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
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