Final Design Document (1)

Window Function Tool Team Design Guide 3 Table Of Contents List of Figures Figure 1 Portable Voltage Powered Tool Page 9 Figure 2 Station Tethered Voltage Powered Tool Page 9 Figure 3 Arduino with Simple PCB Preliminary Circuit Layout Page 15 Figure 4 Arduino with Custom PCB Preliminary Mechanical Layout Page 17 Figure 5 Custom PCB Design Circuitry Page 18 Figure 6 Custom Design PCB Housing Page 18 Figure 7 Linear Power Supply Module Page 19 Figure 8 Internal Circuit Design Page 23 Figure 9 Makita CXT Battery Page 24 Figure 10 Makita Replacement Terminal Page 24 Figure 11 Female Banana Plug Connection Page 25 Figure 12 Banana Plug Connection Placement Page 25 Figure 13 Structural Design Page 26 Figure 14 Structural Dimensions Page 26 Figure 15 Connectors and Internal Crimps Page 27 Figure 16 DR Door Couplers: Door Harness (part-1) Page 29 Figure 17 DR Door Couplers: Door Harness (part-2) Page 30 Figure 18 AS Door Couplers: Door Harness Page 31 Figure 19 RR R Door Couplers: Door Harness Page 32 Figure 20 RR L Door Couplers: Door Harness Page 33 Figure 21 Prototype Multi View CAD Drawings Page 41 Figure 22 Prototype Multi View 3D Model Page 42

Window Function Tool Team Design Guide 6 Chapter Summary Executive Summary…………………………………………………………………………………………………………………..i Chapter 1: Problem Identification Background…………………………………………………………………………………………………………………………..7 Motivation……………………………………………………………………………………………………………………………7 Research………………………………………………………………………………………………...………………………… .... 8 Chapter 2: Preliminary Design Review Preliminary Design Decisions………………………………………………………………………………..……………………..11 Design Concepts…………………………………………………………………………….……………………………………...13 Chapter 3: Detail Design Detail Design………………………………………………………………………………….……………………………………17 Specifications Update…………………….…………………………………………….…………….…………………………….25 Prototype Processes………………………………………………………….…………………….…………………….…………26 Prototype Risk Assessment……………………………………………….………….…………………….……………………….29 Milestones & Future Considerations…………………………………………………….…….…………………….……………..29 Chapter 4: Final Design Prototype Development…………………………………………………………………………………………………………….41 Design Refinements…………………………………………………………………………………………………………….. Risk Assessment……………………………………………………………………………………………………………………47 Business Case…………………………………………………………………………………………………………………… Project Impact………………………………………………………………………………………………………………………49 Budget………………………………………………………………………………………………………………………………50 Future Work…………………………………………………………………………………………………………………...……53 Conclusion………………………………………………………………………………………………………………………….53 References…………………………………………………………………………………………………………………………..56 Appendices………………………………………………………………………………………………………………………….57

Window Function Tool Team Design Guide 9 The door assembly is a sub-assembly process that occurs prior to the door being affixed to the car. Currently, there is no possible way to ensure the quality of the door window run-channel on the Acura RDX before it is affixed to the car. In order to test whether the window run-channel functions properly and meets all specifications, the window must be rolled up into the run-channel. On other models, this can be performed as part of the sub assembly as the windows can be rolled up with a simple applied voltage. On the RDX, this wire harness is covered up by a door liner before the window run-channel is installed, preventing this process from happening. As a result, it is impossible to find and correct any non-conforming window run-channels until the door has been assembled onto the car. The inability to detect these non-conformances has increased Honda’s cost of quality. One of these costs comes in the form of wasting parts. When the window run-channel is pinched and remains that way until the door can be assembled onto the car, it can permanently damage the run channel and require replacement. It is estimated that this occurs five times per day at a cost of $120.00 per occurrence. Another cost is a result of the time it takes to correct these mistakes. Less severe defects need to be corrected in 1-2 minutes before it risks shutting down the line. When a defect can not be fixed in the required time, it must be sent to repair, which costs a significant amount of time and money. A tool that could function the window before assembling the Acura RDX door onto the car would catch any possible error in the window run channel before it could become permanently damaged or risk shutting down the line. This would greatly reduce the time and money spent to fix these problems and thus reduce the cost of quality. By reducing the cost of quality Honda will be able to produce higher quality products at a reasonable price. 1.3 Research The first step in finding a solution is to research the problem more. Research can be done into other solutions for the problem, based on tools that already exist. Furthermore research can be done into current production processes to find how a new solution will fit into those processes. This research will be done by both primary 1.3.1 Primary Research The team has agreed to conduct a primary research based on various different types of user groups. The user groups that were considered to be interviewed are the Process Engineers, Maintenance Engineers, and Line Workers. These particular user groups are important to the primary research process because Honda’s current window function tool is being implemented throughout these different departments. Each of these roles will interact with the window function tool differently and therefore it is important to have all of their feedback to ensure that this tool will be successful and helpful to everyone.

Window Function Tool Team Design Guide 12 language will be used and an accessible port will be added to the tool. These will be decided upon later. The other interface will be the electrical connections of the tool, this will vary significantly as each car, and sometimes even each door have different pinouts that need to be connected to [6]. This means the best solution will be to create known signal outputs on a designated header for the tool, and then each user makes their own header to connect the tool to the output pinouts of their specific door harness. The window glass function tool will be designed for production use only, meaning it will be used in an intermediary process, and not in the hands of the end user. This means that for Honda it will only need to go through an internal review process with their process engineer in charge of the line [6]. This would presumably be the case at other companies, although information about their approval processes are not publicly available.

Window Function Tool Team Design Guide 15 Table 3: Battery vs. Tethered Concept Screening These tradeoffs were analyzed in detail as shown in Table 3, using a concept matrix for each of the designs. As you can see the battery proves much better in non-technical factors such as mobility, ergonomics and ease of use while performing worse in the durability category. Overall each of the designs scored higher with the battery option over being tethered to a workstation so this approach will be applied in each of the designs moving forward. 2.1.3 Drill Tool vs Plastic Box Design Another important consideration is whether to use a drill tool or a plastic box design. Most of the Design concepts focus on having a plastic box design rather than the drill tool design. The benefit of the plastic box design is that it is more durable and reliable while the drill tool will be more feasible and have more ease of repair. Please refer to Table 4: Drill Tool vs Plastic Box Design Matrix for information on how the decision was made.

Window Function Tool Team Design Guide 18 Figure 4: Arduino with Custom PCB Preliminary Mechanical Layout The mechanical layout of the window function tool as seen in Figure 4, has simplicity and ease of use in mind. All of the electrical components will be housed in a strong plastic box anchored down by an insulating glue. The simplicity of the tool will allow operators to focus more on examining the quality of the doors which ultimately is the main goal. The external features being extruded from the tool will improve the tactile feel of the tool but will have to be balanced with durability because external features could be more inclined to break. Further research and testing will be done to optimize these features for best user experience and durability. 2.2.3 Completely Custom PCB The main advantage of this design is that the PCB is completely redesigned. This provides for more flexibility than the re-harnessed proof of concept, and more flexibility than the Arduino because circuits internal to the arduino that are not needed can be left out. This simplification can make troubleshooting easier and make the size of the tool smaller, and more flexible as there will be no need for a blank space on the PCB for the arduino. This design does have drawbacks such as the increased chance for an error and more time required for design and testing. Individual circuits can still be tested, but it is nearly impossible to run an entire system test. Also in the current economic environment it is cost and time prohibitive to get PCBs printed which can be hard on the timeline and price limit given. A completely custom PCB will also require that a new software architecture be developed to implement any code. There is a large array of MCUs that are capable as a LIN driver and CAN node as well. One of these micros is the TLIN1029-Q1 which was used for this design and runs off a 5V line. This all leads to the relatively simple PCB circuit design seen in Figure 5.

Window Function Tool Team Design Guide 21 microcontroller unit (MCU) with a bluetooth antenna inside or would need to hook up an external MCU such as an AdaFruit or another similar bluetooth low energy (BLE) device with universal asynchronous receiver-transmitter (UART) communication capabilities. Please refer to Appendix Figure 6: Custom Design PCB with Bluetooth Module and the Figure 7: Custom Design PCB with Bluetooth Housing for more technical mock up regarding this wireless communication device. 2.3.1 Design Matrix After weighing all of the pros and cons, a weighting system was created that was used in the design matrix that can be seen in Table 5. Based on the requirements given by the sponsor it was decided that reprogrammability was crucial as it would allow the tool to be used for multiple model years. Mobility is also vitally important as it will allow the tool to be used either on the line or within repair providing process flexibility. Then it was decided that functionality is incredibly important because of the limited time and money on this project, and the worst case is the device does not work. After that the decision was made that feasibility and Ease of Repair were crucially important so that the design works most of the time, and when it does not, it is easy to fix and get working again. After that it is important that the design remain ergonomic and easy to use so that it can become a line approved design. Then while remaining wary of the environmental impact of the power consumed by the device it was decided to be well below other considerations, because there are so few of these devices, therefore making its impact negligible. Table 5: Complete Design Matrix

Window Function Tool Team Design Guide 22 After weighing all of these considerations it was decided that it would be best to use the PCB design with the custom Arduino. This design was considerably more reprogrammable than either of the designs that only included the master switch. The design was then considerably more feasible than the wireless connection or the completely custom PCB giving it the win over every other design. The project will still aim to incorporate the harnessed master switch just so more can be learned about the windows function and also the signals, and how they work. It is also intended to learn more about the wireless connections capabilities as the team’s Sponsor found that option particularly intriguing. But for the start the work will be based on the arduino based PCB design using only LIN communication, with the battery powered external from the drill. This will give the project the process flexibility and reprogrammability required, while not compromising on its feasibility.

Window Function Tool Team Design Guide 23 Chapter 3: Detailed Design 3.1 Detail Design Documentation 3.1.1 Arduino and Firmware After consideration and research, the Arduino DUE design has been determined to best suit the needs of the project. This type of Arduino is a more intermediate-level device in the Arduino series. This device has a Direct Memory Access Controller, which helps communication between its MCU and its I/O Pins. Two I/O pins would be used for triggering the input signals from the buttons. The Arduino DUE contains 4 UART communication pins which are used for serial communication but currently only 1 pin would be used to send data to the door MCU, which would trigger the door window motor. The Arduino DUE is powered with the SAM3X8E ARM Cortex Microcontroller that has LIN serial read and write communication capabilities. It functions in the USART mode of operation . The USART mode can generate the serial data in a form corresponding to the LIN Protocol, the one that will be used in order to communicate with the door Transceiver and MCU. The Application Block Diagram for this device shows that this MCU holds USART capabilities for LIN driver and LIN transceiver. Please refer to Figure 18 in the Appendix C Chapter 3 section for the Application Block Diagram. The Firmware code portion in this project will need to have the Arduino DUE send serial data packets to the door. The packet descriptions would be controlled by the two physical switches. There will be two data packets that will tell the door MCU to raise or lower the windows. Since the Arduino Due has not been received, everything in the example code is subject to change in the future. Please refer to Figure 19 in the Appendix C Chapter 3 section for the Arduino Code. All of the functions will be shown in the example code. There are a few functions in the code that are needed in order to establish communication with the Arduino’s MCU. The first function that is needed is the one that begins serial communication. The function that will be used is the serial begin function with a 9600 baud rate. Next, the digital pins will be initialized with inputs with either pull-up or pull-down resistors enabled. The function that will initialize the I/O pins is the pinMode() function. This Project would have two of those, one for the window down button trigger and one for the window up button trigger. Then the same “pinMode()” function will be used in order to set the “TXD Pin 0” pin as an output, this pin would be used directly for the LIN serial communication. For the main void loop, the firmware would need to establish variables to hold the information coming in from the button switches. Since the information coming in from the switches will be either a "1" or a "0", an int function will be used. These variables are initialized as “buttonVal1” and “buttonVal2” in this example code. After the two triggers are initialized, the LIN serial communication portion will need to be set up in order to create LIN data packets and send them out via the UART serial interface. This portion will be started by including Arduino’s “Lin_Stack.h” file. Pin 0 will need to be selected to be the Master so that it can write data using the LIN protocol. The function that will be used for that will be the “lin_stack LIN2()” function. Next the LIN packet description can be initialized with the “Byte()”

Window Function Tool Team Design Guide 24 function. LIN signal packets will lower the windows for all three doors and raise the windows for all three doors. “IF” statements can be set up for the MCU to send out correct signal packets for the 2 button triggers. The LIN data packets will go through each door and then if the door recognizes a specific signal in those packets, it will function accordingly to that particular signal. For this project’s case, it will either raise the windows or lower them. Inside the “IF” statements, there will be LIN serial write functions for those particular packets. 3.1.2 Internal Circuitry The internal circuitry of the tool is intended to accomplish several requirements. The circuit needs to allow power input from both a battery and direct current power supply. To allow for different input voltages, a buck converter will be used to supply the arduino with a consistent power voltage. Schmitt triggers will be used with switches to create a clean digital signal for the arduino. The arduino will have two analog inputs driven high or low by the schmitt trigger, and the output of the schmitt trigger is connected to an LED to provide feedback to the user. The arduino will generate each of the required signals to function the doors which will be wired externally as seen in Figure 8. The input power will also be wired directly to the door harness so that the input voltage to the door can be specified by the use of the power supply. Figure 8: Internal Circuit Design 3.1.3 Power Connections One of the important considerations for the tool is how it will be powered. One of the requirements given by the sponsor is that it be mobile, and not tethered so that it can have operational flexibility. This means that the tool will have to use a battery or non-tethered connection. This has an added benefit of operating with DC voltage which is what the door is operating on. Another sponsor requirement is that the tool operate with a battery already in use on the line.

Window Function Tool Team Design Guide 25 There are two models of batteries that Honda uses on the line, the flat slide in CXT battery seen in Figure 9, as well as the tall clip in Makita batteries. The tall Makita battery was hard to fit into the design because of its size. It also was harder to source a replacement part battery connection for it. The Makita CXT battery has an easily sourced replacement part that can be seen in the Appendix C Figure 9. Figure 9: Makita CXT Battery Figure 10: Makita Replacement Terminal The battery will be held in place by a 3D printed wall holder that can be seen in Figure 10. It has three holes on it that will be drilled into the back of the box that will connect the holder to the box itself. The battery connection will be placed in the middle hole of the battery holder. A small hole will be dremmelled in the back of the box that will feed the wires from the battery connector the wires will then connect and be soldered into the PCB. One of the other requirements is that a variable voltage input be able to be connected to the tool. In order to do this the tool must be connected to a DC power supply. The easiest way to do this is through standard banana clip wires which can be seen pictured in Figure 11. This means that a female banana plug connector, as shown in Figure 12 must be placed on the box. This can be easily done as a hole, the size of the threads can be dremeled out of the box and then the nut can be screwed on to hold it in place. Then internally to the bax the wire can be shorted to the power lines in parallel with the batteries so either can be used at any given time. This design will keep the tool safe as there are no exposed wires to potentially harm anyone.

Window Function Tool Team Design Guide 26 Figure 11: Female Banana Plug Connection Figure 12: Banana Plug Connection Placement 3.1.4 Box Design The structural design for the tool is intended to promote simplicity and ease of use. As shown in Figure 13, the top surface of the tool will have two switches for operating the window glass, one to raise the glass and one to lower the glass. Each switch will be labeled for the operator and have a corresponding LED to provide feedback to the operator. The battery will be connected through an adapter on the side to allow for easy connection and replacement. All of the wire harnesses will be fed out of the box through a strain relief to protect all of the internal components. The dimensions for the structural design are based on components found on McMaster Carr which are listed in the bill of materials in section 3.3. These dimensions were chosen because the box needs to be large enough to comfortably fit the arduino, circuit board, and internal wiring between each of the components. The dimensions for the structural design can be found below in Figure 14.

Window Function Tool Team Design Guide 27 Figure 13: Structural Design Figure 14: Structural Dimensions 3.1.5 Door Harness Connection The door connection will start from the PCB where it will only have one lead wire from each of the voltage rails and the signal. This will help with the simplicity of the PCB, and creates less possible soldering connections. However for each car type the tool will need 5 power signals, 5 ground signals, and 4 LIN signals. This is 2 of power and ground for the driver door and 1 for the other 3 doors and 1 LIN bus for each door harness. The original decision for how to splice these wires was a WAGO wire splicer can be used. The wires will be spliced together inside of the box to keep the appearance neat. This splicer is very simple as you raise the orange tab insert the wire then close the tab locking the wire in place. It makes reworking the wiring very easy, and requires no additional crimping or soldering; however, it is a temporary connection so it may have durability concerns, and will make swapping harnesses difficult.

Window Function Tool Team Design Guide 28 After meeting with the Sponsor a potential solution was decided upon that an external facing female wire connector be attached to the inside of the box and the harnesses can be connected to a matching male header so they can easily be swapped out. This will have difficulties like matching the crimps to the headers, taking the time to crimp all the wires, anchoring the female connector inside the box, difficulty in reworks, and additional errors caused by soldering and crimping. But it would be permanent and easy to swap. A figure showing all of the headers and their crimps can be seen in Figure 15. This design will be tested in parallel with the wire splicers to alleviate concerns over the feasibility of this design. Figure 15: Connectors and Internal Crimps The design that is used to split the wires will have the same connections. The sponsor provided several harness drawings, and these drawings are used to judge how the couplers should connect. The focus should be on the lower left corner of the image, these positions are usually couplers that need to be explored. There are a total of 4 different types of door drawing that need to be analyzed, they are Drivers’ Door (DR Door); Assistant Side Door (AS Door); Rear Right Door (RR R Door) and Rear Left Door (RR L Door). For the drawing of DR Door, the sponsor also provided the image of the run-channel harness on the basis of the wire harness. In the image, there are two parts that are very important to explore the connection of the coupler. They are the circuit table in the upper left corner and the corresponding circuit image. Then the table in the upper left corner can be used to explore the connection and meaning of different elements in each circuit. At the same time it can also help determine the color and function of the line, which are very important for the tools actual operation in the future. The following will be the Coupler connection selection

Window Function Tool Team Design Guide 29 and its corresponding table and image. The position to be selected has been marked yellow. Male connection is also needed for all four kinds of doors which is: Door harness to IP Harness. 3.1.5.1 Couplers Connections for DR Door Harness The DR Door needs two couplers in total. The selected interface is indicated in the figure. The picture shows the circuit link for the door, these highlighted grids show the colors of the wiring that are a great help in connecting design products to the door. The corresponding models of these two couplers are: 91952-S7A-0030-H1 and 91769-T2A-0030-H1. For here, the highlighted grids are: ● X03, Green, LIN power ● G22, Brown, IG2 function ● B21, white, the main power ● B05, Red, back-up power ● Z85, Black, connected to ground power ● Z74, Black, ground ginal. There are six important connections in Table 6 which have important functions.

Window Function Tool Team Design Guide 30 Table 6: Required Signal Connections and Function Description Signal Connection Function X03 LIN Communication B22 External Power (Front Asst. Door)6+ B23 External Power (Rear Doors) Z70 Power Ground (Front Asst. Door) Z75 Power Ground (Rear Doors) PG Power Ground (Driver Door) SG Signal Ground (Driver Door) Figure 16: DR Door Couplers: Door Harness (part-1)

Window Function Tool Team Design Guide 31 Figure 17: DR Door Couplers: Door Harness (part-2) 3.1.5.2 Couplers Connections for AS Door Harness Compared to the DR doors, the AS Door has fewer harness connections and the AS Door needs only one coupler. This graph has the same feature with the DR one, the letter shows the color and the following shows the function of it. The selected interface is indicated in Figure 17. The corresponding model of the coupler is: 91769-T2A-0030-H1. There are three important connections, and their line colors and connection functions are: ● X03: Green: LIN P/W function ● B22: Gray: Power ● Z70: Black: Ground

Window Function Tool Team Design Guide 32 Figure 18: AS Door Couplers: Door Harness 3.1.5.3 Couplers Connections for RR R Door Harness Pretty similar to the AS ones, Rear Right Door (RR R Door) also needs only one coupler and the harness connection is easier. The selected interface is indicated in Figure 18. Still, the graph provides the connection position, the color and the function of it. The corresponding model of the coupler is: 91765-T2A-0030-H1. There are three important connections, and their line colors and connection functions are: ● X03: Green: LIN P/W ● B23: Gray: Power ● Z75: Black: Ground

Window Function Tool Team Design Guide 33 Figure 19: RR R Door Couplers: Door Harness 3.1.5.4 Couplers Connections for RR L Door Harness Rear Left Door (RR L Door) is pretty similar to the RR R door, it also needs only one coupler. The selected interface is indicated in Figure 19. The color for the harness and the function of that shows on the graph. The corresponding model of the coupler is: 91765-T2A-0030-H1. There are three important connections, and their line colors and connection functions are: ● X03: Green: LIN P/W ● B24: Gray: Power ● Z70: Black: Ground

Window Function Tool Team Design Guide 34 Figure 20: RR L Door Couplers: Door Harness The four harnesses for different doors provide enough information to connect the equipment and the prototype to the doors, it gives the foundation to make a test. In reality, the circuit and harness connection of the gate cannot be exactly the same position as shown in the picture, so the color of the wire harness can help a lot to find the correct connection.

Window Function Tool Team Design Guide 35 3.2 Specifications Update 3.2.1 Requirements Table In order to properly create a solution to the problem it is crucial to understand what the sponsor is looking for. The requirements were identified earlier in the document, but as the project is getting closer to being built specific solutions to each of the requirements have been identified and are shown in the table below. Table 7: Requirements Table Sponsor Requirement Solution Tool can be used in a wide range of applications on the line Making it battery powered so it can be used in either assembly or repair. Tool needs to be reprogrammable Using the Arduino DUE gives easy connections, and a prebuilt software architecture that can be built upon. Tool needs to able to communicate with all of the doors The Arduino Due will communicate as a LIN driver, and LIN protocol is already used for the Rear and AS doors. The driver door can be given power and raised from the internal switch. Tool needs to be powered within Honda processes The Makita CXT battery is already in use on the line and was incorporated in the design. Tool needs to be durable All materials are sourced from reliable vendors and durability is used in every design decision. Door needs to be able to be powered at an externally controlled voltage for testing Female Banana clip connectors were incorporated so the tool can connect to a DC power supply. Tool needs to be easy to use A simple two switch layout will be used to raise and lower the window glass, and only harness connections to the door will be kept on the harness. Tools needs to be safe to use Equipment must be safe to use to ensure the safety of operators. Tools needs to be friendly to environment The material of the tool needs to be environmentally friendly, and the operation of the tool can not produce substances or things that are harmful to the environment. Tool needs to be ergonomic The box is sized to be as small as possible while housing the necessary circuitry, and switches are placed on the right so it can be held and operated using only the right hand.

Window Function Tool Team Design Guide 36 3.3 Assembly Processes 3.3.1 Bill of Materials The team has determined items that will be necessary for the completion of the initial testing and prototyping phase of the project. These items and their function in building the tool are described below. Makita Terminal - The terminal is used to connect the tool to the Makita CXT battery. Battery Holder for Makita Cordless Tools - This is a 3D-printed part and is mounted to the tool in order to connect the battery to the battery holder. Arduino DUE - The Arduino is the brain of the tool and is used to send signals to the circuit in order to raise and lower windows of the vehicles. Schmitt Triggers - These are op-amp circuits used to either boost a voltage or lower the voltage. This will provide a clean signal for the Arduino inputs. Wire Harnesses and Pins - The harnesses are specific to each vehicle model and will likely be provided as scrap parts from Honda. They will be the connecting link between the team’s tool build and the cars in order to raise and lower windows. Ready to Build Circuit Board - The circuit board allows the team to ensure connections are mounted securely and in an organized fashion within the tool housing. Switches - Switches allow the user of the device to control the tool, sending signals to the door or stopping the signal depending on which direction the switch is pressed. LED - The green LEDs will provide feedback to the user about which circuit is in use. Plastic Submersible Cord Grip - The cord grip will relieve strain on the wires from the edge of the box if the harness is created internally with the splicing. Enclosure - This is the housing for the tool’s wire connections and will be the part of the tool the users will interact with most in day to day operations. Wire Splicer - The wire splicer will short all of the wires within the splicer together. This will turn one signal into multiple. Two Terminal Switch - This type of switch is an option the team will explore. The capability of the switch to lock in the neutral position allows the tool to be built and used in a more efficient manner since the tool can be programmed to raise windows if pressed in one direction and lower windows if pressed in the other direction. This eliminates the need for two separate switches. Female Harness Connection - This is a female wire harness connection, it allows two wires to be connected. The female end will be anchored into the box. Male Harness Connection - This is a male wire harness connection, it allows two wires to be connected. The male end will be attached to the wire harnesses and will easily be connected to the box's female connection. Female Connector Crimp - A wire crimp is the metal tip that is connected to the end of a wire, this specific crimp will lock inside of the female connector. This means the design will need one for every connection so there will be 15.

Window Function Tool Team Design Guide 37 Male Connector Crimp - This wire crimp will fit within the male connector, and the design will need 15 of them for each wire in the connector. Slide Switch - The slide switch is just another way to incorporate a switch, but is best utilized on a switch you don’t want to move often, so it will sit flush with the box. For this design the switch will control whether the tool is in manual or automatic window raise mode. Insulating Glue - Insulating glue will connect the circuit board to the box, and the insulating feature will keep the box electrically safe. Along with the above items that the team deemed necessary for the prototype, several other items may or may not need to be procured as the project moves forward. These items pertain to its testing and assembly, and are listed and described below. DC Power Supply - A DC Power supply will make it possible to check the banana plug connectors and to test the tools functionality at different input voltages. Soldering Iron Station - Depending on whether or not the lab in which the team works has soldering irons available, the team may need to purchase soldering irons in order to make electrical connections in the circuit. Wire stripper/cutter/crimper - Depending on whether or not the lab in which the team works has wire stripping and crimping tools available, the team may need to purchase these tools in order to work with wires. Banana plug wires - Banana plug wires will be used to connect the DC Power supply to the tool. Wires- Will be used to lengthen any existing wires, or to connect parts on the circuit board. Buck Converter- Used to step down a varying DC input voltage to a steady DC output. The following table is an itemized list of materials that need to be purchased, along with their unit cost, exact quantities needed, and total cost of the units combined.

Window Function Tool Team Design Guide 38 Table 8: Bill of Materials It has been determined that the team’s current prospective total cost of $822.26 is well under the allocated budget of $3500. This leaves much room for error, in case the team needs to purchase extra parts or if any unforeseen circumstances arise and more purchases must be made. 3.3.2 Implementation Methods The implementation of this tool will be rather simple. This tool will only be needed on a small scale as the Sponsor requires less than 10 of these tools. At such a small scale it was decided that it is not worth setting up a mass production assembly process. This means that all the tools will be handmade and then given to the Sponsor.

Window Function Tool Team Design Guide 39 3.4 Prototype Plan The prototyping plan for this design and build will be broken into phases to ensure that all parts of the design work together perfectly. This will reduce scrap and spending on unnecessary parts and be much more time efficient. The first phase in prototyping involves writing code that will generate the proper signals required to function the glass on each of the doors. Once that is working a circuit will be developed that uses switches to operate and provides feedback to the user. This circuit will be created on a ready to use circuit board so that it can be built and adjusted as necessary. This will greatly reduce costs and help perfect the circuit with minimal changes to the rest of the design. Next the tool will need to incorporate battery power and a DC power supply into the circuit to align with Honda's existing processes. Once the circuitry is complete, the harnesses will be built and wired external to the box in a neat and organized manner. One this is perfected, each of the components and internal wiring will be fit into a durable compact box for the final tool. Each phase of prototyping will need to be completed one at a time, thus the entire team will organize tasks to complete each phase together. Table 9: Prototyping Schedule Prototype Phase Expected Date of Completion Phase 1: Arduino Code January 28th Phase 2: Internal Circuitry February 25th Phase 3: Incorporation of battery and DC power supply March 11th Phase 4: External wiring and harness design March 25th Phase 5: Housing in durable container April 1st 3.5 Prototype Risk Assessment 3.5.1 Potential Risks and Contingency Plans The design and build for this tool involves many risks which will need to be accounted for in planning. Many of the components listed in the bill of materials are inclined to break if not used correctly. To allow for errors in design, excess material will be ordered to compensate for such mistakes and prevent delay. Each phase of prototyping may require more or less time than expected. Extra time will be built in for each phase to allow for this, while the goal will be to work ahead of this schedule. Time based goals for prototyping will need to be updated as each phase progresses. The current schedule for completion can be seen in Table 10.

Window Function Tool Team Design Guide 40 Table 10: Risk and Contingency Plan Risk Preventative Measure Component Failure or misuse Order excess components for prototyping Time of design greater than expected Extra time built into schedule Design change needed after build complete Build in phases to ensure everything works and fits together perfectly 3.6 Project Milestones The following table outlines milestones that the team has achieved so far. Table 11: Documentation Progress Problem Identification Presentation September 21, 2021 Preliminary Design Document Submitted October 1, 2021 PDR Presentation to Professors and Sponsors November 4, 2021 System Design Document Submitted November 8, 2021 Detailed Design Presentation December 7, 2021

Window Function Tool Team Design Guide 41 Chapter 4: Final Design 4.1 Prototype Development 4.1.2 Prototype Build Processes The strategy for building the prototype was designed to minimize costly mistakes and to perfect aspects in a modular fashion. The team started from the basics by building each aspect of the tool in order of confidence. It can be seen from the CAD drawings in Figure 21, that the final design of the tool was revised from previous design considerations. The ergonomics and ease of use of the tool were considered in each step to ensure the user needs were met in the best way possible. Keeping this in mind, the team decided to move locations of switches to better suit user comfort needs. Figure 21: Prototype Multi View CAD Drawings

Window Function Tool Team Design Guide 42 Figure 22: Prototype Multi View 3D Model To complete the build, subtractive manufacturing was used to perfectly fit all of the external components. This was done precisely using a drill and a Dremel when necessary. This allowed for more customization for meeting user needs such as ease of use and ergonomics. The tight fits of each component will also improve durability over extended use. The first aspect of the tool that was planned and perfected was the external layout of the box. The battery adapter was measured and screwed into the side of the box and the electrical connector was wired through a hole underneath. Having the battery on the box first was crucial in planning the placement of other elements from an ergonomic perspective. The team decided that having the battery on the bottom opposite the working side provided for the best weight balance and freedom of hand placement. To perfectly fit the battery connector and adapter, the adapter was anchored with screws and the electrical connector was fit in the middle of it. The adapter was trimmed until the battery fit in place clicking fully. The connector was then super glued in place and the battery was clicked in while the glue dried to ensure the connector was held in place with a perfect fit. Figure 23: Battery Connector and Adapter Assembly Holes were cut into the box and lid for each of the necessary external components. This includes the switches that control the automatic and manual functionality and the window up and window

Window Function Tool Team Design Guide 43 down functionality. The up and down switch was placed closer to the side of the top of the box so that it could be operated with a single hand holding the box. While the layout of the box was planned, the team perfected the signal and logical operation of the switches using a breadboard so that it could be integrated when ready. Using the breadboard allowed for more efficient debugging which also resulted in less costs for materials. Using an oscilloscope and sniffer, the correct signals could be created and reproduced using the arduino. Once the signal worked in both automatic and manual modes for both the up and down functionality, the breadboard was replicated by soldering to a customizable pcb board. Using a digital multimeter the connections were checked to ensure that the breadboard matched the soldered pcb. Connecting wire harnesses were also designed and created simultaneously to ensure efficiency. Existing connectors were provided by honda which allowed the team to configure these for our needs while ensuring the connectors fit perfectly. A custom harness was built for each car having three separate connectors, one for the driver door, assistant door, and rear doors. These connectors were wired to one input connector which could be connected to the box in one place. This strategy significantly improves the ease and time of use, cutting down the time taken to replace the connector for each door. It also minimized the amount of wiring needed external to the box which improves durability. 4.1.3 Prototype Challenges and Design Barriers The team ran into many challenges while building the prototype. One challenge the team ran into was the fit of the battery into the adapter and electrical connector. The battery was found to fit perfectly into the adapter; however once installed to the side of the box, the wires connectors blocked the battery from clicking into place. To correct this, small amounts of plastic were removed from the adapter underneath the connector to allow it more room to fit. Additional plastic was removed from the locking feature to allow the battery to lock slightly sooner. This was iterated and tested until the battery fit perfectly snug.

Window Function Tool Team Design Guide 44 Figure 24: Precision Subtractive Manufacturing The largest challenge the team ran into was the discovery of the box material. The team finished building the prototype and discovered that the tool no longer worked. After evaluating potential weak points it was discovered that the interior of the box was coated in a conductive metallic paint. This shorted our ground to power connection and other various connections destroying our arduino. Luckily the team had additional components and the tool could be rebuilt in a different box. Figure 25: Internal Paint Failure Analysis The new box that was ordered was checked to be specifically designed for electronics which ensured this mistake would not occur again. The dimensions for the box were kept the same as the components were able to fit perfectly in the original and the ergonomics of the box had already been perfected.

Window Function Tool Team Design Guide 45 4.1.4 Ideal Prototype Analysis While this prototype meets the user needs that the tool was intended for, additional resources could improve the design further. If time had allowed, the tool could have been made significantly smaller and more durable. With constraints in time for designing and building, a ready to use pcb was used, however wiring from this to an arduino takes up a significant amount of space. If time allowed, a completely custom pcb could be created with all of the electrical connections internal to the board. This board could also regulate the voltage, reducing the need for many other large components. Figure 26: Arduino with Fully Soldered Ready to Use PCB A plastic box was also chosen as the ideal method of housing the electrical components as it could be easily and quickly be customized and had flexibility in design. An ideal prototype might use another material which could sustain drops significantly better such as metal. This would require a laser cutter, metal bender, and welding tools to precisely fit components and into a small and robust housing. This housing would need to be coated so it would not short the internal components. Appropriate DC power jacks would also need to be used to not connect the power source to through the box itself. 4.1.5 Lessons Learned through Prototype Design and Build In building the prototype, many valuable lessons were learned both for the team as engineers and for Honda. One important lesson the team learned the hard way is to not overlook any details. The assumption that the paint inside the plastic box had no impact on the box and simply affected the look of the box, resulted in a major step back when it was discovered to be electrically conductive. This mistake also proved the importance of contingency plans and proper scheduling. Had the team not allotted time to reorder and rebuild the tool, there would not be a

Window Function Tool Team Design Guide 46 working tool. The team also had ordered additional components that proved useful in the rebuild of the tool. An important strategy was also discovered which will prove very valuable to future projects at Honda. The signal documentation provided to the team was found to be not sufficient for our purposes. To solve this problem a signal sniffer was used to track the signal output by the working Honda prototype which was a rewired window switch made from scrap parts. In doing so, the team discovered that the identifier and sequence length differed from that identified in the Honda signal documentation. Using this strategy to identify the working signal components will prove pivotal in further designs and adapting the tool for use with different model cars. 4.2 Validation Testing Results 4.2.1 Changes Made in Validation Testing Procedure Originally part of our testing procedure included giving the tool to the line workers that would use it so they can ensure that it will be usable in your settings. There were limitations in what testing we were able to do from time and build setbacks, as well as logistics of getting it tested by the line workers that will use it. Additional individual circuit tests were added. After the original testing was done the tool did not work as expected. Because the arduino started to burn, it became apparent that one of the arduino inputs was not what was not properly constrained. This led to an additional test of all the internal circuitry with the arduino removed to protect it. Then a multimeter was used to probe each individual circuit once the power was added to see if they were properly bounded. 4.2.2 Validation Testing Failures and Resulting Changes Original tool box had an electrically conductive paint coating which made it so the tool could not pass a safety test. This led to the power supply leads shorting when power was applied. To fix the problem a new box had to be bought, and then all of the circuitry redone in the new box. 4.2.3 Validation Testing Successes and Implementation The first test was that each circuit that is supposed to be shorted all had zero resistance between them. This was done by turning a multimeter to noise mode. Then one lead would be put on one of the wires and then each of the additional wires in the circuit were tested. This helped identify a couple problems in the solder which could then be redone before powering the circuits. It also ensured the battery and DC power supply connections worked. Once every input and output of the tool was checked the test was passed.

Window Function Tool Team Design Guide 47 The next test that occurred in the process was the powered circuit test. This was a similar test to the circuit connection test. The main difference being the tool was connected to the DC power supply for the test. Then the multimeter was turned to DC voltage measurement, and the low lead was stuck in the ground DC power connection as seen below in Figure 27. Then the high voltage lead was used to probe each of the Arduino inputs, as well as the battery connections and the wire harness connections. This showed that the up/down switch was floating when either of the terminals were not connected. A resistor was put in series with ground on each of the terminals. Then the test was redone and every circuit had the voltage we expected and it stayed the same even when the tool was changed between auto and manual and between up and down. Figure 27: Powered Voltage Test The final test was then the functionality test of the tool. The arduino was placed in the circuit and then the tool was tested on all three of the doors that were available. The test procedure was that each door would be raised and lowered three times in succession, and each door was tested at least once with battery power and once with the DC power supply. The test went perfectly as expected as the tool sent the proper signals and the door went up and down as expected. The only problem was the MDX right rear door catches when moving down but that happened to the tool and the proof of concept. 4.3 Final Design Risk Analysis 4.3.1 Evaluation of Future Risks As with any engineering design, there are many risks involved. These risks must be considered heavily to ensure the longevity of the tool and profit in its investment, as well as the safety of the users.

Window Function Tool Team Design Guide 48 There were several different avenues for failure in the design and build in the tool. One potential source of failure for the tool is that the components in the internals may become loosened over time. An example of this is during the plugging and unplugging of a micro-USB cable into the Arduino DUE unit inside the tool, a shear force will be exerted onto the circuit board over time and may cause the glue holding the circuit board to the box to loosen over time. Throughout enough plugging and unplugging cycles of a micro-USB cable, the circuit board will inevitably come loose. This potential problem conflicts with one of the team’s major objectives, making the tool durable. This is a low risk failure however, because in the event that the arduino does free from the glue, the lid may be removed and the arduino can be anchored again with glue. Another risk that arose during the prototyping phase of the tool was the risk of components being short-circuited. This was potentially dangerous since the Arduino DUE microprocessor fried as soon as the Makita battery was connected to the tool. This could have occurred in one of three possible ways: 1.) the metal interior of the original box used to house the tool making contact with the Arduino DUE unit, or 2.) wires inside the box making contact with other metal surfaces, 3.) A floating ground existed, where there was extra voltage being delivered to the Arduino from the battery. 4.3.2 Risk Mitigation The team took several countermeasures to mitigate the tool’s various avenues of risk. In order to increase its durability, Gorilla Glue was used to hold components in place. This prevents pieces from coming loose during regular use of the tool. The team resolved the issue of the Arduino DUE microchip frying by adding two 19k ohm resistors to the wires connecting the switch, since it was determined using a multimeter that this was the location of the voltage excess. Adding the resistors limited the voltage and hence significantly reduced the risk of the Arduino DUE microchip frying again. The team further tested to make sure the battery was safe to connect to the Arduino due, by leaving it plugged in place for a long time. Another way to ensure that no electricity is conducted outside of the circuit was by changing out the metal box to a plastic box. Another severe risk was identified in the powering of the tool. To meet the user’s needs, this tool can be powered using a Makita CXT 12 V battery or through banana jacks using a DC power supply. This poses a significant risk because the battery connector is exposed on the exterior of the tool and will carry the same voltage when supplied by a DC power supply. The exposure of these connectors was identified as a serious safety risk and risk to the longevity of the tool. To reduce this risk, a cover was 3D printed to slide over these connectors when the battery is not in use. This will protect the tool and the user when using the tool in the power supply mode.

Window Function Tool Team Design Guide 49 Figure 27: Makita Battery Connector Cover 4.4 Future Impact 4.4.1 Environmental Impact With the anticipated longevity of use of the window function tool, the environmental impact of the tool must be considered. This includes the build, maintenance, and use of the tool. While considering the build of the tool, the biggest environmental impact came from shipping materials and power usage of the tool required to build it. To mitigate the shipping required, orders were placed in larger quantities or more parts in order to reduce the number of shipments delivered. To reduce the power usage in building the tool, smaller handheld tools were used with negligible power requirements. The team also ordered and used materials sparingly to minimize waste as many of the materials used are metal and plastic which are not biodegradable. Maintenance of the tool will also not have any significant environmental impact. Should the tool break, fixing the tool will require retightening of nuts and potentially glue which is readily available at Honda. The environmental impact in using the tool is also negligible as the tool is powered by a 12 V rechargeable battery or DC power supply and runs very efficiently using these power supplies. 4.4.2 Economic Impact As outlined in section 1.3.2 this tool has the potential to be a very worthy investment for Honda. In analyzing the budget and current costs for the project, the savings potential in reducing the cost of quality far exceeds the money spent to build the tool. One user need that was addressed

Window Function Tool Team Design Guide 50 throughout the build of the tool was reprogrammability. This ensures that the tool will remain useful through many series productions as the signal for each car can be different but the tool can be reprogrammed to accommodate this. The need for this tool spans across the entire automotive market, although there are not many aspects of the tool that are proprietary. Further design might be needed to ensure all components of the tool are proprietary if this device is to be patented and sold. 4.4.3 Global and Societal Impact This tool has the potential to create a global impact if its design proves to be successful in the Honda of America Manufacturing facility. Should this design prove the concept of significant cost savings, its usage could be spread throughout America and Globally. As a result, Honda as a company can invest these savings into further research to improve future automotive development. Globally this will impact consumers who are able to receive higher quality automobiles at a more efficient price. With Honda being a global leader in manufacturing quality automobiles, their cost and quality affects the automotive market as a whole. This means that the impact of a tool with the power to solve one issue could have exponentiated effects due to the position of Honda in the automotive market. 4.5 Final Budget Analysis We have made a total of 4 centralized purchases. During these four purchases, we purchased all the items we needed. We have selected a total of 8 different payees to ensure that we can get the materials we need on time; McMaster Carr and Digikey are our favorite payees; we have submitted three purchase applications to them each. They usually have a more comprehensive inventory and Faster mail service. The following are the main items and prices we purchased. 4.5.1 First purchase Time: 2/3/2022 Cost: $578.03 Payee: Partwarehouse, Mouser Electronics, McMaster Carr, DigiKey

Window Function Tool Team Design Guide 51 Table 12: Cost for the First Purchase 4.5.2 Second purchase Time: 2/22/2022 Cost: $59.63 Payee: Envistiamall, DigiKey Table 13: Cost for the Second Purchase 4.5.3 Third purchase Time: 3/7/2022 Cost: $30.48 Payee: Homedepot, McMaster Carr, Arrow Table 14: Cost for the Third Purchase 4.5.4 Fourth purchase Time: 3/22/2022 Cost: $163 Payee: SteinAir, Digi-Key, McMaster

Window Function Tool Team Design Guide 52 Table 15: Cost for the Fourth Purchase The total cost of the tool is similar to what is seen in Table 8: $822.26. During the design process, the team found that there were additional parts needed that had not been originally considered, such as extra boxes and switches, etc., which cost some additional money. Honda Manufacturing of America provided the team with many of the important components needed to build the harnesses for the tool, saving a significant portion of the budget that would have otherwise been dedicated to this. 4.6 Future Work and Further Design Improvements 4.6.1 Collection of User Feedback for Further Optimization An important aspect of validation testing that was not accomplished due to logistics and time constraints is user validation testing. Many of the features implemented in the tool were designed and built using feedback from user interviews. While this data was pivotal for our design, it would have been useful to get the tool in the hands of the users and iterate the design further. An example of this might be setting the exact length of the harnesses for most convenient use. The tool has also not been subjected to extended use so durability data does not exist for the tool. If the tool can be life tested in Honda Manufacturing of America facilities, further durability measures can be taken. An example of this might be the strength of the 3D printed parts when subjected to drops. A more durable material could be formed if the need arises. 4.6.2 Design Improvements Currently Known The design of the tool was completed as efficiently as possible leaving room for some design improvements that are already known. Refer to section 4.1.4 for design recommendations discovered during prototyping. Future known work on the tool concerns durability and adaptability as these features have minimal test data. Another possible route for future work with this project involves marketability of the tool. Market research can be done to prove the demand for a product like this in the automotive market as a whole. If successful, the product can be made proprietary with custom components and more adaptable software and harnesses to be used throughout the automotive industry. 4.6.3 Firmware Future Work

Window Function Tool Team Design Guide 53 For future recommendations regarding the firmware. It is recommended using a serial sniffer (Serial Port Monitor) in order to obtain the exact signal value required. There might be an issue in the future where there would be more doors that would require 2 IDs to function maybe more. If that type of issue arises again then it is best to recreate the whole signal and test and then eliminate the signals that are not needed. There is also a future concern about adding more additional signals. There is a certain threshold where if one adds too many signals, it can cause the door to jitter. The only possible solution to this is not to put a lot of signals at once or if that is not an option, then have another tool made for specific models. Another future recommendation is to use the Arduino IDE studio for this particular Arduino board. The way the code is written, it requires the IDE studio to build it. The control registers can be modified as well if necessary. 4.7 Window Function Tool Design Conclusion Over the course of the year the team designed, documented, prototyped, and tested a functioning tool that can raise and lower the passenger and rear doors of the Honda CRV, Acura MDX and Acura RDX. This year-long process started with a defining problem, that Honda could not manipulate car windows after placing the inner lining without connecting the door to a car. Through a process of interviewing all relevant parties to the tool additional requirements were added. This led to the design of a tool that could not only do that for all current SUVs that Honda makes but also for all future ones. After an extensive design process in which all major design decisions were methodically decided upon. Then plans were made to purchase parts and develop a prototype. Several setbacks were incurred in circuitry, logic and signal generation, but through allotting extra time, and patience, solutions were created for all hurdles. 4.7.1 Completed Milestones and Project Successes The Gantt Chart seen in Table 16 outlines milestones that the team has completed, throughout the year of 2022. The team has met all goals outlined in the gantt chart throughout the engineering design and prototype phases.

Window Function Tool Team Design Guide 54 Table 16: Gantt Chart of Progress 4.7.2 Final Design Concerns and Future Considerations One concern for the tool moving forward is that no additional circuitry has been added to protect the Arduino Due. The Arduino Due has an internal voltage regulator which allows it to operate on a variable input voltage range of 8-16V and provides protection from short term voltage spikes outside of that range. Due to time and size limitations additional protection was not added in the case of a DC Power Supply exceeding 16V for a sustained amount of time, this could lead to the damaging of the Arduino. Another consideration for future use of the tool is that the tool was developed using the Arduino IDE Studio. This is the easiest way that the group has found to manipulate the code, so for best interfacing with the Arduino it is suggested that that program is used. Also the current code is a great start for adding additional functionality to the tool, as the base of the code. Anything that the MCU can do the Arduino code can do as well just add the command in series with the current raise or lower commands. However if doing this be wary of adding too many signals to the tool, as at a certain point too many commands may make the system jittery, leading to the door improperly reading the signals. These functions can be attained by placing a serial sniffer on the MCU LIN signal output. Then each specific command that the MCU produces can be read and recreated in the Arduino Code.

Window Function Tool Team Design Guide 55 The Arduino also has CAN capabilities, so if any door feature that is not produced by the MCU is desired it can be sniffed and added, it just may require additional manipulation to recreate the CAN bus architecture that hasn’t been done yet. Future work should also consider the usability of the tool. Having all three door harnesses for each car can be cumbersome, and the harnesses have limited support with only three wires connecting to the tool per harness. The wires also change the weight distribution of the tool which may make it less ergonomic.

Window Function Tool Team Design Guide 56 References 1. A. Limited, “Stock photo - plexiglas plates are installed on the car door's assembly sector of the factory on the first day of the reopening of the Toyota Motor Manufacturing after more than a month of,” Alamy , 21-Apr-2020. [Online]. Available: https://www.alamy.com/plexiglas-plates-are-installed-on-the-car-doors-assembly-sector-o f-the-factory-on-the-first-day-of-the-reopening-of-the-toyota-motor-manufacturing-after- more-than-a-month-of-inactivity-due-to-the-covid-19-pandemic-valenciennes-italy-on-ap ril-21-2020-photo-by-julie-sebadelhaabacapresscom-image388054267.html. [Accessed: 30-Sep-2021]. 2. D. Connolly, RE: Window Glass Function Tool Design Team Introduction and Meeting Proposal , 17-Sep-2021. 3. D. Connolloy, “Project Overviews,” 26-Aug-2021. 4. H. Foy, “General Motors dumps stake in Peugeot,” Subscribe to read | Financial Times , 12-Dec-2013. [Online]. Available: https://www.ft.com/content/6cad2faa-630a-11e3-886f-00144feabdc0. [Accessed: 30-Sep-2021]. 5. “Honda Global: Vision.” Honda Global. Vision . [Online]. Available: https://global.honda/about/vision.html. [Accessed: 30-Sep-2021]. 6. W. F. Tool Team, “Honda Capstone: Glass Function Tool Intro Meeting,” 14-Sep-2021.

Window Function Tool Team Design Guide 57 Appendix A: Chapter 1 Figure 1: Portable Voltage Powered Tool [2] Figure 2: Station Tethered Voltage Powered Tool [2] Figure 3: Inner Door Harness [2]

Window Function Tool Team Design Guide 58 Figure 4: Window Run-Channel [2] Figure 5: Door to Car Connecting Harness [3] Figure 6: Proof of Concept Tool [3]

Window Function Tool Team Design Guide 59 Table 1: Competitive Analysis Table [2,3,6] Name Durable Reliable Signal Operated Scalable Reprogrammable Intuitive Voltage Tool Yes Yes No Yes No Yes Proof of Concept No No Yes No No No Questions and Responses Questions for Process engineer (Parrett) 1.) What do you think of the current voltage driven window raising tool? Not Much on an opinion either way. Things I value in a new tool: slimmer design, faster cycle time, battery powered and robust. Tools get tossed around. 2.) How time sensitive is the current tool in the process? (ie. how likely compared to other processes is it to hold up the line) We include the time it takes to raise/lower the glass within our process time. With that said it doesn’t hold up anything. Obviously if we could lower the cycle time the better off we would be. 3.) Where would you ideally want the RDX window garnish checked in the production process? Where it is checked currently is fine. 4.) What do you value most in the tool, ease of use, speed of use, ergonomics, or reliability? The only thing I value in the current tool is that it functions. 5.) If you could change one thing about the tool what would you change? What is the best part of the tool that you would not want changed? The current tool we use is bulky and somewhat heavy for repetitive use. I would prefer something leaner and faster. I like that we do not have to set a coupler to it with a locking feature. We can set the coupler in place and easily pull it back out. Side note: We currently use three of these tools per side to function glass for different purposes. First tool located at the rear glass install is used to raise the glass all the way up for the next process to install a part. The second tool located at glass check is used to raise/lower glass to check function and correct glass set to run channels. Also, to lower glass to install front and rear inner sash garnishes. The third tool located at rear inner handle install is used to raise the glass after the rear inner sash garnish and sunshade

Window Function Tool Team Design Guide 60 hooks are installed. The door ECUs are not installed beforehand which forces us to use multiple couplers to function both front and rear glass. Would we be able to use the external couplers you’re proposing to use to function the glass without the ECUs installed and connected? (For this focus on when ECU is installed. If you can also make it function with internal couplers great, if not through external couplers with ICU connected is fine.) Questions for Maintenance Engineer (Kersten) 1.) What are your thoughts on the current voltage driven window raising tool? What works well with it? Tool works well. Initial cost is expensive, but maintenance is minimal. Are there any pain points? Current wired tool is reliable and maintenance is minimal but confined to the rail. Portable tool is remote and useful for applications away from the process (repair or catch-up downline). 2.) Which tools are easier to maintain/have less frequent problems, battery operated tools or cable-powered tools? Battery tools are not on tool balancers, so location is a concern. Batteries need charged and changed. 3.) What do you value most in the tool, ease of use, speed of use, ergonomics, or reliability? Not answered 4.) How reliable is the current voltage driven tool and what are some common failures experienced using this tool if there are any? Very reliable. The switch to power the coupler is the most frequent failure. 5.) If you could change one thing about the tool what would you change? What is the best part of the tool that you would not want changed? Not answered. Questions for a Line Worker (Svihl) 1.) What do you think of the current voltage driven window raising tool? What would make it easier to use? Not answered. 2.) Is the tool easy to use? Comfortable? Tool is a regular Makita power gun which is used throughout assembly, easy to use. 3.) Does repetitive use of the tool cause you any strain by the end of your shift? No. 4.) On a scale of 1 to 5 (1 being not intuitive at all, 5 being very intuitive) How intuitive is the current process to you?

Window Function Tool Team Design Guide 61 5.) Would you prefer the tool to be handheld (battery operated) or attached at a workstation by cable? Handheld. 6.) What do you value most in the tool, ease of use, speed of use, ergonomics, or reliability? Reliability, speed of use. 7.) If you could change one thing about the tool what would you change? What is the best part of the tool that you would not want changed? Worst? Worst: Tool cannot be used with the door liner installed, must hook up to internal components. Best: Tool is Makita, lightweight easy to function.

Window Function Tool Team Design Guide 62 Appendix B: Chapter 2 Table 1: CAN vs LIN Communication Matrix Table 2: Battery vs. Tethered Concept Screening

Window Function Tool Team Design Guide 63 Table 3:Drill Tool vs Plastic Box Design Matrix

Window Function Tool Team Design Guide 64 Figure 1: Arduino with Simple PCB Preliminary Circuit Layout Figure 2: Arduino with Simple PCB Preliminary Mechanical Layout

Window Function Tool Team Design Guide 65 Figure 3: Custom Design PCB Design Figure 4: Custom Design PCB Housing

Window Function Tool Team Design Guide 66 Figure 5: Linear Power Supply Module Figure 6: Custom Design PCB with Bluetooth Module

Window Function Tool Team Design Guide 67 Figure 7: Custom Design PCB with Bluetooth Housing Table 4: Design Matrix

Window Function Tool Team Design Guide 68 Appendix C: Chapter 3 Figure 8: Makita CXT Battery Figure 9: Makita Replacement Terminal

Window Function Tool Team Design Guide 69 Figure 10: Makita Battery Holder Figure 11: Female Banana Plug Connection Figure 12: Banana Plug Connection Placement

Window Function Tool Team Design Guide 70 Figure 13: Connectors and Internal Crimps Figure 14: Circuit Design Diagram

Window Function Tool Team Design Guide 71 Figure 15: Structural Design Figure 16: Structural Dimensions

Window Function Tool Team Design Guide 72 Figure 18: Application Block Diagram

Window Function Tool Team Design Guide 73 Figure 19: Example Arduino code for LIN serial communication with I/O triggers

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Window Function Tool Team Design Guide 75 Appendix D: Chapter 4 Figure 21: Prototype Multi View CAD Drawings Figure 22: Prototype Multi View 3D Model

Window Function Tool Team Design Guide 76 Figure 23: Battery Connector and Adapter Assembly Figure 24: Precision Subtractive Manufacturing Figure 25: Internal Paint Failure Analysis

Window Function Tool Team Design Guide 77 Figure 26: Arduino With Fully Soldered Ready to Use PCB Figure 27: Makita Battery Connector Cover Table 13: Cost for the First Purchase

Window Function Tool Team Design Guide 78 Table 14: Cost for the Second Purchase Table 13: Cost for the Third Purchase Table 14: Cost for the Fourth Purchase

Window Function Tool Team Design Guide 79 Appendix E: PDR

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Window Function Tool Team Design Guide 83 Appendix F: CDR

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Window Function Tool Team Design Guide 86 Appendix G: Final Design Presentation

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