A.F.C.I. – Group 12 Alumoline Fuel-Cell Instrumentation Nissan GT-R Naman Chopra Suan-Aik Yeo Ronny Wijaya Darin Tanaka Modified Fuel-Cell EV

Aluminum Alloy

Experimental Reactor and Pressure Controller Up to 20 KG of Alloy (88 kWhrs of H 2 )

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 48V-12V Regulator ATOM Board Freescale 9S12C32 Freescale 9S12C32 48 V EV Battery Pack 48 V EV Battery Pack 7 Inch Touch Screen(USB) LCD VCC (5V) ATD2 SPI 4 wire SCI VCC (5V) VGA USB 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) ATD4 ATD3

Packaging

Main Display

Graph Display

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

Converts 48V car battery to 12V for our system Two 12V one 3.3V 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

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

 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

Fanless Cheapest model available that met all requirements: Small form factor, serial port, VGA port, CF slot No built-in power supply ATX power: 2.38A and 0.09A

8” LCD Touchscreen display Xenarc 800TSV VGA in, touchscreen USB out 9V-30V <= 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 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

Major Components LCD Screen Atom Board Pressure Sensor Temperature Sensor Micro Controller

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