STARLight PDR 3 Oct ‘01 I.1 Miller

STARLightSTARLight

Control Module Design

Ryan Miller

STARLight Electrical Engineer

(734) 763-5373

rpmiller@umich.edu

STARLight PDR 3 Oct ‘01 I.2 Miller

STARLightSTARLightOverview

• Control Module Requirements

• Digital Signal Processing

• Data Formatting and Rates

• Hardware Overview

• Power Summary

• Software Overview

• Schedule

STARLight PDR 3 Oct ‘01 I.3 Miller

STARLightSTARLightControl Module Requirements

• Provide overall control for the STARLight instrument

• Allow modification of system parameters– ADC Gain/Offset

– Sample Clock Delay

– Integration Period

• Provide signal processing of sensor data– Inphase and Quadrature correlations for all 10 channels

– Autocorrelations for all 10 channels

• Format and store processed data in non-volatile storage

• Format and store housekeeping data with sensor data

• Provide GSE interface for data download and real-time display and control

STARLight PDR 3 Oct ‘01 I.4 Miller

STARLightSTARLightSystem Block Diagram

DIGITALCORRELATOR

CONTROLCOMPUTER

PENTIUMPC

POWERCONDITIONING

ANDSUPPLIES

+12 VDC @ 400 W

AIRCRAFTAVIONICS1. GPS2. ALTIM3. GYRO4. HEADING

DATASTORAGE

(REMOVABLE)

SENSOR MODULE CONTROL MODULE

REMOTE ON/OFF

SCENE

IR PROFILER

AIRCRAFTPOWER

I/OINTERFACES

PILOTCONTROL

BOX

SYSTEM GO/NO GO

GSE

WARM& COLD

CALSOURCES

IR SCENE

ANTENNAARRAY

LIQUIDHEAT

EXCHANGER

10 DIRECTSAMPLING

DIGITALRECEIVERS

10 THERMALCONTROL PLATES

COLD PLATE

STARLight PDR 3 Oct ‘01 I.5 Miller

STARLightSTARLightCorrelation

• Auto-correlations for each channel (10)

• Cross-correlations for every pair (IxI,IxQ,QxI,QxQ)– 10 pairs of I and Q signals (20 signals)

– 190 correlations

• Selectable integration period (1 to 2 seconds, nominal)

• Correlator Output (one second integration)– 200 channels/second * 30 bits per channel = 6000 bits/sec

X

I1

Q 2

STARLight PDR 3 Oct ‘01 I.6 Miller

STARLightSTARLightData Storage Requirements

• Total Data Rate = 11,000 bits/sec– Sensor: 6000 bps– Housekeeping: 3000 bps– Other: 2000 bps

• Mission Time is approximately 3 hours

• Total on-board storage needed:– 11000 bits/sec * 3 hours * 3600 sec/hour = 15 Megabytes

STARLight PDR 3 Oct ‘01 I.7 Miller

STARLightSTARLightControl Module Electronics Block

Diagram

Correlator Board

Control Computer

Control ModuleData Acquisition

Terminal BoardThermocouple

InterfaceFrom IR Profiler

Sensor Status andControl Interface

High-Speed SensorData Interface

Power SupplySensorPower

Distribution

100 BaseT GSEInterface

Aircraft PowerInput

Ground AuxilliaryPower Input

Serial RS-422Interface from

Avionics

PSMonitors

Pilot StatusInterface

STARLight PDR 3 Oct ‘01 I.8 Miller

STARLightSTARLightCorrelator Block Diagram

Sensor Status andControl Interface

Photodiode andDeserialization

Sensor High-SpeedData Interface

PC/104 Bus Interface

To ControlComputer

Pilot StatusInterface

To Pilot Interface

Xilinx VirtexXCV600 FPGA

FPGAConfiguration

EEPROM

-Receive and decode high-speed sensor data-Perform 200 simultaneous correlations @ 25.7 MHz-Accumulate correlations for 1 integration period-Queue results of each IP for Control Computer

-Pass sensor control commands to Sensor Control Bd-Receive HK and status information from Sensor-Queue results for Control Computer

-Provide registered interface for Pilot Interface Module

STARLight PDR 3 Oct ‘01 I.9 Miller

STARLightSTARLightControl Module Hardware

• PC/104 based system

• Control Computer– Commercial PC/104 Pentium Single Board Computer

• I/O– Commercial PC/104 Data Acquisition Board

– IR Profiler thermocouple interface

– Power supply voltage monitoring

• Correlator– Custom PC/104 style board with interface to the Control Computer

– Custom interfaces to the Sensor Module

– Pilot interface electronics

• Power Conditioning and Supplies– Converts aircraft power to required system voltages

STARLight PDR 3 Oct ‘01 I.10 Miller

STARLightSTARLightPC-104 Mechanical Info

STARLight PDR 3 Oct ‘01 I.11 Miller

STARLightSTARLightPC-104 Mechanical Info (cont.)

STARLight PDR 3 Oct ‘01 I.12 Miller

STARLightSTARLightEBC-TXPlus Single Board Computer

8.0”

5.75”• Intel Pentium 166MMX, AMD-K6• 32 to 256MB of system SDRAM supported

in 168-pin DIMM• Socket for up to 288MB bootable

DiskOnChip• PC-compatible; uses Intel 430TX chip set• Ethernet controller using Intel 82559ER• 4 RS232 serial ports with FIFO, COM1 &

COM2 with optional RS-422/485/J1708 support

• 48 bi-directional TTL digital I/O lines with 24 capable of event sense interrupt generation

• PC/104 and PC/104-Plus expansion connectors

• Three 16-bit counter timers• Extended Operating Temperature

Available for 166 MHz board from -40oC to +85oC

• +5 volt only operation• Real Time Clock, WDT and power fail reset

STARLight PDR 3 Oct ‘01 I.13 Miller

STARLightSTARLightPCM-518 Sensor Interface Module

3.6”

3.8”

• Supports thermocouples, RTD’s, strain gauges, voltage inputs, 4-20 mA current loops, and thermistors

• 8 Channels of 16-bit A/D resolution• Each channel software programmable for

sensor type and gain• Onboard processor unburdens PC/104

system CPU by performing control, linearization, and conversion to engineering units.

• True four-wire circuits for resistive sensors• Pulsed excitation source reduces self-heating

in resistive sensors• Totally electronic calibration - no trimpots to

adjust• Optional ADP-7409TC field termination board

• Screw terminals for easy wiring• Supplied with 8 removable terminal blocks• Integral cold junction temperature sensor for thermocouples

STARLight PDR 3 Oct ‘01 I.14 Miller

STARLightSTARLightPower Summary

Device Power (W)Control Computer 7.0HK Data Acquisition 1.2High-Speed Optical I/F 2.7FPGA 4.0

TOTAL: 14.9

STARLight PDR 3 Oct ‘01 I.15 Miller

STARLightSTARLightSoftware Overview

• Developed using QNX – Real-time Operating System– Provides real-time operation, interrupt handling, TCP/IP networking

• Provides overall system control– Sensor parameter setting– Data collection– Data formatting and storage

• Provides thermal system control– PID Loops using sensor temperature measurements, 10 channels

• Provides GSE interface– 100 BaseT TCP/IP– Realtime data transmission– Stored data collection– Interactive control

STARLight PDR 3 Oct ‘01 I.16 Miller

STARLightSTARLightSoftware Structure

Read CorrelationProducts

Read Sensor HKData

CollectedData

Queue

Read AvionicsData

Read IR ProfilerData

Store data inshared queue

Go to Sleep

IP Complete InterruptMessage from OS

Get SensorTemperature

Readings

Calculate 10 newPWM Values

Add PWM valuesto Sensor Data

Go to Sleep

Data Collection Task

Thermal Control Task

SensorCommand

Queue

System Message

Store PWM-Setcommands in

CommandQueue

Sensor/Themal

DataQueue

Format SensorCommands

Transmit SensorCommands

Go to Sleep

SystemMessage

Format AllCollected Data

Store to Non-Volatile Storage

Go to Sleep

Sensor Command Task

System Message

Data Storage Task

Transmit to GSEif connected

Diskon

Chip

Get commandsfrom GSE / Store

in CommandQueue

Transmit StoredData to GSE if

Requested

Go to Sleep

Net ActivitySystem

Message

GSE Net Command Task

GSE NetConnection

STARLight PDR 3 Oct ‘01 I.17 Miller

STARLightSTARLightSchedule

Task Description Date Complete

Correlator Board Nov-01 Dec-01 Jan-02 Feb-02 Mar-02 Apr-02Schematic 15-Nov-01FPGA Design 1-Dec-01FPGA Code 15-Dec-01PCB Layout 1-Dec-01PCB Parts List 15-Nov-01Order Remaining Parts 1-Dec-01Cable Net Lists 1-Dec-01Cable Parts Lists 1-Dec-01Assemble Cables 15-Dec-01Assemble PCB 1-Jan-02Program FPGA 1-Jan-02Initial Standalone Tests 15-Jan-02

Control Module ElectronicsAssembly Drawing 1-Dec-01Order Remaining Parts 1-Dec-01Cable Parts Lists 1-Dec-01Assemble Cables 15-Dec-01Initial Standalone Tests 1-Jan-02Integration with CM Software 1-Jan-02Integration with Correlator 15-Jan-02Integration with Sensor 1-Feb-02

Control Module SoftwareFormalize Hardware Interfaces 1-Dec-01Setup Development Environment 1-Dec-01Develop GSE Network code 15-Dec-01Develop Sensor Comm code 1-Jan-02Develop Thermal Control code 1-Feb-02Develop Data Collection code 15-Feb-02Develop Data Storage code 1-Mar-02