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318-595 Presentation #3 – Project TEAM 1 Detector Thermal Manager

318-595 Presentation #3 – Project TEAM 1 Detector Thermal Manager. 318-595 Project Presentation #3 – TEAM 1. Team 1: Expertise and Experience. Expertise: Digital, Analog, FPGA, MATLAB Experience: 5 years – GE Healthcare Role: LPI, LMM. Mayank Gupta Naser Aldaihani

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318-595 Presentation #3 – Project TEAM 1 Detector Thermal Manager

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  1. 318-595 Presentation #3 – Project TEAM 1 Detector Thermal Manager

  2. 318-595 Project Presentation #3 – TEAM 1 Team 1: Expertise and Experience • Expertise: Digital, Analog, FPGA, MATLAB • Experience: 5 years – GE Healthcare • Role: LPI, LMM • Mayank Gupta • Naser Aldaihani • Matthew Mulvey • Mohammad Habeeb • Expertise: Electronic, Power Systems. • Experience: Fresh after BSEE • Role: LMP • Expertise: Digital Design, (C,C++) • Experience: Fresh after BSEE • Role: LSD • Expertise: Electronic, DSP, C++. • Experience: Fresh after BSEE • Role: LRM

  3. 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

  4. Main Project – Block Diagram Slide Mechanical Size: 200*125*2.36mm Mounting Holes: 8 mounting holes Shielding: All mounting holes connected to Chassis Ground, nothing else on board will be connected to Chassis Ground.

  5. 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.

  6. 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

  7. 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

  8. Business Case - At 40% mark-up, it will take 10 months to make any profits.

  9. 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

  10. 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 theperformance of the thermal manager, even if there is some negative impact onbusiness (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.

  11. 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.

  12. 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

  13. 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

  14. 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

  15. 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

  16. Main Block Diagram Description for DTM

  17. DTM - Interference Input Power 48V, 10A Power PIC18 Programming Ethernet IP Configuration Pump, 48V, 4A Current Out Current In Power Tach 2 Fans, 48V 2A each 5 Thermistor 1 Velocity Sensor 2 Pressure Sensor SSR Heater Control

  18. DTM – Overall Layout (6 Layer Board)

  19. Power management and Processor Input Power 48V, 10A 48V Filtering 12V, 30mA 5V, 70mA 3.3V, 300mA Power to other blocks PIC18F97J60 256KB EEPROM To and From Other Blocks

  20. 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: • Description: • 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 • Standard Requirements • Market • Price: $160/ board • 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

  21. Power management and Processor - Power • Power Consumption • 48V (=/-5%) – 8A • 12V (+/-5%) – 30mA • 5V (+/-5%) – 70mA • - 3.3V (+/-5%) – 300mA

  22. 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

  23. 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.

  24. Power management and Processor - Microprocessor Top Layer of 6 layer board

  25. Thermistor, Velocity Sensor, Pressure Sensor Multiplexer 5 Thermastor Output to micro controller Velocity Sensor Pressure Sensors Input Selector

  26. Thermistor, Velocity Sensor, Pressure Sensor Purpose: Monitor the performance of 5 Thermistors, 1 Velocity Sensor and 2 Pressure Sensors. • Performance Requirements: • Description: - 5 Thermistors: • Voltage: 5V, 1mA. • Accuracy (+/-0.2C at 36C • - 1 Velocity Sensor: • Voltage: 5V, 1mA. • flow ranges between 0.15-10 m/s (30-2000 fpm) • Accuracy ±0.05 m/s (10 fpm) - 2 Pressure Sensor: • Voltage: 12V, 25mA. • 0-500PSI • Accuracy: +/-2% • Standard Requirements • Market • Price: $20/ board • Power • Input Voltage Range: 12V (+/-5%), 50mA • Input Voltage Range: 5V (+/-5%), 2mA • Mechanical • Mechanical Size: 30*25*2.36mm • Environmental • Operating Temperature: 0 to 85C • Storage Temperature: -40 to 125C • Estimated Product Life: 10 yrs

  27. Thermistor, Velocity Sensor, Pressure Sensor Thermistor and Velocity Sensor Pressure Sensor

  28. 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

  29. Thermistor, Velocity Sensor, Pressure Sensor

  30. Fan and Pump control Requirements-Block Diagram breakdown 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.

  31. Fan and Pump control Requirements Purpose: Control the speed of the pump and fan and interface to processor. • Performance Requirements: • Description: - 2 DC-DC Fans: • Voltage: 48V, 4A. • Control voltage: 0-10V, 0.4mA/ Fan • - 1 Pump: • Voltage: 48V, 4A. • Control voltage: 0-10V, 0.4mA/ Fan • Standard Requirements • Market • Price: $40/ board • Power • Input Voltage Range: 48V (+/-5%), 8A • Input Voltage Range: 12V (+/-5%), 10mA • Input Voltage Range: 5V (+/-5%), 5mA • Mechanical • Mechanical Size: 30*20*2.36mm • Environmental • Operating Temperature: 0 to 85C • Storage Temperature: -40 to 125C • Estimated Product Life: 10 yrs

  32. Fan and Pump Circuit (Circuit concept and component choice by Mayank)

  33. 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

  34. Fan and Pump Circuit

  35. 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.

  36. SSR Heater Control Purpose: Provide On/Off capability to the SSR to control externally a 1KW heater. • Performance Requirements: • Description: - SSR: • Input: Voltage: 12V, 30mA max. • - Photo-relays: • Needs to supply 30mA Output current: Data-sheet value is up to 130mA. • Circuit has 5V inputs from Microcontroller. Photo-relays can tolerate 50mA input current. With typical 2V input drop at photo-relay input, I-in = 3V/10k = 0.3 mA. • Standard Requirements • Market • Price: $25/ board • Power • Input Voltage Range: 12V (+/-5%), 30mA • Input Voltage Range: 5V (+/-5%), 10mA • Mechanical • Mechanical Size: 25*20*2.36mm • Environmental • Operating Temperature: 0 to 85C • Storage Temperature: -40 to 125C • Estimated Product Life: 10 yrs

  37. 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

  38. SSR Heater Control

  39. Ethernet Ethernet: network topology that defines physical connection standards and signal transmission standards, so we don’t have to. Other device Other device Thermal manager Devices with Ethernet capable Microcontrollers (PIC18F97J60) PIC18 PIC18 PIC18 Already exists in many buildings PC Ethernet Network PC File server

  40. 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

  41. Thermal Manager (PCB) Developers PC PIC18 Microcontroller Serial Pins Compiler and TCP/IP stack source code PIC18 Memory Web page xyz C++ Code Web page xyz Web page xyz Web page xyz Web page xyz Web page xyz Web page xyz Web page xyz TCP/IP services Web Server Main Program Users PC Web Browser Web page xyz Pins Ethernet Pins TCP/IP services Circuits for Fan, heater, etc. Ethernet Jack

  42. 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.

  43. 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.

  44. Thermal Manager BOM Total: $224.97

  45. DTM Project Timeline Initial Concept Design and Schematic Layout Fab. Ready BOM PWA Ready Testing Harness Firmware Work Firmware and Hardware Integration

  46. Browser-based user interface for Thermal manager: Fan Speed Thermal Manager Set Fan Speed Therm Temp Pump Speed Set Pump Speed

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