P19104: HABIP-BioX
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Power Detailed Design

Table of Contents

Feasibility: Prototyping, Analysis, Simulation

Zero Pressure Balloon

One source said that zero pressure balloons are made from very thin (7.5 micron) plastic sheet. Another source has that they are made of a 0.8 mil single layer of LLPDE film. This is a similar material to a grocery bag and will allow most of the solar energy to pass through. Will preform experiment with Zero Pressure balloon material when sensor becomes available.
Zero Pressure Balloon

Zero Pressure Balloon

More information can be found at the resources below.

https://sites.wff.nasa.gov/code820/spb_construction_modeling_analysis.html

https://www.eoss.org/faq/zero_pressure

Key Component Selection

Solar Panel

Solar Panel Selection

Solar Panel Selection

MPPT

MPPT Selection

MPPT Selection

Microcontroller

The MSP432 will be used for the PMB to keep consistency throughout the payload. The BioX Cell board is also using this controller.

Preliminary Detailed Design Documents/Power/MSP432P401R.pdf

I2C Addresses

Device Reference Designator I2C Address
Solar Panel Power Sense U4 100 0000
24V Power Sense U5 100 0101
On Board Temp Sensor U6 100 1000
Battery Power Sense U7 100 0001
Battery Temperature Sense N/A 001 1000
Output Current Monitor 1 U8 001 0000
Output Current Monitor 2 U9 001 0010

12V Regulator

A Buck-Boost topology was chosen for the 12V regulator because the battery voltage can vary between 9V and 12.6V. A buck-boost allows to utilize the full battery voltage range.
LTC3119

LTC3119

Preliminary Detailed Design Documents/Power/LTC3119_12V_Regulator.pdf

3.3V Regulator

The 3.3V regulator is the same one that is used on the CBOB. The 3.3V regulator is need to supply power to the microcontroller and sensors.

24V Regulator

A boost topology was chosen for the 24V regulator. This will be stepping up the 12V regulated voltage to 24V to power the motor drive. The converters input was chosen to be the regulated 12V to ensure that the 12V line will always come up before the 24V line.
LM27313

LM27313

Preliminary Detailed Design Documents/Power/LM27313_24V_Regulator.pdf

Preliminary Detailed Design Documents/Power/24V_Webbench_Design.pdf

Power Monitor

LM27313

LM27313

Preliminary Detailed Design Documents/Power/INA226_Power_Monitor.pdf

Component Selection Design File

All calculations necessary for the design were performed using MathCAD. A PDF of the file is linked below.

Preliminary Detailed Design Documents/Power/PMB_Design_File.pdf

Drawings, Schematics, Flow Charts, Simulations

Detailed Power System Block Diagram

Power System Block Diagram Block Diagram

Power System Block Diagram Block Diagram

Power Management Board Schematics

PMB Page 1

PMB Page 1

PMB Page 2

PMB Page 2

PMB Page 3

PMB Page 3

PMB Page 4

PMB Page 4

PMB Page 5

PMB Page 5

A PDF of the entire schematic is linked below.

Detailed Design Documents/Power/PMB_Schematic_12_3_18.pdf

Power Management Board PCB Layout

Top Layer PCB

Top Layer PCB

Detailed Design Documents/Power/Top_Layer_PCB.pdf
Layer 2 PCB

Layer 2 PCB

Detailed Design Documents/Power/Layer2_PCB.pdf
Layer 3 PCB

Layer 3 PCB

Detailed Design Documents/Power/Layer3_PCB.pdf
Bottom Layer PCB

Bottom Layer PCB

Detailed Design Documents/Power/Bottom_Layer_PCB.pdf
All Layers PCB

All Layers PCB

Detailed Design Documents/Power/All_Layers_PCB.pdf
All Layers PCB

All Layers PCB

All Layers PCB

All Layers PCB

Bill of Material (BOM)

The bill of material for the PMB PCB components is shown below. The total cost of components for one board is $129.26. The actual price for components may be less due to decreases in price with higher quantities of parts and requesting free samples when possible.

Power System BOM

Power System BOM

The Excel document for the PCB component BOM is linked below.

The bill of materials for the entire power system is shown below. The total cost of the power system is estimated to be $685.25. This is over the $550 budget for the power system.

Detailed Design Documents/Power/PMB_PCB_Components_BOM.xlsx

Power System BOM

Power System BOM

The Excel document for the Power System BOM is linked below.

Detailed Design Documents/Power/Power_System_BOM.xlsx

Power System Spending Breakdown

Power System Spending Breakdown

Test Plans

Power System Engineering Requirements

Additional Power Engineering Requirements

Additional Power Engineering Requirements

ER35: Turn on voltage Come Alive Voltage Test: Slowly bring up the input voltage on the PMB while monitoring the 12V output to determine the come alive voltage with no load and full load

ER36: Turn off voltage Stay Alive Voltage Test: Slowly bring down the input voltage on the PMB while monitoring the 12V output to determine the stay alive voltage with no load and full load

ER37: 12V Regulation, ER38: 12V Regulator Efficiency 12V Regulation / Efficiency Test : The PMB input power and output power will monitored with various input voltages and various load currents

ER39: Voltage Overshoot from load step The PMB will be power with 12V and the load will be stepped from min to max and max to min

ER40: Ripple Voltage Monitor the ripple voltage on the 12V output with min, typ, and max load conditions

A link to the full test plan document is included below.

Preliminary Detailed Design Documents/Test_Plan_w_ERs.xlsx


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