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Transcript
318-595 Presentation #3 – Project
TEAM 1
Detector Thermal Manager
318-595 Project Presentation #3 – 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 #3 – 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
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
4/
Shielding: All mounting holes connected to Chassis Ground, nothing else on board will be connected
GE Title or job number /
to Chassis Ground.
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.
5/
GE Title or job number /
4/30/2017
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
6/
GE Title or job number /
4/30/2017
Performance Requirements (DTM)
Power
- Voltages: 12V (+/-5%) – 30mA
5V (+/-5%) – 70mA
3.3V (+/-5%) – 300mA
Digital
- Processor: 25MHz, 16bit resolution
- Ethernet: 10MHz
- Thermistor Accuracy: +/-0.2C (YSI44006)
- Velocity Sensor: 5-200fpm (AssuSense F900)
- Pressure Sensor: 0-500psi (+/-3% variation) (EMB 450-75-0010)
- 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
7/
GE Title or job number /
4/30/2017
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.
8/
GE Title or job number /
4/30/2017
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.
Most of the Patents GE patents – Patents selected on this
page are not GE patents
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.
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.
11 /
GE Title or job number /
4/30/2017
Fire, Explosion or Shattering
Mitigation Design/Devices/Materials/Packaging
•
•
•
Fuse
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
12 /
GE Title or job number /
4/30/2017
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
13 /
GE Title or job number /
4/30/2017
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
14 /
GE Title or job number /
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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
15 /
GE Title or job number /
4/30/2017
Main Block Diagram Description for DTM
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 voltages
to different sections of
design, also work on
processor to Ethernet
interface.
48V, 10A
Power Supply
Microcontroller,
Ethernet
None
Naser
Monitoring the
temperatures and velocity
sensors and interface to
the processor.
5V from Block
1
Microcontroller
Thermistor,
Velocity
Sensor Input
to the board.
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,
Tach
None
16 /
GE Title or job number /
4/30/2017
DTM - Interference
Input Power
PIC18
Programming
48V, 10A
Thermal Manager (PCB)
PIC18
Microcontroller
Power
Serial Pins
PIC18 Memory
Web
Web
Web
page
page
page
xyz
xyz
xyz
Ethernet IP
Configuration
Main
Program
Pins
TCP/IP
services
Web
Server
Ethernet Pins
Circuits for Fan,
heater, etc.
Ethernet Jack
Pump, 48V, 4A
PC with
browser
Current
Out
Current
In
Power
Tach
SSR
5 Thermistor
1 Velocity Sensor
2 Pressure Sensor
SSR
Heater
Control
2 Fans, 48V 2A
each
17 /
GE Title or job number /
4/30/2017
DTM – Overall Layout (6 Layer Board)
18 /
GE Title or job number /
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Power management and Processor
Input Power
48V, 10A
48V Filtering
12V, 30mA
5V, 70mA
3.3V, 300mA
PIC18F97J60
Power to
other
blocks
256KB EEPROM
To and From
Other Blocks
19 /
GE Title or job number /
4/30/2017
Power management and Processor
Purpose:
Use 48V DC source and provide multiple voltages to different sections of design, also work on
processor to Ethernet interface.
Performance Requirements:
Standard Requirements
Description:
Market
-
- Price: $160/ board
Input Voltage Range: 12V (+/-5%),
30mA
-
Input Voltage Range: 5V (+/-5%),
70mA
-
Input Voltage Range: 3.3V (+/-5%),
300mA
-
10bits precision of A/D Converter
Power
- Input Voltage Range: 48V (+/-5%), 8A
- Input Voltage Range: 12V (+/-5%), 30mA
- Input Voltage Range: 5V (+/-5%), 70mA
- Input Voltage Range: 3.3V (+/-5%), 300mA
Mechanical
- Mechanical Size: 120*70*2.36mm
Environmental
-Operating Temperature: 0 to 85C
- Storage Temperature: -40 to 125C
- Estimated Product Life: 10 yrs
20 /
GE Title or job number /
4/30/2017
Power management and Processor - Power
Power Consumption
- 48V (=/-5%) – 8A
-12V (+/-5%) – 30mA
- 5V (+/-5%) – 70mA
- 3.3V (+/-5%) –
300mA
21 /
GE Title or job number /
4/30/2017
Power management and Processor - Connectors
7 Connectors Used:
1: Power
2: Ethernet
3: IP Configuration
4: PIC18 programming
5: Fan Connector
6: Thermistor Connector
7: SSR + Pressure Sensor Control
8: Pump Connector
22 /
GE Title or job number /
4/30/2017
Power management and Processor Microprocessor
- Inbuilt MAC and PHY
layer for Ethernet.
- Max Frequency:
42MHz
- 10bit, 16 channel A/D
Modules
- Supply Voltage 2-3.6V
- 5 register banks for
digital, analog, input,
output, and I/o
interfaces.
23 /
GE Title or job number /
4/30/2017
Power management and Processor Microprocessor
Top Layer of 6 layer board
24 /
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Thermistor, Velocity Sensor, Pressure Sensor
5
Thermastor
Output to
micro controller
Velocity
Sensor
Pressure
Sensors
Input Selector
25 /
GE Title or job number /
4/30/2017
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
- 1 Velocity Sensor:
- Input Voltage Range: 5V (+/-5%), 2mA
•
Voltage: 5V, 1mA.
Mechanical
•
flow ranges between 0.15-10
m/s (30-2000 fpm)
•
- Mechanical Size: 30*25*2.36mm
Environmental
-Operating Temperature: 0 to 85C
Accuracy ±0.05 m/s (10 fpm)
- 2 Pressure Sensor:
•
Voltage: 12V, 25mA.
•
0-500PSI
•
Accuracy: +/-2%
- Storage Temperature: -40 to 125C
- Estimated Product Life: 10 yrs
26 /
GE Title or job number /
4/30/2017
Thermistor, Velocity Sensor, Pressure Sensor
Thermistor and
Velocity Sensor
Pressure Sensor
27 /
GE Title or job number /
4/30/2017
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 20mA
28 /
GE Title or job number /
4/30/2017
Thermistor, Velocity Sensor, Pressure Sensor
29 /
GE Title or job number /
4/30/2017
Fan and Pump control Requirements-Block Diagram
breakdown
12V, 20mA max
48V, 8A
48V, 2A,
2 Fans
Tach
Control
Fan and Pump Block
Fans
5V, 20mA
max
48V, 4A
Pump
Control
Pump
Tach
This block controls the fan and pump speed, using digital tach control feedback,
and two voltages, 48V and 0-10V, one to power the fan/pump and the other to
control the speed.
30 /
GE Title or job number /
4/30/2017
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
31 /
GE Title or job number /
4/30/2017
Fan and Pump Circuit (Circuit concept and component choice by Mayank)
Part Number
ADR293
LM2904
AD5314
Fuse1
Fuse2
J3
J7
Quantity
Discription
1 5V Precision Voltage Reference
2
1
2
1
1
1
Low Power Dual Op-Amp
DAC
125V, 3A Slow Blow
250V, 5A, Slow Blow
747845 (Amp)
747844 (Amp)
Power
Package
0.25 TSSOP
0.1 SOP
0.2 MSOP
0.6
0.6
Comments
5V, 15uA (max input), 5mA (max output)
Single Supply, 0.25mA(max/ channel), Inout
Offset 2mV max
10bit resolution, +/-2 bit Accuracy
15pin Sub-D, Amp
9pin Sub-D, Amp
32 /
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Fan and Pump Circuit
- DAC:
- Resolution: 10bits
- Accuracy: +/-0.5LSB
- Bit Resolution: 5/2^10 = 5mV
- Om-Amp:
- Single Supply: 3-32V
- Offset Voltage: 2mV
- DC Voltage Gain: 100dB
- Voltage Reference:
- Initial Accuracy: +/-0.3%
- Output Voltage: 5V
- Supply Current: 15uA
33 /
GE Title or job number /
4/30/2017
Fan and Pump Circuit
34 /
GE Title or job number /
4/30/2017
SSR Heater Control
12V
Digital
outputs
from
PIC18
+
-
SSR
+
-
- Both pairs of digital inputs must be turned on.
- In on state, input of SSR is connected to 12V, and heater is
on.
35 /
GE Title or job number /
4/30/2017
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
•
Power
Input: Voltage: 12V, 30mA max.
- Photo-relays:
- Input Voltage Range: 12V (+/-5%), 30mA
-
Needs to supply 30mA Output
- Input Voltage Range: 5V (+/-5%), 10mA
current: Data-sheet value is up to
Mechanical
130mA.
- Mechanical Size: 25*20*2.36mm
Circuit has 5V inputs from
Environmental
Microcontroller. Photo-relays can
-Operating Temperature: 0 to 85C
tolerate 50mA input current. With
- Storage Temperature: -40 to 125C
typical 2V input drop at photo-relay
- Estimated Product Life: 10 yrs
-
input, I-in = 3V/10k = 0.3 mA.
36 /
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4/30/2017
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
37 /
GE Title or job number /
4/30/2017
SSR Heater Control
38 /
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4/30/2017
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
39 /
GE Title or job number /
4/30/2017
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
40 /
GE Title or job number /
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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
41 /
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Code example for PIC18
This code executes when the button labeled “new button” on the user
interface is clicked:
if (ADRESL > 100)
PORTJbits.RJ4 ^= 1;
•In the first line, “ADRESL” is the analog-to-digital result register. It contains the
value of the analog input pin which is connected to the potentiometer on the
demo board.
•If this value is greater than 100, then the second line executes.
•The second line toggles bit 4 of PortJ. This is a digital output pin which is
connected to an LED on the demo board.
42 /
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DTM Project Firmware Work
Team 1 and 2: (Mayank, Matthew)
- Create control equations, writing of control function in C which implements the equations.
The different types of interfaces are TTL, Schmit Trigger and then some analog I/O and
some Digital I/O
- Writes the “main” program, which handles all of the interfacing and communication
between the microcontroller, PC, and other components on the board. Then based on the
outputs from the control function, the main program can actually control the pins on the
microcontroller, and send data to the user interface.
Team 3 and 4: (Mohammad, Nasir)
- Work on the web-browser for creating the interface to the PIC18 Microprocessor.
- Create capability for adding graphics and creating input and output ports to specific
memory locations on the processor.
43 /
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Thermal Manager BOM
Total:
$224.97
44 /
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DTM Project Timeline
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10 W11 W12 W13 W14 W15
Initial Concept
Design and Schematic
Layout
Fab. Ready
BOM
PWA Ready
Testing
Harness
Firmware Work
Firmware and Hardware Integration
45 /
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Browser-based user interface for Thermal manager:
Fan Speed
Set Fan
Speed
Thermal Manager
Therm
Temp
Pump
Speed
Set Pump
Speed
46 /
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