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318-595 Presentation #2 –
Project TEAM 1
318-595 Project Presentation #2 – TEAM 1
Team 1: Expertise and Experience
• Mayank Gupta
- Expertise: Digital, Analog, FPGA, MATLAB
- Experience: 5 years – GE Healthcare
- Role: LPI, LMM
• Naser Aldaihani
- Expertise: Electronic, Power Systems.
- Experience: Fresh after BSEE
- Role: LMP
• Matthew Mulvey
- Expertise: Digital Design, (C,C++)
- Experience: Fresh after BSEE
- Role: LSD
• Mohammad Habeeb
- Expertise: Electronic, DSP, C++.
- Experience: Fresh after BSEE
- Role: LRM
318-595 Project Presentation #2 – TEAM 1
Team 1: Total Resources
GE Funded
Total Manhours:
- 60hrs/week (15hrs/team member)
- Meetings -Thursday (5:30-6:45PM), Saturday (9:30-11:00AM)
- 3 hrs lab on Tuesday.
GE Resources:
- 3 weeks – Layout and Schematic Design
- Fab. house for board build
CTD Thermal Manager (DTM)
Description:
The project is intended for thermal management of next generation CT system. As we all know thermal management
is a very important part of any design both from optimal functionality and reliability point of view. This document will
describe the functionality of the controller. The detector thermal controller is designed to maintain rails at a uniform
temperature, which is critical for controlling the photodiode and preventing any changes to the rail temperature
profile. Changes in the rail temperature or the temperature profile can lead to IQ errors due to poor diode
temperature control.
- PID Control
- Filter Clogging Detection
12A
- Fan failure Detection
- Error Logs for Various reasons
Advantage to the User:
- Provides capability to the
user to control multiple
devices.
- Every parameter
programmable with PIC
Microcontroller.
- Ethernet communication
with web browser based
design.
100W
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Standard Requirements (DTM)
Market
- Price: $350/ board
Power
- Input Voltage Range: 48V (+/-5%)
- Total Power: 480W
Mechanical
- Mechanical Size: 200*125*2.36mm
- Total PCB Area: 250cm2
Environmental
-Operating Temperature: 0 to 85C
- Storage Temperature: -40 to 125C
- Estimated Product Life: 10 yrs
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Performance Requirements (DTM)
Power
- Voltages: 12V (+/-5%)
5V (+/-5%) – 70mA
3.3V (+/-5%) – 65mA
Digital
- Processor: 25MHz, 16bit resolution
- Ethernet: 10MHz
- Thermistor Accuracy: +/-0.2C
- Target Temperature: 36C
Mechanical
- Mounting Holes: 8 mounting holes
- Shielding: All mounting holes connected to Chassis Ground, nothing else on board will be
connected to Chassis Ground.
Other
- 6 Sub-D Connectors
- 2 RJ-45 Connectors
- 2 LED – Performance Monitoring
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Business Case
Category
Price
Comment
NRE Charges
$15,000
Fab. + Components
PWB (Fab.) Charge
$50/ Board
Production Price
BOM Price
$240/ Board
Production Price
PWA Price (Finished Board)
$350/ Board
Production Price
Category
Price
Comments
Market Quantity
1000 Demand in the Market
Production Cost
$350.00 Product Price for making the controller
Total Production Cost $350,000.00 Total Production cost for 1000 systems
Total Man hours spent in the design with
Manhours
$115,200.00 $150.00/hr, 64hrs/week, 12 weeks
Market Price
$490.00 Market price with mark-up of 40%
Total Sales
$490,000.00 Total sales for 1000 systems
Profit
Total Profit/ first year
$140,000.00 Total profit reducing production price from sales
Amount gained during 1st year after subtracting
$24,800.00 man-hours efforts
- At 40% mark-up,
it will take 10
months to make
any profits.
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Patents
6,997,609: System and method for cooling an x-ray tube in a tomography computer
system: February 14, 2006
• This patent claims a very specific physical arrangement of the fans and coolant
components being used. Our project does not use the same physical arrangement, so
does not violate this patent.
5,444,752: Tomography detector temperature equalization : August 22, 1995
• This patent claims a method for using a thermally massive heat-sink to equalize the
temperature of the detectors. Our project uses a completely different method for
temperature management (computer controlled heaters, pump and fans) so does not
violate this patent.
7,261,466: Imaging inspection apparatus with directional cooling : August 28, 2007
• This patent claims a specific arrangement of fluid deflectors for directing the cooling
fluid to the imaging devices. Our project does not use this method for directing the
cooling fluid (water), so does not violate this patent.
Ethics Issues
1) Device effect on medical diagnosis:
• This ethical issue arises because the performance of the thermal manager has a
direct impact on the accuracy of the CT detector, which in turn has a direct effect on
patient diagnosis. Accurate diagnosis is a crucial part of making medical decisions
which affect the health and well-being of the patient.
• Possible ethical conflict arises because business concerns put pressure on
Engineers to deliver a product quickly.
Mitigation- Because the health and safety of human beings is involved, proper attention
to ethics demands that everything within reason is done to test and confirm the
performance of the thermal manager, even if there is some negative impact on
business (financial) concerns.
2) Environmental Damage:
• On the national level, nearly 70 percent of a typical landfill's heavy metals come from
electronic components. Materials such as lead, cadmium, chromium, and mercury.
Mitigation - Buying components from legitimate suppliers to insure components met
with safety standards.
Main Project – Block Diagram Slide
- PID Control
- Filter Clogging Detection
12A
- Fan failure Detection
- Error Logs for Various reasons
100W
Mechanical Size: 200*125*2.36mm
Mounting Holes: 8 mounting holes
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Shielding: All mounting holes connected to Chassis Ground, nothing else on board will be connected
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4/30/2017
Project 1: CTD Thermal Manager (DTM)
Key Performances and Interfaces:
- DTM will use multiple controls like pump, thermistors, heaters and do performance prediction.
- Its will incorporate ethernet based communication.
- The controller will be used in next generation CT system design and will have following
interface and power characteristics:
- The design will use Ethernet communication with the PC based system
- The controller will control Pump, Thermistors, Fans and Heaters
- Total power ratings for the controller will be 48V, 10A
- Design will incorporate a Microcontroller as the main controlling unit of all other
interfaces.
Good for the team:
- The project requires good experience with Digital design, some knowledge of power and
analog aspect of the design and good programming skills. The team all together has all the
skills needed to make this project a success.
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Min Block Diagram Description
Block
#
Block Name
Owner
1
Power
management
and
Processor
Mayank
2
Thermistor
and pressure
circuits
3
4
Brief Description Of
Block Function
Power
Interface
Digital
Interfaces
Analog
Interface
Use 48V DC source and
provide multiple volatges
to different sections of
design, also work on
processor to Ethernet
interface.
48V, 20A
Power Supply
Microcontroller,
Ethernet
None
Naser
Monitoring the
temperatures and velocity
sensors and interface to
the processor.
5V from Block
1
Microcontroller
None
Heater and
SSR circuits
Matt
SSR control will be
providing control signal to
1KW heater controlled by
SSR, assist in Ethernet
interface.
48V, 12V
Power from
Block 1
Microcontroller
None
Fan and
Pump control
Mohammad
Control the speed of the
pump and fan. Provide
power to 150 W pump
and design there interface
to processor
48V, 12V, 5V
Power from
Block 1
Microcontroller
None
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Electric Shock
Mitigation Design/Devices/Materials/Packaging
−
Proper wiring and wire are used.
− Proper power cord is used.
− All cables and leads at 48V should be sheilded with insulation.
Affected Blocks
−
Blocks 1,2 (All blocks have 48V components)
Test(s) Required to Verify Protection
•
•
Check wire requirements.
Check grounding requirements for systems, circuits, and equipment.
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Fire, Explosion or Shattering
Mitigation Design/Devices/Materials/Packaging
•
•
Proper wiring and wire are used.
No overload wiring circuits.
Affected Blocks
•
Block 1
Test(s) Required to Verify Protection
•
•
•
Check wire requirements.
Check grounding requirements for systems, circuits, and equipment.
61000-3-3 EMC Part 3: Limits - Section 3: Limitation of voltage fluctuations
and flicker in low-voltage supplies <16A
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Electro-Static Discharge
Mitigation Design/Devices/Materials/Packaging
• Shunts or diodes to protect against large voltages.
• Choosing components rated for at least 2.5KV
Affected Blocks
• All blocks with connector interface.
Test(s) Required to Verify Protection
• Test with ESD gun.
• 61000-4-2 EMC Part 4: Test/measurement techniques - Section 2: ESD immunity
tests
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Magnetic Field Energy
Mitigation Design/Devices/Materials/Packaging
• Careful layout for making sure no sensitive signals passing in close vicinity
of inductors.
Affected Blocks
• Block 1,3
Test(s) Required to Verify Protection
• Susceptibility Tests - Stress levels are well defined and a strategy is
employed to gauge and classify the immunity response level of the product
to find the highest stress sensitivities
• 61000-4-8 EMC Part 4: Test/measurement techniques - Section 8: Power
frequency magnetic field immunity tests
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Interference with Other Electronic Systems
Mitigation Design/Devices/Materials/Packaging
• Insulate all the wire to reduce interference.
• Make sure no loops are made.
Affected Blocks
• All the blocks
Test(s) Required to Verify Protection
−
Check all the wires and insulate them
−
IEC: 61000-4-5 EMC : Surge immunity tests
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Power management and Processor
Description:
48V DC Power Supply:

48VDC +/- 10%.

Supply ripple within 2.0 volts peak at 10Hz to 25KHz.

Power traces must be sized to handle 20A minimum current.
Purpose:
Use 48V DC source and provide multiple voltages to different sections of design,
also work on processor to Ethernet interface.
Power management and Processor
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Power management and Processor
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Thermistor, Velocity Sensor, Pressure Sensor
Purpose:
Monitor the performance of 5 Thermistors, 1 Velocity Sensor and 2 Pressure Sensors.
Performance Requirements:
Standard Requirements
Description:
Market
- 5 Thermistors:
- Price: $20/ board
•
Voltage: 5V, 1mA.
Power
•
Accuracy (+/-0.2C at 36C)
- Input Voltage Range: 12V (+/-5%), 50mA
- Input Voltage Range: 5V (+/-5%), 2mA
- 1 Velocity Sensor:
•
Voltage: 5V, 1mA.
- 2 Pressure Sensor:
Mechanical
- Mechanical Size: 30*25*2.36mm
Environmental
•
Voltage: 12V, 25mA.
-Operating Temperature: 0 to 85C
•
0-500PSI
- Storage Temperature: -40 to 125C
- Estimated Product Life: 10 yrs
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Thermistor, Velocity Sensor, Pressure Sensor
Thermistor + Velocity
Sensor
Pressure Sensor
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Thermistor, Velocity Sensor, Pressure Sensor
-Simulation shows 2 plots:
- First Thermistor with 1K
Thermistor resistance.
Current always below 1mA
- Second shows Pressure
Sensor with 50Ohm
resistance. Currant always
below 25mA
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Fan and Pump control Requirements
Purpose:
Control the speed of the pump and fan and interface to processor.
Performance Requirements:
Standard Requirements
Description:
Market
- 2 DC-DC Fans:
- Price: $40/ board
•
Voltage: 48V, 4A.
Power
•
Control voltage: 0-10V,
- Input Voltage Range: 48V (+/-5%), 8A
0.4mA/ Fan
- Input Voltage Range: 12V (+/-5%), 10mA
- 1 Pump:
- Input Voltage Range: 5V (+/-5%), 5mA
•
Voltage: 48V, 4A.
Mechanical
•
Control voltage: 0-10V,
- Mechanical Size: 30*20*2.36mm
0.4mA/ Fan
Environmental
-Operating Temperature: 0 to 85C
- Storage Temperature: -40 to 125C
- Estimated Product Life: 10 yrs
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Fan and Pump Circuit (Circuit concept and component choice by Mayank)
Fan and Pump Circuit
Fan and Pump Input Voltage
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SSR Heater Control
Purpose:
Provide On/Off capability to the SSR to control externally a 1KW heater.
Performance Requirements:
Standard Requirements
Description:
Market
- SSR:
- Price: $25/ board
•
Voltage: 12V, 30mA max.
Power
- Input Voltage Range: 12V (+/-5%), 30mA
- Input Voltage Range: 5V (+/-5%), 10mA
Mechanical
- Mechanical Size: 25*20*2.36mm
Environmental
-Operating Temperature: 0 to 85C
- Storage Temperature: -40 to 125C
- Estimated Product Life: 10 yrs
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SSR Heater Control
The device used in AQV214, PhotoMOS (Tried running simulation, but
couldn’t due to unavailability of the device in P-Spice library)
If = 5mA
Iout = 30mA
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Ethernet
Ethernet: network topology that defines physical connection standards and signal
transmission standards, so we don’t have to.
Devices with Ethernet capable
Microcontrollers (PIC18F97J60)
Already exists in
many buildings
PC
Thermal manager
PIC18
Other device
PIC18
Other device
PIC18
Ethernet
Network
PC
File
server
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Advantages of using an Ethernet - TCP/IP interface between
the Thermal manager and the PC:
• Ethernet and TCP/IP networks are everywhere.
• Well established interfacing standards free the developer from the details of the
Ethernet and TCP/IP guts, freeing up time for other aspects of the project.
• No configuration of the PC is necessary. Any PC already has:
• Ethernet connection and TCP/IP software installed
• Web-browser
• User interface is generated and controlled by microcontroller
Thermal manager
PIC18
PC with
browser
Ethernet – TCP/IP
connection
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We need the PC and the Microcontroller to communicate over the Ethernet
network: Enter TCP/IP
• TCP/IP is one network protocol that can run on Ethernet.
• It defines the addressing and communication standards.
• It is everywhere, (the internet is based on TCP/IP)
• Allows communication between familiar internet building blocks like web servers and web
browsers.
Web server
Web client
(PC with browser)
Fire Fox
Web
Web
Web
page
page
page
xyz
xyz
xyz
Web
page
xyz
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Thermal Manager (PCB)
PIC18
Microcontroller
Serial Pins
Developers PC
Compiler and
TCP/IP stack source code
PIC18 Memory
Web
Web
Web
page
page
page
xyz
xyz
xyz
Main
Program
TCP/IP
services
C++
Web
Web
Code
page
page
xyz
xyz
Web
Web
Web
page
page
page
xyz
xyz
xyz
Web
Server
Users PC
Web Browser
Pins
Circuits for Fan,
heater, etc.
Ethernet Pins
Ethernet Jack
Web
page
xyz
TCP/IP services
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Browser-based user interface for Thermal manager:
Thermal Manager Status
Control Options:
Board power: normal
Rail temp setpoint
PIC18 operation: normal
Fan:
Rail temp: ???
• Auto control
Fan speed: ???
Heater power output: ???
Pump output: ???
• Manual control
123
456
Heater:
• Auto control
• Manual control
Enter
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