project Packaging Specifications

Materials               Tooling                Weight Estimate         Cost Estimate

3/8” poplar dowel       Table saw              20 lbs                  $29
Particle boards (MDF)   Tub drill
1/2"x3/4" poplar        Drill press
1"x1" poplar planks     Screw gun
1/2” MDF paneling       Circular saw
maple veneer            Wood glue
1 1/2" square screws    Super glue
1" screws               CNC mill
4 Case Fans - $1.29     Ruler
12”x12” lexan sheet -   Square
                        Measuring Tape
                        Chop Saw

ECE 477                      Digital Systems Senior Design Project                  Rev 8/09

                            Appendix C: PCB Footprint Layout

J1 - Power source
J8-J12 - Motors (4 dispenser, 1 conveyor)
U1 - 8:1 Sensor Select Multiplexer (5 inputs used)
U2 - 2x1:4 Motor Select (only use one of those two 1:4 multiplexers the chip has)
J2 - Microcontroller
J13 - Sensor emitter power/gnd
J14-J18 - Sensor detectors signal/gnd
T1 - Power transformer
J3 – Ethernet connection


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