Mailert

(Mail Alerting Mailbox System)

Belton Honea-Path & Powdersville High School
Engineering Design & Development Class
Anderson Career & Technology Center
April 25, 2014

Seth Major & Justin Cusmano






Mailert
(Mail Alerting Mailbox System)



Seth Major & Justin Cusmano
Belton Honea-Path & Powdersville High School
Engineering Design & Development Class
Anderson Career & Technology Center
April 25, 2014


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Abstract

Based on a logical survey, we had found that only 30% of all participants knew for certain wither
or not they had mail in their mailbox. The group feels that in this day and age, that is too low of a
figure to be acceptable and have come up with a sufficient and simple system to notify anyone
that there is indeed mail in their mailbox. In this way anyone and everyone will be able to know
whether or not they have mail in their mailbox.
The Group discovered that other mailbox systems can have miss-readings. For example, In a
motion sensor mailbox system, the motion sensor is attached to the door. So when the door is
open, then the sensor goes off, and you are alerted. However, a child can open the mailbox, or
high wind can open the mailbox door. Thus, you can have miss-readings. With the Mailert,
there will always be something in your mailbox. Through research and prototype development,
the Mailert system is a justifiable solution to the problem.









Table of Contents
Abstract...i
1.0 Summary..1
1.1 The Problem......1
1.2 Method of Investigation1
1.3 Conclusion1
1.4 Recommendations.2
2.0 Introduction..3
2.1 Subject.......3
2.2 Purpose..3
2.3 Scope.3
3.0 Methods, and Procedures......4
3.1 Methods.....4
3.2 Procedures..4-5
4.0 Results and Discussion......6
5.0 Conclusion....7
6.0 References.8
7.0 Appendices9

1

1.0 Summary
1.1 The Problem
Upon research of other mail alerting systems we found that the motion and light sensor will
activate and trip the alerting mechanism whenever the device opened; whether there is mail
being placed in the mailbox or not. A redesign of the mail alerting system was conducted to
solve this problem.

1.2 Method of Investigation
The group searched the internet for different types of mail alerting systems, and the group also
viewed videos on how these systems worked. Upon viewing these as well as conducting research
the group found all possible errors that could realistically occur when used with each, including
our own system.

1.3 Conclusion
Problems in the two mail alerting systems the group found were both the same. They both had
problems with saying there is mail when there really wasnt. The reason for these problems was
because of the sensors they used. The light sensor would go off whenever the door was open and
light was let inside into the light sensor, which is every time the door is open even when mail
isnt being placed inside. The motion sensor goes off when it detects the door moving (the door
being opened.) This causes the same problem and goes off every time its opened and not only
when mail is being placed within your mailbox.

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1.4 Recommendations
The mail alerting system has been redesigned to only go off when mail is actually sitting in the
mailbox. Opening and closing of the mailbox door will not affect the alerting mechanism at all.
This change was made by using a weight sensor to detect the weight of mail even down to .001
grams instead of a light or motion sensor, that depended solely on the door opening and closing.




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2.0 Introduction

2.1 Subject
A new, simple, and effective mail notifying system that would make life a little easier and make
sure that everyone knows whether or not they have mail. It is also about how the Mailert is
simpler, and much more reliable than other mail alerting systems. The Mailert focuses on the
actual mail, instead of the mailbox itself, which appeals to many consumers.
2.2 Purpose
After research and gathering data from surveys, the group realized that only 30% of people know
for sure whether or not they have mail in their mailbox. The group feels that this is unacceptable
in our day and age. The group decided to make the Mailert, which the group found to be more
reliable, and more effective than other mail alerting systems. This report is a summary of the
groups findings, data, research, and results.
2.3 Scope
This report provides technical information on the results of the groups research, testing, and a
summary of all the information they have collected. This report also analyses the problems
involving other mailbox alerting systems, as well as the problems the group encountered whilst
creating our prototype. In this report there are also the testing results and the groups data. Not
included in this report are the costs of mass producing this system, future plans for this product,
and the costs for any modifications on this product.

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3.0 Methods, and Procedures
3.1 Methods
A visual analysis of the product along with a bit of research was conducted and resulted
in the discovery of a sensory problem that would render the alerts from the system
invalid. The picture you see in figure 1 is the MAIL CHIME by Hanna Products Inc. the
developers and marketers of this product. This product relies on motion for the alert and
can be purchased from a number of websites for around $45-$50.
The product was digitally examined and documented in my groups engineering
notebooks. Sketches were also documented to have a visual representation of the
product. There is also another system that relies on a light sensor for alerting you that
there is mail within your mailbox. From these systems the group could easily spot the
same flaw coexisting within both of them. The group got to work designing an innovation
of this product while trying to avoid making the same flaw.
The group acquired the parts needed for the system they were creating and measured all
the parts with a dial caliper to the nearest .001 inch and reconstructed the dimensions in
Autodesk Inventor.
3.2 Procedures
1. Purchase and receive an Etekcity kitchen weight scale, SVAT wireless remote
control power outlet, and LED flexible light strip with power supply and remote
2. Acquire a mailbox, breadboard, sheet of plexiglass
3. Plug up the receiver from the SVAT wireless outlet power supply into a standard
power outle

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4. Place the provided 12V battery into the back of the wireless SVAT remote
5. Plug any device you have access to into the SVAT wireless outlet power supply
6. Test the remote by clicking the on button on the SVAT wireless remote, then
check to see if the device plugged into the SVAT outlet power supply is turned on
or will turn on
7. Now turn click off on the SVAT wireless remote and check to see if the device
plugged into the SVAT outlet power supply has turned off
8. Plug the 4 prong connector from the LED light strip into the IR CONTROLLER
9. Plug the IR CONTROLLER into the AC/DC adapter
10. Plug the AC/DC adapter into a standard wall outlet
11. Use the 44 button remote provided with the LED light strip and test out the LEDs
on the strip by clicking through the different colored buttons on the remote
12. Measure the inside of the mailbox using a ruler/dial caliper
13. Get out the plexiglass and cut it to fit snuggly inside the mailbox
14. Take out the weight sensor and make sure it is working correctly
15. Find the screws by prying the edges of the kitchen weight
16. Use a drill to get access to the screws then use a screwdriver to screw them out
17. Now that you have access to those wires get out the wireless SVAT remote
18. Take the small screw out the back of the remote, then remove the cover holding
the battery
19. Take the battery out then pry the edges of the plastic casing until you get it
completely off revealing the circuit board

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4.0 Results and Discussion

In the groups research, they found that there are still problems with our mail. Out of 20 surveys,
only 30% knew that they had mail in their mailbox, for sure. In addition, only 20% have never
had late mail due to knowing whether or not they had mail in their mailbox. The group does not
believe that those are acceptable statistics, and while 70% check their mailbox daily, the mailbox
problem is not yet solved.
In the groups testing, they found that the wireless system they used as absolutely perfect, as it
reached a large distance and through many obstacles, and was always successful. After hitting
their goal of 50ft, they decided to go see just how far they could go. They went 160ft, over 3
times the distance, with 2 walls and 2 doors as obstacles. The wireless system was still
successful.
The accuracy of these results may not be exact: The group believes that these are the ideal results
from their survey, and are subject to human error from both the group, and the applicants. Also,
The Distance of the wireless system is still somewhat untested. The group had wished to
determine just how far the system could reach, but couldnt due to time constraints.



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5.0 Conclusion
Due to time constraints, the group was unable to finish prototyping and wiring the Weight Sensor
to the Wireless Sender. The group found that there was limited mobility while inside the weight
sensor and that the scale could be affected, as they experienced when they tried to take the
coverings off the sensor. In order to wire together the Sensor and the Wireless sender, the group
would have to unsolder the On button from the motherboard of the Sender. If they were to
make a mistake, it could seriously jeopardize their system, as they would have had no way of
turning on their Receiver, which in turn means that the prototype would have failed. They
decided not to risk jeopardizing their product due to time constraints, and thus they were unable
to complete their prototype and properly test it.
In Their findings, they saw that 70% of people check their mailboxes daily. (See Fig. 3). They
believe that while the mail system is becoming obsolete, it is still important in that 80% of
people in their findings still had the possibility of late mail simply due to not checking their
mailbox, or not knowing there was mail in the mailbox. They believe that this is still important,
and that their system would have truly helped in this aspect.
The Group thinks that if it had more time, and or at least more professional help, they would
have been at least able to complete their prototype system. While they think that they would have
been able to achieve more if they hadnt been dealt with the situation they were in, regarding the
wiring of their Sensor and Sender.



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6.0 References
SVAT WRC101 Wireless Remote Control Power Outlet . (n.d.). . Retrieved May 9, 2014, from
http://www.amazon.com/SVAT-WRC101-Wireless-Control-
Outdoor/dp/B000HAVVKG/ref=sr_1_2?ie=UTF8&qid=1394476154&sr=8-
2&keywords=wireless+power+switch
Mail Chime. (n.d.). . Retrieved May 9, 2014, from http://www.amazon.com/Mail-Chime-Wireless-Alert-
System/dp/B00103FDDU
Hanna Products MAIL-1200 Wireless Mail Chime Alert System. (n.d.). Retrieved May 9, 2014, from
http://www.smarthome.com/74661/Hanna-Products-MAIL-1200-Wireless-Mail-Chime-Alert-
System/p.aspx
measuring weight via USB with electronic kitchen scales and the Arduino. (2012, April 19). Retrieved
May 9, 2014, from http://sciencestuff.xperiment.mobi/2012/04/19/measuring-weight-via-usb-with-
electronic-kitchen-scales-and-the-arduino/
Smarthome SELECT Wireless Mailbox Reminder and Mail Alert System. (n.d.). Retrieved May 9, 2014,
from http://www.smarthome.com/74771/Smarthome-SELECT-Wireless-Mailbox-Reminder-and-Mail-
Alert-System/p.aspx
Mailbox Phone Alert. (n.d.). Instructables.com. Retrieved May 9, 2014, from
http://www.instructables.com/id/Mailbox-Phone-Alert/
STI-34200 Wireless Mailbox Alert. (n.d.). STI-34200 Wireless Mailbox Alert. Retrieved May 9, 2014, from
http://www.sti-usa.com/Products/Wireless-Mailbox-Alert-STI-34200.htm
Etekcity 0.05oz High Accuracy 11lb. (n.d.). Retrieved May 9, 2014, from
http://www.amazon.com/Etekcity%C2%AE-Accuracy-Multifunction-precision-
functions/dp/B00F3J9GI0/ref=sr_1_2?ie=UTF8&qid=1395332990&sr=8-
2&keywords=postal+weight+scale
LEDwholesalers 16.4ft RGB Color Changing Kit. (n.d.). Retrieved May 9, 2014, from
http://www.amazon.com/LEDwholesalers-Controller-2034RGB-3315-
3215/dp/B0040FJ27S/ref=sr_1_1?ie=UTF8&qid=1395335372&sr=8-
1&keywords=ledwholesalers+16.4ft+rgb+color+changing+kit+with+led+flexible+strip



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7.0 Appendices
Bill of Materials
Item QTY Part # Vendor Cost
Mailbox 1 1 Teacher Free (Teacher Acquired)
Sheet 1 2 Teacher Free (Teacher Acquired)
Wireless Sender 1 3 Amazon.com $20
Wireless Receiver 1 4 Amazon.com (Came with Wireless Sender)
Weight Sensor 1 5 Amazon.com $11
Lights 1 6 Amazon.com $32





30%
50%
5%
15%
How sure are you in that you have postal
mail in your mailbox? Out of 20 Surveys=
Always
Most of the time
Maybe
No Idea

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70%
30%
0% 0%
How often do you check your mailbox? Out
of 20 Surveys=
Daily(Once a Day)
Only on Mail Day(s)
Every Few Hours
Rarely
5%
20%
0%
65%
10%
How often do you see your postal mail get
delivered? Out of 20 Surveys =
Every Time
Sometimes
50/50
Rarely
Never

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20%
50%
30%
0% 0%
How often do you have late postal mail due
to not knowing you had mail? Out of 20
surveys=
Never
Rarely
Sometimes
Often
Always
65%
20%
10%
0%
5%
How much would you be willing to pay for a
mailbox sensor that could tell you whenever
you had postal mail? Out of 20 Surveys=
$5-10
$11-15
$16-20
$21-25
$26-30

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Gantt Chart

13

Light Bulb

Mailbox


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Plexiglass

SVAT Receiver


15

SVAT Wireless Remote


Kitchen Weight Scale

16

Exploded Assembly

17

Decision Matrix

18


19


20


21


22


23


24


25


26


27


28



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