1. 318-595 Presentation #2 – Project TEAM 1

2. 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

3. 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

4. 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.

5. 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

6. 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

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

12. 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

13. 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.

14. 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.
EMC Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supplies <16A

15. 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.
EMC Part 4: Test/measurement techniques - Section 2: ESD immunity tests

16. 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
EMC Part 4: Test/measurement techniques - Section 8: Power frequency magnetic field immunity tests

17. 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: EMC : Surge immunity tests

18. 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.

19. Power management and Processor

20. Power management and Processor

21. 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

22. Thermistor, Velocity Sensor, Pressure Sensor

23. 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

24. 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

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

26. 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

27. 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

28. 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

29. 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

30. 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

31. 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

32. 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