Arctic Power SystemIntermediate Design Review
Lisa Ferguson, Emily Davy, Dylan Schindler, Austin Sverdrup, Dee Dozier
Overview
• Product Structure• Subsystems
• Overview• Block Diagram• Schematics• Critical Components
• Microcontroller• APS Housing• Schedule
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Product StructureDee Dozier
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Product Structure DiagramRev. Doc Number:
T1 APS 065-0084-00
003-0084-00066-0084-00
366-0084-00
Software Assembly and Test Docs Hardware005-0084-00008-0084-00
Microprocessor Sensors Output Conversion AC Subsystem Hydrogen Subsystem Solar Subsystem Capacitor
200-0391-00 200-0392-00 200-0386-00 200-0387-00 200-0388-00 200-0389-00 200-0390-00
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APS Subsystems
• Output Conversion• AC Conversion• Hydrogen Conversion• Solar Conversion• Arctic Power Microprocessor• Arctic Power Sensor
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Power Inputs
• AC Input• Solar Panel Input• Hydrogen Fuel Cell Input
• 5V Line• 12V Line• 3.3V Line - Microcontroller
Power Outputs
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Power InputsLisa Ferguson
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AC Input
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Overview
• Input• 64 VRMS – 186 VRMS
• Regulated Output• 12 Volts• 2 Amps
• Surge Stopper• Load Switch• Protection Diode
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Block Diagram
Grid Matched AC Power
AC/DC Converter Surge Stopper Load Switch
• USA or European mains wall power
• Wind turbine• Diesel generator
• 20 watt converter• 12 VDC / 1.67 A
regulated output• 3000 VAC isolation
voltage• Continuous short
circuit protection
• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current
Blocking• Reverse Input
Protection• Reverse Output
Protection
• Input Voltage: 3 –20 Volts
• Constant Current: 2.3 Amps
• Surge Current: 10 Amp
• Controlled by Microcontroller
Protection Diode
• Schottky Diode• Maximum Voltage:
30 Volts• Maximum Current:
100 Amps• Voltage Drop:
400 µAmps @ 30V
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SchematicsAC / DC Converter Load Switcher
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Schematic – Surge Stopper
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Critical Components
• RECOM 20W Single Output • RAC20-12SB
• Linear Technology Surge Stopper• LTC4364-1
• Fairchild Load Switch• FDC6330L
• Vishay Protection Diode• SSB43LHE3_A/I
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Solar Panel Input
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Overview
• Input• 3 – 20 Volts Input• 18 Volts – Optimal• 1.11 Amps – Optimal
• Regulated Output• 12 Volts• 1.67 Amps
• Surge Stopper• Load Switch• Protection Diode
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Block Diagram
20 Watt Solar Panel
Buck / Boost Power
ArchitectureSurge Stopper Load Switch
• Optimal Voltage: 18 Volts DC
• Optimal Current: 1.11 Amps
• Operational Temperature Range: -40˚C - 80 ˚C
• Charge Controller Available
• TI LM25118 based Wide-Rage Buck Boost
• Input: 3 – 20 Volts DC
• Regulated Output: 12 Volts DC / 2 Amps
• Designed using TI Webench
• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current
Blocking• Reverse Input
Protection• Reverse Output
Protection
• Input Voltage: 3 –20 Volts
• Constant Current: 2.3 Amps
• Surge Current: 10 Amp
• Controlled by Microcontroller
Protection Diode
• Schottky Diode• Maximum Voltage:
30 Volts• Maximum Current:
100 Amps• Voltage Drop:
400 µAmps @ 30V
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Schematic – Buck/Boost
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Schematic – Surge Stopper
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Buck/Boost Architecture
• TI LM25118• Efficiency: 95%• Power Dissipated: .35 Watts• Power Output: 1.05 Watts – Maximum• Duty Cycle: 61%• Output Current: 20 A – Maximum• BOM Count: 38 components
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Hydrogen Fuel Cell Input
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Overview
• Input• 7.8 Volts – Optimal• 2.56 Amps – Optimal
• Regulated Output• 12 Volts• 2 Amps
• Surge Stopper• Load Switch• Protection Diode
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Block Diagram
20 Watt Hydrogen Fuel Cell
Boost Power ArchitectureSurge Stopper Load Switch
• Optimal Voltage: 7.8 Volts DC
• Optimal Current: 2.6 Amps
• Provided power control line from APS
• Simulated for testing purposes
• TI TPS61088 based Boost
• Input: 3 –10 Volts DC
• Regulated Output: 12 Volts DC / 2 Amps
• Designed using TI Webench
• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current
Blocking• Reverse Input
Protection• Reverse Output
Protection
• Input Voltage: 3 –20 Volts
• Output Current: 2.3 Amps
• Surge Current: 10 Amp
• Controlled by Microcontroller
Protection Diode
• Schottky Diode• Maximum Voltage:
30 Volts• Maximum Current:
100 Amps• Voltage Drop:
400 µAmps @ 30V
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Schematic - Boost
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Schematic – Surge Stopper
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Buck Architecture
• TI LM25118• Efficiency: 97.14%• Power Dissipated: .58 Watts• Power Output: 20 Watts – Maximum• Duty Cycle: 75.5%• Output Current: 20 A – Maximum• BOM Count: 21 components
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Capacitor Storage Bank
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Overview
• Maxwell Technologies Supercapacitor• Capacitance: 58 Farad• Rated Voltage: 16.2 Volts DC• Maximum Voltage: 17 Volts DC• Operating Temperature: -40˚C - 65 ˚C• 10 Year operational lifespan• 4 years storage lifespan• Shock and Vibration rated
• Current draw from capacitor: ~2.7 Amps
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Schematic – Capacitor Bank
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Power OutputsEmily Davy
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5V Output
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Subsystem Overview
• Input• 3 Volts – Minimum• 17 Volts - Maximum
• Regulated Output• 5 Volts – Maximum• 4 Amps – Maximum
• Surge Stopper• Load Switch• Female USB-A Connector
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Block Diagram
Capacitor Bank
Buck / Boost Power
Architecture
Surge Stopper Load Switch
• Optimal Voltage: 16 Volts DC
• Provides “reaction time” for Microcontroller to react
• 6 minutes operation stored energy
• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current
Blocking• Reverse Input
Protection• Reverse Output
Protection
• Input Voltage: 3 – 20 Volts
• Constant Current: 2.3 Amps
• Surge Current: 10 Amp
• Controlled by Microcontroller
Crowbar Circuit
• Analog protection for external load
• Resettable fuses allow for operation after circuit trip
• TI LM25118 based Wide-Rage Buck Boost
• Input: 3 – 17Volts DC
• Regulated Output: 5 Volts DC / 4 Amps Maximum
• Designed using TI Webench
Output
• Female USB-A• No data
transmitted
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Schematics – Buck/Boost
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Schematic – Surge Stopper
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Schematic - Crowbar
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Buck/Boost Architecture
• TI LM25118• Efficiency: 88.7%• Power Dissipated: 2.54 Watts• Power Output: 20 Watts – Maximum• Duty Cycle: 31.3%• Output Current: 20 A – Maximum• BOM Count: 31 components
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12V Output
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Overview
• Input• 3 Volts – Minimum• 17 Volts - Maximum
• Regulated Output• 12 Volts – Maximum• 1.67 Amps – Maximum
• Surge Stopper• Load Switch• Male Barrel Jack
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Block Diagram
Capacitor Bank
Buck / Boost Power
Architecture
Surge Stopper Load Switch
• Optimal Voltage: 16 Volts DC
• Provides “reaction time” for Microcontroller to react
• 6 minutes operation stored energy
• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current
Blocking• Reverse Input
Protection• Reverse Output
Protection
• Input Voltage: 3 – 20 Volts
• Constant Current: 2.3 Amps
• Surge Current: 10 Amp
• Controlled by Microcontroller
Crowbar Circuit
• Analog protection for external load
• Resettable fuses allow for operation after circuit trip
• TI LM25118 based Wide-Rage Buck Boost
• Input: 3 – 17 Volts DC
• Regulated Output: 12 Volts DC / 1.67 Amps Maximum
• Designed using TI Webench
Output
• Male Barrel Jack
• Energized Center pin
• Grounded barrel
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Schematic – Buck/Boost
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Schematic – Surge Stopper
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Schematic – Crowbar
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Buck/Boost Architecture
• TI LM25118• Efficiency: 91.5%• Power Dissipated: .95 Watts• Power Output: 20 Watts – Maximum• Duty Cycle: 71.5%• Output Current: 20 A – Maximum• BOM Count: 38 components
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3.3V Output
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Overview
• Input• 3 Volts – Minimum• 17 Volts - Maximum
• Regulated Output• 3.3 Volts – Maximum• 460 mAmps – Maximum
• Surge Stopper
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Block Diagram
Capacitor BankBuck / Boost
Power Architecture
Surge Stopper
• Optimal Voltage: 16 Volts DC
• Provides “reaction time” for Microcontroller to react
• 6 minutes operation stored energy
• TI LM25118 based Wide-Rage Buck Boost
• Input: 3 – 20 Volts DC
• Regulated Output: 3.3 Volts DC / 460 mAmps
• Designed using TI Webench
• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current
Blocking• Reverse Input
Protection• Reverse Output
Protection
Microcontroller
• TI Delfino Family Microcontroller
• Maximum Voltage: 3.3 Volts
• Maximum Current: 360 mAmps
• Hibernate Current: 300 μAmps
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Schematic – Buck/Boost
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Schematic – Surge Stopper
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Buck/Boost Architecture
• TI LM25118• Efficiency: 81.2%• Power Dissipated: .35 Watts• Power Output: 1.52 Watts – Maximum• Duty Cycle: 20.9%• Output Current: 20 A – Maximum• BOM Count: 28 components
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MicrocontrollerDylan Schindler
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Overview• Microcontroller• Current/Voltage Measurement Circuitry
• ADC modules for measurements • Comparator modules for detection
• Humidity/Temperature Sensor• Measure relative humidity/temperature • Provide alarm when certain humidity reached
• USB Interface• Export binary data files to external system • Allow external system to send commands to MCU
• Load Switching• MOSFET IC with GPIO pin control
Microcontroller - TMS320F2837xS Delfino
Microcontroller - TMS320F2837xS Delfino
• 1MB ECC-Protected Flash Memory• Windowed Watchdog Timer with two zero-pin 10-MHz Oscillators
• Support for external clock reference• Various Low-Power Modes• Two I2C Interfaces• Four 12-Bit ADC Modules (24 external channels)• Eight 12-Bit Windowed Analog Comparators• Peripheral Interrupt Controller• Launchpad available
Block Diagram-Power/Signal
Block Diagram-Voltage/Current Measurement
Voltage/Current Measurements
• 7 Voltage/ 9 Current• 12-Bit ADC module
• Read voltage as needed• Use known resistor value ahead of pin to calculate current
• 12-Bit Windowed Comparator• Provide interrupt• Used with Surge Stoppers• Detect No-Load, Voltage/Current Surges, faults within the system
Voltage/Current Measurements - Circuitry
TransorbOp-Amp
1Op-Amp
2
ADCINA1
ADCINA2
0 –
20 V
0 – 20 V 0 – 20 V -3.3 – 0V
3.3 – 0V
3.3 – 0V
R
Voltage/Current Spike
• Use comparators for interrupts• Voltage < 3V• First three measurement systems
• Check Surge Stopper fault pin• Use pin to determine type of spike
• Reset Surge Stopper
Block Diagram-Humidity/ Temperature
Humidity/Temperature
• Honeywell Humdicon HIH6031-021• 14-Bit I2C output• +/- 4.5 %RH & +/- 1.0 °C accuracy• Alarm High/Low for %RH
USB Interface
• Native USB 2.0 PHY support• Full-Speed (12 Mbps) and Low-Speed (1.5 Mbps)
• Transfer Types: Control, Interrupt, Bulk• Can operate as device or host• 4KB dedicated endpoint memory• Internal Oscillator doesn’t meet standards
• Use external 20MHz crystal oscillator with 10ppm (~15 min/year drift)
Schematic – Microcontroller Pin-Out
APS HousingAustin Sverdrup
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Boundary Shielding
Weatherproof Shielding for :• Power inputs
• Connected and disconnected• Power outputs
• Connected and disconnected• Hydrogen control line
• Connected and disconnected
Environmental Shielding
• Precipitation• Particulates• Relative Humidity• Ambient Internal Temperature• Ambient External Temperature
APS Access
• The system housing shall allow access to the internal APS• Annual Maintenance
• Shall provide a means of accessing the stored APS data logs without exposing the APS to the environment
• Shall provide a means of accessing the APS GPIO control lines without exposing the APS to the environment
Nonfunctional Requirements• Minimum Volume
• 50 x 50 x 50 cm
• Weight• No more than 10 kg
• Mechanical Shock• Shall withstand a fall from 1 m onto a hard, flat surface
• Vibration• Shall withstand a sinusoidal vibration sweep from 10 Hz to 500 Hz
• External Ambient Temperature• Shall operate between -40°C to 40°C
APS ScheduleDee Dozier
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Updated Schedule
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Week-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Task 25-Jan 1-Feb 8-Feb 15-Feb 22-Feb 29-Feb 7-Mar 14-Mar 21-Mar 28-Mar 4-Apr 11-Apr 18-Apr 25-Apr 2-May
A Preiminary Design Review 5
H System Design 5
O PCB Design 3
N Component Research and Selection 2
P Virtual Simulation Verification 3B Intermediate Design Review 0
Z1 Order 1st Prototype Parts 0
Q Finalize Bill of Materials 1D Finalize and Release Specification Sheet 1
K Poster 1
R Software Design 1
I Assemble PCB -1 0
S Power Simulation Testing (Prototype 1) 3 3
T Coding 2 2 1M Write Assembly Procedures 2
U Subsystem Software Testing 2
Z2 Order 2nd Protoype Parts 0G Write Acceptance Test Procedures 2
F Write User Manual 2
J Prototype-2 Testing 4
C Critical Design Review 0
V Full System Environmental Testing 5
L Demonstration (Discovery + Graded) 0
Critical Path
Spring Break
Float
Suggested Time
* Numbers in bar indicate manpower
Thank YouQuestions and Comments
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