A.F.C.I. – GROUP 12Alumoline Fuel-Cell Instrumentation

Ronny, Naman, Darin, Suan

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

Aluminum Alloy

Experimental Reactor and Pressure Controller

Up to 20 KG of Alloy (88 kWhrs of H2)

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.

Block Diagram48V-12V Regulator

ATOM Board

Freescale9S12C32

48 V EV Battery

Pack

7 Inch Touch Screen(USB) LCD

VCC (5V)

ATD2

SPI4 wire

SCIVCC (5V)

VGAUSB

VCC (12V)

12V-5V Regulator

Thermocouple Amplifier (A)

Thermocouple Amplifier (B)

Thermocouple (A)

Thermocouple (B)

SD Card

Pressure Sensor (A)Pressure

Sensor (B)

VCC

5V-3.3V Regulator

ATD1

ATD5

ATD0

Level Sensor (A)

Level Sensor (B)

ATD4ATD3

Packaging

Major Components

LCD Screen Atom Board Pressure Sensor Temperature Sensor Micro Controller

Main Display

Graph Display

Microcontroller:Freescale 9S12C32

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)

Power Supply:VKP100MT 48V-12V regulator

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

12V-5V regulator:LM22677 Switching Regulator

Up to 5A operation

5V-3.3V regulator:TPS7233QP Linear Regulator

Also used in ECE362 mini project

SD reader system

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

Thermocouple Amplifier IC:AD595AQ

Thermocouple Amplifier IC:AD595AQ Translates output of K-type

thermocouples to microcontroller-friendly voltages

10 mV/C output

Thermocouple Temperature SensorsOmega kqss-116u-18

K-type cold junction thermocouple

Pressure Transducer SensorsGE PMP1260

8-30V operation 1-5V output

Intel Atom 3.5” MotherBoardAdvantech PCM-9361

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

8” LCD Touchscreen displayXenarc 800TSV

VGA in, touchscreen USB out 9V-30V operation @ <= 14W Reputable brand Found lightly used model for low

price

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

View from above

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

Interfaces – RS-232

Uses the SCI feature of the µc

Provides the RS-232 header

Interfaced by MAX3232CD

Circuitry mimic the development board

Interfaces – Sensors

Uses the ATD feature of the µc

Cold Junction Thermocouples

Interfaced with amplifiers

Bypass capacitors nearby

Optional external oscillator

Employ the other side

µc Related - Oscillator

I/O pins header for debugging

BDM pins header for programming

Give enough space for trace routing

µc Related – Dev. pins

Power Supply – Regulators

Main power: 48 Volts Battery

Voltage regulator from 48 Volts to 12 Volts

VKP100MTC

Load resistors

Power Supply – Reg. (cont.) 12 Volts to 5 Volts LM22677 For µc

5 Volts to 3.3 Volts TPS7233QP For SD card module

View from above

View from above (auto-route)

Project Timeline

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

Project Timeline cont.-

March 12- initial software for Micro Controller and Atom board- finish routing of PCB

Project Timeline cont.

March 26- Complete software for Atom board- Begin PCB soldering- Complete software for Micro Controller

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

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

Questions ?