From b8704d98e828c14682187c71f99a02adad94c321 Mon Sep 17 00:00:00 2001 From: Sam Anthony Date: Mon, 8 Dec 2025 16:10:32 -0500 Subject: move proposal and midterm report to doc/ --- doc/midterm_report/breadboard.jpg | Bin 0 -> 1317467 bytes doc/midterm_report/midterm_report.tex | 261 ++++++++++++++++++++++++++++++++++ doc/proposal/diagram.fig | 120 ++++++++++++++++ doc/proposal/proposal.tex | 63 ++++++++ doc/references.bib | 100 +++++++++++++ 5 files changed, 544 insertions(+) create mode 100644 doc/midterm_report/breadboard.jpg create mode 100644 doc/midterm_report/midterm_report.tex create mode 100644 doc/proposal/diagram.fig create mode 100644 doc/proposal/proposal.tex create mode 100644 doc/references.bib (limited to 'doc') diff --git a/doc/midterm_report/breadboard.jpg b/doc/midterm_report/breadboard.jpg new file mode 100644 index 0000000..e1974c3 Binary files /dev/null and b/doc/midterm_report/breadboard.jpg differ diff --git a/doc/midterm_report/midterm_report.tex b/doc/midterm_report/midterm_report.tex new file mode 100644 index 0000000..549751d --- /dev/null +++ b/doc/midterm_report/midterm_report.tex @@ -0,0 +1,261 @@ +\documentclass{article} +\usepackage{graphicx} +\usepackage{hyperref} +\usepackage[backend=biber]{biblatex} +\usepackage{amsmath} + +\addbibresource{../references.bib} + +\title{\textsc{Comp} 490 Mid-Term Report} + +\author{Sam Anthony 40271987 \\ +sam@samanthony.xyz \\ s\_a365@concordia.ca +\and +Hovhannes Harutyunyan, PhD \\ +Department of Computer Science and Software Engineering \\ +haruty@encs.concordia.ca +\and +Concordia University \\ +} + +\begin{document} + +\maketitle +\tableofcontents +\pagebreak + + +\section{Project introduction} + +The goal of the project is to build an electronic device for use in cars: it is an interface between the car's CAN bus (controller area network) \cite{can20b}, and some analog gauges installed in the cockpit. +An overview of the system is shown in Figure \ref{fig:system}. + +\begin{figure} + \centering + \includegraphics[width=\textwidth]{"../proposal/diagram.png"} + \caption{System diagram.} + \label{fig:system} +\end{figure} + + +\section{Desiderata} + +The device must be able to perform certain functions. +As well, there are some desirable properties that it should fulfil. + +These function and desirable properties are as follows: + +\begin{enumerate} + \item{Receive standard and extended CAN frames from the bus.} + \item{Decode information in the frames.} + \item{Generate four analog 0--5V signals suitable for driving temperature or pressure gauges.} + \item{Generate two variable-frequency square waves for a tachometer and a speedometer.} + \item{Be user-programmable for any encoding scheme and gauge combination.} + \item{Run on a 12V automotive electrical power supply.} + \item{Operate reliably in an automotive environment: resist heat, vibration, and EMI (electromagnetic interference).} +\end{enumerate} + + +\section{Component selection} + +A car is a harsh environment for an electronic device. +The device is subject to large variations in temperature, vibration, and EMI. +To increase reliability, AEC-certified parts were chosen wherever possible. + + +\subsection{Logic control} + +The microcontroller is at the heart of the design. +A Microchip PIC16F1459 was chosen because of its simplicity and robustness, its feature set, and its low cost \cite{pic16f1459}. +It is an 8-bit microcontroller that features a USB peripheral for communicating with the host PC, an SPI peripheral for communicating with the other ICs, and timers for waveform generation. +The PIC is a proven design that Microchip recommends for automotive applications. +It is available in a DIP package, making it convenient for prototyping on a breadboard (Figure \ref{fig:pic}). + +\begin{figure} + \centering + \includegraphics[width=0.5\textwidth]{"pic16f1459.png"} + \caption{Microchip PIC16F1459 8-bit microcontroller.} + \label{fig:pic} +\end{figure} + +A Microchip MCP2515 serves as the CAN controller \cite{mcp2515}. +It supports CAN 2.0B up to 1Mbps and it has an SPI interface for communicating with the PIC. +An MCP2561 transceiver goes along with it \cite{mcp2561}. +Like the PIC, both these chips are available in DIP packages for prototyping on the breadboard. + + +\subsection{Data storage} + +The EEPROM is used to store the configuration. +This includes the encoding scheme that defines how parameters are encoded in CAN frames, as well as a table that maps parameter values to output signal values. + +There are six such tables: one for each gauge. +Each table has 32 entries, and the mapping is between 16-bit words. +Thus, the required size is $6 \times 32 \times 16 \times 2 = 6144$ bits, or 768 bytes. +The encoding schemes will take a handfull of bytes per gauge in addition. + +a Microchip 25LC160C EEPROM was selected. +Its 16Kib (2KiB) of space is more than adequate to hold the configuration. + + +\subsection{Input/output} + +The PIC has an integrated USB peripheral for communicating with a host computer. +The configuration is sent to the PIC via USB and stored on the EEPROM. + +Four DACs (digital-to-analog converters) generate analog signals to drive the four pressure or temperature gauges. +Based on the characteristics of commonly-used pressure and temperature sensors \cite{bosch_pst}, it was determined that a resolution of 15mV/step was required. +Given the operating voltage of 5V, this meant that the DACs must have at least $5\text{V}/15\text{mV} \approx 333$ steps of resolution. +Thus, an 8-bit DAC with 256 steps would be insufficient, and so a 10-bit DAC was selected: namely a Microchip\footnote{It is purely a coincidence that all the ICs ended up being Microchip parts. I don't have any particular affinity to the company. It just so happens that they make all the right chips for this particular application.} MCP4912. +The MCP4912 incorporates two DACs in a single chip, so there are two chips per board. + + +\subsection{Power supply} + +The ICs require a 5V supply. + +A 12V automotive electrical system operates in a wide range of approximately 9--16V, with a nominal voltage of $\sim$13.7V. +The voltage ripple is often quite significant as well. +Thus, the power supply must be very robust to supply a stable voltage to the ICs. + +The voltage drop $V_\text{Drop} = V_\text{In} - V_\text{Out}$ is $16\text{V} - 5\text{V} = 11\text{V}$ in the worst case. +This ruled out the use of a linear regulator, since it would dissipate too much power. +The power dissipation of a linear regulator is linear in $V_\text{Drop}$: + +\begin{equation} + P = (V_\text{In} - V_\text{Out}) \times I +\end{equation} + +The load current is estimated to be $\le 250$mA \cite{power_budget}. +That means a linear regulator would dissipate up to $11\text{V} \times 0.250\text{A} = 2.75$W. +That amount of power from a single chip would be difficult to cool. +Thus, a switching regulator is the right choice for this design. + +The downside of a switching regulator is that it produces a lot of noise in the PDN (power distribution network). +To isolate the other components from this noise, a two-stage PDN is used. +The first stage is the switching regulator itself, also known as a buck converter. +The buck drops the voltage from 12V down to 7V. + +The second stage is composed of two linear regulators: one for the digital circuitry, and one for the analog circuitry. +The linear regulators drop the voltage from 7V down to the final 5V that the ICs require. + +Just like a buck converter, switched digital ICs introduce noise into the PDN. +Therefore, it is good practice to keep the digital and analog components separate. +The second power stage isolates the ICs from the noisy buck converter, and splitting the stage between two regulators keeps the digital and analog circuits isolated from one-another. +This design is certainly overkill for the application, but it is better than using too weak of a PDN that delivers an unstable voltage. + +The buck converter is a Texas Instruments TPS5430 \cite{tps5430}. +It is surrounded by a couple of LC and RC networks to regulate the voltage and to dampen the output ripple. +See the datasheet and \cite{power_supply} for the process of selecting the accompanying passive components. +The linear regulators are a pair of ST L78M05ABs \cite{l78m}. + + + +\section{PCB design and manufacture} + +KiCad was used to design the schematic (Figure \ref{fig:schematic}) and the PCB (Figures \ref{fig:pcb_pours} \& \ref{fig:pcb_3d}). +JLCPCB was chosen to manufacture the printed circuit board. +At the time of writing, the board design has been finalized and submitted to JLC for manufacturing. +It should arrive any day now. + +\begin{figure} + \centering + \includegraphics[width=\textwidth]{"schematic-v0.2.pdf"} + \caption{Schematic.} + \label{fig:schematic} +\end{figure} + +\begin{figure} + \centering + \includegraphics[width=\textwidth]{"pcb_pours-v0.2.pdf"} + \caption{PCB front and back copper pours; drill holes.} + \label{fig:pcb_pours} +\end{figure} + +\begin{figure} + \centering + \includegraphics[width=\textwidth]{"pcb_3d-v0.2.png"} + \caption{3D render of the PCB.} + \label{fig:pcb_3d} +\end{figure} + +The board is a 4-layer design that uses a combination of surface-mount (SMD) and through-hole (THT) components. +The top and bottom layers are for signals, and the two middle layers are solid ground planes. +This ensures that all signal traces' fields are tightly coupled to ground directly above or below. +Power is routed on the bottom layer. + +As mentioned above, most of the ICs are available in DIP (through-hole) packages, and I have been using them for prototyping on the breadboard (Figure \ref{fig:breadboard}). +Once the PCB arrives, I can transplant the chips into the board, along with the passive components. + +\begin{figure} + \centering + \includegraphics[width=\textwidth]{"breadboard.jpg"} + \caption{Breadboard circuit for MCP2515 system testing.} + \label{fig:breadboard} +\end{figure} + +The power supply parts, on the other hand, are SMD. +It is important to minimize loop lengths in power supply circuits. +That is why power regulator chips are generally only available in smaller SMD packages. +The SMD components will be assembled by JLC, as I have neither the equipment nor the skill for SMD soldering. + +The board was layed out with PCB design best-practices in mind. +Traces are widely-spaced to reduce coupling. +All signal vias are accompanied by a ground via to keep the electric fields from spreading in the dielectric. +All traces are microstripped above a solid ground plane, again to keep the fields tight and to give the current a return path. +The noisy switching regulator is placed far away from the other components to reduce EMI---the sensitive analog signals and the DACs are on the opposite side of the board. + + +\section{Firmware} + +Firmware is the program that runs on the PIC microcontroller. +It is responsible for interacting with the peripherals and transforming data from the CAN bus into output signals for the gauges. + +The firmware is written in C for Microchip's XC8 compiler \cite{xc8}. + +Each peripheral---MCP2515, 25LC160C, and MCP4912---has a corresponding translation unit. +So far, I have written and tested the MCP4912 DAC unit. +The 25LC160C and MCP2515 units are mostly written but still require more testing. + +The firmware must also communicate with a PC via USB. +The Microchip MLA USB library is employed for this purpose \cite{mla_usb}. +However, the USB code uses a lot of the PIC's flash memory. +Some system test builds already fail to link due to lack of space. +As a result, USB may have to be dropped from the project, and another method will have to be devised for programming the user configuration into the EEPROM. +This is a major disappointment, but I will have to work around it seeing as the hardware has already been finalized. + + +\section{Software} + +Software is any program that runs on a host PC, as opposed to on the microcontroller. + +I wrote a program called \texttt{usbcom} that communicates with the PIC via USB \cite{usbcom}. +It connects its standard input to the OUT USB endpoint, and its standard output to the IN USB endpoint. +It is written in Go, and uses libusb. + +\texttt{usbcom} and the PIC firmware communicate using a proprietary text-based protocol over the USB CDC (communications device class) interface. +The message format is defined using EBNF \cite{protocol}. +The semantics are a simple request-reply arrangement. + +I also wrote a Python script---\texttt{bittiming.py}---to calculate CAN bit timing parameters for the MCP2515 \cite{bittiming_py}. + + +\section{Next steps} + +When the board arrives, I will do a visual inspection to ensure that nothing went wrong during manufacturing. +Then I will solder the THT components in place. +Once that is done, I will test the board for continuity and shorts. +With a fully assembled board, I can flash the firmware and migrate system testing from the breadboard to the printed prototype board. +I will finish developing the rest of the firmware, and run through the full suite of system tests that I will have at that point. + +I bought some equipment for testing and debugging the system. +A USBtin USB/CAN interface will allow me test the reception of CAN frames \cite{usbtin}. +The EspoTek Labrador is a combined power supply, oscilloscope, and logic analyzer \cite{espotek_labrador}. +It will be used for powering the board and debugging the SPI lines. + +If I have time, I would also like to do some experiments with the power supply to see how it handles changes in input voltage. + + +\printbibliography + +\end{document} diff --git a/doc/proposal/diagram.fig 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b/doc/proposal/proposal.tex @@ -0,0 +1,63 @@ +\documentclass{article} +\usepackage{graphicx} + +\title{ +Analog Gauge Driver with CAN Interface \\ +\large COMP490 Project Proposal +} +\author{ +Sam Anthony 40271987 \\ +sam@samanthony.xyz \\ s\_a365@concordia.ca +\and +Hovhannes Harutyunyan, PhD \\ +Department of Computer Science and Software Engineering \\ +haruty@encs.concordia.ca +\and +Concordia University \\ +} + +\begin{document} + +\maketitle + +Installing aftermarket gauges in a car typically requires installing sensors as well. +However, such sensors are often already present, and are used by the ECU (engine control unit). +Thus, the installation of aftermarket gauges can result in duplicate sensors which add complexity without augmenting the functionality or reliability of the vehicle. +Sensors installed like this are not redundant. +In fact, they reduce reliability, because each is a single point of failure. + +The proposed device allows gauges to use the sensors already on the car. +It retrieves sensor data from the ECU via the CAN bus (controller area network bus) and transforms the data into a format that the gauges can understand: a 0--5V analog signal in the case of a temperature or pressure gauge, or a square wave in the case of a tachometer or speedometer. + +The device is an embedded system comprising a microcontroller, a CAN controller and transceiver, several DACs (digital-to-analog converters), and PROM (programmable read-only memory). +The CAN interface is used for retrieving data from the ECU via the bus. +The DACs drive analog signals to the temperature and/or pressure gauges. +The microcontroller has an integrated PWM peripheral for driving a square wave to the tachometer and/or speedometer. +The PROM stores the calibration: a table that maps CAN data values to voltages or frequencies. +The microcontroller has a USB interface for programming the PROM from a computer. + +\begin{figure} + \includegraphics[width=\textwidth]{diagram.png} + \caption{System diagram} +\end{figure} + +The project has three parts: hardware design, software development, and testing. +The hardware and software development can be carried out concurrently. +Testing is the final step. + +Hardware design involves selecting ICs (integrated circuits), creating a circuit schematic, and designing a PCB (printed circuit board). +Once the board design is finalized, it can be sent for manufacturing. + +Two pieces of software must be written. +The first runs on the microcontroller. +Essentially, it must communicate with the various peripherals by transforming and transferring data between them. +It must fetch frames from the CAN controller and decipher them. +The CAN data are used to lookup the output value in the ROM. +Either the PWM peripheral or a DAC is used to send the appropriate signal to the gauge. +The microcontroller uses SPI (serial peripheral interface) to communicate with the peripherals. + +The second piece of software runs on the user's computer. +It programs the PROM with calibration data. +It communicates with the microcontroller using a simple text-based protocol over USB. + +\end{document} diff --git a/doc/references.bib b/doc/references.bib new file mode 100644 index 0000000..60fc4b9 --- /dev/null +++ b/doc/references.bib @@ -0,0 +1,100 @@ +@standard{can20b, + title = {CAN Specification}, + subtitle = {Version 2.0}, + part = {B}, + year = {1991}, + organization = {Robert Bosch GmbH}, + url = {http://esd.cs.ucr.edu/webres/can20.pdf}, +}, +@online{pic16f1459, + title = {PIC16F1459}, + subtitle = {8-bit Microcontroller with USB}, + organization = {Microchip Technology Inc.}, + url = {https://www.microchip.com/en-us/product/PIC16F1459}, + urlseen = {2025-10-13}, +}, +@online{mcp2515, + title = {MCP2515}, + subtitle = {Stand-Alone CAN Controller with SPI Interface}, + organization = {Microchip Technology Inc.}, + url = {https://www.microchip.com/en-us/product/MCP2515}, + urlseen = {2025-10-13}, +}, +@online{mcp2561, + title = {MCP2561}, + subtitle = {High-Speed CAN Transceiver}, + organization = {Microchip Technology Inc.}, + url = {https://www.microchip.com/en-us/product/MCP2561}, + urlseen = {2025-10-13}, +}, +@online{tps5430, + title = {TPS543x}, + subtitle = {Wide Input Range Step-Down Converter}, + organization = {Texas Instruments}, + url = {https://www.ti.com/lit/ds/symlink/tps5430.pdf}, + urlseen = {2025-10-13}, +}, +@online{l78m, + title = {L78M}, + subtitle = {Precision 500mA Regulators}, + organization = {STMicroelectronics}, + url = {https://www.st.com/en/power-management/l78m.html}, + urlseen = {2025-10-13}, +}, +@online{bosch_pst, + title = {Pressure Sensor Combined PST-F 1}, + organization = {Bosch Motorsport}, + url = {https://www.bosch-motorsport.de/content/downloads/Raceparts/Resources/pdf/Data%20Sheet_70496907_Pressure_Sensor_Combined_PST-F_1.pdf}, + urlseen = {2025-10-13}, +}, +@online{mla_usb, + title = {MLA USB}, + organization = {Microchip Technology Inc.}, + publisher = {Github}, + url = {https://github.com/MicrochipTech/mla_usb}, + urlseen = {2025-10-13}, +}, +@online{xc8, + title = {MPLAB\textsuperscript{\textregistered} XC8 Compiler}, + organization = {Microchip Technology Inc.}, + url = {https://www.microchip.com/en-us/tools-resources/develop/mplab-xc-compilers/xc8}, + urlseen = {2025-10-14}, +}, +@online{usbtin, + title = {USBtin}, + subtitle = {USB to CAN Interface}, + author = {Thomas Fischl}, + url = {https://www.fischl.de/usbtin/}, + urlseen = {2025-10-13}, +}, +@online{espotek_labrador, + title = {EspoTek Labrador Board}, + organization = {EspoTek}, + url = {https://espotek.com/labrador/}, + urlseen = {2025-10-13}, +}, +@misc{power_budget, + title = {Power Budget Spreadsheet}, + author = {Sam Anthony}, + url = {doc/power/power_budget.ods}, +}, +@misc{power_supply, + title = {TPS5430 Power Supply Spreadsheet}, + author = {Sam Anthony}, + url = {doc/power/power_supply.ods}, +}, +@misc{protocol, + title = {Protocol}, + author = {Sam Anthony}, + url = {doc/protocol}, +}, +@misc{usbcom, + title = {\texttt{usbcom} Program}, + author = {Sam Anthony}, + url = {sw/usbcom}, +}, +@misc{bittiming_py, + title = {\texttt{bittiming.py} Script}, + author = {Sam Anthony}, + url = {sw/bittiming}, +}, -- cgit v1.2.3