ECE 477 Final ReportSpring 2007

Jay Doyle Tom Germon Ryan Schroeder Dave Canada

Team Code Name: ______BatteryMAX___________________________ Team ID: __8__

Team Members (#1 is Team Leader):

#1: _Ryan Schroeder_____________ Signature: ____________________ Date: _________

#2: _Dave Canada_______________ Signature: ____________________ Date: _________

#3: _Jay Doyle__________________ Signature: ____________________ Date: _________

#4: _Tom Germon_______________ Signature: ____________________ Date: _________

ECE 477 Final Report Fall 2006

REPORT EVALUATION

Component/Criterion Score Multiplier Points

Abstract 0 1 2 3 4 5 6 7 8 9 10 X 1

Project Overview and Block Diagram 0 1 2 3 4 5 6 7 8 9 10 X 2

Team Success Criteria/Fulfillment 0 1 2 3 4 5 6 7 8 9 10 X 2

Constraint Analysis/Component Selection 0 1 2 3 4 5 6 7 8 9 10 X 2

Patent Liability Analysis 0 1 2 3 4 5 6 7 8 9 10 X 2

Reliability and Safety Analysis 0 1 2 3 4 5 6 7 8 9 10 X 2

Ethical/Environmental Impact Analysis 0 1 2 3 4 5 6 7 8 9 10 X 2

Packaging Design Considerations 0 1 2 3 4 5 6 7 8 9 10 X 2

Schematic Design Considerations 0 1 2 3 4 5 6 7 8 9 10 X 2

PCB Layout Design Considerations 0 1 2 3 4 5 6 7 8 9 10 X 2

Software Design Considerations 0 1 2 3 4 5 6 7 8 9 10 X 2

Version 2 Changes 0 1 2 3 4 5 6 7 8 9 10 X 1

Summary and Conclusions 0 1 2 3 4 5 6 7 8 9 10 X 1

References 0 1 2 3 4 5 6 7 8 9 10 X 2

Appendix A: Individual Contributions 0 1 2 3 4 5 6 7 8 9 10 X 4

Appendix B: Packaging 0 1 2 3 4 5 6 7 8 9 10 X 2

Appendix C: Schematic 0 1 2 3 4 5 6 7 8 9 10 X 2

Appendix D: Top & Bottom Copper 0 1 2 3 4 5 6 7 8 9 10 X 2

Appendix E: Parts List Spreadsheet 0 1 2 3 4 5 6 7 8 9 10 X 2

Appendix F: Software Listing 0 1 2 3 4 5 6 7 8 9 10 X 2

Appendix G: FMECA Worksheet 0 1 2 3 4 5 6 7 8 9 10 X 2

Technical Writing Style 0 1 2 3 4 5 6 7 8 9 10 X 8

CD of Project Website 0 1 2 3 4 5 6 7 8 9 10 X 1

TOTAL

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ECE 477 Final Report Fall 2006

TABLE OF CONTENTS

Abstract 1 1.0 Project Overview and Block Diagram 2 2.0 Team Success Criteria and Fulfillment 4 3.0 Constraint Analysis and Component Selection 5 4.0 Patent Liability Analysis 7 5.0 Reliability and Safety Analysis 11 6.0 Ethical and Environmental Impact Analysis 13 7.0 Packaging Design Considerations 16 8.0 Schematic Design Considerations 19 9.0 PCB Layout Design Considerations 2110.0 Software Design Considerations 2311.0 Version 2 Changes 2612.0 Summary and Conclusions 2713.0 References 30Appendix A: Individual Contributions A-1Appendix B: Packaging B-1Appendix C: Schematic C-1Appendix D: PCB Layout Top and Bottom Copper D-1Appendix E: Parts List Spreadsheet E-1Appendix F: Software Listing F-1Appendix G: FMECA Worksheet G-1

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ECE 477 Final Report Fall 2006

AbstractBatteryMax is a universal battery charger capable of recharging the four major

varieties of rechargeable batteries, up to 25 volts. BatteryMax is controlled through both an on-

board interface as well as through an embedded web server. BatteryMax will track individual

batteries, building up a history of voltage and current over time that it can report to the user. A

detailed account of the design, assembly, programming and testing of the BatteryMax universal

battery charger is contained in this document.

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ECE 477 Final Report Fall 2006

1.0 Project Overview and Block Diagram

Figure 1.1 – BatteryMax Block Diagram

To charge a battery through a normal wall outlet, a few things need to be done.

Firstly, the 110V AC signal coming into the battery charger goes through a transformer to drop it

down to a 33V AC signal, which then goes through a rectifier to smooth it into a 25V DC

voltage.

The DC signal then goes into the liner regulators which produce 30V, 12V, 5V and

3.3V, with an adjustable regulator producing 0.5V to 25V. The 3.3V signal powers the digital

potentiometers, adjustable regulator, EEPROMs, the relay, the temperature sensor and the

microcontroller. The 5V signal powers the current sensor and the 12V power signal powers the

LCD. The 30V acts as a reference line for the digital potentiometers.

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ECE 477 Final Report Fall 2006

The microcontroller communicates to the LCD through serial port zero (SCI0). Serial

port one (SCI1) is reserved for the background debug module (BDM). The embedded web

server connects to a computer or a network through PHY. The analog to digital converter

communicates with the voltage, current and temperature sensor. The microcontroller’s I2C

interface is used to communicate with the EEPROM and the relay. Finally, the SPI interface is

used to control the adjustable regulator and digital potentiometers.

Figure 1.2 – BatteryMax Completed PCB

Figure 1.3 – BatteryMax Completed Project

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ECE 477 Final Report Fall 2006

2.0 Team Success Criteria and FulfillmentIn order to consider BatteryMax a success, certain success criteria were outlined at

project inception. These five criteria served as a guideline towards completion of the project

throughout the semester. To make the BatteryMax truly universal, it had to be compatible with

the various rechargeable battery technologies on the market today. To be usable, it must be

easily controlled by the user and be able to relay information back to the user.

The project specific success criteria (PSSC) defined at the beginning of the semester:

1) An ability to intelligently recharge multiple battery technologies.

This outcome was met completely.

2) An ability to display and modify settings through a user interface (LCD and keypad).

This outcome was met completely.

3) An ability to display and modify settings through an embedded web page.

This outcome was met completely.

4) An ability to perform technology-specific diagnostic tests on a battery.

This outcome was met completely.

5) An ability to track individual battery statistics via battery identification numbers.

This outcome was met completely.

Each of the five PSSC’s was fulfilled. The first PSSC required that the battery charger

be able to output a voltage greater than the max voltage of the battery, forcing the battery to

charge. Each battery technology has a specific charging algorithm to achieve maximum

efficiency;, however basic charging can be accomplished just by applying an appropriate voltage

across the battery terminals. BatteryMax is able to determine what voltage is appropriate at each

instant throughout the charging process to ensure that each battery is intelligently charged.

The BatteryMax communicates back to the user through an LCD display mounted on

the front side of the case. This LCD panel also has a built in keypad, which allows the user to

control the device.

The battery charger has a built in web page which serves two purposes. The user can

retrieve information about the last 5 battery charges and the user can control the device via a

control page.

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ECE 477 Final Report Fall 2006

BatteryMax is capable of performing battery testing. The device will act as a voltage

meter which allows the user to make sure the battery is outputting the correct voltage. The

device will also perform a quick discharge on the battery, which will facilitate longer battery life

in some rechargeable battery technologies.

The BatteryMax is capable of remembering five batteries by battery identification

number. There was no more room in the microcontroller’s main memory for more than five

batteries. While this fulfils the outcome, this is not large enough for a commercial version.

Some solutions to this might include storing the information on a remote device, such as the

user’s personal computer or using an external flash chip on the printed circuit board.

3.0 Constraint Analysis and Component SelectionBatteryMax is not meant to be portable or battery powered. This allows the focus of

the design to shift from portability and small packaging to functionality. The device will draw a

sizeable amount of power at times and must have the ability to dissipate heat appropriately.

The main design challenge with BatteryMax is interfacing the many external

components to the microcontroller. Initial plans call for an LCD, keypad, external memory,

temperature sensor, current sensor, voltage sensor, and digital potentiometers. Additionally,

Ethernet capability must be provided by the microcontroller to serve the embedded web page.

Computation Requirements

The microcontroller for BatteryMax does not need much in terms of raw

computational power. No special math functions are needed nor is it necessary that the

microcontroller have any specialized instructions. Since no floating point will be used, the

microcontroller should be 16 bit to allow proper scaling when doing calculations. The

microcontroller’s main function will be to read in values from the analog-to-digital converter and

make decisions based on these values. 8-bit resolution on the analog-to-digital values will

provide sufficient accuracy to effectively control charging process. The microcontroller will also

need to refresh the LCD based on current status and user input, as well as handle requests made

on the Ethernet port.

The memory requirements of the microcontroller are were also an important factor.

BatteryMAX will makes use of an embedded web page, which has the potential to take up a

substantial amount of memory space. Also, the storage of data points will required additional

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ECE 477 Final Report Fall 2006

memory. Assuming a maximum rate of three 8-bit data points every fifteen seconds, each hour

of charge time will require 720 bytes of storage space. This can quickly use up the onboard

memory of a microcontroller, so external memory will probably bewas required to support

enough data points to be useful.

Interface Requirements

General purpose I/O waswill be used within BatteryMax as chip selects for the various

peripherals and to control status LEDs on the front of the packaging. Three outputs werewill be

used to control a red, orange, and green LED. These will indicate various status conditions

during the charging process. These output pins will drive the base of an NPN transistor, such

that when the pin is in the high state, current will flow in the transistor and the LED will

illuminate. Six additional outputs werewill be used as chip selects for the digital potentiometers.

All six digital potentiometers communicate via the SPI bus. The wiper levels will be are sent to

the appropriate device based on which chip is selected. One output will bewas used to control

the relay connecting the power supply to the battery. The output pin is connected to the gate of a

MOSFET, such that when the pin is in the high state, current will flow and the relay will connect

the two circuits.

On-Chip Peripheral Requirements

A large number of on-chip peripherals arewill be used. Four 8-bit analog-to-digital

converter inputs will be used to monitor the voltage of the battery, the temperature of the battery,

the current being delivered to the battery, as well as the internal temperature of the unit. Two

SCI channels will be used. One will communicate to a computer terminal for debugging

purposes and the other will communicate with the LCD. One SPI channel will be used to set the

levels of the digital potentiometers. Serial EEPROM will interface with the microcontroller via

the IIC channel.

Power Constraints

BatteryMax is designed for use in a home or on a workbench. As such, the device will

be powered via standard 110V AC power. AC to DC power conversion will take place within

the unit. In order to provide power for the electronic components and still have the flexibility to

charge batteries at a high current rating, the transformer will need to be able to provide 24 33

VAC at 4 A. This allows up to 1 A for the microcontroller and other circuitry, while still being

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ECE 477 Final Report Fall 2006

able to provide a maximum of 3 A to the battery. The 3324VAC will be rectified and reduced in

order to supply voltages of 3.3V, 5V, 12V, and 30V DC to the various parts of the circuit.

Microcontroller

Many different microcontrollers were available which fit within the design constraints

of the project. Those considered were the Rabbit RCM4200, the PIC18F97J60, and the

Freescale MC9S12NE64. Table 3.2.1 summarizes the key features of each microcontroller.

The Rabbit microcontroller was eliminated because it did not have enough SCI

channels to fit within the design constraints. It also did not have IIC communications. The lack

of IIC could have been dismissed because of the large amounts of on-chip memory, as this was

the sole purpose of the IIC. The PIC microcontroller was also considered, but was eliminated

because of the small amount of on-chip RAM. It is also only an 8 bit microcontroller. The

Freescale microcontroller meets all of the needs laid out in the constraint analysis. It has the

necessary peripherals, as well as sufficient RAM and flash to store the main program. The on-

chip Ethernet is also nicea benifit, which helps to reduce the complexity of the overall design.

An added benefit of the Freescale microcontroller is the excellent manufacturer support.

Application notes describe in detail how to get a web server up and running quickly.

Manufacturer Rabbit PIC FreescaleModel RCM 4200 PIC18F97J60 MC9S12NE64Bits 16 8 16Max Clock 58.98 MHz 41.667 MHz 25 MHzPins 60 (headers) 100 112SCI 1 2 2SPI 4 1 1IIC 0 1 1ATD Yes Yes YesEthernet Yes Yes YesRAM 1 MB 3808 8 KBFlash 8 MB 128 KB 64 KB

Table 3.1 – Microcontroller Comparison

4.0 Patent Liability Analysis

BatteryMax is a universal battery charger with a focus on compatibility, safety,

interactivity, and usability. It is an intelligent, microcontroller-driven device controlled by a

keypad and an LCD display. It connects to a cradle for each type of battery that it supports. The

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ECE 477 Final Report Fall 2006

Each cradle will havehas a temperature sensor to monitor the temperature of the battery for

safety reasons. The built-in web server helps the user track an individual battery’s life cycle or

charging progress. There are thousands of different battery- charging products on the market.

Some of these products do charge multiple types of batteries, but none have the level of

interactivity of the BatteryMax.

Results of Patent and Product Search

In order to analyze potential patent conflicts, multiple searches of the United States

Patent and Trademark Office were conducted. Attempts were made to uncover existing patented

technologies that resembled major functions or features of the BatteryMax. The initial search for

the phrase “recharge AND battery” turned up numerous irrelevant patents, but also found some

potential conflicts. One patent, recently awarded to the Milwaukee Electric Tool Corporation,

seems to cover a very broad range of battery charging technologies. Details of this patent follow.

United States Patent: 7157883

Title: Method and system for battery protection employing averaging of measurements

[9]

Filing Date: December 30, 2005

Abstract: A system and method for battery protection. In some aspects, a method for operating a battery pack. The battery pack having a battery pack condition, and the battery pack condition having a range. The method including the acts of conducting an operation including the battery pack, measuring a first measurement of the battery pack condition, measuring a second measurement of the battery pack condition, averaging the first measurement and the second measurement to provide an average measurement and if the average measurement is within the range, continuing the operation including the battery pack.

Key Claims:

1. A method for operating a battery pack safely when the average of two measured conditions is within a specified range.

2. The method as set forth in claim 1 wherein the battery pack condition is a voltage.3. The method as set forth in claim 1 wherein the battery pack condition is a

temperature.4. The method as set forth in claim 1 and further comprising the act of discontinuing

the operation if the average measurement is outside of the range.

Intersil Americas Inc. holds the following patent for a technology for charging Li-ion batteries.

United States Patent: 7141954

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ECE 477 Final Report Fall 2006

Title: Li-ion/Li-polymer battery charger configured to be DC-powered from multiple

types of wall adapters [11]

Filing Date: November 30, 2005

Abstract: A battery charger controller is coupled to DC output terminals of an AC-DC (or DC-DC) adapter containing an AC-DC (or DC-DC) converter. A controlled current flow path between input and output terminals of the battery charger controller circuit is controlled to provide a substantially constant current to charge the battery to a nominal battery voltage. When a constant voltage output of the said adapter transitions to a value that limits available charging current to a value less than programmed constant charging current, current flow drive for the controlled current flow path is increased for a limited time interval. Thereafter, the controlled current flow path gradually reduces charging current as the battery voltage remains at its nominal battery voltage until the charge is complete or otherwise terminated.

Key Claims:

1. An apparatus for charging a battery comprising: power source-coupling input terminals arranged to be coupled to any of a plurality of different types of DC power sources, each of which is capable of providing power sufficient to charge said battery using controlled current flow.

2. The apparatus according to claim 1, wherein said controlled current flow control circuit comprises a controlled electronic circuit device having an input-output current flow path coupled between one of said power source-coupling input terminals and said second output terminal, and a control terminal arranged to receive a control input from a control circuit that controls current throughput of said input-output current flow path of said controlled electronic circuit device.

One commercial product that is very similar to the BatteryMax is the Maha MH-

C777Plus-II [10]. This device has an LCD which is used for displaying voltages and currents of

a battery while the device is in operation. BatteryMax also uses an LCD for this purpose. It has

an adjustable battery bay which fits many special types of battery packs, like what you might

find used in a camcorder. Digital camera and camcorder batteries are the targeted technologies.

The MH-C777Plus-II attempts to guess the intended voltage of the battery. BatteryMax requires

the user to specify battery parameters before charging begins. It supports Lithium Ion, NiCad,

and NiMH and lead-acid battery types. Maha does not appear to have filed for patents for this

device. Perhaps they realized how difficult it would be to convince people that they were the first

to ever make a battery charger.

Analysis of Patent Liability

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ECE 477 Final Report Fall 2006

Each of the above patents claimclaims to cover some of the features of the

BatteryMax. The first patent, owned by Milwaukee Electric Tool Corporation, may literally

conflict with our ability to implement voltage and temperature sensors on the BatteryMax. This

patent also claims rights to the technology which disables the circuit as soon as unacceptable

temperatures or voltages are discovered. Another facet of this patent is a specific design of the

connectors which physically prevents a battery pack from being connected improperly to its

charger. The primary goal of this patent seems to be to obtain exclusive rights to a certain battery

pack design for use in power tools. The BatteryMax does not utilize battery packs though it

would have to emulate the connector for this specific battery pack in order to charge it.

The patent held by Intersil Americas Inc. covering Li-ion charging techniques includes

a voltage stepping technique which is claimed to reduce power dissipation as compared to a

linear charging schedule. The priority of BatteryMax is not to reduce power dissipation so it may

simply use the linear charging algorithm for Li-ion batteries. The name of the patent implies that

the most important part of the patent is the ability of the device to accept multiple types of wall

adapters as input. BatteryMax only needs one type of adapter. If our charging algorithm was

identical to theirs, we would be committing a literal patent infringement. If our device accepted

multiple types of wall adapters, it could be considered an infringement under the doctrine of

equivalents, though this could easily be disputed since there are so many other devices already

doing this.

Action Recommended

In order to minimize the risk of infringing on the patent owned by Milwaukee Electric

Tool Corporation, we should choose not to support its battery pack design. We should not release

a connector intended for use with the patented battery pack. To further reduce the semblance,

BatteryMax should use a standard connector that is not covered by a patent.

The third patent appears to prohibit BatteryMax from utilizing the advanced voltage

stepping charging schedule outlined in the patent. Thus, BatteryMax must avoid duplicating this

technique for Li-ion batteries.

Since the battery charger from Maha is not protected by any patents, there is no risk of

patent violation if the BatteryMax has features similar to the Maha device.

Summary

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ECE 477 Final Report Fall 2006

This report contains the results of a search conducted on the United States Patent and

Trademarks Office website for patents which our project could potentially infringe upon.

Similarities and differences between the patents and the BatteryMax were described. A similar

commercial product was also compared. Finally, Suggestions were made for ways to avoid

infringing upon these patents through design changes. No major changes to the BatteryMax were

found to be necessary, but it will be important to avoid using existing components or techniques

such as connectors from a battery pack to make the design easier as this could cause a patent

infringement.

5.0 Reliability and Safety AnalysisThe BatteryMax project is designed to be operated on a flat surface in a well ventilated

room, with the fan holes exposed and free from obstruction. The voltage regulators get hot, and

so must be cooled. If they are not cooled, they fail, on average, quicker than their cooled

counterparts. This is a critical component to our design, and failure minimization is very

important we want to minimize failures. The voltage regulators, along with the microcontroller,

the temperature sensor, and the digital potentiometer were allwill all be examined for failure rate,

and the entire circuit wwill beas examined to see what happens if any major part fails. In the

BatteryMax project, failure of a part could mean an overload of the battery which could lead to

an explosion that could injure a user.

Reliability Analysis

The BatteryMax project has a microcontroller, a temperature sensor, and two digital

potentiometers. All of these parts have the ability to fail, and they were chosen to be examined

to determine the respective approximate failure rates. The failure rates were calculated using the

procedures outlined in [12] using the numbers from their respective data sheets.

The for each one of the items listed in Table 1 represents the number of failures per 106

hours. It wasis calculated using the equation Failures/106 hours,

where is the part failure rate, is the die complexity failure rate, is the temperature

factor, is the package failure rate, is the environmental factor, is the quality factor,

and is the learning factor. The MTTF (mean time to failure) wasis then calculated by taking

the inverse of .

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ECE 477 Final Report Fall 2006

Table 5.1: and MTTF for 4 devices in circuit

The Mil-Hdbk-217F document did not have specific values for every part chosen, so

some assumptions were made. These included = 2 which corresponded to the parts being

ground fixed and = 1.2 for the digital potentiometer because the datasheet was dated 2005.

Predictably, the least reliable part is the microcontroller which is the most complicated IC on the

circuit. For reliable mass-production of the product, the for the microcontroller would have

to be brought into the 109 failures/hour range, since it affects the safety of the users. This could

be accomplished by adding checking hardware to ground the output if it goes out of range. This

would stop the battery from being overloaded, and make the design much safer. Also, the

numbers calculated from the Mil-Hdbk-217F document gavegive a conservative estimate of the

MTTF, so some error is acceptable for the calculation.

Failure Mode, Effects, and Criticality Analysis (FMECA)

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ECE 477 Final Report Fall 2006

The circuit was split into four categories to assist in finding the failure mode, effects,

and criticality analysis (FMECA). These were the power supply circuit, the charge supply

circuit, the sensor circuit, and the logic circuit. Two criticality levels were suitable for the

design. The “high” level corresponds to any failure that could cause the battery to be overloaded

or a part on the circuit to be overloaded. The “high” level’s acceptable failure rate wasis on the

order of 10-9 failures per hour. The “low” level corresponds to a failure that would cause loss of

functionality or information, but would not pose any threat to the user. The “low” level’s

acceptable failure rate wasis on the order of 10-6 failures per hour. The design does not currently

meet these requirements; however the Mil-Hdbk-217F document gavegives a conservative

estimate.

The FMECA worksheet (appendix BG) outlines the possible failures in the circuit and their

outcomes. Each failure is was given one of the two ratings above, as well as what could cause

the failures. The devices involved in some of the failures had to fail a specific way for the

particular outcome to occur. A2 could not cause damage unless the battery was being charged at

the time of failure. It is was also assumed that since the circuit is housed inside a case, that any

part failure would not cause injury to the user.

Summary

The device in the system that is the most likely to fail is the microcontroller.

Unfortunately it is the most crucial part of the circuit to ensure functionality. Battery charging

cannot be accomplished without it. If the microcontroller fails, the battery will not charge, and if

it fails in the middle of charging, there is a chance that the battery will be overloaded. The

design has many failures that are “high” levels of criticality. Some of them are made safe with

software checks from the microcontroller, but others are not. Unfortunately, some of the failures

are expected to occur every 104 to 106 hours. However, that is was a conservative estimate.

6.0 Ethical and Environmental Impact AnalysisThere are were numerous challenges that go into designing a product that is both

reliable and safe. Before being released to market, the universal battery charger will

undergounderwent numerous tests to ensure that it can operate anywhere a user might need it.

The charger will was also also be tested to make sure that if and when it fails, it will fail in a

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manner that will not harm the user. In addition to making it as safe as possible, the universal

battery charger will havehas explicit warnings and instructions to facilitate safe operation.

Operational Environment Tests

Prior to release, the universal battery charger will undergounderwent numerous

operational and environment tests. If undesirable operation occurs within normal operational

conditions, measures will beare taken the remedy the situation.

Since this device can charge high voltage batteries, it is capable of pulling a lot of

power from the wall outlet. One of the most critical tests that will be performed is the overvolt

and undervolt tests. In case of an out of spec voltage, the charger will not operate. An overvolt

condition should cause the built in fuse to break. An undervolt may not be as much of a

problem, as the device is not likely to have enough power to operate.

One potential use of the universal battery charger is the charging of automobile and

marine batteries. Garages and marinas are often not heated or air conditioned, therefore

temperature testing is critical. Maximum and minimum operational temperatures will be

determined as well as maximum and minimum storage temperatures. A fan inside the charger

should helphelped with the maximum temperature. Garages are often rough places for digital

equipment. Vibration and shock testing is a must if the universal battery charger is to be well

suited for the garage environment. A rugged housing and durable PCB mounting are critical to

the reliability of the device. If the universal battery charger is to be used in a marina setting it

must be able to work in high humidity situations. Since the internal components will need to be

cooled via good ventilation and a cooling fan, water damage will be very hard to prevent.

Altitude is not a major concern since the battery charger will need an AC outlet to

function. The theoretical maximum altitude will be calculated from the maximum altitude listed

in the reference manual for each integrated circuit and other major components. The theoretical

maximum will be placed in the user manual.

If the universal battery charger is to be sold in the United States it must comply with

all FCC regulations, specifically 47-CFR-15 [20][23]. This regulation states that any device

used in the United States, it may not radiate radio frequency energy. It is anticipated that this

device will comply with the FCC regulations but it will be tested regardless.

Warnings to the User

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ECE 477 Final Report Fall 2006

The universal battery charger will be capable of recharging batteries of up to 30 25

volts. The power supply is capable of sourcing just over three amperes at the max voltage, with

increasing current sourcing potential with a reduced required voltage. This large amount of

power inside the device, and the potential for injury, need to be conveyed to the user. A sticker

informing the user of a potential for electric shock will be placed at the battery connection. In

addition, the AC wall plug will have a sticker warning the user to only plug the device into a

120110V 60Hz power outlet.

A simple warning message outlining the dangers of improper use of the device will be

given in the user manual. The device’s operational tolerances will be presented to the user in the

user manual.

Safety Mechanisms

The universal battery charger will have several built in safety mechanisms. First and

foremost, the battery parameters, voltage, current and temperature, are constantly measured

during charging. If the voltage or current are outside of the charging scheme the digital

potentiometer array will be adjusted to achieve the correct voltage and current. If the

temperature is too great the microcontroller will stop charging, notifying the user of the error.

To prevent harm from a power surge or other overvolt conditions, a fuse is built into

the power supply. Should too much power go through the power supply, possibly because the

user is being shocked, the fuse will trip. This should theoretically prevent serious injury to the

user,; however there is always risk due to faulty equipment.

Environmental Impact Analysis

Digital devices can have a large impact on the environment throughout their lifetime.

Numerous chemicals are used in the production of most digital devices and most digital devices

will require a complex recycling process before they can be disposed of.

Environmental Impact of the Manufacturing Process

The universal battery charger will contain several integrated circuit chips, various

resistors and capacitors, and an LCD panel. All these elements will reside on one of two printed

circuit boards (PCBs). The LCD panel itself has its own PCB on which is mounted the control

logic for the panel.

The manufacture of printed circuit boards is, historically, extremely hazardous for the

environment. The modern process includes various steps to minimize the chemical waste that

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ECE 477 Final Report Fall 2006

leaves the factory. Pollution associated with the manufacture of PCBs comes in two main forms:

liquid waste containing heavy metals, and air pollutants which contain acidic particles. [21]

In a modern PCB manufacturing process, acid fumes stemming from the acid cleaning

process are collected via a ventilation hood and sent into a scrubber that removes the hazardous

fumes. The acidic waste is now a liquid and can be neutralized before being released for

treatment. [21]

Waste water from the cleaning process, water from the plating bath and excess copper

from the etching process is often treated and pH-balanced before being released. Chemicals are

used to balance the pH of the solution and to remove solid waste (copper, lead and other

suspended solids). The solid waste is filtered and is sent off to the landfill. [21]

Environmental Impact of Normal Use

The universal battery charger does not produce any pollutants or a large amount of

electro-magnetic energy. It does however use electricity. The universal battery charger will be

designed to use as little electricity as possible. It is intended to charge batteries, which means at

times it will be drawing large amounts of power, but some steps can be taken to reduce power

consumption during idle times.

After a certain amount of inactivity, the universal battery charger will shut off the

backlight to the LCD panel, regardless of charging status. This will cut down on electricity use.

Environmental Impact of Disposal

All printed circuit boards contain hazardous, and sometimes valuable, metals. All

PCBs contain lead and copper components; some PCBs will have gold connections. These

heavy metals necessitate recycling. Elution of these metals into the ground may pollute bodies

of water and can contaminate drinking water. [22]

The universal battery charger will contain multiple PCBs. The universal battery

charger has a central component responsible for charging any type of battery. To allow the

charger to accept the various sized batteries, the main module will have a port which will accept

the various battery housings. Each battery housing will contain a simple PCB containing a

temperature sensor. Both the main module and all battery housing modules contain PCBs. Both

must be recycled.

7.0 Packaging Design Considerations

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ECE 477 Final Report Fall 2006

BatteryMax, by Power4 is an intelligent, universal battery charger whose purpose is to

reduce the production of waste from disposable batteries and to provide a convenient way for its

owners to maintain a collection of usable power sources. The latest electronics technologies

usually create a buzz about what’s inside. Take Sony’s PlayStation®3 for example; this powerful

device boasts a processor containing eight processing units [23]. If nothing more than the raw

power of a game console affected consumer’s decisions, then there would be no competition. In

fact, other features of a product can have a huge affect on its desirability. Other game consoles

are competing quite well with the PlayStation®3 by costing less, having a larger set of games,

and even by having well designed packaging. One of the biggest selling points of the Nintendo

Wii® is its well-designed controller.

BatteryMax is a product with powerful features housed within a professional package.

Its design allows a user to easily connect multiple types of batteries to the BatteryMax. It is large

enough to contain the necessary circuit board and power supply as well as temperature and

voltage sensors for safety. Another important thing to consider is placement of components. For

example, the keypad should be placed in such a way that both a right handed and a left handed

user are able to use it without obstructing the display.

Commercial Product Packaging

Product #1

Product one is the Vanson V-75 Lithium Ion Battery Charger [24]. This is specialized

for charging a single type of battery; model CR-123, often used in digital cameras. The device

itself does not enclose the power supply. Instead, it relies either on a car’s cigarette lighter or a

12-volt DC wall adapter. One benefit of keeping the power supply separate from the battery is

that their temperatures do not affect each other. It is important for a battery to not get too hot

while charging or it will likely be permanently damaged. There is a gap around the battery in this

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design to allow airflow to cool the battery. This is an extremely important feature that will also

be present in the BatteryMax. Unlike the BatteryMax, the V-75 is only able to charge lithium ion

batteries. This device lacks any sort of interactivity. It has only LEDs to give a binary indication

of the charging status. The charging cycle is not intelligent; instead, it simply relies on a timer to

control how long the battery is charged. This could result in batteries being overcharged or

undercharged. Lack of a microcontroller and its reliance on an external power supply allow this

device to be very small and lightweight. The BatteryMax will keep the battery holder separate

from the power supply similar to this product. In order to support multiple battery types and to

make the process more interactive, BatteryMax will need to be larger.

Product #2

The second product is the Tenergy T6278 Universal Smart Fast Charger [25]. This

device is quite different from the previous Device in its scope of features and its packaging. On

the top of the case is a simple LCD display. This display offers little more interactivity than the

charger from Vanson did. Tenergy’s device only shows a battery symbol with up to four bars

representing the charging progress. One good thing about the packaging used in this device is its

compact design. It has rounded edges and a smooth shape which would make less awkward to

transport. While there are ventilation holes at the base, the battery compartment is fully enclosed.

Heat generated by the batteries during the charge cycle cannot easily escape. BatteryMax does

not make this mistake. The Tenergy package is well suited for table-top use;, this is what

BatteryMax will also be intended for.

Project Packaging Specifications

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ECE 477 Final Report Fall 2006

For its enclosure, BatteryMax uses an 12”x7”x4” aluminum Project Box purchased

from Digi-key. The top panel of the box holds the LCD display with its keypad in the center.

There is a plug on the side of the box for different types of batteries are plugged in for charging.

There are two fans which will circulate air within the case to keep internal components cool. An

on/off switch will be placed on the side of the box as well. Inside the box, the LCD is mounted to

the top cover while the PCB and the transformer are fastened to the bottom. The external battery

cradle encourages heat dissipation from the battery itself and facilitates compatibility with

numerous battery types. The weight is estimated to be around 941g. While this may seem heavy,

it is important to consider that the device will be used on a tabletop. Alternative packaging could

be considered if we chose to use an external power supply. The enclosure could be reduced in

size significantly since the PCB and LCD together are much thinner than the transformer is.

Future revisions may add stylistic details like rounded corners or more balanced weight

distribution.

PCB Footprint Layout

The main component of the PCB, our microcontroller, is approximately 16mm x

16mm [26]. Also on the PCB are three 1MB memory chips measuring 10mm x 6mm [27]. Both

components are available in QFP surface mount packages and these are what will be used on our

PCB. In order to facilitate debugging, each pin of our microcontroller is connected one of three

sets of headers measuring 50mm x 5mm. Perhaps the largest piece on the circuit board is the

Ethernet connector at 16mm x 21mm. The overall PCB measures 9” x 6.6”. This PCB size fits

snugly within the project box when the transformer is also in place.

Summary

In section 2.0, two products similar to BatteryMax were analyzed. Both products had

useful and innovative features; however, both also had flaws. It is our goal to avoid these flaws

in BatteryMax to produce a product that does its job very well. Important considerations for the

products size, weight, design, and overall cost were considered. Initial layouts for the PCB imply

a final PCB size that will fit perfectly into the device. Parts chosen will be easily mounted to the

PCB or the project box. Decisions made in this stage will help following steps proceed more

smoothly.

8.0 Schematic Design Considerations

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ECE 477 Final Report Fall 2006

All of the systems of BatteryMax were designed with their primary function in mind.

Operating modes were selected that would provide the best results for each application. Where

possible, design choices were made to facilitate interfacing and communication of components in

order to keep the need for additional circuitry at a minimum.

Microcontroller Operation

The Freescale MC9S12NE64 microcontroller will control the operation of the entire

design. The NE64 requires a 3.3 V supply voltage and can operate at a frequency anywhere

from 0.5 MHz to 25 MHz [26]. An operating frequency of 25 MHz was selected in order for the

on-chip Ethernet controller to run at full 100 Mbps speeds. The ATD sampling period was set at

7μs, which is the maximum allowed for the device. The communications to the LCD will

happen over the SCI at a baud rate of 57600, which is the maximum for the display. A lot of

information will be transferred to the display during normal operation and the faster this

information gets there, the better response time will be experienced by the user. The SCI data

will need to be translated to RS-232 levels. The SPI clock will be set at 4 MHz, which is the

maximum supported by the digital potentiometers.

Power Supply Operation

A standard 110 VAC wall outlet will be used to supply power to the device. A

transformer will convert the 110 VAC to 24 33 VAC. It will then be rectified and filtered to

produce a 34 V DC output. This will be stepped down to 30 V to power the digital

potentiometers. The digital potentiometers require that the supply voltage must be greater than

the voltage difference across the wipers. Since that can theoretically be as high as 30 V, a 30 V

supply was created to power the potentiometers. The 30 V output is stepped down to 12 V in

order to power the LCD and fans, as well as the status LEDs on the exterior of the case. The 12

V supply is stepped down to 3.3 V and 5 V. The 5 V output will power the current sensor, level

translator, and relay. The 3.3 V output will power the microcontroller and external memory.

Adjustable Regulator Operation

The LM350 was chosen to deliver the adjustable voltage to the battery. The LM350

has a minimum output voltage of 1.2 V, and a maximum output voltage of 33 V. The guaranteed

output current is at least 3 A. Two LM350s will be connected in series, one driving the other.

This was done to allow more heat to be dissipated than is possible with just one. Each regulator

will be adjustable by a combination of two digital potentiometers, a 10 kΩ and 100 kΩ in

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ECE 477 Final Report Fall 2006

parallel. This configuration of resistors will allow the output voltage to be highly adjustable.

Changes made on the 100 kΩ resistor will produce small changes on the output, while changes

made on the 10 kΩ resistor will produce larger changes on the output.

Sensor Operation

Various sensors will be used to monitor the charging process. A voltage sensor will

be connected in parallel with the battery to monitor the battery voltage. Since the battery being

charged could have a voltage greater than 3.3 V, the sensed voltage will need to be stepped down

before going to the ATD pin. A digital potentiometer will be used to provide a variable divider.

This allows lower voltage batteries to have a higher resolution for the voltage sensing, while still

providing the ability to charge high voltage batteries. A current sensor will be placed in series

with the battery and will measure the current being delivered to the battery. The current sensor

outputs 5 V at its maximum, so it will also need to be divided down before connecting to the

ATD pin. A temperature sensor will be mounted in close proximity to the battery. This will

monitor the temperature of the battery to ensure it does not overheat. The temperature sensor

will be able to connect directly to the ATD pin.

LCD/Keypad Operation

A 128x64 pixel LCD will provide feedback to the user. The LCD will communicate

with the microcontroller through the SCI port. A RS-232 level translator will sit between the

LCD and SCI port, converting the voltages to the appropriate levels. The LCD has a keypad

module which can be connected to it. The LCD interprets the keypad presses and sends the data

via SCI to the microcontroller.

9.0 PCB Layout Design Considerations The main components of the BatteryMax include a microcontroller, an LCD display, a

power supply, and a set of sensors. These are all attached to the PCB, whether directly, or

through cables, and all have their respective considerations when placing them and routing the

wires on the PCB. For example, the LCD display draws 190mA when the backlight is on and

32mA when it is off, whereas the battery charging line has to go up to 3A, so the trace widths

need to be vastly different [35].

PCB Layout Design Considerations – Overall

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ECE 477 Final Report Fall 2006

There are were a lot of potential issues to taketaken into consideration and avoided

with the device design. The largest consideration is was minimizing EMI within the device. The

power supply for the device is was separated from the rest of the circuit to minimize EMI. Since

the device uses large currents, if any of those lines are were put in parallel with the digital or

analog lines, mutual inductance could cause signals to appear on the lines, resulting in

undesirable functionality in the device. All the traces on the PCB are were routed with 45 degree

angles at the joints, to reduce transmission reflections and minimize the amount of over-etching

in the corners. The trace widths were calculated [32] with a trace width calculator. Please see

Table 2.1 for trace width values.

Current Minimum Trace Width Example Traces3 A 140 mil Battery charging lines1 A 31 mil Power lines500 mA 12 mil Power lines100 mA 5 mil Data lines

Table 9.1: Trace width values, using 1oz/ft2 thickness

The power and ground lines for the PCB were a large concern as well. The design has

no trace loops, and the power supply is connected at only one point to the digital and analog

parts of the circuit. This is was done to minimize the noise associated with the power supply

circuit.

The components are were placed on the board either to ensure separation for EMI

avoidance, or to ensure proximity for signal quality. The Ethernet jack and the oscillator are

were required to be close to the microcontroller, so they are were placed as close as they can

could be. The components in the power supply are were arranged so that there is was very little

complex trace routing between components. There are were also headers for the power going to

the fan and the LCD, since they are were not mounted on the PCB.

Decoupling capacitors are were needed for all ICs across the power and ground

terminals. These axial glass or multi-layer ceramic capacitors are were chosen because the

microcontroller is running at 25MHz. These are to provide instantaneous current to the ICs

during transistor switching. In addition to the decoupling capacitors, a bulk decoupling capacitor

is was needed for the whole circuit. This metalized polycarbonate or tantalum electrolytic

capacitor will support the decoupling capacitors if they deplete their charge reservoirs [33]. The

value of the bulk decoupling capacitor wasis 20 times the size of the IC decoupling capacitor. It

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ECE 477 Final Report Fall 2006

wasis placed at the PCB power terminals. There wasis also a ceramic disk capacitor placed in

parallel with the bulk capacitor, to filter high-frequency noise coming into the circuit [33].

Capacitor Capacitor ValueIC Decoupling Capacitor 0.01uFBulk Decoupling Capacitor 0.2uFCircuit Noise Capacitor 0.1uF

Table 9.2: Capacitor Values

Where possible, the components are were mounted on the top of the PCB, and the

traces are were routed on the bottom. This is was done to make soldering easier, as well as

ensure there wereare no heat-generating components below the PCB. Where possible, no traces

run underneath components. This is was to avoid noise generated by the lines, which could

produce undesirable output in the circuit.

PCB Layout Design Considerations – Microcontroller

The microcontroller used in the BatteryMax is was the Freescale MC9S12NE64. One

of the major requirements for this microcontroller is the need for a decoupling capacitor on each

power input [34]. These capacitors are were mounted on the underside of the PCB where

possible, to ensure the closest possible distance to the microcontroller. Some other requirements

given in the documentation are were the Ethernet jack must be within 1 inch of the

microcontroller, to avoid vias and layer changes between the Ethernet plug and the

microcontroller, and the oscillator must be as close as possible to the microcontroller [34]. The

power traces for the microcontroller are were run next to it, not under it, to avoid noise problems.

The central point for the ground star for the microcontroller should be the VSSX pin [34].

PCB Layout Design Considerations – Power Supply

The power supply contains contained a lot of components, and a lot of heat is

dissipated as the power is stepped down from 110V AC to 3025V DC, 12V DC, 5V DC and

3.3V DC. Since the step-down process is fairly linear, it mademakes sense to lay it out on the

board in a linear fashion, and keep it isolated from the other portions of the circuit, to reduce

noise. The power traces are were much wider than the data traces (140mil compared to 5 mil),

because of the higher current. These were calculated [32] with the trace width calculator. The

adjustable regulators are were placed close to the edge of the PCB because they are were the

hottest parts of the circuit and require required cooling with fans. The adjustable regulators also

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ECE 477 Final Report Fall 2006

require required heat sinks, so empty areas are were placed on the PCB to account for them.

Headers are werepresent placed on the power lines for the fans.

10.0 Software Design ConsiderationsThe Motorola MC9S12NE64 contains an on-chip 8KB SRAM and 64KB flash

memory [35]. Because of the volatility of the SRAM, the program must reside in the 64KB flash

module. This leaves the SRAM free for program variables and the stack. According to the

MC9S12NE64 datasheet, the memory mapping for the SRAM is $0400 through $1FFF [1].

Accordingly, the address for the start of program’s RAM will be mapped to $0400 while the

stack pointer will be mapped to address $2000. (Remember, when something is pushed onto the

stack that the address is decremented before information is stored, therefore the first address used

by the stack will be $1FFF.) The program itself will be stored in the on-chip flash. This is

nonvolatile memory, meaning it will retain the executable code and stored data after power is

disconnected from the chip.

Addresses Module Device$0080 – $009F Analog to Digital Converter (ATD0) Battery Voltage Sensor$0080 – $009F Analog to Digital Converter (ATD1) Battery Current Sensor$0080 – $009F Analog to Digital Converter (ATD2) Battery Temp. Sensor$00C8 – $00CF Serial Communications Interface (SCI0) 16x2 LCD Display$00D8 - $00DF Serial Peripheral Interface (SPI) Digital Potentiometer$0120 – $0123 Ethernet Physical Interface (EPHY) Ethernet Adapter

Table 10.1 Mapping of External Interfaces [35]

The microcontroller will need to interface with multiple devices, through multiple

communication standards for the battery charger to function correctly. Firstly, the voltage,

current and temperature of the battery will be monitored by devices which communicate to the

microcontroller though the analog to digital converter. Each ATD channel will have a range of 0

to 255, accordingly the input from the monitors will need to be scaled according to some

constant and possibly offset to account for negative values. The LCD display communicates

through the SCI. This device is not only a screen, but it also has seven debounced pushbuttons,

requiring two-way communication between the display and the microcontroller. The digital

potentiometers are controlled through the SPI interface. As with all Ethernet capable NE64

microcontrollers, EPHY is used for Ethernet communications.

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ECE 477 Final Report Fall 2006

The main program loop will be organized in a continuous polling fashion. None of the

external devices need interrupt driven polling, nor do they have any specific timing parameters.

Additionally, the enclosure will have a full time fan, so heat is not a concern. Therefore a

continuous polling loop is acceptable in this situation. The loop will check the status of the

battery monitoring devices (voltage, current and temperature) to ensure the battery is still

charging normally; within the charging profile for that specific battery type. If it is not operating

properly, a service routine will handle the irregularity by making changes to the DC-DC

converter and updating the LCD and web-based information outputs. The loop will also check

the status of two of the Ethernet port and handle and HTTP requests if necessary. The only

device which is interrupt- driven is serial communications. The LCD display communicates

back to the microcontroller when a pushbutton is pressed or released via the SCI0 port, meaning

that the buttons are interrupt- driven input. If any of the buttons are pressed, a service routine

will be called to handle any updating that needs to occur. The CMX-MicroNet TCP/IP Stack

written for Freescale for use with the NE64 will be used to handle the Ethernet interface [36].

No consideration has been given to self-tests at this time. However, on initialization,

every device will be initialized to safe values. For example, the output of the DC-DC converter

will be disconnected from the battery charging terminal output by the relay to minimize the risk

of damage to the device and the user. There is a BDM port on the PCB of the device used for

debugging and testing, but this will not be accessible to the user.

At startup, before the battery charger can perform any of its functional duties, it must

go through the setup phase. In setup, the microcontroller writes blank characters to the screen to

clear any garbage data that may be there at boot time. Once the screen has been cleared, the

microcontroller will send it the commands needed to draw the BatteryMax logo to the screen as

well as the root menu at the bottom of the screen. Also during initialization, all the charging

circuitry is initialized to safe values. The digital potentiometers are adjusted such that the lowest

possible voltage (1.5V) will appear across the terminals. The relay is also switched to the off

position, disconnecting the external battery plug from the charging circuit.

Once the battery charger has completed the initialization, it enters into the main

program loop. In the main program loop, the microcontroller will check the three analog to

digital channels, making sure that the values are close to what is expected. If the values are out

of range, then the microcontroller will take corrective measures. After checking the A-to-D

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ECE 477 Final Report Fall 2006

channels, it will call the OpenTCP function, which responds to an HTTP request if one is

pending. As mentioned previously communication with the screen and pushbuttons is interrupt

based, so no polling is necessary for those units.

The menu system implemented on the battery charger has four “soft” buttons, up and

down buttons and an enter button. Users will be required to enter parameters such as voltage and

capacity for each battery they wish to charge. To make this easier on the user, the up and down

buttons are used to input numbers while the four “soft” buttons will perform variable functions

depending on what menu the user is currently in. The bottom line of the screen is used for

displaying the function of each of the soft buttons at a given time.

11.0 Version 2.0 ChangesHaving successfully designed and built BatteryMax, if it could be done again, some

changes would be made. These changes are merely improvements to the design which were

realized at a time when it was too late to implement them. The overall project is still a success,

but these changes would further enhance the design.

The first change would involve the power supply components, including the adjustable

regulators. Currently, linear regulators were used which are quite inefficient. With the

experience of one design behind us, I would like to look at using switching power supplies.

They are much more efficient at providing power. This would have the benefit of not only

producing less waste, but we could possibly reduce the size of the PCB because all of the

heatsinksheat sinks may not be necessary.

The second change would involve the layout of the PCB. Not only would some

footprint errors be fixed, but a lot more helpful things would have been done to aid in assembly

and debugging. A power indicator light would have been put on the board. More vias and probe

points would have been placed on the board, allowing easier access when trying to measure

specific signals. More silkscreen hints would have been applied to the surface to label key nets

and pins. Also, the traces themselves would have been done in a different fashion to decrease

the amount of noise. Noise errors were a big problem in the ATD readings made by the

microcontroller.

The third change would involve the current sensor. After the layout was complete and

the board was sent for manufacturing, a closer look at the datasheet revealed an application

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ECE 477 Final Report Fall 2006

which would increase the gain on the current sensor. The default gain is 185 mV/A. Using a

single supply op-amp as described in the datasheet, the gain could be increased to 610 mV/A.

This would have allowed greater sensitivity when trying to detect the current being delivered to

the battery.

The fourth change would have been to add a supervisory circuit to control when the

microcontroller was in and out of reset. With the large capacitors on the input to the power

supplies, they store quite a bit of charge once the main power is shut off. This residual power

continues to supply the microcontroller enough to operate. It slowly is used up, but the

microcontroller eventually goes in to a brown out condition every time the power is turned off.

A supervisory circuit would be able to pull the reset pin low to send the microcontroller into the

reset state while the remaining power is being dissipated.

The final change would have involved the use of the external EEPROM. It was not

utilized in the initial version. It was installed but never used. It would have been nice to use the

external memory to store more data points, as well as have the option to update the firmware of

the microcontroller in case new battery technologies are introduced.

12.0 Summary and Conclusions At the end of last semester, BatteryMax began as nothing more than an idea, but over

the course of a single semester it was transformed into reality through a logical sequence of steps

where every aspect of the project was analyzed in detail. The design process began with the

formulation of a block diagram and the outlining of five project specific success criteria (PSSC)

for the final design proposal by the end of the second week. In order to come up with viable

PSSCs, much time was spent thinking about what exactly would be possible. Restrained by a

limited amount of time, and a limited budget, it was clear that not all goals could be met. The

PSSCs were selected to be challenging, yet still achievable. With an approved proposal in hand,

work started on constraints analysis and component selection. Major components such as the

microcontroller and power supply components were researched and selected during this stage.

Other parts were chosen to complement the main components such as external EEPROM

memory to provide more storage space for recorded statistical data. It was important for this step

to be completed early since all subsequent steps depended on the decisions made at this time.

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ECE 477 Final Report Fall 2006

The lack of an electrical engineer in the group made early hardware design steps difficult. There

was a lot of helpful information given in lectures, so lecture slides were a very valuable resource.

Once the basic design was settled on, some time was spent ensuring that the design

would be a complete success. First, a search was conducted for patents which the BatteryMax

risked violating. Luckily, battery charging is such a common practice that there was little risk.

Next, the reliability of the device was estimated using FMECA. The high voltages with which

BatteryMax operates were a safety concern, so steps were taken to improve the safety and

reliability. For example, a relay was added to the charging circuit to make disconnecting the

battery in the event of a failure easier and a fuse was added to protect sensitive circuits from

being damaged by too much current. Also during this stage, the importance of heat sinks and

proper ventilation were realized. Before the design process could continue, one final

consideration had to be analyzed; the impact of the device on the environment and any ethical

implications. Battery recharging technology is a significant benefit to the environment since less

waste is produced as a result. This benefit far outweighs the costs of lost energy due to the

imperfect efficiency of the recharging process. The optimal operating environment of the device

was also found. The main requirement is that the surrounding environment be cool enough to

keep the components from overheating.

Design resumed with the decision of how to package BatteryMax. This was a simple

choice, the enclosure needed to be large to accommodate the power supply, and it needed to be

able to withstand heat. An aluminum box was chosen for its heat resistance and light weight.

During the time when the packaging was being worked out, the schematic was finalized and

presented. This required quite a bit of time since it required intimate knowledge of Orcad

software, something that Computer Engineers don’t often have. Once the schematic was

finished, it was time to begin the layout process. This was even more difficult since the layout

design tools were not taught in any previous course. The final PCB turned out well, in the end

there were only a few footprint errors which were easily corrected by rotating parts or with

strategically placed solder. With hardware in hand, software development began. This turned out

to be far more difficult than was anticipated. It would have been wise to begin software

development sooner using a development board. Unfortunately, there would have been no way to

make significant progress without being able to actually test the LCD and the charging circuitry

of the BatteryMax PCB. While debugging the software, it was tempting to be quick to blame any

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ECE 477 Final Report Fall 2006

problems on faulty components, but in many instances, through careful hardware debugging, the

problem was found to be caused by improper usage of the component. Review of the datasheet

often unearthed new, useful information.

As the semester comes to an end, the impressive scope of what was accomplished by

this project is finally becoming clear. An intelligent, universal battery charger was completed

meeting all PSSCs. The entire process, from objectives to evaluation, follows the development

process which occurs in industry where many ECE477 students will soon be. Along the way,

design review sessions provided valuable feedback from both students and instructors which led

to improvements in the device. This course has taught many useful skills including the

importance of documenting work as it progresses, the necessity of pre-planning stages, and the

benefits of good teamwork. Knowledge gained through lectures, the lessons learned through

hands on experience, and interaction with experts are all critical components of a complete ECE

education.

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13.0 References

[1] Freescale, “MC9S12NE64 Data Sheet,” [Online Document], January 2007, http://www.freescale.com/files/microcontrollers/doc/data_sheet/MC9S12NE64V1.pdf.

[2] Rabbit, “RCM4200 Data Sheet,” [Online Document], January 2007,http://www.rabbitsemiconductor.com/products/rcm4200/rcm4200.pdf

[3] Microchip, “PIC18F97J60 Data Sheet,” [Online Document], January 2007,http://ww1.microchip.com/downloads/en/DeviceDoc/39762b.pdf

[4] Crystalfontz, “CFA633 Data Sheet,” [Online Document], January 2007,http://www.crystalfontz.com/products/633/data_sheets/CFA633-YYB_k1.9c.pdf

[5] Fairchild, “MM74C922 Data Sheet,” [Online Document], January 2007,http://www.fairchildsemi.com/ds/MM/MM74C922.pdf

[6] Microchip, “24FC1025 Data Sheet,” [Online Document], January 2007,http://ww1.microchip.com/downloads/en/DeviceDoc/21941C.pdf

[7] Analog Devices, “AD5231 Data Sheet,” [Online Document], January 2007,http://www.analog.com/UploadedFiles/Data_Sheets/AD5231.pdf

[8] National Semiconductor, “LM117A Data Sheet,” [Online Document], January 2007,http://www.national.com/ds.cgi/LM/LM117.pdf

[9] United States Patent: 7157883; Method and system for battery protection employing averaging of measurements; January 2, 2007; [INTERNET] http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&u=%2Fnetahtml%2FPTO%2Fsearch-adv.htm&r=52&f=G&l=50&d=PTXT&p=2&S1=(recharge+AND+battery)&OS=recharge+AND+battery&RS=(recharge+AND+battery)

[10] United States Patent: 7152168; Recharging power storage devices with power over a network; December 19, 2006; [INTERNET] http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&u=%2Fnetahtml%2FPTO%2Fsearch-adv.htm&r=79&f=G&l=50&d=PTXT&p=2&S1=(recharge+AND+battery)&OS=recharge+AND+battery&RS=(recharge+AND+battery)

[11] United States Patent: 7141954; Li-ion/Li-polymer battery charger configured to be DC-powered from multiple types of wall adapters; November 28, 2006; [INTERNET] http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&u=%2Fnetahtml%2FPTO%2Fsearch-adv.htm&r=137&f=G&l=50&d=PTXT&p=3&S1=(recharge+AND+battery)&OS=recharge+AND+battery&RS=(recharge+AND+battery)

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[12] Department of Defense, “Military Handbook Reliablity Prediction of Electronic Equipment”, [Online Document], accessed February 2007, http://cobweb.ecn.purdue.edu/~dsml/ece477/Homework/Fall2006/Mil-Hdbk-217F.pdf

[13] Freescale, “MC9S12NE64 Data Sheet,” [Online Document], accessed February 2007,http://www.freescale.com/files/microcontrollers/doc/data_sheet/MC9S12NE64V1.pdf

[14] National Semiconductor, “LM150 3-Amp Adjustable Regulators,” [Online Document], accessed February 2007,http://www.national.com/ds/LM/LM150.pdf

[15] Analog Devices, “Low Voltage Temperature Sensors,” [Online Document], accessed February 2007,http://www.analog.com/UploadedFiles/Data_Sheets/32847740TMP35_6_7_c.pdf

[16] Analog Devices, “Digital Potentiometer AD5290,” [Online Document], accessed February 2007,http://www.analog.com/UploadedFiles/Data_Sheets/AD5290.pdf

[17] Environmental Protection Agency, “Household Batteries Facts,” [Online Document], accessed February 2007, http://www.epa.state.oh.us/pic/facts/hhwbatt.html

[18] The Mail, “Toyota Factory Turns Landscape to Arid Wilderness,” [Online Document], accessed February 2007, http://www.mailonsunday.co.uk/pages/live/articles/news/news.html?in_article_id=417227&in_page_id=1770

[19] Cell Power, “Battery Charging Tips,” [Online Document], accessed February 2007, http://www.cellpower.com/battery_tips.cfm

[20] Wikipedia, “Part 15 (FCC Rules),” [Online Document], accessed February 2007, http://en.wikipedia.org/wiki/Part_15

[21] Internation Network for Environmental Compliance and Enforcement, “Printed Circuit Board Manufacturing,” [Online Document], accessed February 2007, http://www.inece.org/mmcourse/chapt7.pdf

[22] NEC Corporation, “Recycling of Printed Circuit Boards,” [Online Document], accessed February 2007, http://www.ipr-nec.com/en/pickup/technology/print/print.html

[23] “SONY COMPUTER ENTERTAINMENT INC. TO LAUNCH ITS NEXT GENERATION COMPUTER ENTERTAINMENT SYSTEM, PLAYSTATION 3 IN SPRING 2006,” [Online document] 2005 May 16, [cited 2007 Jan 24], Available HTTP: http://www.us.playstation.com/News/PressReleases/279

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[24] “Welcome to Quo Vadis Vanson Charger V-8000,” [Online document] 2005 [cited 2007 Jan 24], Available HTTP: http://www.quovadis.tv/75.html

[25] “Free Shipping: T6278 Universal Smart Fast Charger with 26-cell package (8AA/8AAA/4C/4D/2 9V)-New!!,” [Online document] 2005 [cited 2007 Jan 24], Available HTTP: http://www.all-battery.com/index.asp?PageAction=VIEWPROD&ProdID=1663&HS=1

[26] Freescale, “MC9S12NE64 Data Sheet,” [Online Document], accessed February 2007, http://www.freescale.com/files/microcontrollers/doc/data_sheet/MC9S12NE64V1.pdf.

[27] Crystalfontz, “CFA633 Data Sheet,” [Online Document], accessed February 2007,http://www.crystalfontz.com/products/633/data_sheets/CFA633-YYB_k1.9c.pdf

[28] Analog Devices, “AD5290 Data Sheet,” [Online Document], accessed February 2007,http://www.analog.com/UploadedFiles/Data_Sheets/AD5290.pdf

[29] National Semiconductor, “LM150 Data Sheet,” [Online Document], accessed February 2007,http://www.national.com/ds.cgi/LM/LM150.pdf

[30] National Semiconductor, “Battery Charging,” [Online Document], accessed February 2007,http://www.national.com/appinfo/power/files/f7.pdf

[31] Analog Devices, “TMP37 Data Sheet,” [Online Document], accessed February 2007, http://www.analog.com/UploadedFiles/Data_Sheets/32847740TMP35_6_7_c.pdf

[32] “PCB Trace Width Calculator”, [Online Document], accessed February 2007, http://circuitcalculator.com/wordpress/2006/01/31/pcb-trace-width-calculator/.

[33] Motorola, “Semiconductor Application Note”, [Online Document], accessed February 2007, http://cobweb.ecn.purdue.edu/~dsml/ece477/Homework/CommonRefs/AN1259.pdf

[34] Freescale, “MC9S12NE64 Data Sheet,” [Online Document], accessed February 2007, http://www.freescale.com/files/microcontrollers/doc/data_sheet/MC9S12NE64V1.pdf

[35] Freescale, “MC9S12NE64 Data Sheet,” [Online Document], accessed February 2007, http://www.freescale.com/files/microcontrollers/doc/data_sheet/MC9S12NE64V1.pdf.

[36] Freescale, “Basic Web Server Development with MC9S12NE64 and CMX-MicroNet TCP/IP Stack”, [Online Document], accessed February 2007, http://www.freescale.com/files/microcontrollers/doc/app_note/AN2700.pdf

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Appendix A: Individual Contributions

A.1 Contributions of Ryan Schroeder:As the team leader, I contributed a lot to the overall project. Early on, I was mainly

responsible for coming up with the idea to do a battery charger. I was the main person in charge

of forming the group. Once the semester began, I was in charge of both the initial project

description homework and final project description homework. In the final project description

homework, the team came up with areas of expertise for each person. Since the group consisted

of all computer engineers, nobody was really comfortable with the area of expertise that dealt

with circuit design. I chose to take on that responsibility because I felt I had a better idea of what

the project needed in terms of circuit design.

I began by identifying what circuit components would be necessary to charge a

battery. An adjustable voltage would be applied to a battery, which in turn would control how

much current would be delivered. A collection of sensors would monitor the voltage, current,

and temperature at the battery. The microcontroller would control both of these components, as

well as act as the server for the on-chip web page. I selected an adjustable linear regulator to

deliver the voltage to the battery because I felt the details of such a circuit would be easier than a

switching power supply. A current sensor was also an important component selection that I

made. As a team, we all agreed that we would prefer to stick with a Freescale microcontroller

because we had all had experience with them. As for the other components, the group weighed

in their opinions, but I ended up making the final decision about all of the components.

Since I had selected all of the components, I completed Homework 3 on the

component selection. The overall schematic for the circuit was the next step. Once again,

having done most of the thought process associated with the circuit design, I felt it was natural

for me to create the schematic. Using OrCad, I created a schematic that was basically broken

down into five major areas: power supply, adjustable regulator, sensors, microcontroller, and

communications. I completed Homework 5 which covered the details of how the circuit

operated and specific features of the schematic.

With the schematic complete, the next major step in the design process was the layout

of the printed circuit board (PCB). I worked closely with Tom on the initial phases of the layout.

Some of our biggest considerations involved heat dissipation while trying to keep the functional

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blocks of the circuit separated. I created custom footprints for the Ethernet jack, terminal block,

reset switch, 8 mH inductor, relay, and trimmer potentiometers.

In preparation for the design review, I put together the slides associated with the

Schematic and Theory of Operation. This was also the section that I presented during the design

review. After the design review, some key issues were brought to our attention which needed

addressing. The discharge circuit had to be modified in order to function properly. I updated the

schematic to reflect the changes. The PCB layout also had to be modified. Much of the original

layout was carried over to the final version, but I had to make a lot of changes in order to get

everything to fit properly. Seven heatsinks were used in the design, which caused a lot of space

issues when laying out the PCB. Having selected the parts that would be used in the design, I

also felt it a good idea to order them myself through Digi-key. This was done to ensure the

correct part was ordered. I even found it difficult because of the sheer number of choices

available, even between parts of the same model number.

When we were waiting for the circuit board to be completed, we began working on the

programming for the microcontroller. As a help to Dave, I went through the NE64 datasheet and

found all of the registers that were relevant to the different peripherals that we would be using.

This really helped to speed up the software development process.

When the circuit board arrived, I worked with Tom to start populating the board. We

decided to do the assembly in modules, so that we could ensure proper functionality as each

module was completed. I began with the power supply components and ensured the incoming

AC voltage was properly rectified and stepped down to the appropriate levels. After Tom

installed the microcontroller and associated bypass capacitors, I finished off the board by

installing the adjustable regulators. They were actually installed rather late in the process. This

was done to ensure we had the proper programming in place to control them before they were

installed.

With the team mostly going separate ways for the Easter weekend, I decided to take

the project home to work on packaging. None of us had any knowledge of CAD programs, so it

would have been difficult for us to come up with a diagram that could be used for the machine

shop. I also did not have access to very many tools at Purdue. By taking the project home, I was

able to complete a good portion of the packaging. A large hole was cut in the top of the box for

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the LCD and additional holes were cut in the sides for the fans, fuse holder, and power switch. I

also created the small modules for the different battery types that we were going to prototype.

With the packaging complete, I turned my focus back to the programming. I

experimented with some battery charging algorithms. I had to go back to the design to verify

what could and could not be done. I also needed to identify the proper state that the program

should start up in to keep the user safe, should a battery already be attached. These functions

were written in such a way that they could be slipped in the existing flow of the program.

Once the unit was operational, time was running out in order to get a video

demonstration completed to present for bonus credit. After polling the group, nobody had any

experience in editing video besides me. Once the footage was collected, I put together the video

that we used for the bonus presentation for ECE 362.

Overall, I had a great experience serving as team leader and working with Dave, Jay

and Tom. We worked really well together as a team and this project would not have been a

success without everyone’s hard work.

A.2 Contributions of Jay Doyle:At the beginning of the semester, the group gathered our thoughts on what would be

required to make a universal battery charger. We came up with four major components,

breaking the project into what we thought were four roughly equal sections. As it turned out, it

is nearly impossible to determine how much work something is going to be ahead of time, which

lead to an unbalanced workload for the four team members of BatteryMax.

I was responsible for the embedded web site on the microcontroller. The embedded

web site would need to convey information to the user about individual battery statistics, and

also allow the user to control the device through a web browser. To accomplish the first part, I

wrote a JavaScript graphing script which would take the data provided by the microcontroller

and present it to the user in a readable graph. The second part was achieved by a control page on

the embedded web site. This control page was a direct mapping of the physical pushbuttons.

The embedded website alone did not prove to be a large enough portion of the project;

the graphing function was mostly completed before spring break. Controlling the device over

the web was a different matter, though. Dave and I got that working near the end of the project,

as it required a physically working battery charger to built and test. It was a simple matter of

requesting webpages from the microcontroller and allowing the web server to parse the requests

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into commands. Because of the small portion of the total project work I had gotten, I decided to

take on most of the documentation for the end of the semester.

At the beginning of the semester, the homework assignments were assigned to various

group members. I chose to work on Homework 10 – Software Design and Narrative and

Homework 12 – Ethical Environmental Impact. The software design document was a major part

of the design for the project. It laid out a diagram of how the software would be written and how

it would operate. The ethical and environmental impact analysis was less crucial to the project in

terms of design, but was useful in terms of education. I had not previously considered much of

the impact of printed circuit boards and integrated circuits.

As the semester came to an end, I started working on the final documentation we

would need to submit. I finished most of Homework 13 – User Manual, but handed it off to

Dave for completion after I read that each team member should have a hand in writing it. I also

did Homework 17 – Group Poster for the team. The parts of Homework 16 – Final Report which

were not condensed homework assignments were written by me, apart from the last two sections.

In addition to the writing of documents, I was mainly responsible for the images seen

in the reports. I have some experience with Flash, and it proved to be an invaluable tool for

making diagrams and charts needed for the documentation and presentations. The User manual

especially needed accurate diagrams of the project, which Flash was able to produce easily.

(Though making the images was time consuming.) I also made and maintained the group

website throughout the semester.

When looking back on the project after graduation, I will remember it as an overall

fun and rewarding project. Seeing something come to life in the way our project did is always

fulfilling. Though if I had to do it all over again, I would put more work into the programming

of the project. I enjoy programming, and was disappointed that I couldn’t play more of a role in

programming our device. Overall I feel my contribution was fair, but that our project may have

been too simple for four people.

A.3 Contributions of Dave Canada:Though a battery charger may sound like a simple project, BatteryMax was anything

but simple. Designing and constructing any embedded system will always be a time consuming

and challenging process, but with the help of a dedicated team, anything is possible. My role in

the group was the primary software developer.

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At the start of the semester, my contributions were primarily related to completing

homework assignments. Working with the rest of the team, I helped write the Team Building and

Project Idea homework and the Final Project Proposal in the first two weeks. After that, I

researched online and in local electronics stores for good and bad examples of packaging used in

existing devices. I used these examples for the Packaging Specifications and Design homework

in which I proposed a design for BatteryMax which included a main enclosure which housed the

massive power supply circuit along with an external battery holder which would separate the

battery being charged from the heat generated by the power regulation circuit. I was extremely

concerned by the risk of BatteryMax overheating and damaging itself or injuring myself or a

teammate so I worked to make sure that there was ample room within the enclosure for heat

sinks and I placed fans on the case to help circulate air. Immediately after the packaging

homework was complete, I moved on to the Patent Liability Analysis homework. I found that

there was little risk of the BatteryMax violating any existing patents since battery technology is

so widespread now. When it came time to begin designing the schematic, I worked with Jay to

re-familiarize ourselves with Orcad’s software. I found that many of our parts were missing from

Orcad’s part database so I designed parts for our microcontroller, temperature sensor, and

regulators. At this time, the Freescale MC9S12NE64 microcontroller had been selected, so I

began reading up on its datasheet and support documentation in anticipation of the long software

development process ahead.

Once we obtained the NE64 development board from Freescale along with the

CodeWarrior software, I began to write simple programs which I thought would be useful for our

final code. Ryan and I implemented a program which would detect when buttons were pressed

and would light up a corresponding LCD. After that, I moved on to working with OpenTCP code

which would be the basis of Battery Max’s built-in web server. Early on, it was clear that the

RAM space available on the NE64 would be a significant hindrance of our goal of tracking

battery statistics over time. Since there was no way to add external memory to the dev board, I

came up with a plan for how to make battery statistics data available through the website. We

decided to build a JavaScript file which contained empty data arrays that the microcontroller

would be able to populate and serve to the user through the web server. The JavaScript file

would then be processed at the client side to create a graph of the statistic data over time. Jay

wrote this JavaScript graphing page. I also got the SCI sending code working in preparation for

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controlling our LCD. Not much more programming could be done on the dev board without our

LCD and charging circuit, so once our PCB and components arrived, I brushed up my soldering

skills on the practice boards, but in the end, Tom and Ryan soldered most of the components to

our PCB. The first section of the board to be populated was the microcontroller. Once the PCB

was ready for our LCD I began to code some wrapper functions for the various commands

supported by our LCD which would make it easy to display text or draw shapes on the LCD.

With a working LCD, I developed a menu system for controlling the BatteryMax. This involved

writing an SCI Receive function using interrupts to get keypress responses from the LCDs

keypad and developing a state machine to track the current menu state so that the next menu state

could be determined. Once the menu system was working, I developed a scheme for controlling

the device through the web server. Instead of adding large UDP code to our project and

developing a client-side software control solution, I chose to modify the hashing function which

the web server uses to find what data to return for an HTTP GET request so that it would

recognize certain requests and perform special actions. One of the biggest challenges I faced was

developing a method of manipulating the data within the existing JavaScript data file described

earlier. The data positions are known, and the microcontroller modifies one position at a time. If

the array fills up, previous data points are all moved back and the current data is placed in the

last spot of the array. I also incorporated battery charging code developed by Ryan into our main

project.

I am proud of what I have accomplished as an individual and as a member of such an

excellent team. I look forward to more digital systems design experiences like this one in my

future.

A.4 Contributions of Tom Germon:We built the BatteryMax Universal Battery Charger as a team, but the work was

divided among the team members. Wwhen designing and building the BatteryMax, I worked on

the initial circuit design. I helped make the original considerations for the project into a working

circuit. I helped do the research on the charging curves for the different battery types. I

designed some parts for the circuit design that were not in the existing libraries, and I built a

library to hold those parts. I designed some of the PCB layout footprints for several parts that

were not in the existing database. I created a library to hold those parts. I ordered some extra

sample parts to be used in our project, just in case we permanently damaged our existing ones,

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specifically microcontrollers. I soldered the microcontroller and the peripherals for the

microcontroller onto the PCB. The first time I soldered the microcontroller, I ended up

damaging it and had to remove it. The second time went much better than the first. The

peripherals I soldered included the bypass capacitors, the oscillator, the Ethernet module and the

resistors that are required to make the microcontroller work. I also soldered most of the surface

mount parts on the PCB. I tested the parts that I put on the board to ensure functionality and

connectivity.

I created one of the layout versions for the PCB. ; sSpecifically the one that was given

in the midterm design review. I made the PowerPoint and gave the presentation for TCSP2. I

made the slides for my part of the midterm design review, as well as talked about it in the review

itself. I made the PowerPoint for the bonus presentation for ECE362, and talked about my slide

during the presentation.

I assisted with homework 1: the Team Building and Project Idea. I assisted with

homework 2: the Final Project Proposal. I assisted with homework 3: the Design Constraint

Analysis. I assisted with homework 4: the Packaging Specifications and Design. I completed

the initial homework 6: the Printed Circuit Board Layout Narrative, and revised it to be included

with the final report. I completed the initial homework 11: the Reliability and Safety Analysis,

and revised it to be included with the final report. I completed homework 15: the ECE Senior

Design Report.

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Appendix B: Packaging

Figure B1 – Front Panel with LCD Display

Figure B2 – Side Panel with Power Connection

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Figure B3 – Side Panel with Ethernet Port

Figure B4 – Back Panel with Cooling Fans

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Figure B5 – AA Battery Holder

Figure B6 – Isometric Product View

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Appendix C: Schematic

Figure C1 – Microcontroller and Supporting Circuitry

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Figure C2 – Power Supply and Linear Regulators

Figure C3 – Digital Potentiometers

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Figure C4 – Serial Ports and Flash Memory Modules

Figure C5 – Relay, Battery Connector, Current Sensor, Voltage Sensor, Discharge Circuit, Fans

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Appendix D: PCB Layout Top and Bottom Copper

Figure D1 – PCB Top Copper Layer with Silk Screen

Figure D2 – PCB Bottom Copper Layer with Silk Screen

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Appendix E: Parts List Spreadsheet

Vendor Manufacturer Part No. Description Unit Cost Qty Total CostDigi-Key Freescale MC9S12NE64CPV 16-bit Microcontroller, 112 pin LQFP $15.74 1 $15.74Digi-Key Triad VPS24-5400 Power Transformer, 24V @ 5.4A $35.53 1 $35.53Digi-Key Fairchild LM317T 3-Terminal Adjustable Regulator $0.48 4 $1.92Digi-Key Fairchild LM350T 3-Terminal Adjustable Regulator $1.05 2 $2.10Digi-Key Allegro ACS 712 Hall-effect Current Sensor $2.90 1 $2.90Digi-Key Analog Devices AD22103 Temperature Sensor $2.86 5 $14.30Digi-Key Microchip 24FC1025 1024K IIC Serial EEPROM $6.75 3 $20.25Digi-Key Pulse J1012FC21CNL Ethernet Jack w/ Magnetics $5.88 1 $5.88Digi-Key Analog Devices AD5290 Digital Potentiometer $4.19 6 $25.14Digi-Key Triad CMT908-H2 Common Mode Inductor $4.78 1 $4.78Digi-Key Nichicon UVR1H332MRD6 3300 uF Capacitor $2.01 1 $2.01Digi-Key Nichicon UVR1H103MRD 10000 uF Capacitor $6.17 1 $6.17Digi-Key Hammond 1411X 12”x7”x4” Utility Case $28.55 1 $28.55Digi-Key Sunon KDE1204 40 mm, 12 V dc fan $4.84 2 $9.68ACS ACS 128X64 128 X 64 pixel LCD $114.95 1 $114.95

TOTAL $289.90

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Appendix F: Software Listing////////////////////////////////////////////////// system.h// Contains Constants and global variables used// among different files.////////////////////////////////////////////////

#ifndef SYSTEM_H_INCLUDE#define SYSTEM_H_INCLUDE

#include "os.h"#include "ne64api.h"

#include "datatypes.h"#include "globalvariables.h"

/** \def OPENTCP_VERSION * \brief OpenTCP major version number * * This define represents OpenTCP version information. Version * is in the format MAJOR.MINOR.PATCH. */#define OPENTCP_VERSION "1.0.4"

/* Boolean values*/#define TRUE 1 /**< Boolean TRUE value as used in the OpenTCP */#define FALSE 0 /**< Boolean FALSE value as used in the OpenTCP */

/** \def NETWORK_TX_BUFFER_SIZE * \ingroup opentcp_config * \brief Transmit buffer size * * NETWORK_TX_BUFFER_SIZE defines the size of the network buffer * used for data transmission by ICMP as well as TCP and UDP applications. * * See net_buf documentation for more reference on the shared transmit * buffer. *///#define NETWORK_TX_BUFFER_SIZE 1518//#define NETWORK_TX_BUFFER_SIZE 1024#define NETWORK_TX_BUFFER_SIZE 128

/** \struct netif system.h * \brief Network Interface declaration * * This structure holds information about the network interface. This means * that all of the network-related information are stored in this kind * of structure. */struct netif{ /** \brief IP address of a device * * IP address of a happy device using OpenTCP :-). This must hold * proper-value IP address in order for the networking stuff to work. * * Possible scenarios for filling this field are: * \li By assigning static IP address to a device always after reset * \li By allowing user to choose IP address by some tool (e.g. through * serial communication, storing that information to some external * flash,...)

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* \li By using BOOTP or DHCP clients for obtaining dynamically * assigned address * \li By obtaining the IP address from the first ICMP packet * the device receives * * First three approaches can also be used for obtaining gateway * and subnet-mask information. */ LWORD localip; /** \brief Ethernet address given to a device * * This array holds an Ethernet address assigned to a device. Note that * these must be unique so if you're shipping your product to outside * world you must purchase sufficient address range. * */ BYTE localHW[6]; /** \brief Default network gateway * * IP address of a default network gateway. This is needed if the * device is to communicate with the outside network (Internet) and * not only intranet. */ LWORD defgw; /** \brief Network submask * * Network submask. Also needed if the the device is to communicate * with the outside network. Used when determining whether the * host we're sending some data to is on the local network (send * data directly) or not (send through gateway). */ LWORD netmask;};

/* System variable definitions */

#define MASTER_MS_CLOCK base_timer /**< Interrupt driven msec free-running clock */#define TXBUF net_buf /**< TXBUF points to transmit network buffer */

/* System macros */

/** \def RESET_SYSTEM * \brief Macro used to reset the MCU * * By default this macro is only an infinite loop and the system is * reset by the (presumably) running watchdog timer. * * Change this if another form of reset is desired/needed. */#define RESET_SYSTEM() for(;;) {} /* Let the watchdog bite */

/** \def OS_EnterCritical * \brief Macro used to enter critical sections * \todo * \li Move this to other arch-dependant place * * This is highly dependant on the architecture that is used and/or * possible operating system beeing used so it will be moved to some * other place in the future.

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* * Usually disabling globally interrupts works just fine :-) */#define OS_EnterCritical OS_ENTER_CRITICAL

/** \def OS_ExitCritical * \brief Macro used to exit critical sections * \todo * \li Move this to other arch-dependant place * * This is highly dependant on the architecture that is used and/or * possible operating system beeing used so it will be moved to some * other place in the future. * * For now this only globally enables interrupts */#define OS_ExitCritical OS_EXIT_CRITICAL

/** \def RECEIVE_NETWORK_B * \brief Use this macro to read data from Ethernet controller * * This macro should be used to read data from the Ethernet * controller. Procedure for doing this would be as follows: * \li Initialize reading of data from certain address in the * Ethernet controller (usually you will do that based on buf_index * value of ip_frame, udp_frame or tcp_frame type of variables; * in certain special situations you can also use buf_index from * ethernet_frame type of var. * \li Keep invoking RECEIVE_NETWORK_B() to read one byte at a time from * the ethernet controller. Take care not to read more data than * actually received * \li If needed, reinitialize reading of data again and start all * over again * \li When finished discard the current frame in the Ethernet * controller by invoking NETWORK_RECEIVE_END() macro * */#define RECEIVE_NETWORK_B() NE64ReadByte()

/** \def RECEIVE_NETWORK_W * \brief Use this macro to read data from Ethernet controller * * This macro should be used to read data from the Ethernet * controller. Procedure for doing this would be as follows: * \li Initialize reading of data from certain address in the * Ethernet controller (usually you will do that based on buf_index * value of ip_frame, udp_frame or tcp_frame type of variables; * in certain special situations you can also use buf_index from * ethernet_frame type of var. * \li Keep invoking RECEIVE_NETWORK_W() to read one word at a time from * the ethernet controller. Take care not to read more data than * actually received * \li If needed, reinitialize reading of data again and start all * over again * \li When finished discard the current frame in the Ethernet * controller by invoking NETWORK_RECEIVE_END() macro * */#define RECEIVE_NETWORK_W() NE64ReadWord()

/** \def RECEIVE_NETWORK_BUF * \brief Use this macro to read data from Ethernet controller to a buffer

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* * This macro should be used to read data from the Ethernet * controller to a buffer in memory. Procedure for using this macro * is the same as for using RECEIVE_NETWORK_B() macro. * */#define RECEIVE_NETWORK_BUF(c,d) NE64ReadBytes(c,d)

/** \def SEND_NETWORK_B * \brief Use this macro to write data to Ethernet controller * * This macro should be used to write data to Ethernet * controller. Procedure for doing this would be as follows: * \li Initialize writing of data to certain address in the * Ethernet controller. Buffer space in Ethernet controller is * divided among the protocols in the following way: * \li 256 byte Tx for ARP (see ARP_BUFFER ) * \li 1536 byte Tx for ICMP (see ICMP_BUF) * \li 1536 byte Tx for TCP (see TCP_BUF) * \li 1536 byte Tx for UDP (see UDP_BUF) * \li Write the data by using SEND_NETWORK_B() macro * \li When all of the data is written instruct the Ethernet controller * to send the data by calling the NETWORK_COMPLETE_SEND() macro with * number of bytes to send as a parameter * */#define SEND_NETWORK_B(c) NE64WriteByte(c)

/** \def SEND_NETWORK_W * \brief Use this macro to write data to Ethernet controller * * This macro should be used to write data to Ethernet * controller. Procedure for doing this would be as follows: * \li Initialize writing of data to certain address in the * Ethernet controller. Buffer space in Ethernet controller is * divided among the protocols in the following way: * \li 256 byte Tx for ARP (see ARP_BUFFER ) * \li 1536 byte Tx for ICMP (see ICMP_BUF) * \li 1536 byte Tx for TCP (see TCP_BUF) * \li 1536 byte Tx for UDP (see UDP_BUF) * \li Write the data by using SEND_NETWORK_W() macro * \li When all of the data is written instruct the Ethernet controller * to send the data by calling the NETWORK_COMPLETE_SEND() macro with * number of bytes to send as a parameter * */#define SEND_NETWORK_W(c) NE64WriteWord(c)

/** \def SEND_NETWORK_BUF * \brief Use this macro to write data from buffer to Ethernet controller * * This macro should be used to write data from a buffer to Ethernet * controller. Usage is the same as for the SEND_NETWORK_B() macro. */#define SEND_NETWORK_BUF(c,d) NE64WriteBytes(c,d)

/** \def NETWORK_CHECK_IF_RECEIVED * \ingroup periodic_functions * \brief Use this macro to check if there is recieved data in Ethernet controller * * Invoke this macro periodically (see main_demo.c for example) to check

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* if there is new data in the Ethernet controller. * * If there is new data in the Ethernet controller, this macro (function * that it points to that is) will return a value of TRUE and fill in * the appropriate values in the received_frame variable. Otherwise it * returns FALSE. */#define NETWORK_CHECK_IF_RECEIVED() NE64ValidFrameReception()

/** \def NETWORK_RECEIVE_INITIALIZE * \brief Initialize reading from a given address * * This macro initializes reading of the received Ethernet frame from * a given address in the Ethernet controller. */#define NETWORK_RECEIVE_INITIALIZE(c) NE64InitializeOffsetToReadRxBuffer(c)

/** \def NETWORK_RECEIVE_END * \ingroup periodic_functions * \brief Dump received packet in the Ethernet controller * * Invoke this macro when the received Ethernet packet is not needed * any more and can be discarded. */#define NETWORK_RECEIVE_END() NE64FreeReceiveBuffer()

/** \def NETWORK_COMPLETE_SEND * \brief Send the Ethernet packet that was formed in the Ethernet controller * * After the data has been written to the Ethernet controller, use this * function to instruct the Ethernet controller that data is in it's * internal buffer and should be sent. */#define NETWORK_COMPLETE_SEND(c) NE64StartFrameTransmission(c)

/** \def NETWORK_SEND_INITIALIZE * \brief Initialize sending of Ethernet packet from a given address * * Use this function to initialize sending (or creating) of an Ethernet * packet from a given address in the Ethernet controller. */#define NETWORK_SEND_INITIALIZE(c) NE64InitializeTransmissionBuffer(c)

/** \def NETWORK_ADD_DATALINK * \brief Add lower-level datalink information * * This implementation adds Ethernet data-link information by * invoking WriteEthernetHeader() function that writes Ethernet * header based on information provided (destination and source ethernet * address and protocol field). */#define NETWORK_ADD_DATALINK(c) NE64WriteEthernetHeaderToTxBuffer((struct TEthernetFrame*)c)

/* System functions */

extern void kick_WD (void);extern void wait (INT16);extern void enter_power_save (void);extern void exit_power_save (void);extern INT16 __strlen (UINT8*, UINT16);extern INT16 bufsearch (UINT8*, UINT16, UINT8*);

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extern UINT16 hextoascii (UINT8);extern void __itoa (UINT16, UINT8*);extern void __ltoa (UINT32, UINT8*);extern INT16 __atoi (UINT8*, UINT8);extern UINT8 asciitohex (UINT8);extern UINT8 isnumeric (UINT8);extern void mputs (INT8*);void mputhex (UINT8);extern UINT32 random (void);extern void dummy (void);extern UINT8 __tolower (UINT8);extern UINT8 __toupper (UINT8);

/* External functions */

extern void init(void);extern void WriteToSCI0(const char *);extern void WriteToSCI1(const char *);//extern uint8 ReadSCI1(void);//extern void SCI1Interrupt(void);

/* LCD Functions */

extern void LCDPixel(int8,int8,int8);extern void LCDLine(int8,int8,int8,int8,int8);extern void LCDCircle(int8,int8,int8,int8);extern void SetBacklight(int8);extern void LCDClear(uint8);extern void LCDPrint(int8,int8,int8,int8,int8,char *);extern void LCDTone(int16,int8);extern void LCDGraphic(int8,int8,int8);extern void LCDBox(int8,int8,int8,int8,int8);extern void LCDMenu(void);extern void LCDMenuText(char *);

//mainwebserver.c#define MAX_CAPACITY 5000#define MAX_VOLTAGE 250#define MAX_BATTERY_ID 4 // 0-4#define NUM_TECHS 4#define NUM_DATA_POINTS 20extern void StartCharging(void);extern void StartTesting(void);extern void StartDraining(void);extern void Stop(void);extern void StartCharging(void);//extern void DoCharging(void);//extern void CheckStatus(void);//extern void SetBatteryType(enum BatteryTypes);extern void SetBatteryTech(enum BatteryTechnologies);extern void SetKeypress(uint8 button);//Menuenum LCDmenu {Main,New,Charge,Drain,Status,Setup,SelID,List,Add,SetupT,SetupV,SetupC};//enum BatteryTypes {AAA,AA,C,D,NineV,noType};enum BatteryTechnologies {NiCad=0,NiMH,LiIon,LeadAcid,noTech};

//extern enum BatteryTypes selectedType;struct batteryProfile { unsigned int voltage; unsigned int currentCapacity; enum BatteryTechnologies selectedTech; };extern struct batteryProfile batteries[MAX_BATTERY_ID+1];

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//extern enum BatteryTechnologies selectedTech;extern uint8 scrollMenuSelected; //Starts at the 4th menu itemextern uint8 isCharging;extern uint8 isDraining;extern uint8 buttonPressed;//Flag which is set only if the menu is changed.//This allows us to avoid spamming the LCD with commands which slow our loop considerablyextern uint8 menuchanged; //Set initially so that the menu gets displayed on resetextern const char battTechs[][9];//extern unsigned int voltage; // Last digit is one decimal place//extern unsigned int currentCapacity; //mAhextern uint8 batteryID;

//charging.c#define BM_ATD_CTL2 0xC0 //11000000#define BM_ATD_CTL3 0x20 //00100000#define BM_ATD_CTL4 0x73 //01110011#define BM_ATD_START ATDCTL5#define BM_ATD_READ_ALL 0x10#define BM_ATD_DONE ATDSTAT0_SCF#define BM_ATD_VOLTAGE ATDDR0H#define BM_ATD_CURRENT ATDDR1H#define BM_ATD_BTEMP ATDDR2H#define BM_ATD_UTEMP ATDDR3H#define BM_SPI_BAUD 0x40#define BM_SPI_CR1 0x50#define BM_SPI_CR2 0x00#define BM_SPI_DONE SPISR_SPTEF#define BM_POT_DATA SPIDR#define BM_POT_SELECT PORTB#define BM_POT_NONE 0xFF#define BM_POT_FINE1 0xFD#define BM_POT_COURSE1 0xFE #define BM_POT_FINE2 0xF7#define BM_POT_COURSE2 0xFB#define BM_POT_VSENSE 0xEF#define BM_POT_DISCHARGE 0xDF#define BM_POT_ALL 0xC0#define BM_OP_IDLE 0#define BM_OP_CHARGING 1#define BM_OP_DISCHARGING 2#define BM_OP_TESTING 3#define BM_OP_COMPLETE 4#define BM_CURRENT_MULTIPLIER 70#define BM_VOLTAGE_MULTIPLIER 330#define BM_TEMP_MULTIPLIER 180 / 255#define BM_NIMH_MAX_DELTA_T 255#define BM_NICAD_MAX_DELTA_T 255#define BM_LEAD_MAX_DELTA_T 255#define BM_LIION_MAX_DELTA_T 255

#define rlyRelay PTG_PTG0#define ON 1;#define OFF 0;enum chargeState {initialize=0,rampup,constantcurrent,constantvoltage,terminate,complete};extern enum chargeState bmOperationState;

extern void InitATD(void);extern void InitSPI(void);extern void InitIIC(void);extern void InitRelay(void);

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extern void ReadATD(void);extern void SetPOT(uint8, uint8);extern void ChargeVoltageInit(uint8);extern void ChargeVoltageIncrease(void);extern void ChargeVoltageDecrease(void);extern void ChargeCircuitOn(void);extern void ChargeCircuitOff(void);extern void ChargeBattery(void);extern void DischargeBattery(void);extern void TestBattery(void);extern void ChargeNIMH(void);extern void ChargeNICAD(void);extern void ChargeLIION(void);extern void ChargeLEAD(void);extern void DischargeNIMH(void);extern void DischargeNICAD(void);extern void DischargeLEAD(void);extern void DischargeLIION(void);extern uint8 atdVoltage;extern uint8 atdCurrent;extern uint8 atdBTemp;extern uint8 atdUTemp;//extern uint8 bmOperationState;extern uint8 spiDPot1Fine;extern uint8 spiDPot1Course;extern uint8 spiDPot2Fine;extern uint8 spiDPot2Course;extern uint8 spiDPotVSense;extern int bmChargeCurrent;extern int bmChargeVoltage;extern int bmChargeBTemp;extern int bmChargeUTemp;

#endif

////////////////////////////////////////////////// http_server.c// OpenTCP http server code with some modifications// done to the hash function to allow control// through the web.////////////////////////////////////////////////

#include"datatypes.h"#include"globalvariables.h"#include"debug.h"#include"system.h"#include"tcp_ip.h"#include"http_server.h"

UINT8 https_enabled = 0; /**< Defines whether https_init has already been invoked or not */

/** \brief Used for storing state information about different HTTP sessions * * This is an array of http_server_state structures holding various state * information about the HTTP sessions. HTTP server uses this information * to determine actions that need to be taken on sockets.

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*/struct http_server_state https [NO_OF_HTTP_SESSIONS];

/** \brief Initialize HTTP server variables * \author * \li Jari Lahti (jari.lahti@violasysems.com) * \date 13.10.2002 * * This function should be called before the HTTP Server application * is used to set the operating parameters of it */INT8 https_init(void){ UINT8 i; INT8 soch;

for( i=0; i<NO_OF_HTTP_SESSIONS; i++) { https[i].state = HTTPS_STATE_FREE; https[i].ownersocket = 0; https[i].fstart = 0; https[i].fpoint = 0; https[i].flen = 0; https[i].funacked = 0; soch = tcp_getsocket(TCP_TYPE_SERVER, TCP_TOS_NORMAL, TCP_DEF_TOUT, https_eventlistener); if(soch < 0) { DEBUGOUT("HTTP Server uncapable of getting socket\r\n"); RESET_SYSTEM(); /*return(-1);*/ } https[i].ownersocket = soch; kick_WD(); soch = tcp_listen(https[i].ownersocket, HTTPS_SERVERPORT); if(soch < 0) { DEBUGOUT("HTTP Server uncapable of setting socket to listening mode\r\n"); RESET_SYSTEM(); /*return(-1);*/ } } https_enabled = 1; return(i); }

/********************************************************************************Function: https_run

Parameters: void

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Return val: void Date: 13.10.2002

Desc: This function is main 'thread' of HTTP server program and should be called periodically from main loop.*********************************************************************************/

void https_run (void){ UINT8 i; INT16 len; static UINT8 ses = 0; if( https_enabled == 0) return; /* Walk thru all sessions until we found something to send or so */ for(i=0; i<NO_OF_HTTP_SESSIONS; i++) { kick_WD();

if(ses >= NO_OF_HTTP_SESSIONS) ses = 0;

/* Keep sockets listening */

if(tcp_getstate(https[ses].ownersocket) < TCP_STATE_LISTENING) { (void)tcp_listen(https[ses].ownersocket, HTTPS_SERVERPORT); ses++; continue; }

if(https[ses].state != HTTPS_STATE_ACTIVE) { ses++; continue; }

if(https[ses].funacked != 0) { ses++; continue; }

if(https[ses].fstart == 0) { ses++; continue; }

/* End of data? */

if( https[ses].fpoint >= https[ses].flen) { (void)tcp_close(https[ses].ownersocket); (void)tcp_abort(https[ses].ownersocket); https_deletesession(ses);

ses++;

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return;

}

/* More data to send */

len = https_loadbuffer(ses, &net_buf[TCP_APP_OFFSET], NETWORK_TX_BUFFER_SIZE - TCP_APP_OFFSET); if(len<0) return;

len = tcp_send(https[ses].ownersocket, &net_buf[TCP_APP_OFFSET], NETWORK_TX_BUFFER_SIZE - TCP_APP_OFFSET, len);

if(len<0) { (void)tcp_close(https[ses].ownersocket); https_deletesession(ses);

ses++;

return; }

https[ses].funacked = len;

/* Serve another session on next run */ ses++;

return; }}

/********************************************************************************Function: https_eventlistener

Parameters: INT8 cbhandle - handle to TCP socket where event is coming from UINT8 event - type of event UINT32 par1 - parameter the meaning of depends on event UINT32 par2 - parameter the meaning of depends on event Return val: INT32 - depends on event but usually (-1) is error of some kind and positive reply means OK Date: 13.10.2002

Desc: This function is given to TCP socket as function pointer to be used by TCP engine to make callbacks to inform about events on TCP e.g. arriving data. *********************************************************************************/

INT32 https_eventlistener (INT8 cbhandle, UINT8 event, UINT32 par1, UINT32 par2){ /* This function is called by TCP stack to inform about events */ INT16 i; INT16 session; par2 = 0; if( https_enabled == 0)

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return(-1); if(cbhandle < 0) return(-1); /* Search for rigth session */ session = https_searchsession(cbhandle); switch( event ) { case TCP_EVENT_CONREQ: /* Do we have a session for requesting socket? */ if(session < 0) return(-1);

/* Try to get new session */ session = https_bindsession(cbhandle); if(session < 0) /* No resources */ return(-1);

return(1); case TCP_EVENT_ABORT: if(session < 0) return(1); https_deletesession((UINT8)session); return(1); case TCP_EVENT_CONNECTED: if(session < 0) return(-1); https_activatesession((UINT8)session); return(1); case TCP_EVENT_CLOSE: if(session < 0) return(-1); https_deletesession((UINT8)session); return(1); case TCP_EVENT_ACK: if(session < 0) return(-1);

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https[session].fpoint += https[session].funacked; https[session].funacked = 0; return(1); case TCP_EVENT_DATA: /* Check for GET request */ if(session < 0) return(-1); if(https[session].fstart == 0) { if(par1 <= 3) return(1); /* Check for GET */ if(RECEIVE_NETWORK_B() != 'G') return(1); if(RECEIVE_NETWORK_B() != 'E') return(1); if(RECEIVE_NETWORK_B() != 'T') return(1); par1 -= 3; /* Search for '/' */ for(i=0; i<(INT16)par1; i++) { if(RECEIVE_NETWORK_B() == '/') { i++; break; } } par1 -= i; /* Calculate Hash */ i = https_calculatehash(par1); if(i < 0) { /* Invalid GET */ return(1); } /* Get FileRef */ i = https_findfile((UINT8)i, (UINT8)session); return(1); } return(1); case TCP_EVENT_REGENERATE:

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if(session < 0) return(-1); if(https[session].state != HTTPS_STATE_ACTIVE) return(-1); i = https_loadbuffer((char)session, &net_buf[TCP_APP_OFFSET], (UINT16)par1); if(i<0) return(-1); (void)tcp_send(https[session].ownersocket, &net_buf[TCP_APP_OFFSET], NETWORK_TX_BUFFER_SIZE - TCP_APP_OFFSET, i); return(i); default: return(-1); }

}

void https_deletesession (UINT8 ses){ https[ses].state = HTTPS_STATE_FREE; https[ses].fstart = 0; https[ses].fpoint = 0; https[ses].flen = 0; https[ses].funacked = 0;

}

INT16 https_searchsession (UINT8 soch){ UINT8 i; for(i=0; i<NO_OF_HTTP_SESSIONS; i++) { if(https[i].ownersocket == soch) return(i); } return(-1);

}

INT16 https_bindsession (UINT8 soch){ UINT8 i; for(i=0; i<NO_OF_HTTP_SESSIONS; i++) { if(https[i].ownersocket == soch) { if(https[i].state == HTTPS_STATE_FREE) { https[i].state = HTTPS_STATE_RESERVED; return(i); } }

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} return(-1);

}

void https_activatesession (UINT8 ses){ https[ses].state = HTTPS_STATE_ACTIVE;

}

/* read two encoded bytes from HTTP URI and return * decoded byte */UINT8 https_read_encoded(void){ UINT8 temp,ch; temp = RECEIVE_NETWORK_B(); if ((temp>='0') && (temp<='9')) { ch = (temp-'0')<<4; } else { if ((temp>='a') && (temp<='f')) { ch = (temp-'a'+10)<<4; } else { ch = (temp-'A'+10)<<4; } } temp = RECEIVE_NETWORK_B(); if ((temp>='0') && (temp<='9')) { ch |= (temp-'0'); } else { if ((temp>='a') && (temp<='f')) { ch |= (temp-'a'+10); } else { ch |= (temp-'A'+10); } } return ch;}

INT16 https_calculatehash (UINT32 len){ UINT8 hash=0; UINT8 ch; UINT8 i;

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/* Read Max 60 characters */ if(len > 60) len = 60; for( i=0; i<len; i++) { ch = RECEIVE_NETWORK_B(); if ( ch ==' ') /* End reached? */ break; /* encoded HTTP URI ? */ if ( ch == '%') { ch = https_read_encoded();

/* is this UNICODE char encoded? (for now allow only * one byte encoded UNICODE chars) */ if ( ( ch & 0xe0 ) == 0xc0 ) { /* yes */ ch = ( ch & 0x1F ) << 6; (void)RECEIVE_NETWORK_B(); /* skip first % */ ch |= (https_read_encoded() & 0x3F); } }

hash *= 37; hash += ch; } if(i==len) return(-1); /* construct address for Hash table */ if(hash == 0) /* User asked default file */ { /* Set hash to index.htm value */// hash = 115;//0x0B; /* Set hash to index.html value */ hash = 11; } else if(hash == 197) { //stopcharging hash = 13; //Settings confirmed// WriteToSCI0("Stopped Charging"); Stop(); } //TECHNOLOGIES else if(hash == 39) { //setTechNiCad hash = 13; SetBatteryTech(NiCad); } else if(hash == 32) { //setTechNiMH hash = 13; SetBatteryTech(NiMH); } else if(hash == 251) { //setTechLeadAcid hash = 13; SetBatteryTech(LeadAcid);

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} else if(hash == 107) { //setTechLiIon hash = 13; SetBatteryTech(LiIon); } //Keypad else if(hash == 2) { //keypad0 hash = 16; //Settings page SetKeypress(0); } else if(hash == 3) { //keypad1 hash = 16; //Settings page SetKeypress(1); } else if(hash == 4) { //keypad2 hash = 16; //Settings page SetKeypress(2); } else if(hash == 5) { //keypad3 hash = 16; //Settings page SetKeypress(3); } else if(hash == 6) { //keypad4 hash = 16; //Settings page SetKeypress(4); } else if(hash == 7) { //keypad5 hash = 16; //Settings page SetKeypress(5); } else if(hash == 8) { //keypad6 hash = 16; //Settings page SetKeypress(6); } /* Now we have hash value calculated */ return( hash );

}

/****************************************************************************** * * (c) Freescale Inc. 2004 All rights reserved * * File Name : FileSys.c * Description : Filesystem is created for use by the web server. All web * are defined here. Hash value is used to find requested pages * * Version : 1.0 * Date : Mar/05/2004 * * ******************************************************************************/ #include "FileSys.h"

/********* Include Web server files here *************/#include "index.h"#include "graph.h"#include "contacts.h"#include "footer.h"#include "style.h"

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#include "bg.h"#include "graph_sub.h"#include "header.h"#include "settings.h"#include "settings_changed.h"#include "statistics.h"#include "digijock.h"#include "intro.h"/*****************************************************/

const TFileEntry FAT [] = { { 11, index_file, 1014 }, { 13, settings_changed_file, SETTINGS_CHANGED_FILE_LEN }, { 16, settings_file, SETTINGS_FILE_LEN }, { 28, style_file, STYLE_FILE_LEN }, { 46, statistics_file, STATISTICS_FILE_LEN }, { 122, bg_file, BG_FILE_LEN }, { 139, graph_file, GRAPH_FILE_LEN }, { 146, footer_file, FOOTER_FILE_LEN }, { 150, intro_file, INTRO_FILE_LEN }, { 151, digijock_file, DIGIJOCK_FILE_LEN }, { 170, contacts_file, CONTACTS_FILE_LEN }, { 180, header_file, HEADER_FILE_LEN }, { 206, graph_sub_file, GRAPH_SUB_FILE_LEN },// { , _file, _FILE_LEN }, { 0, (unsigned char *)0, 0 }};

/************************************************************************** * * Copyright (C) 2003 Freescale Semiconductor, Inc. * and 2000-2002 Viola Systems Ltd. * All Rights Reserved * * File Name : mainwebserver.c * Description : Adapted from the Freescale UDP Demo code. This file * contains wrapper functions for starting and stopping * both charging and discharging. It also contains the * main loop of the program which operates a state machine * for the menu system and handles polling of the ATD. * Also defines many of the global variables used for * tracking battery parameters. * * *** NOTE: This project is for demonstration purposes only. * * Version : 1.0 * ***************************************************************************/

#include "debug.h"#include "datatypes.h"#include "timers.h"#include "system.h"#include "ethernet.h"#include "arp.h"#include "ip.h"#include "tcp_ip.h"#include "http_server.h"#include "digijock.h"

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#include "ne64driver.h"#include "ne64api.h"#include "mBuf.h"#include "ne64config.h"#include "address.h"#include "MC9S12NE64.h"#include "system.h"

/* Including used modules for compiling procedure */

/* Network Interface definition. Must be somewhere so why not here? :-)*/struct netif localmachine;

extern void RTI_Enable (void);//extern void porth_isr_handler (void);

extern tU08 gotlink;

//============================================================/*tU08 OldSwitchValue=255;tU16 Pot=0;tU16 OldPot=1050;tU08 OldB1=255; tU08 OldB2=255;tU08 OldB3=255;tU08 OldB4=255;*///GLOBAL BATTERY PARAMETERSenum LCDmenu currentMenu = Main;//enum BatteryTypes selectedType = noType;uint8 scrollMenuSelected = 3; //Starts at the 4th menu itemuint8 isCharging = 0;uint8 isDraining = 0;uint8 buttonPressed = -1;uint8 batteryID = 0;//Flag which is set only if the menu is changed.//This allows us to avoid spamming the LCD with commands which slow our loop considerablyuint8 menuchanged = 1; //Set initially so that the menu gets displayed on resetuint8 numtypes = 21;const char battTechs[][9] = { "NiCad", "NiMH", "Li-Ion", "LeadAcid" };//unsigned int voltage = 0; // Last digit is one decimal place//unsigned int currentCapacity = 0; //mAh//enum BatteryTechnologies selectedTech = NiCad;struct batteryProfile batteries[MAX_BATTERY_ID+1];char buff[15];uint16 startingbyteC[MAX_BATTERY_ID+1];uint16 startingbyteV[MAX_BATTERY_ID+1];uint8 currentByte[MAX_BATTERY_ID+1];

//============================================================/*#pragma CODE_SEG NON_BANKEDinterrupt void PortHInterrupt (void){ // porth_isr_handler();

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}#pragma CODE_SEG DEFAULT*/

//============================================================//Initialize ATD//============================================================

void Stop(void) { //Set all voltages to 0 //Leave parameters untouched isCharging = 0; isDraining = 0; ChargeCircuitOff(); bmOperationState = complete;// LCDMenu(); StartTesting();}

void StartCharging(void) { //Set voltage according to battery type //Set up parameters if(isDraining == 0 && isCharging == 0){ isCharging = 1; bmOperationState = initialize; LCDMenu(); }}

void StartDraining(void) { if(isCharging == 0){ isDraining = 1; LCDMenu(); }}

void StartTesting(void) {

uint16 i; LCDClear(63); buff[0] = atdCurrent/100+'0'; buff[1] = (atdCurrent%100)/10+'0'; buff[2] = atdCurrent%10+'0'; buff[3] = '\r'; buff[4] = '\n'; buff[5] = '\0'; WriteToSCI0(buff); buff[0] = bmChargeVoltage/1000+'0'; buff[1] = (bmChargeVoltage%1000)/100+'0'; buff[2] = (bmChargeVoltage%100)+'0'; buff[3] = (bmChargeVoltage%10)+'0'; buff[3] = '\r'; buff[4] = '\n'; buff[5] = '\0'; WriteToSCI0(buff); buff[0] = spiDPotVSense/100+'0'; buff[1] = (spiDPotVSense%100)/10+'0'; buff[2] = spiDPotVSense%10+'0';

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buff[3] = '\r'; buff[4] = '\n'; buff[5] = '\0'; WriteToSCI0(buff);

if(isCharging == 1) LCDPrint(0, 0, 4, 1, 1, "Charging"); else if(isDraining == 1) LCDPrint(0, 0, 4, 1, 1, "Draining"); else LCDPrint(0, 0, 4, 1, 1, "Testing"); //Voltage __itoa(bmChargeVoltage/10,(UINT8*)buff); i=0; while(buff[i] != '\0') { i++; } buff[i++] = '.'; buff[i++] = bmChargeVoltage%10+'0'; buff[i++] = ' '; buff[i++] = 'V'; buff[i] = '\0'; LCDPrint(1, 0, 4, 1, 1, buff); //Current if(isCharging == 1 || isDraining == 1) { __itoa(bmChargeCurrent,(UINT8*)buff); i=0; while(buff[i] != '\0') { i++; } buff[i++] = ' '; buff[i++] = 'm'; buff[i++] = 'A'; buff[i] = '\0'; LCDPrint(2, 0, 4, 1, 1, buff); //Battery Temperature __itoa(bmChargeBTemp/10,(UINT8*)buff); i=0; while(buff[i] != '\0') { i++; } buff[i++] = '.'; buff[i++] = bmChargeBTemp%10+'0'; buff[i++] = ' '; buff[i++] = ' '; buff[i++] = 'F'; buff[i] = '\0'; LCDPrint(3, 0, 4, 1, 1, buff); //Unit Temperature __itoa(bmChargeUTemp/10,(UINT8*)buff); i=0; while(buff[i] != '\0') { i++; } buff[i++] = '.'; buff[i++] = bmChargeUTemp%10+'0'; buff[i++] = ' '; buff[i++] = ' '; buff[i++] = 'F'; buff[i] = '\0'; LCDPrint(4, 0, 4, 1, 1, buff);

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} if(currentByte[batteryID]<NUM_DATA_POINTS) { //Current digijock_file[startingbyteC[batteryID]+(4*currentByte[batteryID])] = (atdCurrent/100)+'0'; digijock_file[startingbyteC[batteryID]+1+(4*currentByte[batteryID])] = ((atdCurrent%100)/10)+'0'; digijock_file[startingbyteC[batteryID]+2+(4*currentByte[batteryID])] = (atdCurrent%10)+'0'; //Voltage digijock_file[startingbyteV[batteryID]+(4*currentByte[batteryID])] = (atdVoltage/100)+'0'; digijock_file[startingbyteV[batteryID]+1+(4*currentByte[batteryID])] = ((atdVoltage%100)/10)+'0'; digijock_file[startingbyteV[batteryID]+2+(4*currentByte[batteryID])] = (atdVoltage%10)+'0'; currentByte[batteryID]++; } else { //Copy each data point back one for(i=0;i<NUM_DATA_POINTS-1;i++) { //Current digijock_file[startingbyteC[batteryID]+(4*i)] = digijock_file[startingbyteC[batteryID]+(4*i)+4]; digijock_file[startingbyteC[batteryID]+1+(4*i)] = digijock_file[startingbyteC[batteryID]+5+(4*i)]; digijock_file[startingbyteC[batteryID]+2+(4*i)] = digijock_file[startingbyteC[batteryID]+6+(4*i)]; //Voltage digijock_file[startingbyteV[batteryID]+(4*i)] = digijock_file[startingbyteV[batteryID]+(4*i)+4]; digijock_file[startingbyteV[batteryID]+1+(4*i)] = digijock_file[startingbyteV[batteryID]+5+(4*i)]; digijock_file[startingbyteV[batteryID]+2+(4*i)] = digijock_file[startingbyteV[batteryID]+6+(4*i)]; } //Current digijock_file[startingbyteC[batteryID]+(4*19)] = (atdCurrent/100)+'0'; digijock_file[startingbyteC[batteryID]+1+(4*19)] = ((atdCurrent%100)/10)+'0'; digijock_file[startingbyteC[batteryID]+2+(4*19)] = (atdCurrent%10)+'0'; //Voltage digijock_file[startingbyteV[batteryID]+(4*19)] = (atdVoltage/100)+'0'; digijock_file[startingbyteV[batteryID]+1+(4*19)] = ((atdVoltage%100)/10)+'0'; digijock_file[startingbyteV[batteryID]+2+(4*19)] = (atdVoltage%10)+'0'; }} void SetBatteryTech(enum BatteryTechnologies tech) { if(isCharging == 0 && isDraining == 0) { batteries[batteryID].selectedTech = tech; } LCDMenu();}//Accepts keypresses from the web pagevoid SetKeypress(uint8 button) { buttonPressed = button;}

//============================================================/* main *///============================================================void main(void){

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uint16 len; uint16 i = 0; //Loop counter uint16 j = 0; //Loop counter char sendstring[30]; uint8 sendstringpos; /* System clock initialization */

CLKSEL=0; CLKSEL_PLLSEL = 0; /* Select clock source from XTAL */ PLLCTL_PLLON = 0; /* Disable the PLL */ SYNR = 0; /* Set the multiplier register */ REFDV = 0; /* Set the divider register */ PLLCTL = 192; PLLCTL_PLLON = 1; /* Enable the PLL */ while(!CRGFLG_LOCK); /* Wait */ CLKSEL_PLLSEL = 1; /* Select clock source from PLL */ INTCR_IRQEN = 0; /* Disable the IRQ interrupt. IRQ interrupt is enabled after CPU reset by default. */ init(); //Initialize SCI0 and SCI1 InitATD(); InitSPI(); InitIIC(); InitRelay();

//// Initialize Charging Circuit SetPOT(BM_POT_FINE1, 0); SetPOT(BM_POT_COURSE1, 0); SetPOT(BM_POT_FINE2, 0); SetPOT(BM_POT_COURSE2, 0); SetPOT(BM_POT_VSENSE, 0); SetPOT(BM_POT_DISCHARGE, 0); bmOperationState = initialize; //spiDPot1Fine = 127; //spiDPot1Course = 127; //spiDPot2Fine = 0; // spiDPot2Course = 6; // spiDPotVSense = 0; //Initialize Batteries for(i=0; i<MAX_BATTERY_ID; i++) { batteries[i].voltage = 0; batteries[i].currentCapacity = 0; batteries[i].selectedTech = NiCad; } //The last batteryID is pre-set to Ryan's Creative battery specs/* batteries[MAX_BATTERY_ID].voltage = 12; batteries[MAX_BATTERY_ID].currentCapacity = 1800; batteries[MAX_BATTERY_ID].selectedTech = NiMH; */ batteryID = 0; //Initialize starting bytes of the digijock javascript data file to be //modified.

startingbyteC[0] = 79; startingbyteC[1] = startingbyteC[0]+107; startingbyteC[2] = startingbyteC[1]+107; startingbyteC[3] = startingbyteC[2]+107; startingbyteC[4] = startingbyteC[3]+107;

startingbyteV[0] = 651;

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startingbyteV[1] = startingbyteV[0]+107; startingbyteV[2] = startingbyteV[1]+107; startingbyteV[3] = startingbyteV[2]+107; startingbyteV[4] = startingbyteV[3]+107;

currentByte[0] = 0; currentByte[1] = 0; currentByte[2] = 0; currentByte[3] = 0; currentByte[4] = 0;

//// Initialize Ethernet localmachine.localip = *((UINT32 *)ip_address); // IP address localmachine.defgw = *((UINT32 *)ip_gateway); // Default gateway localmachine.netmask = *((UINT32 *)ip_netmask); // Subnet mask

/* Ethernet (MAC) address */ localmachine.localHW[0] = hard_addr[0]; localmachine.localHW[1] = hard_addr[1]; localmachine.localHW[2] = hard_addr[2]; localmachine.localHW[3] = hard_addr[3]; localmachine.localHW[4] = hard_addr[4]; localmachine.localHW[5] = hard_addr[5];

/* Init system services */ timer_pool_init(); /* Initialize all buffer descriptors */ mBufInit ();

/*interrupts can be enabled AFTER timer pool has been initialized */ /* Initialize all network layers */ EtherInit(); //Initialize required network protocols arp_init(); (void)tcp_init(); (void)https_init ();

//Enable RTI RTI_Enable ();

LCDClear(255); //Clear all rows LCDMenu(); LCDMenuText("Chrg Drain Status New");

/* main loop */// DEBUGOUT(">>>>>>>>>Entering to MAIN LOOP>>>>>>>>>\n\r"); for (;;) { // 5 // 6 // 4 //0 1 2 3

ReadATD(); //Handle action to be done to battery if(isCharging == 1) { ChargeBattery();

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} else if(isDraining == 1) { DischargeBattery(); }

//Handle Menu Change menuchanged = 1; switch(currentMenu) { ///////////////////////Level 1 case Main: switch(buttonPressed) { case 0: //Switch to Charge menu currentMenu = Charge; break; case 1: //Switch to Drain menu currentMenu = Drain; break; case 2: //Switch to Status menu currentMenu = Status; break; case 3: currentMenu = New; break; default: menuchanged = 0; break; } break; case New: switch(buttonPressed) { case 0: currentMenu = Main; break; case 1: if(isCharging == 0 && isDraining == 0) currentMenu = SelID; break; case 2: currentMenu = List; break; case 3: currentMenu = Add; break; default: menuchanged = 0; break; } break; ///////////////////////Level 2 //Charge Submenu case Charge: switch(buttonPressed) { case 0: currentMenu = Main; //Back break; case 1: //Start charging StartCharging(); currentMenu = Status;// LCDMenu(); //menuchanged = 0;

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break; case 2: currentMenu = Setup; break; case 3: //Stop charging, but stay in this menu Stop(); default: menuchanged = 0; break; } break; //Drain Submenu case Drain: switch(buttonPressed) { case 0: currentMenu = Main; //Back break; case 1: //Start Draining StartDraining(); currentMenu = Status;// LCDMenu(); //menuchanged = 0; break; case 2: currentMenu = Setup; break; case 3: //Stop charging, but stay in this menu Stop(); default: menuchanged = 0; break; } break; //Status Submenu case Status: switch(buttonPressed) { case 0: LCDMenu(); currentMenu = Main; //Back break; case 1: //SHOW REFRESH STUFF StartTesting(); menuchanged = 0; break; case 2: LCDMenu(); currentMenu = Setup; break; case 3: //Stop charging, but stay in this menu Stop(); default: menuchanged = 0; break; } break; case Setup: switch(buttonPressed) { case 0:

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currentMenu = Status; //Back break; case 1: if(isCharging == 0 && isDraining == 0) currentMenu = SetupT; break; case 2: if(isCharging == 0 && isDraining == 0) currentMenu = SetupV; break; case 3: if(isCharging == 0 && isDraining == 0) currentMenu = SetupC; break; default: menuchanged = 0; break; } break; case SetupT: if( buttonPressed == 5) { //Up if(batteries[batteryID].selectedTech < NUM_TECHS-1) { batteries[batteryID].selectedTech++; } else { batteries[batteryID].selectedTech = 0; } break; } else if( buttonPressed == 4) { //Down if(batteries[batteryID].selectedTech > 0) { batteries[batteryID].selectedTech--; } else { batteries[batteryID].selectedTech = NUM_TECHS-1; } break; } else if(buttonPressed == 6) { //Enter currentMenu = Setup; //Back to setup LCDMenu(); break; } menuchanged = 0; break; case SetupV: if( buttonPressed == 2) { //Down 1 if(batteries[batteryID].voltage > 9) { batteries[batteryID].voltage -= 10; } else { batteries[batteryID].voltage = MAX_VOLTAGE+batteries[batteryID].voltage-10; } break; } else if( buttonPressed == 3) { //Up 1 if(batteries[batteryID].voltage < MAX_VOLTAGE-9) { batteries[batteryID].voltage += 10; } else { batteries[batteryID].voltage = batteries[batteryID].voltage%10; } break; } else if( buttonPressed == 5) { //Up if(batteries[batteryID].voltage < MAX_VOLTAGE) {

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batteries[batteryID].voltage++; } else { batteries[batteryID].voltage = 0; } break; } else if( buttonPressed == 4) { //Down if(batteries[batteryID].voltage > 0) { batteries[batteryID].voltage--; } else { batteries[batteryID].voltage = MAX_VOLTAGE; } break; } else if(buttonPressed == 6) { //Enter currentMenu = Setup; //Back to setup LCDMenu(); break; } menuchanged = 0; break; case SetupC: //menuchanged = 0; if( buttonPressed == 5) { //Up if(batteries[batteryID].currentCapacity < MAX_CAPACITY) { batteries[batteryID].currentCapacity += 100; } else { batteries[batteryID].currentCapacity = 0; } break; } else if( buttonPressed == 4) { //Down if(batteries[batteryID].currentCapacity > 0) { batteries[batteryID].currentCapacity -= 100; } else { batteries[batteryID].currentCapacity = MAX_CAPACITY; } break; } else if(buttonPressed == 6) { //Enter currentMenu = Setup; //Back to setup LCDMenu(); break; } menuchanged = 0; break; case SelID: if( buttonPressed == 5) { //Up if(batteryID < MAX_BATTERY_ID) { batteryID++; } else { batteryID = 0; } break; } else if( buttonPressed == 4) { //Down if(batteryID > 0) { batteryID--; } else { batteryID = MAX_BATTERY_ID; } break; }

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else if(buttonPressed == 6) { //Enter currentMenu = New; //Back to setup LCDMenu(); break; } menuchanged = 0; break; case List: switch(buttonPressed) { case 0: currentMenu = New; //Back to parent list "New" LCDMenu(); break; case 1: case 2: case 3: default: menuchanged = 0; break; } break; case Add: currentMenu = Main; break; default: menuchanged = 0; break; }

buttonPressed = -1;

if(menuchanged == 1) { switch(currentMenu) { case Main: LCDMenuText("Chrg Drain Status New"); break; case New: LCDMenuText("Back SelID List Add"); break; case Charge: LCDMenuText("Back Chrg Setup Stop"); break; case Drain: LCDMenuText("Back Drain Setup Stop"); break; case Status: StartTesting(); LCDMenuText("Back Refrsh Setup Stop"); break; case List: LCDClear(127); for(j=0;j<=MAX_BATTERY_ID;j++) { __itoa(batteries[j].voltage/10,(UINT8*)buff); sendstringpos=0; i=0; while(buff[i] != '\0') { sendstring[sendstringpos++] = buff[i++]; } sendstring[sendstringpos++] = '.'; sendstring[sendstringpos++] = (batteries[j].voltage%10)+'0'; sendstring[sendstringpos++] = 'V'; sendstring[sendstringpos++] = ' ';

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i=0; while(battTechs[batteries[j].selectedTech][i] != '\0') { sendstring[sendstringpos++] = battTechs[batteries[j].selectedTech][i++]; } sendstring[sendstringpos++] = ' '; __itoa(batteries[j].currentCapacity,(UINT8*)buff); i=0; while(buff[i] != '\0') { sendstring[sendstringpos++] = buff[i++]; } sendstring[sendstringpos++] = 'm'; sendstring[sendstringpos++] = 'A'; sendstring[sendstringpos++] = 'h'; sendstring[sendstringpos] = '\0';

if(j == batteryID) { LCDPrint(j, 0, 2, 2, 1, sendstring); } else { LCDPrint(j, 0, 2, 1, 1, sendstring); } } LCDMenuText("Back "); break; case Add:// LCDMenuText("Tech Name"); break; case Setup: LCDMenuText("Back Tech Voltage CurrCap"); break; case SetupT: LCDClear(127); LCDPrint(3, 0, 4, 1, 1, (char *)battTechs[batteries[batteryID].selectedTech]); LCDMenuText("Select Technology"); break; case SetupV: LCDClear(127); __itoa(batteries[batteryID].voltage/10,(UINT8*)buff); i=0; while(buff[i] != '\0' && i < 13) { i++; } buff[i++] = '.'; buff[i++] = (batteries[batteryID].voltage%10)+'0'; buff[i++] = ' '; buff[i++] = 'V'; buff[i] = '\0'; LCDPrint(3, 0, 4, 1, 1, buff); LCDMenuText("Select Voltage -1 +1"); break; case SetupC: LCDClear(127); __itoa(batteries[batteryID].currentCapacity,(UINT8*)buff); i=0; while(buff[i] != '\0') { i++; } buff[i++] = ' '; buff[i++] = 'm'; buff[i++] = 'A'; buff[i++] = 'h'; buff[i] = '\0'; LCDPrint(3, 0, 4, 1, 1, buff);

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LCDMenuText("Select Current Capacity"); break; case SelID: LCDClear(127); __itoa(batteryID,(UINT8*)buff); i=0; while(buff[i] != '\0') { i++; } buff[i] = '\0'; LCDPrint(3, 0, 4, 1, 1, buff);

__itoa(batteries[batteryID].voltage/10,(UINT8*)buff); sendstringpos=0; i=0; while(buff[i] != '\0') { sendstring[sendstringpos++] = buff[i++]; } sendstring[sendstringpos++] = '.'; sendstring[sendstringpos++] = (batteries[batteryID].voltage%10)+'0'; sendstring[sendstringpos++] = 'V'; sendstring[sendstringpos++] = ' '; i=0; while(battTechs[batteries[batteryID].selectedTech][i] != '\0') { sendstring[sendstringpos++] = battTechs[batteries[batteryID].selectedTech][i++]; } sendstring[sendstringpos++] = ' '; __itoa(batteries[batteryID].currentCapacity,(UINT8*)buff); i=0; while(buff[i] != '\0') { sendstring[sendstringpos++] = buff[i++]; } sendstring[sendstringpos++] = 'm'; sendstring[sendstringpos++] = 'A'; sendstring[sendstringpos++] = 'h'; sendstring[sendstringpos] = '\0';

LCDPrint(6, 0, 2, 1, 1, sendstring); LCDMenuText("Select Battery ID"); break; default: break; } menuchanged = 0; }

if (gotlink) { /* take care of watchdog stuff */ /* Try to receive Ethernet Frame */ if( NETWORK_CHECK_IF_RECEIVED() == TRUE ) { switch( received_frame.protocol) { case PROTOCOL_ARP: process_arp (&received_frame); break; case PROTOCOL_IP: len = process_ip_in(&received_frame); if(len < 0) break; switch (received_ip_packet.protocol) {/* case IP_ICMP:

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process_icmp_in (&received_ip_packet, len); break; case IP_UDP: process_udp_in (&received_ip_packet,len); break;*/ case IP_TCP: process_tcp_in (&received_ip_packet, len); break; default: break; } break; default: break; } /* discard received frame */ NETWORK_RECEIVE_END(); } arp_manage(); /* Application main loops */ /* TCP/IP stack Periodic tasks here... */ tcp_poll(); https_run (); } } //End of for loop}

////////////////////////////////////////////////// LCD.c// Functions which are used to format commands// to be sent to the LCD in SOH/ETX mode.////////////////////////////////////////////////

#include "datatypes.h"#include "MC9S12NE64.h"#include "system.h"

char command [40]; //35 needed?

//============================================================// LCD Functions//============================================================void LCDSendCommand(const char *text) {// WriteToSCI0(text); //Dev Board WriteToSCI1(text); //Our PCB}/*void LCDPixel(int8 x,int8 y,int8 color) { command[0] = 0x01; //<SOH> command[1] = 'X'; //X is 80 dec command[2] = hextoascii(x >> 4); //Row? 0-127 Two Digit ASCII Hex command[3] = hextoascii(x & 0x0F); command[4] = hextoascii(y >> 4); //Column? 0-63 Two Digit ASCII Hex command[5] = hextoascii(y & 0x0F); command[6] = hextoascii(color & 0x01); //Color (0=OFF,1=ON) Single Digit ASCII Hex

command[7] = 0x03; //<ETX> command[8] = '\0'; //null terminate the command

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LCDSendCommand(command);}*/void LCDLine(int8 sx,int8 sy,int8 ex,int8 ey,int8 color) { command[0] = 0x01; //<SOH> command[1] = 'L'; command[2] = hextoascii(sx >> 4); //Starting Row? 0-127 Two Digit ASCII Hex command[3] = hextoascii(sx & 0x0F); command[4] = hextoascii(sy >> 4); //Starting Column? 0-63 Two Digit ASCII Hex command[5] = hextoascii(sy & 0x0F); command[6] = hextoascii(ex >> 4); //Ending Row? 0-127 Two Digit ASCII Hex command[7] = hextoascii(ex & 0x0F); command[8] = hextoascii(ey >> 4); //Ending Column? 0-63 Two Digit ASCII Hex command[9] = hextoascii(ey & 0x0F); command[10] = hextoascii(color & 0x01); //Color (0=OFF,1=ON) Single Digit ASCII Hex

command[11] = 0x03; //<ETX> command[12] = '\0'; //null terminate the command

LCDSendCommand(command);}/*void LCDCircle(int8 centerX,int8 centerY,int8 radius,int8 color) { command[0] = 0x01; //<SOH> command[1] = 'l'; //lowercase l command[2] = hextoascii(centerX >> 4); //Row? 0-127 Two Digit ASCII Hex command[3] = hextoascii(centerX & 0x0F); command[4] = hextoascii(centerY >> 4); //Column? 0-63 Two Digit ASCII Hex command[5] = hextoascii(centerY & 0x0F); command[6] = hextoascii(radius >> 4); //radius 0-127 Two Digit ASCII Hex command[7] = hextoascii(radius & 0x0F); command[8] = hextoascii(color & 0x01); //Color (0=OFF,1=ON) Single Digit ASCII Hex

command[9] = 0x03; //<ETX> command[10] = '\0'; //null terminate the command

LCDSendCommand(command);}*//*void SetBacklight(int8 level) { // 0 = off // 1 = on // 2 = on timed// char command [5]; //35 needed? command[0] = 0x01; //<SOH> command[1] = 'b'; command[2] = hextoascii(level & 0x0F); // + level; command[3] = 0x03; //<ETX> command[4] = '\0'; //null terminate the command

LCDSendCommand(command);}*/void LCDClear(uint8 row) { command[0] = 0x01; //<SOH> command[1] = 'C'; //C// command[2] = 'F'; //Row, bit mask, 0-255, two digit ascii hex// command[3] = 'F'; command[2] = hextoascii(row >> 4); //Row, bit mask, 0-255, two digit ascii hex command[3] = hextoascii(row & 0x0F);

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command[4] = '0'; //starting column 0-127 (00-7F), two digit ascii hex command[5] = '0'; command[6] = '7'; //ending column 0-127 (00-7F), two digit ascii hex command[7] = 'F'; command[8] = 0x03; //<ETX> command[9] = '\0'; //null terminate the command LCDSendCommand(command);}void LCDPrint(int8 row,int8 column,int8 font, int8 type, int8 justification,char *text) { int i;

//rows 0-7 for font 4 row = 1 << row;

command[0] = 0x01; //<SOH> command[1] = 'P'; //P is50 hex command[2] = hextoascii(row >> 4); //Row 0-255 bit mask command[3] = hextoascii(row & 0x0F); command[4] = hextoascii(column >> 4); //Column 0-127 command[5] = hextoascii(column & 0x0F); command[6] = hextoascii(font & 0x0F); //Row 0-3 bit mask command[7] = hextoascii(type & 0x0F); //1,2,4,8 (0-F hex) 1: black on white, 2: inverted command[8] = hextoascii(justification & 0x0F); //Row 0-3 bit mask

i = 0; while(text[i] != '\0') { //Copy text into the command. Don't include the null terminator command[9+i] = text[i]; i++; if(i == 25) break; } command[9+i] = 0x03; //<ETX> command[9+i+1] = '\0'; //null terminate the command

LCDSendCommand(command);}void LCDTone(int16 frequency,int8 duration) { command[0] = 0x01; //<SOH> command[1] = 'T'; //T command[2] = hextoascii( (frequency >> 8) & 0x0F ); //26-4095 (1A-FFF) Three Digit ASCII Hex. Freq of 0 turns off any tone command[3] = hextoascii( (frequency >> 4) & 0x0F ); command[4] = hextoascii(frequency & 0x00F); command[5] = hextoascii(duration >> 4); //Duration 0-255 Two Digit ASCII Hex. Fiftieths of a second command[6] = hextoascii(duration & 0x0F);

command[7] = 0x03; //<ETX> command[8] = '\0'; //null terminate the command

LCDSendCommand(command);}/*void LCDGraphic(int8 row,int8 column,int8 data) { command[0] = 0x01; //<SOH> command[1] = 'G'; command[2] = hextoascii(row >> 4); //Row 0-255 bit mask command[3] = hextoascii(row & 0x0F); command[4] = hextoascii(column >> 4); //Column 0-127 bit mask

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command[5] = hextoascii(column & 0x0F); command[6] = hextoascii(data >> 4); //Data 0-255 binary pattern command[7] = hextoascii(data & 0x0F);

command[8] = 0x03; //<ETX> command[9] = '\0'; //null terminate the command

LCDSendCommand(command);}*/void LCDBox(int8 tlx,int8 tly,int8 brx,int8 bry,int8 color) { command[0] = 0x01; //<SOH> command[1] = 'B'; command[2] = hextoascii(tlx >> 4); //Top Left X 0-127 command[3] = hextoascii(tlx & 0x0F); command[4] = hextoascii(tly >> 4); //Top Left Y 0-63 command[5] = hextoascii(tly & 0x0F); command[6] = hextoascii(brx >> 4); //Bottom Right X 0-127 command[7] = hextoascii(brx & 0x0F); command[8] = hextoascii(bry >> 4); //Bottom Right Y 0-63 command[9] = hextoascii(bry & 0x0F); command[10] = hextoascii(color & 0x01);

command[11] = 0x03; //<ETX> command[12] = '\0'; //null terminate the command

LCDSendCommand(command);}void LCDMenu(void) { char buff[5]; char sendstring[30]; uint8 i; uint8 sendstringpos;

LCDClear(127); //Clear all rows except last LCDBox(26,4,92,42,1); LCDBox(92,19,96,28,1); LCDPrint(1, 0, 4, 1, 1, "BatteryMAX"); //Normal text LCDPrint(2, 0, 4, 1, 1, "Universal"); //Normal text LCDPrint(3, 0, 4, 1, 1, "Battery"); //Normal text LCDPrint(4, 0, 4, 1, 1, "Charger"); //Normal text

__itoa(batteries[batteryID].voltage/10,(UINT8*)buff); sendstringpos=0; sendstring[sendstringpos++] = hextoascii(batteryID); sendstring[sendstringpos++] = ':'; sendstring[sendstringpos++] = ' '; i=0; while(buff[i] != '\0') { sendstring[sendstringpos++] = buff[i++]; } sendstring[sendstringpos++] = '.'; sendstring[sendstringpos++] = hextoascii(batteries[batteryID].voltage%10); sendstring[sendstringpos++] = 'V'; sendstring[sendstringpos++] = ' '; i=0; while(battTechs[batteries[batteryID].selectedTech][i] != '\0') { sendstring[sendstringpos++] = battTechs[batteries[batteryID].selectedTech][i++]; } sendstring[sendstringpos++] = ' '; __itoa(batteries[batteryID].currentCapacity,(UINT8*)buff); i=0;

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while(buff[i] != '\0') { sendstring[sendstringpos++] = buff[i++]; } sendstring[sendstringpos++] = 'm'; sendstring[sendstringpos++] = 'A'; sendstring[sendstringpos++] = 'h'; sendstring[sendstringpos] = '\0';

LCDPrint(6, 0, 2, 1, 1, sendstring); LCDLine(0,55,127,55,1); //Bar above menu text}//LCDPrint(row,column,font,type,justification,char *text) {void LCDMenuText(char *text) {// LCDPrint(7, 0, 2, 2, 1, text); //Inverse text LCDClear(128); LCDLine(0,55,127,55,1); //Bar above menu text LCDPrint(7, 0, 2, 1, 1, text); //Normal text}

////////////////////////////////////////////////// Init.c// Contains initialization routines and functions// for sending data through SCI0 and SCI1////////////////////////////////////////////////

#include "ne64debug.h"#include "datatypes.h"#include "MC9S12NE64.h"

//BE SURE TO ADD PROTOTYPES TO SYSTEM.Hextern uint8 buttonPressed;

//===================================================/* send string via SCI *///===================================================void sendtext(tS08 * s){ while (*s != 0) { while (!(SCI0SR1 & 0x80)); SCI0DRL =*s; s++; }}void WriteToSCI0(const char *text){ while (*text != '\0'){ while (!(SCI0SR1 & 0x80)); // wait for output buffer empty SCI0DRL = *text++; } //while (!(SCI0SR1 & 0x80)); // wait for output buffer empty //SCI0DRL = '\r'; //while (!(SCI0SR1 & 0x80)); // wait for output buffer empty //SCI0DRL = '\n';

}//LCD is SCI1void WriteToSCI1(const char *text){ while (*text != '\0'){ // wait for output buffer empty while (!(SCI1SR1 & 0x80)); //TDRE Transmit Data Register Empty SCI1DRL = *text++; }}

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interrupt void SCI1Interrupt(void) { char command[10]; int i; i=0; command[i] = SCI1SR1; while(i < 5) { if(SCI1SR1 & 0x20) { command[i] = SCI1DRL; i++; } } command[i] = '\0'; buttonPressed = command[3]-'0';

// WriteToSCI0("Received:");// WriteToSCI0(command);}

/**************************************************************************************************************************************************************/void init (void){

#define BAUD_RATE 9600//#define BAUD_RATE 57600#define ECLK 25000000 /**< this is BUSCLK */ #define BAUD_DIV ECLK/16/BAUD_RATE

//Debug Inits _INIT_DEBUG(); SCI0BD= BAUD_DIV; //Clearing the M bit in SCICR1 = 8-bit SCI0CR1= 0; SCI0CR2= SCI1CR2_TE_MASK | SCI1CR2_RE_MASK | SCI1CR2_RWU_MASK ;

// SCI1BDL = (unsigned char)((25000000UL /* OSC freq */ / 2) / 9600 /* baud rate */ / 16 /*factor*/); // SCI1CR2 = 0x2C; SCI1BD= BAUD_DIV; SCI1CR1= 0; SCI1CR2= SCI1CR2_RIE_MASK | SCI1CR2_TE_MASK | SCI1CR2_RE_MASK | SCI1CR2_RWU_MASK ;}

////////////////////////////////////////////////// charging.c// Contains functions for charging and discharging// batteries. Also contains initialization routines// for SPI, ATD, I2C, and the relay circuit.////////////////////////////////////////////////

#include <system.h> /* common defines and macros */#include <MC9S12NE64.h> /* derivative information */

// Added to system.h uint8 atdVoltage; uint8 atdCurrent; uint8 atdBTemp;

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uint8 atdUTemp; enum chargeState bmOperationState; uint8 spiDPot1Fine; uint8 spiDPot1Course; uint8 spiDPot2Fine; uint8 spiDPot2Course; uint8 spiDPotVSense; int bmChargeCurrent; int bmChargeVoltage; int bmChargeBTemp; int bmChargeUTemp;//char spiDischarge;char sciKey;char fNewBattery;char fKeypad;char fTimeToSave;char bmOperation;char bmID;char bmProfile;//char bmType;char bmDeltaT;char bmChargeTimeD;char bmChargeTimeH;char bmChargeTimeM;char bmChargeTimeS;char bmTotalTimeD;char bmTotalTimeH;char bmTotalTimeM;char bmTotalTimeS;char bmSaveInterval;char bmSaveVoltage;char bmSaveCurrent;char bmSaveTemp;char bmSaveCount;//char bmSavedData[128];char bmSavedDataCount;char sysTime;

void InitATD(){ ATDCTL2 = BM_ATD_CTL2; ATDCTL3 = BM_ATD_CTL3; ATDCTL4 = BM_ATD_CTL4;}

void InitSPI(void){ DDRB = 0xFF; PORTB = 0xFF; SPIBR = BM_SPI_BAUD; SPICR1 = BM_SPI_CR1; SPICR2 = BM_SPI_CR2;}

void InitIIC(void){ IBAD = 0xFF; IBFD = 0xBF; IBCR = 0x80;}

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void InitRelay(void){ NETCTL = 0x00; DDRG = 0x01; RDRG = 0x00; PERG = 0x00; PPSG = 0x00;}

void ReadATD(void){ BM_ATD_START = BM_ATD_READ_ALL; while(!BM_ATD_DONE); atdVoltage = BM_ATD_VOLTAGE; atdCurrent = BM_ATD_CURRENT; atdBTemp = BM_ATD_BTEMP; atdUTemp = BM_ATD_UTEMP; bmChargeCurrent = (atdCurrent-127) * BM_CURRENT_MULTIPLIER; bmChargeVoltage = atdVoltage * BM_VOLTAGE_MULTIPLIER / spiDPotVSense; bmChargeBTemp = (atdBTemp * BM_TEMP_MULTIPLIER + 32) * 10; bmChargeUTemp = (atdUTemp * BM_TEMP_MULTIPLIER + 32) * 10;}

void SetPOT(uint8 chip, uint8 value){ byte temp = SPISR; BM_POT_SELECT = chip; WriteToSCI0(" \b \b \b \b \b"); BM_POT_DATA = value; WriteToSCI0(" \b \b \b \b \b"); while(!BM_SPI_DONE); BM_POT_SELECT = BM_POT_NONE;}

void ChargeVoltageInit(uint8 v){ //int temp; //temp = ((MAX_VOLTAGE - v) / 2) + v; //spiDPot1Course = VTable[temp]; //spiDPot1Fine = VTable[temp]; //spiDPot2Course = VTable[v]; //spiDPot2Fine = 0; int temp = 123; temp = temp + v; if (temp > 255) { temp = 255; } spiDPot1Fine = temp; spiDPot1Course = temp; spiDPot2Fine = 127; spiDPot2Course = 0; SetPOT(BM_POT_FINE1, spiDPot1Fine); SetPOT(BM_POT_COURSE1, spiDPot1Course); SetPOT(BM_POT_FINE2, spiDPot2Fine); SetPOT(BM_POT_COURSE2, spiDPot2Course);

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}

void ChargeVoltageIncrease(void){ if (spiDPot2Fine == 255) { if (spiDPot2Course == 255) { return; } spiDPot2Course++; spiDPot2Fine = 127; } else { spiDPot2Fine++; } SetPOT(BM_POT_FINE2, spiDPot2Fine); SetPOT(BM_POT_COURSE2, spiDPot2Course); }

void ChargeVoltageDecrease(void){ if (spiDPot2Fine != 0) { spiDPot2Fine--; } if (spiDPot2Course != 0) { spiDPot2Course--; } SetPOT(BM_POT_COURSE2, spiDPot2Course); SetPOT(BM_POT_FINE2, spiDPot2Fine); }

void ChargeCircuitOn(void) { unsigned int temp; temp = 255 * 33 / (batteries[batteryID].voltage * 5 / 4); if (temp > 255) { temp = 255; } spiDPotVSense = temp; SetPOT(BM_POT_VSENSE, spiDPotVSense); rlyRelay = 1;}

void ChargeCircuitOff(void) { spiDPotVSense = 255; SetPOT(BM_POT_VSENSE, spiDPotVSense); rlyRelay = 0;}

void ChargeBattery(void) { switch (batteries[batteryID].selectedTech) { case NiMH: ChargeNIMH(); break; case NiCad: ChargeNICAD(); break; case LiIon: ChargeLIION();

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break; case LeadAcid: ChargeLEAD(); break; default: break; }}

void DischargeBattery(void){ switch (batteries[batteryID].selectedTech) { case NiMH: DischargeNIMH(); break; case NiCad: DischargeNICAD(); break; case LiIon: DischargeLIION(); break; case LeadAcid: DischargeLEAD(); break; default: break; }}

void TestBattery(void){ switch (batteries[batteryID].selectedTech) { case NiMH: TestNIMH(); break; case NiCad: TestNICAD(); break; case LiIon: TestLIION(); break; case LeadAcid: TestLEAD(); break; default: break; }} void ChargeNIMH(void){ char buff[20]; buff[0] = atdVoltage/100+'0'; buff[1] = (atdVoltage%100)/10+'0'; buff[2] = atdVoltage%10+'0'; buff[3] = '\0'; WriteToSCI0(buff); switch (bmOperationState) { case initialize:

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ChargeVoltageInit(batteries[batteryID].voltage); ChargeCircuitOn(); bmOperationState = rampup; break; case rampup: if (bmChargeVoltage > batteries[batteryID].voltage * 5 / 4) { ChargeVoltageDecrease(); break; } if (bmChargeCurrent < batteries[batteryID].currentCapacity) { ChargeVoltageIncrease(); } else { bmOperationState = constantcurrent; } break; case constantcurrent: if (bmDeltaT > BM_NIMH_MAX_DELTA_T) { bmOperationState = terminate; break; } if (bmChargeVoltage > batteries[batteryID].voltage * 5 / 4) { ChargeVoltageDecrease(); break; } if (bmChargeCurrent < batteries[batteryID].currentCapacity) { ChargeVoltageIncrease(); } else if (bmChargeCurrent > batteries[batteryID].currentCapacity) { ChargeVoltageDecrease(); } break; case terminate: ChargeCircuitOff(); bmOperationState = complete;// break; case complete:// break; default: break; }}

void ChargeNICAD(void){ switch (bmOperationState) { case initialize: ChargeVoltageInit(batteries[batteryID].voltage); ChargeCircuitOn(); bmOperationState = rampup; break; case rampup: if (bmChargeCurrent < batteries[batteryID].currentCapacity) {

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ChargeVoltageIncrease(); } else { bmOperationState = constantcurrent; } break; case constantcurrent: if (bmDeltaT > BM_NICAD_MAX_DELTA_T) { bmOperationState = terminate; break; } if (bmChargeCurrent < batteries[batteryID].currentCapacity) { ChargeVoltageIncrease(); } else if (bmChargeCurrent > batteries[batteryID].currentCapacity) { ChargeVoltageDecrease(); } break; case terminate: ChargeCircuitOff(); bmOperationState = complete;// break; case complete:// break; default: break; }}

void ChargeLIION(void){ switch (bmOperationState) { case initialize: ChargeVoltageInit(batteries[batteryID].voltage); ChargeCircuitOn(); bmOperationState = rampup; break; case rampup: if (bmChargeVoltage > batteries[batteryID].voltage * 5 / 4) { ChargeVoltageDecrease(); break; } if (bmChargeCurrent < batteries[batteryID].currentCapacity) { ChargeVoltageIncrease(); } else { bmOperationState = constantcurrent; } break; case constantcurrent: if (bmChargeVoltage > batteries[batteryID].voltage * 5 / 4) { ChargeVoltageDecrease(); break; }

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if (bmChargeVoltage >= batteries[batteryID].voltage) { bmOperationState = constantvoltage; break; } if (bmChargeCurrent < batteries[batteryID].currentCapacity) { ChargeVoltageIncrease(); } else if (bmChargeCurrent > batteries[batteryID].currentCapacity) { ChargeVoltageDecrease(); } break; case constantvoltage: if (bmChargeCurrent < (batteries[batteryID].currentCapacity / 10)) { bmOperationState = terminate; break; } case terminate: ChargeCircuitOff(); bmOperationState = complete;// break; case complete:// break; default: break; }}

void ChargeLEAD(void){ switch (bmOperationState) {//enum chargeState {initialize=0,rampup,constantcurrent,constantvoltage,terminate,complete}; case initialize: ChargeVoltageInit(batteries[batteryID].voltage); ChargeCircuitOn(); bmOperationState = rampup; break; case rampup: if (bmChargeCurrent < batteries[batteryID].currentCapacity) { ChargeVoltageIncrease(); } else { bmOperationState = constantcurrent; } break; case constantcurrent: if (bmDeltaT > BM_LEAD_MAX_DELTA_T) { bmOperationState = terminate; break; } if (bmChargeCurrent < batteries[batteryID].currentCapacity) {

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ChargeVoltageIncrease(); } else if (bmChargeCurrent > batteries[batteryID].currentCapacity) { ChargeVoltageDecrease(); } break; case terminate: ChargeCircuitOff(); bmOperationState = complete;// break; case complete:// break; default: break; }}

void DischargeNIMH(void) {

}void DischargeNICAD(void) {

}void DischargeLEAD(void) {

}void DischargeLIION(void) {

}

/****************************************************************************** * * (c) Freescale Inc. 2004 All rights reserved * * File Name :Vectors.c * Description : Interrupt table which points to interrupt handling functions * * Version : 1.0 * Date : Jun/22/2004 * ******************************************************************************/#include "MC9S12NE64.h"

//ISR STUFF ON PAGE 62

extern void near _Startup(void); /* Startup routine */extern void near RealTimeInterrupt(void); extern void near emac_ec_isr(void);extern void near emac_lc_isr(void);extern void near emac_b_rx_error_isr(void);extern void near emac_rx_b_b_o_isr(void);extern void near emac_rx_b_a_o_isr(void);extern void near emac_rx_error_isr(void);extern void near emac_mii_mtc_isr(void);extern void near emac_rx_fc_isr(void);extern void near emac_f_tx_c_isr(void);extern void near emac_rx_b_b_c_isr(void);extern void near emac_rx_b_a_c_isr(void);extern void near ephy_isr(void);extern void near PortHInterrupt(void);

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extern void near SCI1Interrupt(void);

//************************************************************************// SOFTWARE TRAP FUNCTION// DESCRIPTION:// Function that traps all unexpected interrupts. Used for debugging // software to find runaway code.//************************************************************************

#pragma CODE_SEG __NEAR_SEG NON_BANKED /* Interrupt section for this module. Placement will be in NON_BANKED area. */ __interrupt void software_trap(void){ for(;;); }#pragma CODE_SEG DEFAULT /* Change code section to DEFAULT. */

//************************************************************************

typedef void (*near tIsrFunc)(void);const tIsrFunc _vect[] @0xFF80 = { /* Interrupt table */ software_trap, /* 63 Default (unused) interrupt */ software_trap, /* 62 Default (unused) interrupt */ software_trap, /* 61 Default (unused) interrupt */ software_trap, /* 60 Default (unused) interrupt */ software_trap, /* 59 Default (unused) interrupt */ software_trap, /* 58 Default (unused) interrupt */ software_trap, /* 57 Default (unused) interrupt */ software_trap, /* 56 Default (unused) interrupt */ software_trap, /* 55 Default (unused) interrupt */ software_trap, /* 54 Default (unused) interrupt */ software_trap, /* 53 Default (unused) interrupt */ software_trap, /* 52 Default (unused) interrupt */ software_trap, /* 51 Default (unused) interrupt */ software_trap, /* 50 Default (unused) interrupt */ software_trap, /* 49 Default (unused) interrupt */ software_trap, /* 48 Default (unused) interrupt */ emac_ec_isr, // 47 emac_lc_isr, // 46 emac_b_rx_error_isr, // 45 emac_rx_b_b_o_isr, // 44 emac_rx_b_a_o_isr, // 43 emac_rx_error_isr, // 42 emac_mii_mtc_isr, // 41 emac_rx_fc_isr, // 40 emac_f_tx_c_isr, // 39 emac_rx_b_b_c_isr, // 38 emac_rx_b_a_c_isr, // 37 ephy_isr, // 36 software_trap, /* 35 Default (unused) interrupt */ software_trap, /* 34 Default (unused) interrupt */ software_trap, /* 33 Default (unused) interrupt */ software_trap, /* 32 Default (unused) interrupt */ software_trap, /* 31 Default (unused) interrupt */ software_trap, /* 30 Default (unused) interrupt */ software_trap, /* 29 Default (unused) interrupt */ software_trap, /* 28 Default (unused) interrupt */ software_trap, /* 27 Default (unused) interrupt */ software_trap, /* 26 Default (unused) interrupt */// PortHInterrupt, /* 25 Default (unused) interrupt */ software_trap, /* 25 Default (unused) interrupt */ software_trap, /* 24 Default (unused) interrupt */ software_trap, /* 23 Default (unused) interrupt */ software_trap, /* 22 Default (unused) interrupt */

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SCI1Interrupt, /* 21 Default (unused) interrupt */ software_trap, /* 20 Default (unused) interrupt */ software_trap, /* 44 Default (unused) interrupt */ software_trap, /* 45 Default (unused) interrupt */ software_trap, /* 46 Default (unused) interrupt */ software_trap, /* 47 Default (unused) interrupt */ software_trap, /* 48 Default (unused) interrupt */ software_trap, /* 49 Default (unused) interrupt */ software_trap, /* 50 Default (unused) interrupt */ software_trap, /* 51 Default (unused) interrupt */ software_trap, /* 52 Default (unused) interrupt */ software_trap, /* 53 Default (unused) interrupt */ software_trap, /* 54 Default (unused) interrupt */ software_trap, /* 55 Default (unused) interrupt */ RealTimeInterrupt, /* 7 Default (unused) interrupt */ software_trap, /* 6 Default (unused) interrupt */ software_trap, /* 5 Default (unused) interrupt */ software_trap, /* 4 Default (unused) interrupt */ software_trap, /* 3 Default (unused) interrupt */ software_trap, /* 2 Default (unused) interrupt */ software_trap, /* 1 Default (unused) interrupt */ _Startup /* 0 Reset vector */ };

////////////////////////////////////////////////// digijock.js// Contains initialization routines and functions// for sending data through SCI0 and SCI1////////////////////////////////////////////////

var batteries=5;//Array for tracking current statisticsvar c_array = new Array(batteries);c_array[00] = new Array(128,128,128,128,128, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0);c_array[01] = new Array(129,128,127,129,129,127,128, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0);c_array[02] = new Array(128,129,129,128,128,127,128,127,129, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0);c_array[03] = new Array(129,129,128,128,127,129,128,129,128,128,128,130,129,127,130,130, 0, 0, 0, 0);c_array[04] = new Array(128,129,127,128,128,128,128,129,128,128,129,128,129,129,128,130,129,129,129,128);//Array for tracking voltage statisticsvar v_array = new Array(batteries);v_array[00] = new Array(000,032,033,033,032, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0);v_array[01] = new Array(000,033,032,032,032,032,033, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0);v_array[02] = new Array(000,031,032,032,032,032,033,032,032, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0);v_array[03] = new Array(000,031,032,031,032,032,033,032,032,032,032,033,032,032,032,032, 0, 0, 0, 0);v_array[04] = new Array(255,255,255,255,255,255,255,255,255,255,255,255,255,255,255,255,255,255,255,255);

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Appendix G: FMECA Worksheet

Failure No.

Failure Mode Possible Causes Failure Effects Method of Detection

Criticality Remarks

A1 VAA = 0V Transformer failure, bridge failure, or resistor failure

Circuit will not operate

Observation Low No damage to parts, however basic functionality lost

A2 VBB = 0V Regulator failure Microcontroller will not operate

Observation High Possible damage to battery, if failure occurs in the middle of charging

A3 VCC = 0V Regulator failure Current sensor will not operate

Microcontroller software detect

Low No damage to parts, however basic functionality lost

A4 VDD = 0V Regulator failure LCD will not operate

Observation Low User will get no output, however circuit functionality still present

A5 VEE = 0V Regulator failure Battery will not be charged

Microcontroller software detect

Low Battery will not be charged

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A6 VAA out of acceptable range

Transformer malfunction, regulator malfunction

Damage to circuit from high voltage/current

Observation High Chance to damage all parts of circuit and overload battery, possibly causing injury

A7 VBB out of acceptable range

Divider resistor failure

Damage to circuit from high voltage/current

Observation High Chance to damage microcontroller, temperature sensor, Ethernet jack, or BDM

A8 VCC out of acceptable range

Divider resistor failure

Damage to circuit from high voltage/current

Observation High Chance to damage current sensor

A9 VDD out of acceptable range

Divider resistor failure

Damage to circuit from high voltage/current

Observation High Chance to damage LCD and LCD controller

A10 VEE out of acceptable range

Divider resistor failure

Damage to circuit from high voltage/current

Observation High Chance to damage digital potentiometers

FigureG1 - Power Supply Circuit

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Failure No.

Failure Mode Possible Causes Failure Effects Method of Detection

Criticality Remarks

B1 VFF = 0V Both digital potentiometer failure or digital potentiometer malfunction

Battery will not be charged

Microcontroller software detect

Low Battery will not be charged

B2 VFF out of acceptable range

Digital potentiometer failure or regulator malfunction

Damage to circuit from high voltage/current

Observation High Chance to damage current sensor and to overload battery

Figure G2 - Charge Supply Circuit

Failure No.

Failure Mode Possible Causes Failure Effects Method of Detection

Criticality Remarks

C1 Battery overload Current sensor malfunction or resistor failure

Battery overload, with possible injury to user

Observation High Chance to overload battery and cause injury

C2 Battery overheat Temperature sensor malfunction

Battery overheat, with possible injury to user

Microcontroller software detect

High Chance to overheat battery and cause injury

Figure G3 - Sensor Circuit

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Failure No.

Failure Mode Possible Causes Failure Effects Method of Detection

Criticality Remarks

D1 Battery stops charging

Microcontroller failure

Battery stops charging

Observation High Battery stops charging, however could be indicative of other problems, and could cause damage

D2 Bad data through RJ-45

Microcontroller malfunction

Bad data or possible damage to Ethernet line and remote computer

Observation Low Web interface won’t work properly or could damage lines

D3 Bad data on LCD LCD controller malfunction

Bad data or possible damage to LCD

Observation Low “Pseudo-random” characters on LCD

Figure G4 - Logic Circuit

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