Transcript Display

REV-2
Project Carna Detailed Design Review
Team Carna [P08025]
WEBSITE
View Project Summary
Customer Needs List
Specifications
CARNA System Diagram
10 Pump Test Modules
Data Management Centers
Control
DAQ
Charger & Batteries
& DC-DC converters
LUI
Data
Storage
LUI
Data
Storage
Data Storage
Mock Circulation
Loop
Sensors/
Actuators
Control
Tank
Sensors/
Actuators
Health
Monitor
Power
Plant
Tank System and Modular Loop – Rev1
Modular Loop Sensor and Control Brick
Tank System and Modular Loop – Rev2
Tank System and Modular Loop – Rev3
Comparison of Two Tank vs. Inline Pump Design
Pressure Needed at inlet of loop to obtain max pressure at inlet of LVAD
96
Pressure Loss + Pressure at LVAD inlet (inH2O)
90
84
78
72
66
60
54
48
42
36
30
24
0
1
2
3
4
5
6
7
8
Flow rate (L/m in)
Tw o Tank -- 3/4" tubing w ith 1" globe valve
Inline Pump -- 1/2" tubing w ith 1" globe valve
9
10
Flow/Pressure Control
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
Globe Valve Overview
 Best Suited Control: Linear and Equal
percentage
 Recommended Uses:
1. Throttling service/flow regulation
2. Frequent operation
 Applications: Liquids, vapors, gases, corrosive
substances, slurries
 Advantages:
1. Efficient throttling
drop
2. Accurate flow control
3. Available in multiple
ports
http://www.cheresources.com/valvezz.shtml
Disadvantages:
1. High pressure
2. More expensive
than other valves
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]
FUTURE WORK
Phone on
A Chip
Cellular Network
MCU
Health Network
Health Monitor
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.
FUTURE WORK
Power Plant (Single Fault Tolerant Switch) – Rev1
Manuel by-pass
main power
A.T.S.
(Automatic
auxiliary power
Transition
Switch)
Quality Surge
Suppression
Energy Storage 1
Create requested
output voltages
V1A
Fault
Tolerant
Switching
Energy Storage 2
Manuel by-pass
Create requested
output voltages
V1B
V10A
V10B
VAC,1
VAC,2
Off the shelf UPS
FUTURE WORK
Power Plant – Off the Shelf Industrial Supply Concept – Rev2
Main
Aux
Auto
Transfer
Switch
Surge
Suppression
DC
Power
Supply
Battery
Backup
Module
Redundancy
Module
DC
Batteries
DC
Power
Supply
Redundancy
Module
Battery
Backup
Module
Batteries
UPS
AC1
AC2
UPS
Data Management Center – Rev 1
Loop and Tank
Parameters
Accessible
From LUI
DAQ 1
DAQ 2
Internal Network
Switch
10/100/1000 Base-T
Who is Master DAQ ?
LUI
Organize Data
WEB Server
SFTP
SMTP
Redundant Storage Array
SSH
Health Network RS232
Firewall
World-Access
Control Network RS232
Send Master Data Only??
DMC
Data Management Center – Rev2
LUI
PTM
Comm.
PTM #1
Heartbeat
PTM #2
Node 1
Internet
MySql Database
PTM #3
PTM #6
PTM #7
PTM #8
Parallel
Ethernet
Switch
LUI
Node 2
MySql Database
Firewall
RAID-1
Storage
Services
PTM #9
PTM #10
Heartbeat
PTM
Comm.
PTM #5
RAID-1
Storage
Firewall
PTM #4
Services
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.
CARNA [Dry]: Parallel redundant PCs
100BaseT Internal Network
Breakout Box
Multiplexer
Multiplexer
Data Management
Center
LUI
Health Monitor
System Signals Line from [Wet] CARNA and Pumps
Health Network
Breakout Box
Control Network
DAQ 2
(PC)
Health Network
DAQ 1
(PC)
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
PTM 1
Pump 2
Loop 2
PTM 2
Pump 3
Loop 3
PTM 3
Pump 4
Loop 4
PTM 4
Pump 5
Loop 5
PTM 5
Single Fault Tolerance
If one PTM unit fails, ALL pump
signals are still measured.
Pseudo Double Fault Tolerance
Pump 6
Loop 6
PTM 6
Pump 7
Loop 7
PTM 7
Pump 8
Loop 8
PTM 8
Pump 9
Loop 9
PTM 9
Pump 10
Loop 10
PTM 10
If 2 non-adjacent PTM units fail,
ALL pump signals are still
measured.
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 microcontroller, 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 sec ond
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
Pump Test Module Rev 4.0
1+
11
> 80 GB Harddrive
2+
2-
16:1 MUX
> 1 GHz
uProcessor
Analog
Out
Ethernet
USB
32
Digital
I/O
42+
42-
Messages to
& from DMC
USB 2.0
16:1 MUX
…..
…..
Analog
In
Health Monitor
1 GB RAM
RS232
RS232
NI - USB6225
Small PC
4
MUX select
Instrumentation Amps
Flow Loop
Control
Filters and Power
Amplifiers
Data to DMC
Flow Loop
Pump 1
DMC Node 1
Loop 1
Handshake
Re-circulating RAM Buffer
NI DAQmx
RAID
Buffer
Label
Pump / Loop Analysis
PTM
Out-of-Control
Thin Data
All Data
MySql – RAID-1
Handshake
Schedule
Valve
Control
NI DAQmx
Label
Pump 2
In-Control
Loop 2
Hub
DMC Node 2
Handshake
Re-circulating RAM Buffer
Pump / Loop Analysis
In-Control
Out-of-Control
Thin Data
All Data
MySql – RAID-1
HANDSHAKE
PTM
Ready?
Data Compression
Receive
If ready
Ready?
De-Compression
If not ready,
Record Who and When
Pass to the buffer
Split Handshake
Flags to Health Monitor
HANDSHAKE
DMC
TCP/IP
Send
HANDSHAKE
Node Specific
PTM
Ready?
Receive
Buffer Data from RAID
Ready?
If not ready, wait…
If ready, then catch up
and return to shared
Handshaking.
De-Compression
Pass to the buffer
DMC
Flags to Health Monitor
SPLIT HANDSHAKE
Pump Simulator
HE 1
HE 2
Differenced HE 1
HE 4
Differenced HE 2
HE 5
LVADR2-Simulator
(Microcontroller or
PC NI/Labview)
HE 6
HE 7
HE 8
DAC Array
HE 3
Differenced HE 3
Differenced HE 4
AMB 1
AMB 1
AMB 2
AMB 2
Motor Speed
Motor Speed
GRND
Digital Signals
5V
Analog Voltages
CARNA
LVAD simulator
Overview
 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
LVAD simulator
Overview

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
LVAD simulator
Voltage divider
Resistors about 10k
8 HE sensor signals
NI DAQ card
(4 analog out)
Input Current
AMB current
Motor current
simulate
•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
•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
User interface
menus
Play a set of recorded data
choose
Set1
Provided by
Customer
Set2
Set3…
Simulate data
choose
Normal
functionni
ng
Cases of
failure..
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.