318-595 Presentation #2 – Project TEAM 1

318-595 Project Presentation #2 – TEAM 1 Team 1: Expertise and Experience Mayank Gupta Naser Aldaihani Matthew Mulvey Mohammad Habeeb Expertise: Digital, Analog, FPGA, MATLAB Experience: 5 years – GE Healthcare Role: LPI, LMM 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

318-595 Project Presentation #2 – 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

CTD Thermal Manager (DTM) Description: The project is intended for thermal management of next generation CT system. As we all know thermal management is a very important part of any design both from optimal functionality and reliability point of view. This document will describe the functionality of the controller. The detector thermal controller is designed to maintain rails at a uniform temperature, which is critical for controlling the photodiode and preventing any changes to the rail temperature profile. Changes in the rail temperature or the temperature profile can lead to IQ errors due to poor diode temperature control. Advantage to the User: Provides capability to the user to control multiple devices. Every parameter programmable with PIC Microcontroller. Ethernet communication with web browser based design.

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

Performance Requirements (DTM) Power Voltages: 12V (+/-5%) 5V (+/-5%) – 70mA 3.3V (+/-5%) – 65mA Digital Processor: 25MHz, 16bit resolution Ethernet: 10MHz Thermistor Accuracy: +/-0.2C 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

Business Case Category Price Comment NRE Charges $15,000 Fab. + Components PWB (Fab.) Charge $50/ Board Production Price BOM Price $240/ Board PWA Price (Finished Board) $350/ Board - At 40% mark-up, it will take 10 months to make any profits.

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.

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 the performance of the thermal manager, even if there is some negative impact on business (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.

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.

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.

Min Block Diagram Description # Block Name Owner Brief Description Of Block Function Power Interface Digital Interfaces Analog Interface 1 Power management and Processor Mayank Use 48V DC source and provide multiple volatges to different sections of design, also work on processor to Ethernet interface. 48V, 20A Power Supply Microcontroller, Ethernet None 2 Thermistor and pressure circuits Naser Monitoring the temperatures and velocity sensors and interface to the processor. 5V from Block 1 Microcontroller 3 Heater and SSR circuits Matt SSR control will be providing control signal to 1KW heater controlled by SSR, assist in Ethernet interface. 48V, 12V Power from Block 1 4 Fan and Pump control Mohammad Control the speed of the pump and fan. Provide power to 150 W pump and design there interface to processor 48V, 12V, 5V Power from Block 1

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.

Fire, Explosion or Shattering Mitigation Design/Devices/Materials/Packaging 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

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

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

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

Power management and Processor Description: 48V DC Power Supply: 48VDC +/- 10%. Supply ripple within 2.0 volts peak at 10Hz to 25KHz. Power traces must be sized to handle 20A minimum current. Purpose: Use 48V DC source and provide multiple voltages to different sections of design, also work on processor to Ethernet interface.

Power management and Processor

Power management and Processor

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: - 2 Pressure Sensor: Voltage: 12V, 25mA. 0-500PSI 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

Thermistor, Velocity Sensor, Pressure Sensor

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 25mA

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: 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

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

SSR Heater Control Performance Requirements: Standard Requirements Purpose: Provide On/Off capability to the SSR to control externally a 1KW heater. Performance Requirements: Description: - SSR: Voltage: 12V, 30mA max. 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

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

Ethernet Network Ethernet PC PC File server Ethernet: network topology that defines physical connection standards and signal transmission standards, so we don’t have to. Devices with Ethernet capable Microcontrollers (PIC18F97J60) Already exists in many buildings PC PIC18 Thermal manager Ethernet Network PC PIC18 Other device File server PIC18 Other device 28

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 PC with browser PIC18 Thermal manager Ethernet – TCP/IP connection 29

We need the PC and the Microcontroller to communicate over the Ethernet network: Enter TCP/IP TCP/IP is one network protocol that can run on Ethernet. It defines the addressing and communication standards. It is everywhere, (the internet is based on TCP/IP) Allows communication between familiar internet building blocks like web servers and web browsers. Web client (PC with browser) Web server Fire Fox Web page xyz Web page xyz Web page xyz Web page xyz 30

TCP/IP stack source code 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 Pins Ethernet Pins Web page xyz Circuits for Fan, heater, etc. TCP/IP services Ethernet Jack 31

Browser-based user interface for Thermal manager: Thermal Manager Status Control Options: Board power: normal PIC18 operation: normal Rail temp: ??? Fan speed: ??? Heater power output: ??? Pump output: ??? Rail temp setpoint Fan: Auto control Manual control Heater: 123 456 Enter 32