ASI-STS

AERO SIMULATION INC.

SMART
TEMPERATURE SENSOR
THE BEST TEMPERATURE
SENSORS FOR ALL YOUR FLIGHT
SIMULATION NEEDS.

Our team

Alexis Johndrow
Alexander Dalzell
Chris Williams
Clayton Dale

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

Our Backing
Our Adviser:
Dr. Uysal
RFID and Signal
Processing

Our Company
Partner:
Aero Simulation Inc

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

Problem

Overheating computer banks take

days to fix
Our system stops this by:
Monitoring the system
Allowing personnel to know when there is a
problem
Shutting down systems before real problems
occur

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

ASI-STS

Aero Simulation Inc. Smart Temperature

Sensor

Legacy Design Overview

Over-temp Warning System

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

AC/DC Power System

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

AC/DC Power System

5 VDC Power Supply (Meanwell)

2 AMP max continuous

DIN rail mounted
Built in protection
1.
2.
3.

Overload
Over voltage
Short Circuit

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

AC/DC Power System

Interconnectivity

120 VAC feedthrough socket

Standard Nema power cord
Phoenix terminal blocks

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

I2C System

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

I2C System

Microprocessor (FRDM KL25Z)

32 Bit ARM Cortex-M0+ Core

48MHz, 16KB RAM, 128KB FLASH
I2C x 2
GPIO x 50

Temperature Sensors (TI TMP100)

12 bits of resolution
8 configurable addresses

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

I2C System

LCD (Newhaven Character LCD)

20x2 display format

Chip on glass
Transflective
Only one address allocation

1 to 8 I2C mux (TI)

Expands an I2C master bus

Combines 8 slave buses with master bus
Configure in any combination
Used for devices with limited address allocation

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

I2C System

Interconnectivity

Shielded RJ-45 feedthrough connectors

Shielded CAT5 cables
Phoenix terminal blocks

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

Host Notification System

If temp < 90F, DO = 0

If temp >= 90F, DO = 1

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

Host Notification System

FTD Interface Socket

Ideal for 22 gauge signal wire

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

LED Warning System

If temp < 90F, LED OFF

If temp >= 90F, LED ON

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

LED Warning System

Red panel mount LED

2.2 VDC/20 mA

2N3904 BJT

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

Buzzer Warning System

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

Buzzer Warning System

Buzzer: 3 28 VDC
Momentary Push Button
2N3904 BJT

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

System Overview

Wireless System

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

19

System Overview

Bluetooth Modules

Master & Slaves: BlueGiga BLE112

Bluetooth 4.0

Up to 7 simultaneous connections

Low Power
SPI communication
U.FL connector for external antenna
Edge pins for soldering ease

Microcontroller

On sensor boards only

Atmel ATXMEGA128A3U

I2C and UART capability

TQFP footprint for easier soldering
More familiar and easier to program

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

20

System Overview
Prototype Phase

Schematics

Layout

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

Fabrication

21

System Overview
Bluetooth Board

Two versions:

Hub

Sensor
Both versions use same board
Hub:

No MCU

Powered by rail

Hub program on BT module

Master with up to 8 connections

Sensor:

Atmel Xmega MCU

Powered by battery or rail

Sensor program on BT module and MCU

Slave with only 1 connection

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

22

System Overview
Android App

Connects to sensor directly

Displays:

Sensor data in real time

Device address

Raw data format

Three temperature formats:

Fahrenheit

Celsius

Kelvin
Configurable alarm
Future Capabilities:

Connect to hub as slave

Display all 14 sensors at once

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

23

Calculations
LEDs

LED supply approximations

Red
2.2V forward voltage
20 mA

LED

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

24

Calculations
Design Considerations

LED Simulation Data (Multisim)

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

25

Calculations

Buzzer supply approximations

4V forward voltage
20 mA

5V

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

26

Calculations

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

27

Calculations

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

28

Code overview

Sort and display proper data

Microprocessor FRDM Kl25Z
The data will be received from the temperature sensor
and sorted by the microprocessor

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

29

Coding

Essentials:
Declare sensor and LCD addresses
2.
Declare read and configure arrays
3.
Declare all variables
4.
Initialize and configure all devices
While(1){
5.
Read temperature values
6.
Convert to floating Fahrenheit values
7.
Check LED and error conditions
8.
Check buzzer and reset button
9.
Write to LCDs
1.

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

30

System Overview

Testing and Integration

8 Phases
1.

Operate and configure 2 x TMP100 sensors

2.

Integrate 1 x LCD with 2 x TMP100 sensors

.
.
.
.

3.

Ensure accurate temp data

Data displayed on PC monitor
Verification method: Demonstration/Observation (Test Equipment: hair
dryer)

Display both temps on the single LCD

Include error functionality into code
Include LEDs illumination into the code
Verification method: Demonstration/Observation (Test Equipment: hair
dryer)

Integrate 8 x TMP100 sensors, 1 x (1 to 8 I2C mux), and 4 x LCDs

.

Verification method: Demonstration/Observation (Test Equipment: hair

dryer)
EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

31

System Overview

Testing and Integration

4.

Assemble Over-temperature Warning Tray Assembly

5.

Done on site at ASI

Equipment and Technician guidance provided
All parts requiring special equipment and/or mounting
Drills, saws, crimpers, and various other tools used
Verification method: Inspection

Complete Hardwired Test

Involves all 14 x TMP100 sensors and 7 x LCDs

Includes host notification via DOs
Includes audible buzzer alarm and silence pushbutton
13 x 10 CAT5 cables and 1 x 80 CAT5 cable
Test equipment: hair dryer and digital multi-meter
Verification method: Demonstration/Observation

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

32

System Overview

Testing and Integration

6.

Single Sensor Bluetooth Test

7.

2 Sensor Bluetooth Test

8.

Only 1 x TMP100 sensor connected over Bluetooth

Test equipment: hair dryer and digital multi-meter
Verification method: Demonstration/Observation

Only 2 x TMP100 sensor connected over Bluetooth

Test equipment: hair dryer and digital multi-meter
Verification method: Demonstration/Observation

Complete Bluetooth Test

All components tested simultaneously wirelessly

Test equipment: hair dryer and digital multi-meter
Verification method: Demonstration/Observation

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

33

Major Feats

I2C Problems: Wire Length

Integration and Compatibility

Microprocessor

Capacitance of the bus

Insufficient discharge rate
Tau = RC
2200 220
100Hz Frequency

LCDs
Temperature Sensors
LEDs/Alarms

Application Capabilities
EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

34

Major Feats

Bluetooth

Serial Data Line andSerial Clock Linetiming issues

Draining batteries

Adjusted timing manually via bit bang code.

Backup power supply port using AA batteries

Limited funds, tools and skillsets

Free software, group paneling, and parts that could be hand

soldered

Diptrace
Multism Blue
Amel Studio
OSH Park

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

35

Obstacles

Wireless Design
Budget Constraint

Website Information Relay

Language conflict

Application Capability

Relaying more than one temperature

Aesthetics

Component spacing
Wiring

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

36

Mechanical Design | Demo

EEL 4906.001 - Engineering Design1, Jamal Haque Ph.D.

37