1. 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

2. Aluminum Alloy

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

4. 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.

5. 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

6. Packaging

7. Main Display

8. Graph Display

9. Microcontroller: Freescale 9S12C32

10. 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)

11. Power Supply: VKP100MT 48V-12V regulator

12. 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

13. 12V-5V regulator: LM22677 Switching Regulator  Up to 5A operation

14. 5V-3.3V regulator: TPS7233QP Linear Regulator  Also used in ECE362 mini project

15. SD reader system

16. 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

17. Thermocouple Amplifier IC: AD595AQ

18.  Translates output of K-type thermocouples to microcontroller-friendly voltages  10 mV/C output

19. Thermocouple Temperature Sensors Omega kqss-116u-18  K-type cold junction thermocouple

20. Pressure Transducer Sensors GE PMP1260  8-30V operation  1-5V output

21. Intel Atom 3.5” MotherBoard Advantech PCM-9361

22. 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

23. 8” LCD Touchscreen display Xenarc 800TSV VGA in, touchscreen USB out 9V-30V operation @ <= 14W Reputable brand Found lightly used model for low price

24. 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

25. View from above

26. 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

27. Interfaces – RS-232 Uses the SCI feature of the µc Provides the RS-232 header Interfaced by MAX3232CD Circuitry mimic the development board

28. Interfaces – Sensors Uses the ATD feature of the µc Cold Junction Thermocouples Interfaced with amplifiers

29. µc Related - Oscillator Bypass capacitors nearby Optional external oscillator Employ the other side

30. µc Related – Dev. pins I/O pins header for debugging BDM pins header for programming Give enough space for trace routing

31. Power Supply – Regulators Main power: 48 Volts Battery Voltage regulator from 48 Volts to 12 Volts VKP100MTC Load resistors

32. Power Supply – Reg. (cont.) 12 Volts to 5 Volts LM22677 For µc 5 Volts to 3.3 Volts TPS7233QP For SD card module

33. View from above

34. View from above (auto-route)

35. Project Timeline March 5 - Complete proof of parts - finalize sensor installation - finish layout of PCB schematic - installation of Ubuntu on CF and environment setup

36. Project Timeline cont.- March 12 - initial software for Micro Controller and Atom board - finish routing of PCB

37. Project Timeline cont. March 26 - Complete software for Atom board - Begin PCB soldering - Complete software for Micro Controller

38. 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

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

40. 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