Ronny, Naman, Darin, Suan
Alumoline Fuel-Cell Instrumentation
A.F.C.I. – GROUP 12
Outline
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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 Diagram
5V-3.3V
Regulator
12V-5V
Regulator
48V-12V
Regulator
48 V
EV Battery
Pack
VCC
SD
Card
SPI
4 wire
VCC (5V)
ATD0
Freescale
9S12C32
ATD1
ATD2
Thermocouple
Amplifier (A)
Thermocouple
Amplifier (B)
ATD3
ATD4
ATD5
SCI
Thermocouple
(A)
Thermocouple
(B)
Pressure Sensor
(A)
Pressure Sensor
(B)
Level Sensor (A)
ATOM Board
USB
VCC (5V)
Level Sensor (B)
VGA
7 Inch Touch Screen(USB)
LCD
VCC (12V)
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
Sensors
Omega kqss-116u-18
 K-type cold junction thermocouple
Pressure Transducer Sensors
GE PMP1260
 8-30V operation
 1-5V output
Intel Atom 3.5” MotherBoard
Advantech PCM-9361
Intel Atom 3.5” MotherBoard
Advantech 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 display
Xenarc 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
µc Related - Oscillator
 Bypass capacitors nearby
 Optional external oscillator
 Employ the other side
µc Related – Dev. pins
 I/O pins header for debugging
 BDM pins header for programming
 Give enough space for trace routing
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
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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 ?