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Merge pull request #288 from joshua-jerred/0.8_doc_updates
buck converter prototypes and 0.8 release doc updates
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# Giraffe Flight Computer Power Supply | ||
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The power supply for GFC is responsible for taking the input voltage from the | ||
battery and creating a stable 5V and 3.3V output for the whole system. | ||
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*** | ||
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## Requirements | ||
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### Power Output and Consumption | ||
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The raspberry pi zero 2 W requires 5V to operate and has a maximum tolerance of | ||
5%. The Raspberry Pi Zero 2 W idles at 280ma and under load can consume up to | ||
600ma. Due to the computational requirements of the flight software, a duty | ||
cycle of 95% should be assumed. | ||
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The radio module, SA868 can operate from 3.3V to 5.5V. The radio module requires | ||
1000ma to transmit at high power when at 5V, 900 at 4.2V. At low transmit power, | ||
the module consumes 550ma at 5V and 450ma at 4.2V. In receive mode, the module | ||
consumes 70ma. The radio module should be assumed to be in receive mode when not | ||
transmitting. Assuming a possible configuration of APRS location and | ||
telemetry packets transmitted (3s, 1 per minute), two way telemetry packets | ||
(3s, 1 per minute), Robot36 SSTV images (36s, every 10 minutes), a realistic | ||
upper bound duty cycle is 15%. | ||
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The Pi camera module requires 250ma to operate. This needs to be tested, but for | ||
now assume that it takes 3 seconds to power on, take a picture, and power off. | ||
If a picture is taken every 30 seconds, the duty cycle is 10%, so ~25ma. | ||
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As things are still changing, there is no point in trying to calculate the power | ||
consumption of the other onboard ICs. After a quick run through, it should be | ||
less 200ma at peak. This needs to be tested. | ||
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The flight hardware does have connectors for external sensors. The DS18B20 | ||
sensors are negligible. There is a single I2C connector available for expansion. | ||
100ma should be allocated for this. This also means that the Pi's 3.3V rail | ||
can not be used for the 3.3V components. | ||
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The following table summarizes the power consumption of the components. | ||
**Note**: The table below does not distinguish between 3.3V and 5V components. | ||
The 3.3V components are are a small fraction of the total power consumption. | ||
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| Component | Base Current (ma) | Peak Current (ma) | Duty Cycle | Average Current (ma) | | ||
| ------------------------- | ----------------- | ----------------- | ---------- | -------------------- | | ||
| Raspberry Pi Zero 2 W | 280 | 600 | 95% | 584 | | ||
<!-- | SA868 Radio Module (High) | 70 | 1000 | 15% | 210 | --> | ||
| Pi Camera Module | 0 | 250 | 5% | 25 | | ||
| Other Onboard ICs | 50 | 200 | 5% | 125 | | ||
| External Sensors | 0 | 100 | 5% | 5 | | ||
| **Total** | **400** | **1150** | | **949** | | ||
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- REQ: The battery voltage will be regulated to 5V with a buck or boost converter, dependant on pack configuration. | ||
- REQ: The 5V regulator must be able to supply at least 2.5A. | ||
- REQ: The 3.3V bus will be regulated from the 5V bus with an LDO. | ||
- REQ: The acceptable voltage tolerance of 3.3V and 5V bus is 5%. | ||
- REQ: The power supply will have current sensing. | ||
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### Battery Cells | ||
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The battery cells should be Lithium-Ion cells. Of the form factors available, | ||
cylindrical cells provide safety benefits over pouch cells. There should be | ||
consideration of the battery being in vacuum and impacting the ground. Looking | ||
at the available form factors, 18650 and 21700 cells are the most widely | ||
available. The 21700 cells have a higher energy density. Given energy density, | ||
decent safety, and availability, NMC/INR cells should be used. The cells should | ||
be from a reputable manufacturer as there are many poor quality products out | ||
there. Capacity should be the priority over current rating as this is a fairly | ||
low power system. | ||
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https://archive.org/details/httpsntrs.nasa.govapicitations20100037250downloads20100037250.pdf | ||
https://www.batterypowertips.com/18650-21700-30700-4680-and-other-li-ions-whats-the-difference-faq/ | ||
https://blog.satsearch.co/2021-06-23-satellite-batteries-for-cubesats-nanosats-and-other-form-factors | ||
https://web.archive.org/web/20240405003314/https://www.thunderheartreviews.com/2021/12/samsung-21700-50G-48G-50E-test-comparison.html | ||
https://batteryuniversity.com/article/bu-302-series-and-parallel-battery-configurations | ||
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- REQ: The battery cells must be 21700 NMC/INR cylindrical Lithium-Ion cells. | ||
- REQ: The battery cells must have a capacity of at least 4000mAh. | ||
- REQ: The battery cells must be from a reputable manufacturer and distributor. | ||
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### Cell Configuration and Power Supply Architecture | ||
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Depending on the battery cell configuration, the power supply architecture will | ||
change. The battery configurations that can be considered are 1S2P, 2S1P, and | ||
2S2P. The 1S2P configuration would require a boost converter and a single ADC | ||
channel to monitor the battery voltage. The 2S1P/2S2P configurations would | ||
require a buck converter and two ADC channels, or a BMS, to monitor the battery. | ||
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- REQ: The battery pack must weigh less than 350g | ||
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### Pack Design | ||
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### Battery Management | ||
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- REQ: The battery SOC should be considered 100% at 4.2V and 0% at 3.0V | ||
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*** | ||
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## Design | ||
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### Battery | ||
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Going with a 2SxP configuration, the power supply will consist of a buck | ||
converter. | ||
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Tentatively, the cell choice is INR21700-50E, which has is 17Wh at a 2A draw. | ||
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### Current Sensing | ||
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High side current sensing will be used with the shunt resistor placed between | ||
the battery and the buck converter. | ||
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Currently looking at the INA226 for current sensing. | ||
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INA180A | ||
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### Buck-Converter | ||
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Decided on the TPS56320X, specifically the TPS563201. For $0.43, it meets all | ||
requirements, goes up to 3A, and comes in a easier to use SOT-23 (Thin) package. | ||
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The TPS563201 specifically uses Pulse Skip Mode, because it's not CCM it does | ||
not have a fixed frequency. The hope is that this will not be an issue EMI/EMC | ||
wise. |
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