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lab:ninjascc:hardware [2016/03/15 19:52] – chronolab:ninjascc:hardware [2016/03/25 20:23] – chrono
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-====== NinjaSCC Hardware ======+====== NinjaSCC Hardware Design Specifications ======
  
 {{:lab:ninjascc:ninjascc.sch.svg|}} {{:lab:ninjascc:ninjascc.sch.svg|}}
  
-# Design Specifications 
  
 Desired NinjaSCC Specs to have a common frame of reference during design and Desired NinjaSCC Specs to have a common frame of reference during design and
 documentation phase. documentation phase.
  
-## Input+===== Electrical =====
  
-| Symbol           | Parameter                  | Min  | Typ  | Max  | Unit | +==== PV Input ====
-|:----------------:|:--------------------------:|:----:|:----:|:----:|:----:| +
-| V<sub>MPP</sub>  | PV MPP Voltage             | 11.5 |  18  | 36   | V    | +
-| V<sub>OC</sub>   | PV Open-Circuit Voltage    |      |      | 45   | V    | +
-| I<sub>SC</sub>   | PV Short-Circuit Current   |      |      | 15   | A    | +
-| P<sub>MPP</sub>  | PV MPP Power               |      |      | 250  | W    | +
-| -                | Panel/Cell Configuration   |  18  |  36  | 72   | Cells|+
  
-## Battery+^                   Symbol                    ^         Parameter          ^  Min   ^  Typ  ^  Max  ^  Unit   ^ 
 +|  V<html><sub></html>MPP<html></sub></html>  |       PV MPP Voltage       |  11.5  |  18   |  36   |    V    | 
 +|  V<html><sub></html>OC<html></sub></html>   |  PV Open-Circuit Voltage   |        |       |  45   |    V    | 
 +|  I<html><sub></html>SC<html></sub></html>   |  PV Short-Circuit Current  |        |       |  15   |    A    | 
 +|  P<html><sub></html>MPP<html></sub></html>  |        PV MPP Power        |        |       |  250  |    W    | 
 +|                      -                      |  Panel/Cell Configuration  |   18   |  36   |  72   |  Cells  |
  
-| Symbol           | Parameter                  | Min  | Typ  | Max  | Unit | +==== Battery ====
-|:----------------:|:--------------------------:|:----:|:----:|:----:|:----:| +
-| V<sub>Bat</sub>  | Charge Voltage             | 5    | 13.4 | 45   | V    | +
-| I<sub>Bat</sub>  | Charge Current             |      |      | 15   | A    |+
  
-NinjaSCC will by default fall into a 12V system. Any other check, charge, +^                      Symbol                      ^      Parameter      ^  Min  ^  Typ   ^  Max  ^  Unit  ^ 
 +|    V<html><sub></html>Bat<html></sub></html>     |   Charge Voltage    |   5   |  13.4  |  45   |   V    | 
 +|    I<html><sub></html>Bat<html></sub></html>     |   Charge Current    |       |        |  15   |   A    | 
 +|  Ripple<html><sub></html>rms<html></sub></html>  |  Output Ripple RMS  |       |   15   |       |   mV   | 
 +|  Ripple<html><sub></html>p-p<html></sub></html>  |  Output Ripple P-P  |       |   40   |       |   mV   | 
 + 
 +NinjaSCC will by default fall into a 12V system. Any other check, charge,
 equalize and float setpoints can easily be overriden in software to leave equalize and float setpoints can easily be overriden in software to leave
-more headroom for all kinds of use-cases and many battery types from lead-acid,+more headroom for all kinds of use-cases and many battery types like lead-acid,
 gel,agm and lithium battery packs in the 12V to 36V range. gel,agm and lithium battery packs in the 12V to 36V range.
  
-## Load+Output Current/Voltage ripple and RF noise need to be kept at a minimum, to 
 +increase battery lifetime and allow RF sensitive devices, like remote 
 +SDRs, to be powered by NinjaSCC as well. 
 + 
 +==== Load ==== 
 + 
 +^                    Symbol                    ^       Parameter        ^  Min  ^  Typ  ^  Max  ^  Unit  ^ 
 +|  V<html><sub></html>Load<html></sub></html>  |     Output Voltage     |   5   |       |  45   |   V    | 
 +|  I<html><sub></html>Load<html></sub></html>  |  Cont. Output Current  |       |       |  15   |   A    | 
 + 
 +==== Efficiency ==== 
 + 
 +^                      Symbol                       ^          Parameter          ^  Min  ^  Typ   ^  Max  ^  Unit  ^ 
 +|  BK-MPP<html><sub></html>Eff<html></sub></html>   |  Buck-Mode MPP Efficiency   |       |  98.5  |       |   %    | 
 +|  BST-MPP<html><sub></html>Eff<html></sub></html>  |  Boost-Mode MPP Efficiency  |       |  98.5  |       |   %    | 
 +|    TR<html><sub></html>Eff<html></sub></html>     |     Transit Efficiency      |       |  99.5  |       |   %    | 
 + 
 +==== ADC ==== 
 + 
 +10-bit ARef 5V (Arduino) 
 +12-bit ARef 5V (4 channel external ADC via I2C) 
 + 
 +===== Environment ===== 
 + 
 +^  Symbol  ^          Parameter           ^  Min  ^  Typ  ^  Max  ^  Unit  ^ 
 +|   Temp   |    Operating Temperature     |  -40  |  25   |  85   |   °C   | 
 +|   OTP    |  Overtemperature Protection  |       |  +85  |       |   °C   | 
 +|   OVP    |    Overvoltage Protection    |       |       |  45   |   V    | 
 + 
 +===== PCB ===== 
 + 
 +^   Parameter    ^   Value   ^ 
 +|     Layers     |     2     | 
 +|   Thickness    |   2 mm    | 
 +|     Copper     |   70 µm   | 
 +|   Silkscreen   |   White   | 
 +|   Soldermask   |   Black   | 
 +|  Substrate HQ  |  P96/P26  | 
 +|  Substrate MQ  |   IS410   | 
 +|  Substrate LQ  |    FR4    | 
 + 
 +===== Protection ===== 
 + 
 +==== Electrical ==== 
 + 
 +  * Short-Circuit [HW] 
 +  * Over-Voltage [HW+SW] 
 +  * Over-Current [HW+SW] 
 +  * Adjustable Current Limiter [HW+SW] 
 +  * LVD (Low-Voltage Disconnect of Load) [SW] 
 +  * UVLO (Under-Voltage Lock-Out) [HW] 
 +  * Uncontrolled Back-Channel DC GND return (High-Side Load Switch) [HW] 
 +  * Electromagnetic and Lightning induced extraneous Voltage Transients [HW] 
 +  * Local ESD [HW] 
 + 
 +==== Environmental ==== 
 + 
 +  * Battery Temperature Monitoring (via external 100k thermistor) 
 +  * PV Panel Temperature Monitoring (optional) 
 +  * PCB Temperature Monitoring 
 +  * Over-Temperature controlled Shutdown 
 +  * Fan-Control 
 +  * Assembly PU-Coating 
 + 
 +===== Modes of Operation ===== 
 + 
 +Based on real-time assessment of the operating conditions, NinjaSCC dynamically 
 +determines the optimal operating mode in order to track the maximum power point 
 +of the PV panel, keeping overall conversion efficiency close to 99%. 
 + 
 +  * MPP Tracking Buck-Only (BK) 
 +  * MPP Tracking Boost-Only (BST) 
 +  * MPP Tracking Buck-Boost-Interleaved (BB) 
 +  * Transit (TR)
  
-| Symbol           | Parameter                  | Min  | Typ  | Max  | Unit | +===== Controller =====
-|:----------------:|:--------------------------:|:----:|:----:|:----:|:----:| +
-| V<sub>Load</sub> | Output Voltage             | 5    |      | 45   | V    | +
-| I<sub>Load</sub> | Cont. Output Current       |      |      | 15   | A    |+
  
 +Since Arduinos have been around for a while and have a very broad
 +spectrum of documentation, HOWTOs and open-source code to learn from, the
 +AVR ATMega32U4 8-Bit Microcontroller (with built-in USB support so that
 +we can [[https://hackaday.com/tag/ftdigate/|give FTDI the finger]]) was
 +chosen as the main controller in a fully Arduino-Micro compatible
 +configuration, while adding a couple of protective features to it.
 +This way, NinjaSCC can be used and flashed over USB like any other
 +Arduino-Micro board.
  
-## Efficiency+===== Dedicated USB Charging Port (DCP) =====
  
-| Symbol               | Parameter                | Min  | Typ  | Max  | Unit | +As other USB power sources, like most wall warts and auto adapters, 
-|:--------------------:|:------------------------:|:----:|:----:|:----:|:----:| +NinjSCC does not enumerate the USB output port. Charging can begin 
-| BK-MPP<sub>Eff</sub> | Buck-Mode MPP Efficiency |      | 98.5 |      | %    | +immediately, without any digital communication/negotiation, as defined 
-| BST-MPP<sub>Eff</sub>| Boost-Mode MPP Efficiency|      | 98.5 |      | %    | +in the supplementary USB Battery Charging Specification, Rev 1.1, 
-| TR<sub>Eff</sub>     | Transit Efficiency       |      | 99.5 |      | %    |+4/15/2009 (BC1.1).
  
 +  * Supply 5V up to 1.5A
 +  * DCP mode identified by a short between D+ to D-
 +  * Short-Circuit, Over-Voltage, Over-Current, Over-Temperature protected
 +  * Shares EN pin with Load Switch to maintain LVD ability by default,
 +but can be selected with a solder bridge/0R
  
-## Environment+===== Monitoring & Metrics =====
  
-| Symbol           | Parameter                  | Min  | Typ  | Max  | Unit | +Constantly monitor and collect all relevant system metrics and operating 
-|:----------------:|:--------------------------:|:----:|:----:|:----:|:----:| +parameters and deliver a high-resolution, real-time metrics stream 
-| Temp             | Operating Temperature      | -40  |  25  |  85  | °C   | +over USB to be live-viewed and/or shipped into a metrics storage engine 
-| OTP              | Overtemperature Protection |      | +85  |      | °C   | +like [[https://github.com/influxdata/influxdb|influxdb]] to achieve full 
-| OVP              | Overvoltage Protection     |      |      | 45   | V    |+real-time, remote system awareness, gather long-term data to optimize 
 +the system even further and have a means to analyze/identify sub-optimal 
 +operating conditions which might lead to failure like: Battery temperatures 
 +that are consistently above ambient may indicate high ripple, overcharging 
 +or internal cell shorting.
  
-## PCB+===== Remote Control =====
  
-| Parameter            | Value    | +Any DC/DC regulation parameter can be overriden in software by remote 
-|:--------------------:|:--------:| +controlling NinjaSCC over USB, so playing and experimenting on a live, 
-| Layers               |  2       | +working converter with instant metric feedback will be a great opportunity 
-| Thickness            |  2 mm    | +to study its behaviour while changing parameters and operating modes 
-| Copper               |  70 µm   | +manually. And of course, a fun and hands-on learning assistance while 
-| Silkscreen           |  White   | +teaching buck/boost technology to others.
-| Soldermask           |  Black   | +
-| Substrate HQ         | P96/P26  | +
-| Substrate MQ         |  IS410   | +
-| Substrate LQ         |   FR4    |+
  
-## Protection+===== Resilience =====
  
-### Electrical+Designed in a built-to-last approach, almost all components have been 
 +selected in a range between automotive qualified and up to 
 +aerospace/military grade quality. A non-profit approach is the key here, 
 +because this way the focus gets back where it should belong: On the 
 +product and the component quality it is made of. With attention to detail 
 +and without undue compromise.
  
-    * Short-Current  +To further decrease the chance of total system failure, most important 
-    * Over-Voltage +system blocks and components have been set up n+1 redundant, wherever 
-    * Over-Current +possible and reasonable.
-    * LVD (Low-Voltage Disconnect) +
-    * Undesired/Fatal Back-Channel DC GND return (High-Side Load Switch) +
-    * Electromagnetic and Lightning induced extraneous Voltage Transients +
-    * Local ESD +
-     +
-### Environmental+
  
-    * Battery Temperature Monitoring (optional) +NinjaSCC must withstand gale force sub-arctic winds at -40°C while still 
-    * PV Panel Temperature Monitoring (optional) +providing power to the camera you’ve put out there for over a year, 
-    * PCB Temperature Monitoring +to make a movie about glacier calving or you are in a remote desert at 
-    * Over-Temperature controlled Shutdown ++55°C ambient temperature and need power to operate your water pump.
-    * Fan-Control +
-    * Assembly PU-Coating+
  
 +When you’re truely off-grid, this is the device that must not fail
 +(or at last reasonably max out the chance that it does), because murphy
 +dictates: it usually does so at the worst possible point in time.
  
 First concept: First concept:
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