Preliminary Design
Version 7 (Aaron Harper, 02/07/2013 06:05 pm)
1 | 6 | Aaron Harper | h1. Power/Temp Monitor and Control System (EPS/ECLSS) Preliminary Design |
---|---|---|---|
2 | 1 | Aaron Harper | |
3 | 2 | Aaron Harper | {{toc}} |
4 | 2 | Aaron Harper | |
5 | 2 | Aaron Harper | h3. Introduction |
6 | 2 | Aaron Harper | |
7 | 2 | Aaron Harper | This design document is broken down in to multiple sections: the Preliminary Design Criteria Review, the Preliminary Schematic, the Preliminary Bill of Materials, and finally the Preliminary Budget. Each of these sections has information which is preliminary in nature, yet attempts have been made to make these as accurate as possible. |
8 | 2 | Aaron Harper | |
9 | 2 | Aaron Harper | h3. Preliminary Design Criteria Review |
10 | 2 | Aaron Harper | |
11 | 2 | Aaron Harper | * *EPSRR 1.1* The EPS board uses a Texas Instruments MSP430 microcontroller to measure and store the sensor data |
12 | 2 | Aaron Harper | * *EPSRR 1.2* the EPS board is made from components which are rated beyond the specification as listed, and the system will operate without direct intervention by an operator. |
13 | 2 | Aaron Harper | |
14 | 2 | Aaron Harper | * *EPSRR 2.1* The EPS board is designed in such a way that it may be installed by any person with solar power or electrical wiring experience. |
15 | 2 | Aaron Harper | * *EPSRR 2.2* The EPS board will have screw holes to mount the board using #10 screws. Alternatively, a DIN rail clip may be used. |
16 | 7 | Aaron Harper | * *EPSRR 2.3* The EPS board can draw it's power from any 6-30VDC source. |
17 | 2 | Aaron Harper | |
18 | 2 | Aaron Harper | * *EPSRR 3.1* The EPS board shall measure predefined parameters. |
19 | 2 | Aaron Harper | ** *EPSRR 3.1.1* The EPS board measures the ambient temperature in the enclosure using a sensor on the board. |
20 | 2 | Aaron Harper | ** *EPSRR 3.1.2* The EPS board measures voltages of two separate circuits directly with a chip that has built in isolation. |
21 | 2 | Aaron Harper | ** *EPSRR 3.1.3* The EPS board limits the input voltage to the sensor to safe levels using a zener and current limiter. |
22 | 2 | Aaron Harper | ** *EPSRR 3.1.4* The EPS board measures the current of two separate circuits using a directly with a chip that has built in isolation. |
23 | 2 | Aaron Harper | * *EPSRR 3.2* The EPS board transmits measurement data or fault conditions to the server using a MAC chip with full TCP/IP stack. |
24 | 2 | Aaron Harper | ** *EPSRR 3.2.1* The EPS board will transmit measurement data on demand (web page request). |
25 | 2 | Aaron Harper | ** *EPSRR 3.2.2* The EPS board will be capable of transmitting measurement data on a schedule (FTP or email). |
26 | 2 | Aaron Harper | |
27 | 2 | Aaron Harper | * *EPSRR 4.1* The EPS board consumes minimal power. Design maximum is 24mW. |
28 | 2 | Aaron Harper | * *EPSRR 4.2* See *EPSRR 2.3*. |
29 | 2 | Aaron Harper | * *EPSRR 4.3* The EPS board meets all criteria in this area, having a tolerance for massive overvoltage and 12 bit accuracy. |
30 | 2 | Aaron Harper | * *EPSRR 4.4* The EPS board measures temperature within from -20 to 85C with 12 bit accuracy. |
31 | 2 | Aaron Harper | * *EPSRR 4.5* The EPS board meets all criteria in this area, having a tolerance for massive overcurrent and 12 bit accuracy. |
32 | 2 | Aaron Harper | * *EPSRR 4.6* The EPS board meets all criteria in this area, having a MAC controller IC with a fully functional TCP/IP stack and Ethernet Jack with Magnetics. |
33 | 2 | Aaron Harper | |
34 | 2 | Aaron Harper | * *EPSRR 6.1* The EPS board is read using standard web protocols which are standardized across all platforms. |
35 | 2 | Aaron Harper | * *EPSRR 6.2* The EPS board uses standardized connections including Screw terminals and Ethernet. |
36 | 2 | Aaron Harper | * *EPSRR 8.1* The EPS board is optimized for ease of production. |
37 | 2 | Aaron Harper | * *EPSRR 8.2* See ESPRR 8.1. |
38 | 2 | Aaron Harper | |
39 | 3 | Aaron Harper | * *EPSRR 9.2* The production units appear to cost around $60.00 in parts. |
40 | 2 | Aaron Harper | |
41 | 2 | Aaron Harper | * *EPSRR 11.4* Attention has been paid into the durability of the design to keep waste to an absolute minimum. |
42 | 2 | Aaron Harper | |
43 | 2 | Aaron Harper | |
44 | 1 | Aaron Harper | h3. Preliminary Schematic |
45 | 1 | Aaron Harper | |
46 | 1 | Aaron Harper | !Schematic_1.png! |
47 | 1 | Aaron Harper | |
48 | 2 | Aaron Harper | h3. Preliminary Bill Of Materials |
49 | 1 | Aaron Harper | |
50 | 2 | Aaron Harper | |_.Schematic|_.Description|_.Package | |
51 | 2 | Aaron Harper | | C1|68uF Capacitor|SMD | |
52 | 2 | Aaron Harper | | C2|120uF Capacitor|Axial | |
53 | 2 | Aaron Harper | | Cf1|1uF capacitor|SMD | |
54 | 2 | Aaron Harper | | Cf2|1uF capacitor|SMD | |
55 | 2 | Aaron Harper | | D1|1N5817 Schottky diode|SMD | |
56 | 2 | Aaron Harper | | L1|100uH Inductor|SMD | |
57 | 2 | Aaron Harper | | Ra1|47k Ohm .25W Resistor|SMD | |
58 | 2 | Aaron Harper | | Rb1|47k Ohm .25W Resistor|SMD | |
59 | 2 | Aaron Harper | | Rb2|47k Ohm .25W Resistor|SMD | |
60 | 2 | Aaron Harper | | Rf1|4.7 Ohm .25W resistor|SMD | |
61 | 2 | Aaron Harper | | Rf2|4.7 Ohm .25W resistor|SMD | |
62 | 2 | Aaron Harper | | Rf3|4.7 Ohm .25W resistor|SMD | |
63 | 2 | Aaron Harper | | Rf4|4.7 Ohm .25W resistor|SMD | |
64 | 2 | Aaron Harper | | RL1|180 Ohm .5W resistor|SMD | |
65 | 2 | Aaron Harper | | RL2|180 Ohm .5W resistor|SMD | |
66 | 2 | Aaron Harper | | Rs1|.068 Ohm 10W resistor|Axial | |
67 | 2 | Aaron Harper | | Rs2|.068 Ohm 10W resistor|Axial | |
68 | 2 | Aaron Harper | | U1|LM2594M-3.3/NOPB Voltage regulator|SSOP-8 | |
69 | 2 | Aaron Harper | | U2|TMP102 Temp sensor (I2C)|SSOP-6 | |
70 | 2 | Aaron Harper | | U3|INA226 Current and voltage sensor|SSOP-10 | |
71 | 2 | Aaron Harper | | U4|INA226 Current and voltage sensor|SSOP-10 | |
72 | 2 | Aaron Harper | | |3 position jumper block|Std | |
73 | 2 | Aaron Harper | | |5mm barrel jack, 2.1mm center pole|Std | |
74 | 2 | Aaron Harper | | |8 position screw terminals|Std | |
75 | 2 | Aaron Harper | | |Populated Ethernet Booster Pack (MSP430 MCU)|Board | |
76 | 4 | Aaron Harper | | |EPS PC board|Board | |
77 | 2 | Aaron Harper | |
78 | 2 | Aaron Harper | h3. Preliminary Budget |
79 | 2 | Aaron Harper | |
80 | 2 | Aaron Harper | |_.Schematic|_.Description|_.Prototype Cost|_.Production Cost | |
81 | 2 | Aaron Harper | | C1|68uF Capacitor|$.49|$1.15 | |
82 | 2 | Aaron Harper | | C2|120uF Capacitor|$0.62|$0.62 | |
83 | 2 | Aaron Harper | | Cf1|1uF capacitor|$0.14|$1.15 | |
84 | 2 | Aaron Harper | | Cf2|1uF capacitor|$0.14|$1.15 | |
85 | 2 | Aaron Harper | | D1|1N5817 Schottky diode|$0.27|$0.19 | |
86 | 2 | Aaron Harper | | L1|100uH Inductor|$0.18|$0.09 | |
87 | 2 | Aaron Harper | | Ra1|47k Ohm .25W Resistor|$0.37|$0.03 | |
88 | 2 | Aaron Harper | | Rb1|47k Ohm .25W Resistor|$0.37|$0.03 | |
89 | 2 | Aaron Harper | | Rb2|47k Ohm .25W Resistor|$0.37|$0.03 | |
90 | 2 | Aaron Harper | | Rf1|4.7 Ohm .25W resistor|$0.37|$0.03 | |
91 | 2 | Aaron Harper | | Rf2|4.7 Ohm .25W resistor|$0.37|$0.03 | |
92 | 2 | Aaron Harper | | Rf3|4.7 Ohm .25W resistor|$0.37|$0.03 | |
93 | 2 | Aaron Harper | | Rf4|4.7 Ohm .25W resistor|$0.37|$0.03 | |
94 | 2 | Aaron Harper | | RL1|180 Ohm .5W resistor|$0.37|$0.03 | |
95 | 2 | Aaron Harper | | RL2|180 Ohm .5W resistor|$0.37|$0.03 | |
96 | 2 | Aaron Harper | | Rs1|.068 Ohm 10W resistor|$2.14|$2.14 | |
97 | 2 | Aaron Harper | | Rs2|.068 Ohm 10W resistor|$2.14|$2.14 | |
98 | 2 | Aaron Harper | | U1|LM2594M-3.3/NOPB Voltage regulator|$2.70|$2.70 | |
99 | 2 | Aaron Harper | | U2|TMP102 Temp sensor (I2C)|$5.95|$1.69 | |
100 | 2 | Aaron Harper | | U3|INA226 Current and voltage sensor|$6.33|$3.38 | |
101 | 2 | Aaron Harper | | U4|INA226 Current and voltage sensor|$6.33|$3.38 | |
102 | 2 | Aaron Harper | | |3 position jumper block|$.22|$.13 | |
103 | 2 | Aaron Harper | | |5mm barrel jack, 2.1mm center pole|$4.95|$1.12 | |
104 | 2 | Aaron Harper | | |8 position screw terminals|$2.45|$2.45 | |
105 | 1 | Aaron Harper | | |Populated Ethernet Booster Pack (MSP430 MCU)|$25.00|$25.00 | |
106 | 5 | Aaron Harper | | |EPS PC board (in qty. 10)|$0.00|$12.00 | |
107 | 3 | Aaron Harper | | |Subtotal|$58.21|$60.75 | |
108 | 3 | Aaron Harper | | |Labor|$1362.50|$135.52 | |
109 | 3 | Aaron Harper | | |*TOTAL*|*$1420.71*|*$196.27* | |