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A.F.C.I. – Group 12

Alumoline Fuel-Cell Instrumentation. Ronny, Naman , Darin, Suan. A.F.C.I. – Group 12. Outline. Project overview Project-specific success criteria Block diagram Packaging design Component selection rationale Schematic and theory of operation PCB layout

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A.F.C.I. – Group 12

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  1. Alumoline Fuel-Cell Instrumentation Ronny, Naman, Darin, Suan A.F.C.I. – Group 12

  2. Outline • Project overview • Project-specific success criteria • Block diagram • Packaging design • Component selection rationale • Schematic and theory of operation • PCB layout • Software design/development status • Project completion timeline • Questions / discussion

  3. Aluminum Alloy

  4. Experimental Reactor and Pressure Controller Up to 20 KG of Alloy (88 kWhrs of H2)

  5. Project Specific Success Criteria • An ability to receive and correctly record values from various sensors. • An ability to give appropriate warnings and troubleshooting instructions if a sensor detects something wrong. • An ability to store data on external memory. • An ability to use a touch screen to send commands to the microcontroller to control the logging of data and to provide a user configurable display for the logging of data from multiple sensors. • An ability for the microcontroller to receive and execute commands to remotely enable, disable and control the sampling rate of multiple sensors.

  6. Block Diagram 48 V EV Battery Pack 5V-3.3V Regulator 12V-5V Regulator 48V-12V Regulator VCC VCC (5V) SPI 4 wire SD Card Freescale 9S12C32 ATD0 Thermocouple Amplifier (A) Thermocouple (A) ATD1 Thermocouple Amplifier (B) Thermocouple (B) ATD2 Pressure Sensor (A) ATD3 ATD4 Pressure Sensor (B) ATD5 SCI Level Sensor (A) ATOM Board VCC (5V) Level Sensor (B) VGA USB 7 Inch Touch Screen(USB) LCD VCC (12V)

  7. Packaging

  8. Major Components • LCD Screen • Atom Board • Pressure Sensor • Temperature Sensor • Micro Controller

  9. Main Display

  10. Graph Display

  11. Microcontroller:Freescale 9S12C32

  12. Microcontroller:Freescale 9S12C32 • Used in ECE362 – CodeWarrior familiarity. • Has all the requirements we need (SCI, SPI, 8 ATDs) • Might get a bigger version in family (depending on eventual code size)

  13. Power Supply:VKP100MT 48V-12V regulator

  14. Power Supply:VKP100MT 48V-12V regulator • Converts 48V car battery to 12V for our system • Two 12V channels @4.2A • one 3.3V channel @30A • More elegant and easier than using separate 12V battery for our system

  15. 12V-5V regulator:LM22677 Switching Regulator • Up to 5A operation

  16. 5V-3.3V regulator:TPS7233QP Linear Regulator • Also used in ECE362 mini project

  17. SD reader system

  18. SD reader system • Sparkfun breakout SD reader module (used successfully in 362 mini-project) • Maxim 3378E bidirectional 4-channel logic level converter • 4 signals need to be level-shifted: MISO, MOSI, Slave select and CLK

  19. Thermocouple Amplifier IC:AD595AQ

  20. Thermocouple Amplifier IC:AD595AQ • Translates output of K-type thermocouples to microcontroller-friendly voltages • 10 mV/C output

  21. Thermocouple Temperature SensorsOmega kqss-116u-18 • K-type cold junction thermocouple

  22. Pressure Transducer SensorsGE PMP1260 • 8-30V operation • 1-5V output

  23. Intel Atom 3.5” MotherBoardAdvantech PCM-9361

  24. Intel Atom 3.5” MotherBoardAdvantech PCM-9361 • Fanless • Cheapest model available that met all requirements: Small form factor, serial port, VGA port, CF slot • No built-in power supply • ATX power: 5V @<= 2.38A and 12V @<= 0.09A

  25. 8” LCD Touchscreen displayXenarc 800TSV • VGA in, touchscreen USB out • 9V-30V operation @ <= 14W • Reputable brand • Found lightly used model for low price

  26. PCB General consideration • Grouped by their functionality • Give enough floor space for each component • Adapt the orientation to the connecting pins • Interfaces need to be placed on the edge • Except for development purpose pins • µc has the most connected pins • µc is treated as an anchor on the center • Locate bypass capacitors close to the IC

  27. View from above

  28. Interfaces – SD Card • Uses the SPI to SD card module • Afford space and the 11 pins header • Through a 4 channels 5 - 3.3 V shifter • The shifter requires both 5 V and 3.3 V • Connected to all SPI pins from the µc

  29. Interfaces – RS-232 • Uses the SCI feature of the µc • Provides the RS-232 header • Interfaced by MAX3232CD • Circuitry mimic the development board

  30. Interfaces – Sensors • Uses the ATD feature of the µc • Cold Junction Thermocouples • Interfaced with amplifiers

  31. µc Related - Oscillator • Bypass capacitors nearby • Optional external oscillator • Employ the other side

  32. µc Related – Dev. pins • I/O pins header for debugging • BDM pins header for programming • Give enough space for trace routing

  33. Power Supply – Regulators • Main power: 48 Volts Battery • Voltage regulator from 48 Volts to 12 Volts • VKP100MTC • Load resistors

  34. Power Supply – Reg. (cont.) • 12 Volts to 5 Volts • LM22677 • For µc • 5 Volts to 3.3 Volts • TPS7233QP • For SD card module

  35. View from above

  36. View from above (auto-route)

  37. Project Timeline • March 5 - Complete proof of parts - finalize sensor installation - finish layout of PCB schematic - installation of Ubuntu on CF and environment setup

  38. Project Timeline cont.- • March 12 - initial software for Micro Controller and Atom board - finish routing of PCB

  39. Project Timeline cont. March 26 - Complete software for Atom board - Begin PCB soldering - Complete software for Micro Controller

  40. Project Timeline cont. • April 2 • Complete PCB soldering • Assembly of PCB with LCD and Atom board complete • April 9 - Connect sensors on golf cart to our system

  41. Software Design • The system will be setup similar to a server-client architecture • The Micro will be the server and the atom board the client • The atom board will send a request to the micro asking for the sensor values • Messages will be exchanged via “strings” • GUI will be implemented using Java w/ Java Comm API

  42. Questions ?

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