engineering presentation owner: jhnw rev f tech lead: vvsk 001-85174 rev f design win replication:...

Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK

001-85174 Rev *F

Design Win Replication:

PSoC 4 Solution forThermal Management

Fail-Safe Thermal Management for Mission-Critical Systems:Simplify Your Design with a Customized One-Chip Solution

Presentation: To provide an engineering overview to customers for a Cypress solution.Title slide: To define what the presentation will cover. The subtitle is a one-sentence statement of the key opportunity.


Thermal Management Must Be Fail-SafeFail-safe Thermal Management is required for mission-critical systemsIndustrial: automated teller machines, vending machines and arcade games

Test and measurement: spectrum analyzers, signal generators and oscilloscopes

Medical equipment: infant incubators, ultrasound carts and MRI scanners

Communications: Ethernet switches, networking routers and rack-mounted servers

Thermal Management provides mission-critical functions to continuously maintain system temperature within a specified range

Mission-critical systems require a customized, fail-safe Thermal Management solution

Market Vision: To define the market opportunity. Presents compelling data and end product photos relevant to the local market. 3

Infant Incubatorby Ningbo David Medical

One fan and two Temperature Sensors per incubator

Two fans and two Temperature Sensors per machine

Automated Teller Machine

PSoC 4

CPU

Air out

Air out

Air out

Report to the Central System Controller

Fan control 1

Fan control 2

Fan control 3

Temperature Sensor 1 Temperature Sensor 3

Temperature Sensor 2

Temperature Sensor 4

Generic PSoC® 4 Thermal Management System

One PSoC 4 measures four temperatures, including air and CPU temperatures. It then drives three fans independently, each to a precise speed. The system is redundant and reports to the central system controller.


Terms You Will Hear Today

Terms of Art (ToAs): To clearly define for engineers all ToAs used in the presentation. To carefully and fully define Cypress-proprietary ToAs needed to explain our system solution.

Temperature

ValuesTemperature

SensorsTemperature

SensingThermal Algorithm

Fan Controller

Analog

OutputsFan rpm

targetsFans

rpm targets

rpm actuals

4a

Thermal Management SystemMaintains specified temperature ranges in your mission-critical system

Temperature SensorsConvert temperature to an electrical signalResistance Temperature Detector (RTD): changes ~0.387 Ω/°C, requires Current Source and ADC Thermistor: changes ~400 Ω/°C at room temperature, requires Voltage Source and ADC Thermocouple (e.g., type K, J, T): generates ~40 µV/oC, requires ADC and a reference temperature sensorTemperature diode: changes ~250 µV/°C, requires Current Source and ADC

Temperature SensingConverts the analog output signal of the Temperature Sensors to a digital temperature valueRequires special analog ICs and a microcontroller running firmware algorithms to correct and linearize the digital measurements

Thermal AlgorithmCalculates target fan revolutions per minute (rpm) from temperature measurements for proper temperature controlRequires a microcontroller and complex firmware algorithms to calculate the target fan rpm

Fan ControllerDrives fans to target rpm by making continuous adjustments in a closed-loop system


Additional Terms


Current/Voltage SourceAn IC that generates a precise current or voltage supply

Current-Output Digital-to-Analog Converter (IDAC)An IC that generates a precise Current Source for Sensors from a digital input

Analog-to-Digital Converter (ADC)An IC that converts an analog signal, such as a Temperature Sensor output, to a digital signal

Pulse Width Modulator (PWM)A digital circuit that creates square waves with controlled, variable pulse widths (duty cycle)

Used by the Fan Controller to drive fans at rpm targets

Tachometer (TACH)Measures actual fan rpm with Hall-effect sensors

Used by the Fan Controller to set the fan rpm and detect failures

Host ProcessorMain system processor that controls one or more Thermal Management Systems

I2CIndustry-standard serial communication bus used in embedded systems

Used for communication between the Host Processor and one or more

Thermal Management Systems

4b

Host Processor Communicating with Multiple Thermal Management Systems

Thermal Management System 1

Host Processor

…

I2C

Thermal Management System n

Each Thermal Management System communicates the fan status and temperature information to the Host Processor over I2C


PSoC Terms100+ other Components to complete the system design

PSoC Creator™PSoC 3, PSoC 4 and PSoC 5LP Integrated Design Environment (IDE)Software that installs on your PC that allows: Concurrent hardware and firmware design of PSoC systems, or Hardware design followed by export to popular IDEs

ComponentsFree embedded ICs represented by an icon in PSoC Creator software

Used to integrate multiple ICs and system interfaces into one PSoC

Dragged and dropped as icons in PSoC Creator to design systems

Thermal Management Components are designed specifically to perform the temperature control functions

Component Configuration ToolsSimple graphical user interfaces in PSoC Creator

Provided for each Component

Used to customize Component parameters

Accessed by right-clicking a Component

PSoC 4 Fan Controller Application NoteDemonstrates the use of Thermal Management Components to create customized designs with up to four fans and 14 Temperature Sensors

Provides the Thermal Management Example Project, with ready-to-use schematics and firmware, to control two fans and read three Temperature Sensors

Inherent system bus connection

MCU

One Fan Controller Component supports up to four fans by controlling fan rpm and monitoring for fan failures

Fan Controller Component


Thermal Management Components:Fan Controller, ADC, IDAC, RTD, Thermistor and I2C

4c


Design Problems Engineers Face

Traditional Approach and Challenges: To present the traditional approach and the challenges engineers will face when using it to realize the Market Vision. Ends with a one-sentence segue clearly stating the benefit of the Cypress solution.

Mission-critical systems cannot tolerate Thermal Management failuresWhen fans wear out or become blocked

When I2C interfaces to the Host Processor go down

Fans create noise and consume significant power at maximum rpmThey must be driven at the minimum feasible rpm to minimize noise and power

They require a microcontroller running Thermal Algorithms to calculate the minimum feasible rpm

Every design requires difficult, time-consuming customization for:A different number of fans and different types of Temperature Sensors

Specialized analog ICs for each Temperature Sensor

Microcontroller-based firmware algorithms to correct and linearize sensor outputs

Configuration of the I2C interface to communicate with the Host Processor

PSoC solves these problemsPSoC monitors for fan failures and supports redundant I2C interfaces to the Host Processor

The PSoC Fan Controller Component includes Thermal Algorithms to minimize fan noise and power

One PSoC can control and monitor up to 4 fans and support up to 14 Temperature Sensors

PSoC integrates the specialized analog ICs for each Temperature Sensor, including the ADC and IDAC ICs

PSoC Temperature Sensor Components provide firmware algorithms for accurate, linearized sensor output conversion

PSoC Component Configuration Tools enable the creation of customized Thermal Management designs in minutes

PSoC creates a one-chip, customized, fail-safe Thermal Management solution

5

Each unit has up to four fans and one Temperature Sensor

Spectrum Analyzer


PSoC One-Chip SolutionEthernet Switch by Avaya

To create a one-chip, customized, fail-safe Thermal Management solution.

To get started, you should:Download the PSoC 4 Fan Controller Application Note, which includes the Thermal Management Example Project

Download and install PSoC Creator software on your PC

Buy the $25 PSoC 4 Pioneer Kit (CY8CKIT-042)

Buy the $25 PSoC Shield Adapter Kit (CY8CKIT-019)

Buy the $129 Thermal Management Kit (CY8CKIT-036)

Open the Thermal Management Example Project in PSoC Creator

Use the PSoC 4 Fan Controller Application Note for complete system design guidelines

Cypress Solution: To introduce CY products and show compellingly how they solve the challenges highlighted on the previous slide.To provide a short, clear list of what to do to get started.

That integrate common Thermal Management ICs, and that are customized by Component Configuration Tools…

The Thermal Management Example Project provides PSoC Creator Components…

Fan Controller Component Configuration Tool


6a

PSoC 4 Thermal Management Design Using PSoC Creator Components

PSoC 4 Thermal Management System Prototype

And that are prototyped and validated using the PSoC 4 Pioneer Kit, the PSoC Shield Adapter Kit and the Thermal Management Kit…


System Design in PSoC Creator IDE

Cypress Solution: Compelling CY Creator introduction to solve the challenges highlighted on a previous slide.Provides a short, clear list of what to do to get started.

1. Explore the library of 100+ Components

2. Drag and drop Component icons to complete your hardware system design in the main design workspace

3. Configure Components using the Component Configuration Tools

4. Access Component datasheets directly from the Component Configuration Tools

5. Codesign your application firmware and hardware in the PSoC Creator IDE

6. Use the PSoC 4 Fan Controller Application Note for complete system design guidelines

Thermal Management Example Project in PSoC Creator IDE

6b


Configure the Fan Controller ComponentCreate a custom closed-loop Fan Controller in minutesDrag and drop the Fan Controller Component into the main design workspace

Right-click the Component to customize your parameters with the Component Configuration Tool

Choose the number of fans to be controlled and monitored (up to 4 with speeds of up to 25,000 rpm)

Enter parameters from the manufacturer’s datasheet to map PWM duty cycle to fan rpm

Set up alerts for stalled fans and speed regulation failures (optional)

Enter control loop period (in seconds) to specify how frequently the PWM duty cycles are adjusted

Enter tolerance (in %) to specify the acceptable difference between the target rpm and the actual rpm

Select the acoustic noise reduction option to reduce noise by limiting fan rpm acceleration


Cypress Solution: To give details on CY products and show compellingly how they solve the challenges highlighted on a previous slide. To provide a short, clear list of what to do to get started.

Fan (PWM) outputs used to drive fans at the target fan rpm

TACH inputs used to measure the actual fan rpm

6c

Fan Controller Component Configuration Tool Customize Your Fan Controller Parameters


Prototype Your PSoC 4 Thermal Management System

Cypress Solution: To give details on CY products and show compellingly how they solve the challenges highlighted on a previous slide. To provide a short, clear list of what to do to get started.

Use the Thermal Management Kit (CY8CKIT-036) to prototype your systemConnect the PSoC 4 Pioneer Kit (CY8CKIT-042) to the PSoC Shield Adapter Kit (CY8CKIT-019)

Connect the Thermal Management Kit (CY8CKIT-036) to the PSoC Shield Adapter Kit (CY8CKIT-019)

Prototype with the two fans provided

Or attach your own fans using the on-board connectors

Open the Thermal Management Example Project

Configure your Fan Controller Component using the Component Configuration Tool

Watch our demo video: www.cypress.com/go/ThermalManagement

Thermal Management Kit (CY8CKIT-036)

Diode Temperature Sensors

Temperature Sensor with I2C interface

Fan Socket

I2C connector

Temperature Sensor with a PWM output

PSoC 4 Thermal Management System Prototype

PSoC 4 Pioneer Kit(CY8KIT-042)

PSoC Shield Adapter Kit (CY8CKIT-019)

The PSoC 4 on the Pioneer Kit runs the Thermal Management Example Project, which reads the temperature sensor outputs and controls the fan rpm on the Thermal Management Kit

Thermal Management Kit (CY8CKIT-036)

6d


Solution Examples: To give detailed one-page PSoC Solution Examples from the field in the specified format. 7

PSoC® 4 Thermal Management Solution Example (Four Fans, Six Thermistors)Block Diagram

ARM® Cortex™-M0 MCU

PSoC 4 One-Chip Solution

ADC Fan

Controller

4

4

32

EEPROM(emulated)

FlashSRAMI2C

Digital Temperature

Measurement

PWM Fan Speed Control

TACH Actual Fan Speed

Design ProblemsLinearize sensor outputs for temperature measurementMinimize fan noise and powerCommunicate with the Host Processor

PSoC 4 SolutionProvides firmware algorithms to linearize sensor outputsReduces fan noise and power using Thermal AlgorithmsCommunicates with the Host Processor via I2C

PSoC Value

Integrates multiple ICs:AMUX (Analog Multiplexer)ADC (converts analog to digital)Temperature Sensing Algorithm1

Fan Controller (controls and monitors fans)I2C (Host Processor communications interface)Thermal Algorithm1

1 Configurable firmware embedded in Thermal Management Components

PSoC Creator Components

32

2 32 Thermal Management Components

SixThermistors

Analog Outputs

Thermistor Reference Voltage

Host Processor

Ethernet Switch by AvayaThermal ManagementSystem with four fans and six thermistors

Thermal Algorithm

Temperature Sensing

Algorithm Target Fan rpm

Temperature Values

Vdd

MUX

A


PSoC 4 Solution vs. Competition’s

Feature PSoC 4 ADI ADT7470

TI LM96000

MAXIM MAX6639

MCHP/SMSCEMC2302

No. of Fans 4 4 3 2 2

No. of Temp. Sensing Channels

14 1 2 2 0

Sensor Types Diode, RTD, Thermistor

TMP05/06 Diode Diode -

I2C Sensors Yes No No Yes No

Price1 $1.92 $2.18 $1.95 $1.50 $0.80

System Cost2 $1.92 $2.74 $3.19 $3.10 $2.44

Competitive Comparison: To define key features of the Cypress solution and demonstrate its superiority over the Next Best Alternatives(NBAs). Must be credible and objective to the salesperson and customer.

8

1 1ku pricing from supplier websites on 7/7/20142 System implementation based on the generic solution example on page 7 using thermistors or diodes for Temperature Sensing


Competitor fan controller ADT7470ARQZ-REEL7 B59041R120A10 instead of ADI PWM Temperature Sensor TMP05 effort to customize the Thermal Algorithm

Value Added: $0.103Price: $0.682

Reduced Engineering Effort: PSoC 4 saves 2 man-weeks of Price: $2.791

Additional Value

Sensor Cost Reduction: EPCOS Thermistor

Thermal Management IC: ADI temperature sensor hub and

$2.79

$0.68

$0.10

$0.78

$3.57

Competitor

Sensor Cost Reduction

Reduced Engineering Effort

Total Additional Value

Total Value Delivered

Target PSoC Solution: Total Cost:

41% Total Savings:

CY8C4245AXI-483$2.091

$1.48

1Digikey website 1ku pricing on 7/7/2014 the total estimated production volume of 100ku

2Digikey website 1350 unit pricing on 7/7/20143Savings of 2 man-weeks of engineering effort at the rate of $5K per man-week; amortized over

EVC Slide: To clearly define the value of the Cypress solution, including BOM integration and unique functionality.

PSoC 4 Thermal Management Solution Value

9a


Competitor three-fan controller LM96000CIMTX/NOPB one-fan controller LM96163CISD/NOPB of effort to customize the thermal algorithm

Value added: $0.102Price: $1.281

Additional Value

Reduced engineering effort: PSoC 4 saves two man-weeksPrice: $2.401

BOM Integration

Thermal management IC: TI temperature sensor hub and

Thermal management IC: TI temperature sensor hub and

$2.40

$1.28

$1.28

$0.10

$0.10

$3.78

Competitor

Thermal Management IC

BOM Integration Value

Reduced Engineering Effort




45% Total Savings:

CY8C4245AXI-483$2.09 1

$1.69

1 Digikey website 1ku pricing on 7/7/2014 man-week; amortized over an assumed production volume of 100ku

2 Savings of two man-weeks of engineering effort at the rate of $5K per EVC Slide: To clearly define the value of the Cypress solution, including BOM integration and unique functionality.


9b


Competitor and two-fan controller MAX6639AEE+ and two-fan controller MAX6639AEE+ of effort to customize the thermal algorithm

Value added: $0.103Price: $1.502

Additional Value

Reduced engineering effort: PSoC 4 saves two man-weeksPrice: $1.502

BOM Integration

Thermal management IC: Maxim temperature sensor hub

Thermal management IC: Maxim temperature sensor hub

$1.50

$1.50

$1.50

$0.10

$0.10

$3.10

Competitor

Thermal management IC


Reduced engineering effort




33% Total Savings:

CY8C4245AXI-483$2.091

$1.01


2 Supplier website 1ku pricing on 7/7/20143 Savings of two man-weeks of engineering effort at the rate of $5K per



9c


Competitor EMC2302-1-AIZL-TR EMC2302-1-AIZL-TR hub EMC1074-1-AIZL-TR

Price: $0.742

Additional Value

Reduced engineering effort: PSoC 4 saves two man-weeks of effort to customize the thermal algorithmValue added: $0.103Price: $0.802

Temperature sensor hub: MCHP/SMSC temperature sensorPrice: $0.802

BOM Integration

Fan controller IC: MCHP/SMSC two-fan controller

Fan controller IC: MCHP/SMSC two-fan controller

$0.80

$0.80

$0.74

$1.54

$0.10

$0.10

$2.44

Competitor

Fan controller IC

Temperature sensor hub


Reduced engineering effort




14% Total Savings:

CY8C4245AXI-483$2.091

$0.35


2 Supplier website 1ku pricing on 7/7/20143 Savings of two man-weeks of engineering effort at the rate of $5K per



9d


PSoC Thermal Management Solutions

Feature PSoC 1 PSoC 3 PSoC 4 PSoC 5LP

Core M8C 8051 ARM Cortex-M0 ARM Cortex-M3

No. of Fans 2 to 8 8 to 16 2 to 4 8 to 16

No. of Temp. Sensing Channels

8 to 24 16 to 32 10 to 14 16 to 32

Sensor Types Diode, RTD, Thermistor

Diode, RTD, Thermistor



I2C Sensors Yes Yes Yes Yes

Price Range1 $1.53 to $3.22 $3.48 to $4.73 $1.74 to $1.92 $5.00 to $5.59

PSoC Solutions Portfolio: To show the capabilities of CY solutions.To enable customers to select the appropriate CY solution for their requirements.

1 1ku pricing from Cypress website on 7/31/2014

9e


1. Watch our demo video: www.cypress.com/go/ThermalManagement

2. Buy the Thermal Management Kit ($129), the PSoC 4 Pioneer Kit ($25) and the PSoC Shield Adapter Kit ($25):

CY8CKIT-036: www.cypress.com/go/CY8CKIT-036



3. Install PSoC Creator software:

www.cypress.com/PSoCCreator

Here’s How to Get Started

Call to Action: To tell customers how to start their design process. 11

Infant Incubatorby Ningbo David Medical

Each incubator has one fan and two Temperature Sensors to measure body and air temperatures

Automated Teller Machine

Each machine has up to two fans and two Temperature Sensors

Each unit has up to four fans and one Temperature Sensor

Spectrum Analyzer


References and LinksDemo video: www.cypress.com/go/ThermalManagement Demonstrates the CY8CKIT-036 Thermal Management Kit

Thermal Management Kit (CY8CKIT-036): www.cypress.com/go/CY8CKIT-036 Contains the kit documentation

PSoC 4 Pioneer Kit (CY8CKIT-042): www.cypress.com/go/CY8CKIT-042

PSoC Shield Adapter Kit (CY8CKIT-019): www.cypress.com/go/CY8CKIT-019

Component datasheet for Fan Controller: www.cypress.com/go/FanControllerComponent

Fan Controller Application Note (AN89346): www.cypress.com/go/AN89346Contains the Thermal Management Example Project

Diode Application Note (AN60590): www.cypress.com/go/AN60590

Cypress Platform PSoC Product Roadmap: www.cypress.com/go/PSoCRoadmaps

References and Links: Provide a comprehensive view of resources to assist in learning about and adopting the solution. 13

engineering presentation owner: jhnw rev *f tech lead: vvsk 001-85174 rev *f design win replication:...

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engineering presentation owner: jhnw rev f tech lead: vvsk 001-85174 rev f design win replication:...