p14452: subsystems design review
DESCRIPTION
P14452: Subsystems Design Review. Review. Where we left off. Updated Engineering Specifications. Previous Functional Decomposition. Capture Data. Store Data. Power Device. Protect Device. Chosen Concept. Materials Analysis. Building a Better Box. Plan. Comparisons of Materials - PowerPoint PPT PresentationTRANSCRIPT
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P14452: Subsystems Design Review
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ReviewWhere we left off
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Updated Engineering Specifications
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Previous Functional Decomposition
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Capture Data
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Store Data
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Power Device
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Protect Device
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Chosen ConceptConcept # 4
Power Source UltraCapStart Capture Reed SwitchStop Capture Timer
Sensor Connection 4-WireSet Sampling Rate Digital Knob
Mount Device MagnetHigh Pressure Composite
High Temp Insulated/PassiveOily Env. Gaskets/Plugs
Data Storage microSDProcessor μC
Data Access USBSample Bit Width 16-bit
Sample Rate 10kHz
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Materials AnalysisBuilding a Better Box
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Plan
• Comparisons of Materials• Acetal Resin (Delrin®-150)• Polysulfone• Polyester (Ertalyte® PET-P)• Aluminum 6061
• Applied Loads• 100psig applied to external surfaces• 200F applied to bodies
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Acetal Resin (Delrin®-150)
Properties• Max Operating Temp
• 180F• Yield Strength
• 10400psi• Modulus
• 450ksi• CTE
• 278μin/in-°F
• Cost: 1.5”x6”x6” sheet• $35.71
• Max Deformation• .060”
• Max Stress• ?
ANSYS Simulation
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Polysulfone (PSU)
Properties• Max Operating Temp
• 285F• Yield Strength
• 10900psi• Modulus
• 390ksi• CTE
• 29.4μin/in-°F
• Cost: 1.5”x6”x6” sheet• $147.83
• Max Deformation• .006”
• Max Stress• 6862 psi
ANSYS Simulation
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Polyester (Ertalyte® PET-P)
Properties• Max Operating Temp
• 210F• Yield Strength
• 12400psi• Modulus
• 490ksi• CTE
• 33μin/in-°F
• Cost: 1.5”x6”x6” sheet• $48.57
• Max Deformation• .007”
• Max Stress• 9744 psi
ANSYS Simulation
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Aluminum 6061
Properties• Max Operating Temp
• 500F• Yield Strength
• 40000psi• Modulus
• 1000ksi• CTE
• 13.1μin/in-°F
• Cost: 1.5”x6”x6” sheet• $53.44
• Max Deformation• .003”
• Max Stress• ?
ANSYS Simulation
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Weight
• Density:• Acetal:
• .0513 lb/in3
• Polysulfone:• .0448 lb/in3
• Polyester:• .0361 lb/in3
• Aluminum:• .0975 lb/in3
• Mass:• Acetal:
• .0671 lb (30.4g)• Polysulfone:
• .0586 lb (26.6g)• Polyester:
• .0472 lb (21.4g)• Aluminum:
• .1275 lb (57.8g)
Volume: 1.3075
in3
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Other Properties
• Thermal Conductivity• Acetal:
• 2.5 BTU-in/hr-ft²-°F• Polysulfone:
• 3 BTU-in/hr-ft²-°F• Polyester:
• 2 BTU-in/hr-ft²-°F• Aluminum:
• 1160 BTU-in/hr-ft²-°F
• Electrical Resistivity• Acetal:
• 1015 ohm-cm• Polysulfone:
• 1016 ohm-cm• Polyester:
• 1012 ohm-cm• Aluminum:
• 10-6 ohm-cm
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Pugh AnalysisDelri
n PSU PET Al
Strength -
DATUM
+ +Operating
Temp - - +
Cost + + +
Weight s + -Thermal
Conductivity
s s -
ElectricalResistivity s s -
Total 1/2 3/1 3/3
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Case GeometryThe Best Things Come in Small Sizes
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PCB DimensionsShow 3D Rendering
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Mounting• Two part solution
• Flange Base• Through Hole in each corner• Can be used to mount directly
• Adapter Plates• Attach to flange base• Allow for Mounting on existing holes• Allow for adhesive, zelcro, magnets,
etc.
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Generalized Design• Rectangular Prism
• 1-3 Ports for Analog I/O• 1 Micro-USB Port
• Charging• Data Access
• Flange Base• Fasten from Bottom
• Locks access to inside of device when mounted
• Provides Mounting Holes
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MicrocontrollersChoosing a Better Brain
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Criteria 1: ADC Accuracy
Bit Width # of Values LSB (Accuracy)10 1024 19.53 mV12 4096 4.88 mV14 16384 1.22 mV16 65536 305 uV18 262144 76.3 uV20 1048576 19.1 uV24 16777216 1.19 uV
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Criteria 2: ADC TypeSuccessive Approximation
• 10-12 bit Accuracy• Fast Sample Rate (>200kS/s)• Requires External Low-pass Filter
• Costs Board Space• 3 Op-amps (Bi-Quad)• Resistors and capacitors
Sigma-Delta• 12-24 bit Accuracy• Slow Sample Rate (<200kS/s)• No External Low-pass Filter
• Filter is part of sampling process• Must be careful of bit width effect on
frequency range
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Criteria 3: Serial Throughput (SD)
Bit Width Bits/s (1 Ch)* Bytes/hr (1 Ch)*
Bits/s (4 Ch)* Bytes/hr (4 Ch)*
10 100k 42.915 MB 400k ~172 MB12 120k 51.498 MB 480k ~206 MB14 140k 60.081 MB 560k ~240 MB16 160k 68.885 MB 640k ~276 MB18 180k 77.248 MB 720k ~309 MB20 200k 85.831 MB 800k ~345 MB24 240k 102.997 MB 960k ~412 MB* at 10kHz sampling
rate
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Criteria 4: I/O Capability
• SD Card• 1 SPI interface• 1 Serial Clock
• USB Data Access• 1 USB UART
• ADC• 1-4 ADC Channels
• GPIO• 1 Digital (SD)• >2 Digital for Hardware Sampling Rate (per
channel)
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Criteria 5: Processor Speed• ADC requirement
• 10000 Samples/s per Channel• May take more than 1 cycle per sample to read
from ADC
• Estimated Minimum Speed• 40000 Samples/s (4 Channels)• 2 Cycles per Sample Read• 112 Cycles per Sample Write
• 5 Bytes Data• 1 Bytes Channel ID• 5 Bytes Timestamp• 2 Bytes “,”• 1 Byte CR
• 4.56 MHz
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MicrocontrollersSTM32F373• 32-bit ARM M4F (72 MHz)
• Floating Point• DSP Instructions
• 1-3 Sigma-Delta ADC• 16-bit• 16.66 kHz max per channel• DMA Interface• ADC Synchronization
• 3 SPI (18 Mbit/s)• Up to 84 GPIO• 1 USB UART (12 Mbit/s)
MSP430F67XX• 16-bit RISC ( 8-25 MHz)
• No Floating Point• No DSP Instructions
• 3 Sigma-Delta ADC• 24-bit• 31 kHz per channel max• DMA Interface• ADC Synchronization
• 2 SPI (5 Mbit/s)• 52 or 72 GPIO• No USB
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Input ConditioningThe Large Signal Problem
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Attenuation Circuit
• Use resistor bridge to reduce the voltage for input to microcontroller • Set a unity gain • Also decreases the
current going into the uC
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Simplified Circuit • Simplified circuit
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Final Circuit
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Attenuator Non-ideality
10 100 1000 10000012345678
f(x) = − 5.74854197E-09 x² + 0.00080073565 x + 0.000515302233
Percent Error vs Sensor Output Im-pedance
Series1
Sensor Ouput Impedance (Ohms)
Perc
ent
of E
rror
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Power SourcePhenomenal Cosmic Power. Itty Bitty Living Space.
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LiPo vs. Ultra Capacitor Ultra Capacitor (KEMET FT0H105ZF)• Diameter = 21.5mm (0.846in) • Height = 13mm(0.512in)• Area= 1502mm^3• Max Voltage 5.5V• 1F capacitance• Max current is 1.5mA for 30 mins• Weight = 10 grams• Price 1$4.23, 10$38.03• KEMET FT Series pages 2-4
LiPo Battery (All-battery.com 602025)• Base: 25mm x 20mm• Height: 6mm• Area=3000mm^3• Voltage = 3.7V• 240 mAh• Max Current is 48mA for 5 Hours• Weight = 4 grams• Price for 5-10$3.25 each• http://www.all-battery.com/polymerli-ionbatte
ry37v240mah602025.aspx
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LiPo Charging• Spark Fun Power Cell – LiPo Charger/Booster• Micro USB
charging• $19.99 breakout
board for testing• Eagle Files
Available for PCB layout
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Schematic for LiPo Charging and Booster
https://www.sparkfun.com/products/11231
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Components Required LiPo Charger and Booster
• MCP73831/2: LiPo Charging IC• Can get free samples
• TPS61200: 5 volt, 600mA boost converter • Can get free samples • Used for powering sensors
and other components • JST connector $0.95• Micro USB SMD Connector
$1.95• Resistors and Capacitors
<$2.00
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Action ItemsThe Road Ahead
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Mechanical Action ItemsMaterials and Modelling• Choose Final Material• Solid Modelling
• Small Device• Large Device
• Ansys Simulations• Small Device• Large Device
Sensor Characterization• Catalog Existing Sensors in
Compressor• Centralized Collection of Data Sheets• Reference Card for Sensors
• Voltage Range• Current Output• Frequency Ranges• Optimal Sampling Rate• Voltage to Unit Conversion Factor
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Electrical Action Items
PCB• Finalize Electrical Schematics
• Small Device• Large Device
• Finalize PCB Designs• Small Device• Large Device
• Final Component Selection
Analog Analysis• Attenuator Final Design• Differential Amplifier• Precision Voltage Reference• Input Voltage Clamping
• Overvoltage Protection• LiPo Charging Circuitry
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Computer Action Items
Algorithms• Digital Filtering• Sample Ordering• Timestamp Calculation• Processor Initialization Routines
Processes• Sampling Procedure
• Channel Switching• Multiple Sampling Rate Switching
• DMA transfers• Offload SPI• Offload ADC• Processor can focus on filtering and
coordinating
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Questions?El fin.