Most component failures in a severe vibration environment will be due to cracked solder joints, cracked seals, or broken electrical lead wires. Vibration-related Failure Cause: Due to stresses from relative motion between component body, electrical lead wires, and the PCB Solutions: Tying or cementing component to PCB to eliminate resonance
Proper component placement on rectangular PCB Attributes Most severe during resonant conditions Can develop when component body acts as mass and lead wires act as springs Most severe conditions at center of PCB On rectangular PCB, most severe conditions are when component part is parallel to short side of board
= 4 Where C = Modal constant E = 2.7e6 b = 30mm =1.18 inches h =1/8 inch I = bh3/12 = 0.000192 g = 386 in./s2 p = 1850 kg/m = .0668 lb/in3 L = 35mm = 1.378 inches
W = pbhL = 0.0136 lb w = W/L = .00985 lb/in. =3.56 ( 2.7 106 ) .000192 386 .00985 1.378 =8450 Hz 4 Solutions Aluminum Case
Aluminum Case for Harsh Environment Watertight Integrated Standoff No Integrated Flange Mount Hammond Mfg. 1590Z Series Various Sizes Available Plastic Case
Hammond Mfg. 1551 FL Series Various Sizes Available Lightweight Plastic Case Integrated Flange Mount Integrated PCB Standoff Black or Grey!! Test Plan Eng Name Spec ES1 Easily Mountable ES14 Mountable on Moving Part
ES2 Small Size ES13 Harsh Environment Measure Process Possible Volume Passing of Subspecifications ES13.1 High Temperature Temp ES13.2 High Pressure Pressure
ES13.3 ES13.4 ES3 ES4 ES5 ES7 ES7.1 ES7.2 ES6 ES8 Possible Acceleration Present Not Present Present Capacity (Time)
Present Present # of Different Sensors Voltage ES9 ES10 ES11 ES12 ES12.1 ES15 ES16 Oily Environment Withstand Vibration Set Sampling Rate in Field No External Wires
Universal Sensor Connector Data Storage Start Capture Stop Capture Types of Sensor Power To Sensors Multiple Sampling Frequencies Timestamps High Sampling Frequency Digital Bit Width (Accuracy) Voltage Accuracy Multiple Sensors Sensor Voltage Range Method
Instrument Measure Volume Ruler Passing Criteria Small (1in3) Raise ambient Temp Test at Reaches 140F CIMS
Test at Reaches Raise ambient Pres CIMS 100psi Submerge in oil Oil tank Withstands oil Raise Vibration Vibe table Reaches 5G Store Data Computer Stores 60 min - Frequency Accuracy Max Sampling Frequency Bits per Sample
ADC LSB Maximum Sensors Voltage Measure Max Freq Max Accuracy 20kHz 12bit - Analog Design Sensing the World Low-pass Filter Passes low frequency signals and attenuates signals with higher frequencies than the cutoff
Used for smoothing data Reduces noise Necessary for SAR style ADC First order LPF Circuit above is a inverting op-amp with a RC 1st Order LPF MAX7403 8th Order LPF 8th order Low-pass Elliptic Filter 8 times faster cutoff than 1st order LPF Lower Band Reject frequency
Lower ADC sampling rate Eliminates the need for discrete resistors in the Analog Signal Path Maxim EE-SIM MAX7403 Interfacing I2C interfacing Set the cutoff frequency in software to accommodate other sampling rates 8 pin package About 1mV offset at 85C
Maxim DS4420 Programmable gain amplifier -35dB-40dB Range -11 dB attenuation on 010V range yields 0-2.818 signal 2.88 mV accuracy with 12 bit ADC Up to 8 devices on the same I2C bus Example Compatible Sensors ADXL203
AC2626 2 axis Accelerometer +/- 1.7, 5 , 15 g range 0.5 C Accurate Temperature Sensor
2.5 kHz bandwidth -55 C 150 C 0 5V range 0 Vs Voltage Range LiPo Charging Spark Fun Power Cell LiPo Charger/
Booster Micro USB charging $19.99 breakout board for testing Eagle Files Available for PCB layout Schematic for LiPo Charging and Booster https://www.sparkfun.com/products/112 31 Components Required LiPo Charger and Booster MCP73831/2: LiPo Charging IC
Can get free samples TPS61200: 5 volt, 1.2A boost converter Can get free samples Used for powering sensors and other components JST connector $0.95 Micro USB SMD Connector $1.95 Resistors and Capacitors <$2.00 Li-Po Temperature Issues Prof. Landi, Chemical Engineering, said that he does not know of any technologies that can operate up to 200F
Batterys composition layers begin to breakdown at max temperature Risk explosion if operating over the indicated max operating temperature (60C) Digital Design As easy as 0xABC123 Microcontroller Selection Necessary Features ADC 1-4 Channels 12-bit Accuracy 25 kHz Sampling Rate per channel
3 x 3 mm footprint 48 MHz ADC 12-bit 12 Channels ~800 kS/s Max SPI I2C PWM (6 Ch + 2 Ch) ~$2 ea.
$13 FRDM-KL05Z Dev Board Software Processes Modes of Operation Charging Not Sampling Peripherals Disabled Delay Not Sampling Peripherals Initialized Timer Running Normal Sampling Timer Running
Main Program Execution Peripheral Initialization Sampling Process (ADC Subroutine) Write Process (SPI Subroutine) Moving Forward The long road to graduation BOM Small Design Component Price Quantity Total Plastic Case
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