Abhijit Kshirsagar Kshirsagar
2 years ago
2 changed files with 67 additions and 0 deletions
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Balu Mahesh |
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1. Design a system using a conductive water sensor (basically two metal probes that are very close together - when water is present between the probes it conducts) to detect when water level in a tank falls below 20% and when that happens, turn on a pump. The pump is a 3-phase 3-wire 1kW rated. This is for an industrial application where the water is being used for a chemical process. Design the system with some fail-safe such that the tank should never become empty. |
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2. Design summary is ok but could have been a little more detailed. Where is the fail-safe to prevent the tank from being completely empty? |
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How do you prevent overflow? How do you prevent the motor from running when input supply is not present? What about when the pump fails? |
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Basically there is no mention of the failsafe requirement. |
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What are the tadeoffs? How are you balancing cost, efficiency, and reliability? |
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What is the meaning of "Zero PCB or card board"? |
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3. Block diagram: what is roof of the tank? The top of the tank? Or is the tank on the roof of a building? |
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The block diagram is confusing: what is the meaning of "exception?" Which of thse lines are signal and which are power?? |
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4. Power supply design is totally absent. |
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5. Industrial Design: |
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Your text is directly lifted from https://sg.rs-online.com/web/c/enclosures-server-racks/enclosures/pcb-mounting-enclosures/ |
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6. KICAD Design |
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Schematic: |
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Did you use this circuit? even the values are identical: https://easyelectronicsproject.com/wp-content/uploads/2020/10/Water-Pump-Auto-Switch-Pic-12.jpg?x56667 |
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PCB: |
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Layout seems ok |
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DRC is not passing because there is no outline. |
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7. Pricing / Assembly: Items costs are ok although grossly underestimated. No mention of materials for the actual probes, wiring, etc ??? |
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Name: Lokesh |
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1. Question text: |
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Design a system using this Honeywell ammonia sensor (https://drive.google.com/file/d/164WvPD7GauvseOfH-K3v8iZ4YYmQFkq-/view?usp=sharing ) |
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to detect when ammonia concentration in ambient atmosphere exceeds 100 ppm an alert an operator in a control room about 100m away. |
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This device will be mounted in various sections of an industrial processing plant. The complete plant will need a fairly large number (~20) |
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of sensors so unit costs needs to be kept under control. Also, once mounted it will be very difficult to remove/service/repair the sensing devices. |
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2. Design summary: |
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Your design is well thought out. Using the cascaded power supply for local boards and wireless link to control room is also a good point. |
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In reality you will have to check if the industry allows wireless, which bands, or whether they want some MODbus type system. |
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One major issue in your design is that you are using a FET as the frontend - how will you account for variations in the FET gm? Each board |
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will have a different gain which you need to calibrate. Similarly each sensor has a different gain and sensitivity which you need to calibrate, |
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you should have mentioned that. |
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3. Block diagram |
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Block diagram is fine. |
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Some details are missing - for example what are the protocols / signal levels between the boards? |
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What happens when multiple sensors go off - are there some ways to tell the control room wchich sensors have gone off? |
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Or how many? |
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4. Power supply design |
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Why have you chosen a rectifier supply? Can you not choose an off the shelf switching sypply? |
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Are you gonig to supply different PSU for every different voltage level in industry? |
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5. Industrial Design: |
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Mostly ok - dimensioning could be better. Also, are there wires coming out of the box? |
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Or are there connectors on the edge? or are there some cable glands? |
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6. KICAD Design |
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Schematic: |
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Major flaw in circuit design - your 5V regulated is not ground referenced. So any noise / disturbance in the power line will make it into the output. |
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PCB: |
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Board outline is missing and DRC fails |
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Why mix SMT and THT components? Also interesting that your THT components are on the back. Why? |
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Some unconnected stubs on your board - e.g. |
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7. Pricing / Assembly |
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