preliminary design review nasa wireless smart plug (nwsp) experimental control logic labs october 29...
TRANSCRIPT
Preliminary Design ReviewNASA Wireless Smart Plug (NWSP)
Experimental Control Logic Labs
October 29th, 2012
2PDR Agenda1. Update of documents developed and baselined since SDR
2. Matured Concept of Operations
3. Updates to Engineering Specialty Plans
4.Top-level Requirements and Flowdown to the next level of requirements since SDR
5. Review Design-to Specifications (hardware and software) and Drawings, Verification and Validation plans, and Interface documents at lower levels; CAD model for all physical components of the system
6.Trade Studies that have been preformed since SDR and their results
7.Engineering Development Tests and Results
8.Select a baseline design solution
9.Review and discuss internal and external interface design solutions (and any interface control documents needed). This includes interface information provided by NASA since SDR
10.Review system operations
11.Design Analyses and Results
12.Risk Management Plan
13.Cost and Schedule data
3Update of Documents Developed and Baselined System Architecture
Lower level details provided to depict the use of NASA requested components based on the X-Hab Solicitation
Functional Block Diagram Fuses in primary 28V-DC and 120V-DC load lines have been
removed after NASA requirement’s were clarified that the NWSP is not to operate as a safety device
Nivis ISA100.11a Release Version Habitat Demonstration Unit (HDU) gateway currently running
release 2.6.39 HDU VN210 firmware currently running version 4.3.14
(Upg_VN210_FullAPI_SpeedupSPI_ExtWakeup_v04_03_14)
4Matured System Architecture
Nivis VersaRouter 900 Master Control UnitWindows OSLabVIEW GUI
1 sample/secondISA100.11aIEEE 802.15.4
NASA Wireless Smart Plug
DSHNetwork
End Device
x5
120V-DCor
28V-DC
120V-DCand/or
28V-DC
Nivis VersaNode 210
5Matured Concept of Operations
• NASA Wireless Smart Plug (NWSP) is a proof-of-concept prototype
• Installed in the Deep Space Habitat (DSH) mock-up for testing and evaluation purposes only (not space qualified)
• Used to monitor and control power usage of DSH and its installed equipment
• Monitor current draw from end device, and define actions based on measurement (i.e. wireless communication, manual disconnect, load shedding).
Updates to Engineering Specialty PlansNivis Equipment that was supplied by NASA on
October 26th: PCB with MSP430 and Nivis 210 Radio
Nivis VersaRouter 900
Nivis equipment to be supplied by NASA: Embedded software for MSP430 and Nivis 210 Radio
6
7Top-Level RequirementsPower Control
Support for 120V/28V DC Near real-time monitoring Fail safe Windows based master control unit
Communications Wireless configuration, control, monitoring and reporting Data rate: 1 sample/second Use a Nivis VN210 radio Support a Nivis VR900 router Standards: SPI, ISA 100.11a
Form Factor & Fit Small form factor Cannon-type connector Integration with DSH Deliver five NWSP units for evaluation
Requirements Flow Down 1/3
Power Control
Voltages Monitor Fail Safe Threshold GUI
28VDC
120VDC
0 to 5A
3% Full Scale
0 to 5A
0.1A Inc.
Alert
Standalone Executable
Windows OS
8
Requirements Flow Down 2/3
Communications
Data Rate Equipment Protocol
1 sample/s
Alert Within 3s
Nivis VN210
Nivis VR900
ISA100.11a IEEE 802.15.4
SPI
9
Requirements Flow Down 3/3
Form Factor & Fit
Size Integration
3” x 3” x 3”
Cannon-type Connector
5 NWSP
DSH Install
10
11Design-to Specifications Voltage:
Input: 28VDC and/or 120VDC Output: 28VDC or 120VDC
Monitor Current: 5A, ± 3% of full scale Data Collection: 1 sample/second User Interface: Standalone application on Windows-based
MCU. Communication:
Integrate into DSH wireless mesh with Nivis VR 900 gateway Radio: Nivis VN 210 Standard: ISA100.11a
Size: 3” x 3” x 3” target. Power Consumption: Minimal Deliverables: 5 NWSP units, installed on DSH mockup.
12CAD Model for Physical Components
Trade Studies and Results:Current Sensor
13
Device Type Pros Cons Cost
ACS714 Hall Effect Small package Negligible power
dissipation Single 5V supply 40A Range
• Requires offset, gain, and low pass filter
$3.89
CMS2015 MagnetoResistiveCurrent Sensor
Electrical Isolation 15A Range Small package
Bipolar 15V supply Relatively expensive
$35.20
VCS1625 High Precision Shunt Resistor Very small package
Non inductive, non capacitive
No ringing
Power Dissipation Heat
$20
Trade Studies and Results:120VDC to 28VDC Conversion
14
Device Type Pros Cons Cost
667-ERA-8AHD300V
Voltage Divider • Inexpensive• Small package
• Power dissipation• Heat• Fluctuations in output
$2.53
MC33363B High Voltage Switching Regulator
• Small Package• Inexpensive• Negligible heat
• Noisy• Large current draw of >1A• Requires 40V supply
$1.60
TL783 High Voltage Linear Regulator
• Adjustable Vout • Limited output current• Significant waste heat
$2.55
Trade Studies and Results:Voltage Regulator
15
Device Type Pros Cons Cost
LM317L Linear Voltage Regulator
• Low output noise• Programmable output• Cheap
Inefficient Heat
$.49
ADP111 Switching Regulator Efficient
Low Heat
Relatively Expensive $2.44
N/A? Hybrid Regulator Efficient Low Heat Low Noise
Larger space required Relatively Expensive
N/A?
Trade Studies and Results:Voltage Switch
16
Device Type Pros Cons Cost
Micropac 53238
OptocoupledPower Mosfet
• Small package• Operates up to 125V• Can handle 5A
continuous• Radiation tolerant• Can be controlled with
pin from MSP430
• Heat • Power dissipation• Long lead time
Unknown
AV3712613 Relay • Can be controlled with pin from MSP430
• Inexpensive
• Mechanical• Power dissipation
$1.61
SH20DC20-16 High Power DC Solid-State Relay
• Can handle up to 20A continuous
• Low control voltage of 3.5V
• Can be controlled with pin from MSP430
• Large $23.56
Trade Studies and Results:Connector
17
Device Manufacturer Pros Cons Cost
HBL2513 Hubbell • Operates up to 208V• Can handle 20A
continuous• Fits NASA requirement• Available locally• Locking
• Not quarter turn $73.44
Veam GRH Cannon • Operates up to 250V• Can handle 15A
continuous• Quarter turn locking• High shock and vibration
resistance• Fits NASA requirement
• Not available locally Unknown
PDS-222-4 Amphenol • Operates up to 200V• Can handle 10A
continuous• Designed for space
operation• Quarter turn locking
• No 5 pin layout available• Not available locally
Unknown
18Trade Studies and Results:Microcontroller
Manufacturer Microcontroller Pros Cons Price per Unit
Texas Instruments
MSP430F5438A • Large memory size of 256KB• Low operating voltage (1.8 ~ 3.6V)
• High cost $11.73
Microchip PIC24FJ128GA110 • Cost • Less precise A/D convertor of 10 bits
$4.76
Freescale MC56F8257VLH • Fast processing speed of 60MHz
• No UART communication• Higher supply voltage necessary
$7.15
19Engineering Development Tests: Analog-to-Digital Converter 12-bit ADC Internal to MSP430F5438A
Internal Reference (2.5V) Sample-and-Hold 14 External Channels
Offset
Gain
LPF
20Baseline Design Solution:Functional Block Diagram Overview
21Functional Block Diagram:Voltage Step Down and Regulation
22Functional Block Diagram:Current Sense and Disconnect
23Functional Block Diagram:Nivis VN210 SPI Interfacing
24Internal and External Interface Design Solutions: SPI
Serial Peripheral Interface Bus (SPI) Synchronous serial data link standard Full duplex mode Master/Slave mode where the master device initiates the data frame Multiple slave devices are allowed with individual slave select (chip
select) lines The SPI bus specifies four logic signals:
SCLK: serial clock (output from master) MOSI: master output, slave input (output from master) MISO: master input, slave output (output from slave) SS: slave select (active low, output from master)
25Internal and External Interface Design Solutions: SPI
Advantages•Full duplex communication•Complete protocol flexibility for the bits transferred •Typically lower power requirements due to less circuitry (including pull up resistors)•Slaves use the master's clock, and don't need precision oscillators•Slaves don't need a unique address — unlike I²C or GPIB or SCSI•Transceivers are not needed•Uses only four pins on IC packages, and wires in board layouts or connectors; fewer than parallel
interfaces•At most one unique bus signal per device (chip select); all others are shared•Not limited to any maximum clock speed, enabling potentially high throughput
Disadvantages•No in-band addressing; out-of-band chip select signals are required on shared buses•No hardware flow control by the•No hardware slave acknowledgment•Supports only one master device•No error-checking protocol is defined•Generally prone to noise spikes causing faulty communication•Only handles short distances compared to RS-232, RS-485, or CAN-bus•SPI does not support hot plugging (dynamically adding nodes).
26System Operations:Initialization
Connect NWSP male input
receptacle to DSH
Run LabVIEW GUI executable
Request parameters from
NWSP configuration
Set end device parameters
Current Threshold
Priority
Test connection between NWSP
and GUI
Established Connection?
Reset physical connection and
executable
No
Parameters Set?
Yes
NoConnect end
device to NWSP female output
receptacle
Yes (A)
Mode
27System Operations:Standard Operation
(A) Close switch of primary supply line to allow end device
operation
NWSP measures actual current and
voltage(s)
Actual Exceed
Threshold?
Compare actual current against
configured threshold current
Send all measured values to GUI
Actual Current of Primary
Voltage Point 1
through 7
Mode?
Send all measured values to GUI
Yes
NoSend all measured
values to GUIPrompt user to
disconnect
Manual
Automatic
DisconnectPrimary supply line from end device
Notify user of disconnect
User Request
Disconnect?
No
Yes (B)
(E or F)
(D)
(C)
28System Operations:Disconnect and Reset
(B)
DisconnectPrimary supply line from end device
Notify user of disconnect
Prompt user to reconnect
User Reconnect?
Wait for user to manually reconnect
No
Reconnect Device
Yes
(F)
(F)
(D)
User Disconnect?
(C)
Yes No(E)
GUI Updates - Detailed View
GUI Updates
Master Control Software Logic
Master Control Software Logic
33Design Analyses:Sampling and Decision Algorithm Process of averaging multiple samples for noise
compensation through statistical analysis: Defining the population of concern Specifying a sampling frame, a set of items or events possible to
measure Specifying a sampling method for selecting items or events from
the frame Determining the sample size Implementing the sampling plan Sampling and data collecting
Factors Nature and quality of the frame Availability of auxiliary information about units on the frame Accuracy requirements, and the need to measure accuracy Whether detailed analysis of the sample is expected Cost/operational concerns
34Design Analyses:Power Budget
Device Max Current DrawVersaNode210 60 mAMSP430F5438 312 uAACS714 Current Sensor IC 13 mASH20DC20-16 TL783LM713L
35Risk Management Plan:PMI Risk Management Process
• Identify
• Evaluate
• Develop Response
• Control
36Risk Prioritization MatrixPriority Total Overall Risk Comparison
3 7 High 1. Project goes overschedule
9 1 Low 2. Injury or damage from 120V source 12
10 0 Low 3. Funding delayed 1 2 3 3
1 10 High 4. Delay in parts procurement. 1 2 34 4 4
2 8 High 5. Solving 120V/28V available power problem
1 2 3 45 5 5 5
5 5 Medium 6. Limited financial resources 1 2 3 4 56 6 6 6 6
7 3 Low 7. Loss of a team member 1 2 3 4 5 67 7 7 7 7 7
8 2 Low 8. Unable to source proper 120V DC 1 2 3 4 5 6 78 8 8 8 8 8 8
4 6 Medium 9. Further revisions necessary 1 2 3 4 5 6 7 89 9 9 9 9 9 9 9
6 4 Medium 10. Selected solution found unfeasible 1 2 3 4 5 6 7 8 910 10 10 10 10 10 10 10 10
37Risk Evaluation
PROBABILITYOF
OCCURRENCE
SEVERITY OF IMPACT
LOW HIGH
HIGH
LOW
5 4
6,9 1
10
3 7 8 21. Project over-schedule2. Injury/damage from 120V3. Funding delayed4. Delay in parts5. Solving 120V step-down6. Limited financial resources7. Loss of a team member8. Unable to source 120V DC9. Further revisions necessary10. Selected solution found unfeasible
Legend
38Cost Data
NASA Cost Sharing• Labor $40,915 • Travel $3,000• Equipment $5,000 (TI)• ODCs $5,000• Overhead/Indirect $22,501
(TAMU)_____________________________________________ Total Cost to Sponsor $48,915 $27,501
Actual Project Value 76,416
39Capstone Labor
Total # of Boxes: 133Total # of Work Packages: 95
Expected Number of Man Hours: 2259 HoursResearch: 160 HoursDesign: 363 HoursSimulation: 60 Hours Implementation: 370 HoursTesting: 260 HoursDocumentation: 1046 HoursClose Out: 6 Hours
Gantt Chart
Research
Design
Simulation
Implementation
Testing
Documentation
Close-out
28-Aug-12 17-Oct-12 6-Dec-12 25-Jan-13 16-Mar-13 5-May-13
11/1/12
11/25/12
4/17/13
4/18/13
4/29/13
5/6/13
5/10/13
NWSP Gantt Chart
Duration
Ph
ase
41NASA DeliverablesDate Activity Deliverable1/8/12 Kickoff Meeting Draft System Design Process (SDP)19/9/12 SDR Presentation
Power Point SlidesVideo
29/10/12 PDR PresentationPower Point SlidesVideo
5/12/12 CDR PresentationPower Point SlidesVideo
10/12/12 Final SDP ReportWeekly Project Status Meetings13/2/13 Progress Checkpoint #1 Presentation and PPT Slides
Alpha SchematicAlpha Board LayoutSoftware Hierarchical ChartsTest Matrix
5/3/13 Final Design Review Presentation and PPT Slides3/4/13 Progress Checkpoint #2 Final Schematics
Final Board LayoutSoftware Flow ChartsTest Plan
15/5/13 Progress Checkpoint #3 Final Demonstration 20/5/13 Final Presentation Final Report
Five Smart Plugs15/6/13 Integration with DSH Field Test Plan15/8/13 DSH Integrated Testing Field Test Report15/9/13 Final Acceptance
42Questions/Comments