A.F.C.I. – Group 12

Alumoline Fuel-Cell InstrumentationNissan GT-R

Naman ChopraSuan-Aik Yeo

Ronny WijayaDarin Tanaka

Modified Fuel-Cell EV

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 Diagram48V-12V

Regulator

ATOM Board

Freescale9S12C32

48 V EV Battery

Pack

7 Inch Touch Screen(USB) LCD

VCC (5V)

ATD2

SPI4 wire

SCI

VCC (5V)

VGAUSB

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)

ATD4ATD3

Packaging

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 SensorsOmega kqss-116u-18

K-type cold junction thermocouple

Pressure Transducer SensorsGE PMP1260

8-30V operation 1-5V output

Intel Atom 3.5” MotherBoardAdvantech PCM-9361

Intel Atom 3.5” MotherBoardAdvantech 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 displayXenarc 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

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