Detailed Design Review - EDGEedge.rit.edu/edge/P08025/public/Detailed Design Review.pdfProject Carna...

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Transcript of Detailed Design Review - EDGEedge.rit.edu/edge/P08025/public/Detailed Design Review.pdfProject Carna...

  • Project Carna Detailed Design Review

    Team Carna [P08025]

    View Project Summary

    WEBSITE

    REV-2

  • Customer Needs List

  • Specifications

  • CARNA System Diagram

    DAQ

    Data

    Storage

    Power

    PlantHealth

    Monitor

    LUI

    Tank

    Control

    Sensors/

    Actuators

    Mock Circulation

    Loop

    Control

    Sensors/

    Actuators

    Data Storage

    Charger & Batteries& DC-DC converters

    10 Pump Test Modules

    Data

    StorageLUI

    Data Management Centers

  • Tank System and Modular Loop Rev1

  • Modular Loop Sensor and Control Brick

  • Tank System and Modular Loop Rev2

  • Tank System and Modular Loop Rev3

  • Pressure Needed at inlet of loop to obtain max pressure at inlet of LVAD

    24

    30

    36

    42

    48

    54

    60

    66

    72

    78

    84

    90

    96

    0 1 2 3 4 5 6 7 8 9 10

    Flow rate (L/min)

    Pre

    ssu

    re L

    oss +

    Pre

    ssu

    re a

    t L

    VA

    D in

    let

    (in

    H2O

    )

    Tw o Tank -- 3/4" tubing w ith 1" globe valve Inline Pump -- 1/2" tubing w ith 1" globe valve

    Comparison of Two Tank vs. Inline Pump Design

  • What is needed?

    Flow control at the inlet and outlet of LVAD

    What are the specifications?

    Inlet: -20 to 50 mmhg (-0.39 to 0.97 psi)

    Outlet: 0 to 150 mmhg (0 to 2.9 psi)

    What is the proposed solution?

    Integrate a globe valve before and after the

    LVAD, to be controlled by a modulating

    electric actuator

    Flow/Pressure Control

  • Globe Valve Overview

    Best Suited Control: Linear and Equal percentage

    Recommended Uses:1. Throttling service/flow regulation2. Frequent operation

    Applications: Liquids, vapors, gases, corrosive substances, slurries

    Advantages: Disadvantages:1. Efficient throttling 1. High pressure drop2. Accurate flow control 2. More expensive 3. Available in multiple than other valves

    portshttp://www.cheresources.com/valvezz.shtml

  • Globe Valve Selection

    Johnson Controls

    VG7243NT 1 globe

    valve

    Bronze with Stainless

    Steel trim

    Compatible with saline environment

    Factory coupled with

    modulating electric

    actuator

  • Electric Actuator

    Johnson Controls VA-7152 electric valve actuator

    Proportional control

    An electronic controller provides the proportional input signal

    This signal is compared to the actual valve position via the internal feedback potentiometer

    Failsafe open

  • Heat Transfer of Tank

    Tank Template [Excel]

  • MCUPhone on

    A Chip

    Health N

    etw

    ork

    Function:

    Communicate with

    main subsystems. Get

    health status. Periodically

    ship data to the Server

    for long-term storage. The

    ability to voice-call/sms and

    email through cellular

    network.

    Cellular Network

    Health Monitor

    FUTURE WORK

  • Fault Tolerant Switching

    Create requested output voltages

    main power

    auxiliary power

    A.T.S.(AutomaticTransition Switch)

    Quality Surge Suppression

    Energy Storage 1

    Energy Storage 2Create requested output voltages

    Manuel by-pass

    Manuel by-pass

    V1A

    V1B

    V10A

    V10B

    Off the shelf UPS

    VAC,1

    VAC,2

    Power Plant (Single Fault Tolerant Switch) Rev1

    FUTURE WORK

  • AutoTransfer

    Switch

    SurgeSuppression

    DCPower

    Supply

    BatteryBackup

    Module

    UPS

    UPS

    Batteries

    RedundancyModule

    DCPower

    Supply

    BatteryBackup

    Module

    Batteries

    RedundancyModule

    DC

    AC1

    AC2

    Main

    Aux

    Power Plant Off the Shelf Industrial Supply Concept Rev2

    FUTURE WORK

  • Data Management Center Rev 1

    DAQ 1

    DAQ 2

    Contro

    l Netw

    ork

    RS

    232

    LUI

    WEB Server

    SFTP

    SMTP

    SSHRedundant Storage Array

    Internal Network

    Switch

    10/100/1000 Base-T

    DMC

    Health Network RS232

    Who is Master DAQ ?

    Organize Data

    Send M

    aste

    r Data

    Only

    ??

    Firewall

    World-Access

    Loop and Tank

    Parameters

    Accessible

    From LUI

  • RAID-1

    Storage

    Parallel

    Ethernet

    Switch

    Data Management Center Rev2

    MySql Database

    Fire

    wall

    Serv

    ices

    PTM #2

    PT

    M

    Com

    m.

    RAID-1

    Storage

    MySql Database

    Fire

    wall

    Serv

    ices

    PT

    M

    Com

    m.

    Node 1

    Node 2

    Heartbeat

    Heartbeat

    PTM #4

    PTM #1

    PTM #7

    PTM #3

    PTM #8

    PTM #10

    PTM #5

    PTM #6

    PTM #9

    Internet

    LUI

    LUI

    Touch

    Screen

    Display

  • Pump Test Module Version 1.0 (Redundant DAQ and Multiplexing)

    Two computers with each having a DAQ card recording data (signals

    from CARNA).

    Information is then passed into the DMC (Data Management Center)

    through Ethernet.

  • 100BaseT Internal Network

    DAQ 1(PC)

    DAQ 2(PC)

    Breakout Box Breakout Box

    Multiplexer Multiplexer

    Data ManagementCenter

    Health Monitor

    Health

    Network

    System Signals Line from [Wet] CARNA and Pumps

    Control N

    etwork

    Health

    Network

    LUI

    CARNA [Dry]: Parallel redundant PCs

  • Pump Test Module - Conflicts with v 1.0

    Very expensive in purchasing two DAQ cards for dual PCs

    Repetitive tasks are done in recording data, the two PCs and the DMC

    all recording data.

    Electrical design will be more complicated and more time intensive.

    The added complexity of having all the multiplexing and two PCs did not

    seem robust or cost effective.

  • Pump Test Module Revision 2.0 (One Micro-controller)

    Pump Test Module (PTM) has one micro-controller (with an Ethernet

    daughterboard connected to it - for network access) attached to a pump

    controller

    Handles the signals coming from CARNA and distributes the data

    between the DAQ Controller and Main Controller

    Pseudo Double-fault tolerance achieved by a daisy chain configuration.

    Each PTM watches two pumps.

  • Pump 1 Loop 1

    Pump 2 Loop 2

    Pump 3 Loop 3

    Pump 4 Loop 4

    Pump 5 Loop 5

    Pump 6 Loop 6

    Pump 7 Loop 7

    Pump 8 Loop 8

    Pump 9 Loop 9

    Pump 10 Loop 10

    PTM 1

    PTM 2

    PTM 3

    PTM 4

    PTM 5

    PTM 6

    PTM 7

    PTM 8

    PTM 9

    PTM 10

    Single Fault Tolerance

    If one PTM unit fails, ALL pump

    signals are still measured.

    If 2 non-adjacent PTM units fail,

    ALL pump signals are still

    measured.

    Pseudo Double Fault Tolerance

  • Pump Test Module - Conflicts with v 2.0

    Amount of data moving from between the DAQ Controller and Main

    Controller (294 Kb/sec) is large, using a 8-bit bus

    PIC 24 micro-controllers can execute around 40 million instructions per

    second.

    Large amount of data will cause bottleneck traffic with only one micro-

    controller, this will cause the micro-controller to spend most of its time

    moving the data.*

    136 instructions executed within a micro-controller is too much, since it

    also have to handle all or their other individual tasks.

    4000000 instructions per second

    294000 bytes per second=136 instructions per second

    *

  • Pump Test Module Revision 3.0 (Using two micro-controllers)

    By increasing the data bus to 16-bits, the number of transfers can be cut

    in 2.

    Instead of using a parallel interface, SPI (serial peripheral interface) bus

    can be used.

    Using a daisy chain SPI configuration with the other PTMs will allow the

    first slave output being connected to the second slave input, etc.

  • Pump Test Module Revision 3.0

    Two micro-controllers will handle 42 analog inputs.

    The PTM micro-controllers (2) must:

    Sample 28 inputs at 5kHz

    Sample 14 inputs at 500Hz

    Organize the data into blocks

    Transfer the data to Flash (temporary storage)

    Control the Ethernet controller

    Control the flow loop actuators

    One micro-controller would do the analog-to-digital conversion and store

    the data in its RAM in a large FIFO buffer.

    The other micro-controller would handle all other tasks, and read the

    data from the first micro-controller.

  • Pump Test Module Revision 3.0 - Overall Layout

  • Pump Test Module - Overall Sampled Signals

  • Pump Test Module - Conflicts with v 3.0

    SPI modules do have several disadvantages:

    No in-band addressing; out-of-band chip select signals are

    required on shared buses

    No hardware flow control

    No slave acknowledgement, the master could be talking to

    nothing and not know it.

    Once the data is in the Main Controller, it has to be buffered, sent to

    the flash chip (temporary storage), and sent out through the Ethernet.

    Multiple instruction cycles are needed to perform the data transfers.

  • Pump Test Module Revision 4.0 (Redundant PTM modules)

    Use of NI PCI-6225 card, replaces the two micro-controllers

    In addition, PTM needs a PC in order to:

    Receive data from the DAQ

    Receive control messages from the DMC

    Store the data locally

    Send the data to the DMC through Ethernet

    Communicate with the Health Monitor

  • Specifications of NI PCI 6225

    80 Analog Inputs; 16 Bit resolution

    2 Analog output; 16 Bit resolution

    Analog Output Range; +/- 10V

    24 Digital I/O Lines

    8 Correlated (clocked) I/O's, 1 Mhz

  • Pump Test Module Revision 4.0

    Role of the PCI-6225 DAQ

    Sample 26 critical signals

    Sample 16 critical signals, 14 at 5Khz, and 2 at 500Hz

    Buffer Data and store locally on Shuttle PC

    Send buffered data to the Data Management Center through Ethernet

  • Analog

    In

    Eth

    ern

    et

    Data to DMC

    Pump Test Module Rev 4.0

    1

    32

    ..

    NI - USB6225

    USB> 1 GHz

    uProcessor

    RS232

    1 GB RAM

    > 80 GB Harddrive

    US

    B 2

    .0

    Small PC

    RS232

    Digital

    I/O

    MUX select

    Health Monitor

    Flow Loop Control Flow Loop

    Filters and Power Amplifiers

    Messages to & from DMC

    4

    Analog

    Out

    16

    :1 M

    UX

    16

    :1 M

    UX

    ..

    1+1-

    2+2-

    42+42-

    Instrumentation Amps

  • Hub

    DMC Node 1

    DMC Node 2

    Pump 1 Loop 1

    Pump 2 Loop 2

    Handshake

    Handshake

    Re-circulating RAM Buffer

    Pump / Loop Analysis

    In-Control

    Thin Data

    Out-of-Control

    MySql RAID-1

    Handshake

    Re-circulating RAM Buffer

    Pump / Loop Analysis

    In-Control

    Thin Data

    Out-of-Control

    MySql RAID-1

    All Data

    All Data

    NI DAQmx

    NI DAQmx

    RAID

    Buff

    er

    Label

    LabelValve

    Control

    Schedule

    PTM

  • TCP/IP

    HANDSHAKE HANDSHAKE

    HANDSHAKE

    Ready?

    Ready?

    Data Compression

    De-Compression

    Send

    If not ready,

    Record Who and When

    If r

    ead

    y Pass to the buffer

    ReceiveF

    lags to

    Health

    Monito

    r

    Split Handshake

    Ready?

    De-Compression

    Pass to the buffer

    Receive

    Fla

    gs to

    Health

    Monito

    r

    SPLIT HANDSHAKE

    Ready?

    Node Specific

    If not ready, wait

    Buffer Data from RAID

    If ready, then catch up

    and return to shared

    Handshaking.

    PTM

    PTM

    DMC

    DMC

  • LVADR2-Simulator

    (Microcontroller or

    PC NI/Labview) DA

    C A

    rra

    y

    HE 1

    HE 2

    HE 3

    HE 4

    HE 5

    HE 6

    HE 7

    HE 8

    CARNA

    Differenced HE 1

    Differenced HE 2

    Differenced HE 3

    Differenced HE 4

    5VGRND

    AMB 1

    AMB 2

    Motor Speed

    AMB 1

    AMB 2

    Motor Speed

    Digital Signals Analog Voltages

    Pump Simulator

  • LVAD simulator

    Simulates LVAD Signals (Provided by LVAD-R2 Controller)

    8 Hall Effect sensors, to characterize the displacements of the

    Impellers overtime

    AMB currents: active magnetic bearing are to correct the

    position of the impeller, LVAD outputs 2 signals

    Motor current, voltage related to the current consumed in a 3

    phase, brushless DC motor

    Power consumption

    Overview

  • LVAD simulator

    Waveforms generated by National Instruments card

    NI6052-E or NI6221, those cards can both produce 2 outputs with an

    aggregate sampling rate of above 360kS/sec.

    The LVAD simulator will simulate normal functioning of the LVAD-R2 and

    Controller and to simulate failures

    The LVAD simulator will also help test and validate the functioning of the

    DMC and PTM.

    Testing the sampling and recording capacities of our system

    Testing the abilities to recognize and to treat failures so that the DMC

    can thin, or not, the data

    Overview

  • NI DAQ card(4 analog out)

    Voltage divider

    Resistors about 10k8 HE sensor signals

    Input Current

    AMB current

    Motor current

    Simulate: 8 HE sensors generating 8 signals in the real LVAD, we simulate only one , divide its

    voltage to distinguish between the 8 signals

    AMB currents simulated by one signal

    simulate

    Motor current, voltage related to the current consumed in a 3 phase, brushless DC motor, simu

    Power consumption (Input Current at a fixed voltage?

    LVAD simulator

  • Play a set of recorded data

    Simulate data

    Provided by

    Customer

    choose

    Set1 Set2 Set3

    choose

    Normal functionni

    ng

    Cases of failure..

    User interface

    menus

    LVAD simulator

  • Failures to simulate:

    HE sensor signal going out of range. Statistical calculations based on the available sets of data can highlight an amplitude range beyond which LVAD is malfunctioning

    HE frequency too high. The typical frequency should not exceed 500Hz, for the HE sensor signal

    Inconsistent motor current : The motor current should not be stuck to a value, but instead of

    oscillating periodically.

    Those cases of failures will be discussed later while specifying what kind of failures DMC will be

    sensitive to. The DMC will decide to thin to data, ie to store less data when there is no obvious

    problem is the pump. Based on what criteria it uses, other cases of failure will be generated by the LVAD simulator.

    Some more complex cases might require more outputs dedicated to one type of signal. For

    example, the slamming of the impeller against the shaft, extreme case, would require more than 1

    HE output to be simulated. Our software will allow the assignment of several outputs of the NI DAQ card to one type of signal (HE, AMB current, motor current) to simulate complex cases.

    LVAD simulator