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Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
001-85174 Rev *F
Design Win Replication:
PSoC 4 Solution forThermal Management
Fail-Safe Thermal Management for Mission-Critical Systems:Simplify Your Design with a Customized One-Chip Solution
Presentation: To provide an engineering overview to customers for a Cypress solution.Title slide: To define what the presentation will cover. The subtitle is a one-sentence statement of the key opportunity.
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Thermal Management Must Be Fail-SafeFail-safe Thermal Management is required for mission-critical systemsIndustrial: automated teller machines, vending machines and arcade games
Test and measurement: spectrum analyzers, signal generators and oscilloscopes
Medical equipment: infant incubators, ultrasound carts and MRI scanners
Communications: Ethernet switches, networking routers and rack-mounted servers
Thermal Management provides mission-critical functions to continuously maintain system temperature within a specified range
Mission-critical systems require a customized, fail-safe Thermal Management solution
Market Vision: To define the market opportunity. Presents compelling data and end product photos relevant to the local market. 3
Infant Incubatorby Ningbo David Medical
One fan and two Temperature Sensors per incubator
Two fans and two Temperature Sensors per machine
Automated Teller Machine
PSoC 4
CPU
Air out
Air out
Air out
Report to the Central System Controller
Fan control 1
Fan control 2
Fan control 3
Temperature Sensor 1 Temperature Sensor 3
Temperature Sensor 2
Temperature Sensor 4
Generic PSoC® 4 Thermal Management System
One PSoC 4 measures four temperatures, including air and CPU temperatures. It then drives three fans independently, each to a precise speed. The system is redundant and reports to the central system controller.
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Terms You Will Hear Today
Terms of Art (ToAs): To clearly define for engineers all ToAs used in the presentation. To carefully and fully define Cypress-proprietary ToAs needed to explain our system solution.
Temperature
ValuesTemperature
SensorsTemperature
SensingThermal Algorithm
Fan Controller
Analog
OutputsFan rpm
targetsFans
rpm targets
rpm actuals
4a
Thermal Management SystemMaintains specified temperature ranges in your mission-critical system
Temperature SensorsConvert temperature to an electrical signalResistance Temperature Detector (RTD): changes ~0.387 Ω/°C, requires Current Source and ADC Thermistor: changes ~400 Ω/°C at room temperature, requires Voltage Source and ADC Thermocouple (e.g., type K, J, T): generates ~40 µV/oC, requires ADC and a reference temperature sensorTemperature diode: changes ~250 µV/°C, requires Current Source and ADC
Temperature SensingConverts the analog output signal of the Temperature Sensors to a digital temperature valueRequires special analog ICs and a microcontroller running firmware algorithms to correct and linearize the digital measurements
Thermal AlgorithmCalculates target fan revolutions per minute (rpm) from temperature measurements for proper temperature controlRequires a microcontroller and complex firmware algorithms to calculate the target fan rpm
Fan ControllerDrives fans to target rpm by making continuous adjustments in a closed-loop system
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Additional Terms
Terms of Art (ToAs): To clearly define for engineers all ToAs used in the presentation. To carefully and fully define Cypress-proprietary ToAs needed to explain our system solution.
Current/Voltage SourceAn IC that generates a precise current or voltage supply
Current-Output Digital-to-Analog Converter (IDAC)An IC that generates a precise Current Source for Sensors from a digital input
Analog-to-Digital Converter (ADC)An IC that converts an analog signal, such as a Temperature Sensor output, to a digital signal
Pulse Width Modulator (PWM)A digital circuit that creates square waves with controlled, variable pulse widths (duty cycle)
Used by the Fan Controller to drive fans at rpm targets
Tachometer (TACH)Measures actual fan rpm with Hall-effect sensors
Used by the Fan Controller to set the fan rpm and detect failures
Host ProcessorMain system processor that controls one or more Thermal Management Systems
I2CIndustry-standard serial communication bus used in embedded systems
Used for communication between the Host Processor and one or more
Thermal Management Systems
4b
Host Processor Communicating with Multiple Thermal Management Systems
Thermal Management System 1
Host Processor
…
I2C
Thermal Management System n
Each Thermal Management System communicates the fan status and temperature information to the Host Processor over I2C
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
PSoC Terms100+ other Components to complete the system design
PSoC Creator™PSoC 3, PSoC 4 and PSoC 5LP Integrated Design Environment (IDE)Software that installs on your PC that allows: Concurrent hardware and firmware design of PSoC systems, or Hardware design followed by export to popular IDEs
ComponentsFree embedded ICs represented by an icon in PSoC Creator software
Used to integrate multiple ICs and system interfaces into one PSoC
Dragged and dropped as icons in PSoC Creator to design systems
Thermal Management Components are designed specifically to perform the temperature control functions
Component Configuration ToolsSimple graphical user interfaces in PSoC Creator
Provided for each Component
Used to customize Component parameters
Accessed by right-clicking a Component
PSoC 4 Fan Controller Application NoteDemonstrates the use of Thermal Management Components to create customized designs with up to four fans and 14 Temperature Sensors
Provides the Thermal Management Example Project, with ready-to-use schematics and firmware, to control two fans and read three Temperature Sensors
Inherent system bus connection
MCU
One Fan Controller Component supports up to four fans by controlling fan rpm and monitoring for fan failures
Fan Controller Component
Terms of Art (ToAs): To clearly define for engineers all ToAs used in the presentation. To carefully and fully define Cypress-proprietary ToAs needed to explain our system solution.
Thermal Management Components:Fan Controller, ADC, IDAC, RTD, Thermistor and I2C
4c
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Design Problems Engineers Face
Traditional Approach and Challenges: To present the traditional approach and the challenges engineers will face when using it to realize the Market Vision. Ends with a one-sentence segue clearly stating the benefit of the Cypress solution.
Mission-critical systems cannot tolerate Thermal Management failuresWhen fans wear out or become blocked
When I2C interfaces to the Host Processor go down
Fans create noise and consume significant power at maximum rpmThey must be driven at the minimum feasible rpm to minimize noise and power
They require a microcontroller running Thermal Algorithms to calculate the minimum feasible rpm
Every design requires difficult, time-consuming customization for:A different number of fans and different types of Temperature Sensors
Specialized analog ICs for each Temperature Sensor
Microcontroller-based firmware algorithms to correct and linearize sensor outputs
Configuration of the I2C interface to communicate with the Host Processor
PSoC solves these problemsPSoC monitors for fan failures and supports redundant I2C interfaces to the Host Processor
The PSoC Fan Controller Component includes Thermal Algorithms to minimize fan noise and power
One PSoC can control and monitor up to 4 fans and support up to 14 Temperature Sensors
PSoC integrates the specialized analog ICs for each Temperature Sensor, including the ADC and IDAC ICs
PSoC Temperature Sensor Components provide firmware algorithms for accurate, linearized sensor output conversion
PSoC Component Configuration Tools enable the creation of customized Thermal Management designs in minutes
PSoC creates a one-chip, customized, fail-safe Thermal Management solution
5
Each unit has up to four fans and one Temperature Sensor
Spectrum Analyzer
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
PSoC One-Chip SolutionEthernet Switch by Avaya
To create a one-chip, customized, fail-safe Thermal Management solution.
To get started, you should:Download the PSoC 4 Fan Controller Application Note, which includes the Thermal Management Example Project
Download and install PSoC Creator software on your PC
Buy the $25 PSoC 4 Pioneer Kit (CY8CKIT-042)
Buy the $25 PSoC Shield Adapter Kit (CY8CKIT-019)
Buy the $129 Thermal Management Kit (CY8CKIT-036)
Open the Thermal Management Example Project in PSoC Creator
Use the PSoC 4 Fan Controller Application Note for complete system design guidelines
Cypress Solution: To introduce CY products and show compellingly how they solve the challenges highlighted on the previous slide.To provide a short, clear list of what to do to get started.
That integrate common Thermal Management ICs, and that are customized by Component Configuration Tools…
The Thermal Management Example Project provides PSoC Creator Components…
Fan Controller Component Configuration Tool
Fan Controller Component
6a
PSoC 4 Thermal Management Design Using PSoC Creator Components
PSoC 4 Thermal Management System Prototype
And that are prototyped and validated using the PSoC 4 Pioneer Kit, the PSoC Shield Adapter Kit and the Thermal Management Kit…
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
System Design in PSoC Creator IDE
Cypress Solution: Compelling CY Creator introduction to solve the challenges highlighted on a previous slide.Provides a short, clear list of what to do to get started.
1. Explore the library of 100+ Components
2. Drag and drop Component icons to complete your hardware system design in the main design workspace
3. Configure Components using the Component Configuration Tools
4. Access Component datasheets directly from the Component Configuration Tools
5. Codesign your application firmware and hardware in the PSoC Creator IDE
6. Use the PSoC 4 Fan Controller Application Note for complete system design guidelines
Thermal Management Example Project in PSoC Creator IDE
6b
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Configure the Fan Controller ComponentCreate a custom closed-loop Fan Controller in minutesDrag and drop the Fan Controller Component into the main design workspace
Right-click the Component to customize your parameters with the Component Configuration Tool
Choose the number of fans to be controlled and monitored (up to 4 with speeds of up to 25,000 rpm)
Enter parameters from the manufacturer’s datasheet to map PWM duty cycle to fan rpm
Set up alerts for stalled fans and speed regulation failures (optional)
Enter control loop period (in seconds) to specify how frequently the PWM duty cycles are adjusted
Enter tolerance (in %) to specify the acceptable difference between the target rpm and the actual rpm
Select the acoustic noise reduction option to reduce noise by limiting fan rpm acceleration
Fan Controller Component
Cypress Solution: To give details on CY products and show compellingly how they solve the challenges highlighted on a previous slide. To provide a short, clear list of what to do to get started.
Fan (PWM) outputs used to drive fans at the target fan rpm
TACH inputs used to measure the actual fan rpm
6c
Fan Controller Component Configuration Tool Customize Your Fan Controller Parameters
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Prototype Your PSoC 4 Thermal Management System
Cypress Solution: To give details on CY products and show compellingly how they solve the challenges highlighted on a previous slide. To provide a short, clear list of what to do to get started.
Use the Thermal Management Kit (CY8CKIT-036) to prototype your systemConnect the PSoC 4 Pioneer Kit (CY8CKIT-042) to the PSoC Shield Adapter Kit (CY8CKIT-019)
Connect the Thermal Management Kit (CY8CKIT-036) to the PSoC Shield Adapter Kit (CY8CKIT-019)
Prototype with the two fans provided
Or attach your own fans using the on-board connectors
Open the Thermal Management Example Project
Configure your Fan Controller Component using the Component Configuration Tool
Watch our demo video: www.cypress.com/go/ThermalManagement
Thermal Management Kit (CY8CKIT-036)
Diode Temperature Sensors
Temperature Sensor with I2C interface
Fan Socket
I2C connector
Temperature Sensor with a PWM output
PSoC 4 Thermal Management System Prototype
PSoC 4 Pioneer Kit(CY8KIT-042)
PSoC Shield Adapter Kit (CY8CKIT-019)
The PSoC 4 on the Pioneer Kit runs the Thermal Management Example Project, which reads the temperature sensor outputs and controls the fan rpm on the Thermal Management Kit
Thermal Management Kit (CY8CKIT-036)
6d
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Solution Examples: To give detailed one-page PSoC Solution Examples from the field in the specified format. 7
PSoC® 4 Thermal Management Solution Example (Four Fans, Six Thermistors)Block Diagram
ARM® Cortex™-M0 MCU
PSoC 4 One-Chip Solution
ADC Fan
Controller
4
4
32
EEPROM(emulated)
FlashSRAMI2C
Digital Temperature
Measurement
PWM Fan Speed Control
TACH Actual Fan Speed
Design ProblemsLinearize sensor outputs for temperature measurementMinimize fan noise and powerCommunicate with the Host Processor
PSoC 4 SolutionProvides firmware algorithms to linearize sensor outputsReduces fan noise and power using Thermal AlgorithmsCommunicates with the Host Processor via I2C
PSoC Value
Integrates multiple ICs:AMUX (Analog Multiplexer)ADC (converts analog to digital)Temperature Sensing Algorithm1
Fan Controller (controls and monitors fans)I2C (Host Processor communications interface)Thermal Algorithm1
1 Configurable firmware embedded in Thermal Management Components
PSoC Creator Components
32
2 32 Thermal Management Components
SixThermistors
Analog Outputs
Thermistor Reference Voltage
Host Processor
Ethernet Switch by AvayaThermal ManagementSystem with four fans and six thermistors
Thermal Algorithm
Temperature Sensing
Algorithm Target Fan rpm
Temperature Values
Vdd
MUX
A
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
PSoC 4 Solution vs. Competition’s
Feature PSoC 4 ADI ADT7470
TI LM96000
MAXIM MAX6639
MCHP/SMSCEMC2302
No. of Fans 4 4 3 2 2
No. of Temp. Sensing Channels
14 1 2 2 0
Sensor Types Diode, RTD, Thermistor
TMP05/06 Diode Diode -
I2C Sensors Yes No No Yes No
Price1 $1.92 $2.18 $1.95 $1.50 $0.80
System Cost2 $1.92 $2.74 $3.19 $3.10 $2.44
Competitive Comparison: To define key features of the Cypress solution and demonstrate its superiority over the Next Best Alternatives(NBAs). Must be credible and objective to the salesperson and customer.
8
1 1ku pricing from supplier websites on 7/7/20142 System implementation based on the generic solution example on page 7 using thermistors or diodes for Temperature Sensing
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Competitor fan controller ADT7470ARQZ-REEL7 B59041R120A10 instead of ADI PWM Temperature Sensor TMP05 effort to customize the Thermal Algorithm
Value Added: $0.103Price: $0.682
Reduced Engineering Effort: PSoC 4 saves 2 man-weeks of Price: $2.791
Additional Value
Sensor Cost Reduction: EPCOS Thermistor
Thermal Management IC: ADI temperature sensor hub and
$2.79
$0.68
$0.10
$0.78
$3.57
Competitor
Sensor Cost Reduction
Reduced Engineering Effort
Total Additional Value
Total Value Delivered
Target PSoC Solution: Total Cost:
41% Total Savings:
CY8C4245AXI-483$2.091
$1.48
1Digikey website 1ku pricing on 7/7/2014 the total estimated production volume of 100ku
2Digikey website 1350 unit pricing on 7/7/20143Savings of 2 man-weeks of engineering effort at the rate of $5K per man-week; amortized over
EVC Slide: To clearly define the value of the Cypress solution, including BOM integration and unique functionality.
PSoC 4 Thermal Management Solution Value
9a
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Competitor three-fan controller LM96000CIMTX/NOPB one-fan controller LM96163CISD/NOPB of effort to customize the thermal algorithm
Value added: $0.102Price: $1.281
Additional Value
Reduced engineering effort: PSoC 4 saves two man-weeksPrice: $2.401
BOM Integration
Thermal management IC: TI temperature sensor hub and
Thermal management IC: TI temperature sensor hub and
$2.40
$1.28
$1.28
$0.10
$0.10
$3.78
Competitor
Thermal Management IC
BOM Integration Value
Reduced Engineering Effort
Total Additional Value
Total Value Delivered
Target PSoC Solution: Total Cost:
45% Total Savings:
CY8C4245AXI-483$2.09 1
$1.69
1 Digikey website 1ku pricing on 7/7/2014 man-week; amortized over an assumed production volume of 100ku
2 Savings of two man-weeks of engineering effort at the rate of $5K per EVC Slide: To clearly define the value of the Cypress solution, including BOM integration and unique functionality.
PSoC 4 Thermal Management Solution Value
9b
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Competitor and two-fan controller MAX6639AEE+ and two-fan controller MAX6639AEE+ of effort to customize the thermal algorithm
Value added: $0.103Price: $1.502
Additional Value
Reduced engineering effort: PSoC 4 saves two man-weeksPrice: $1.502
BOM Integration
Thermal management IC: Maxim temperature sensor hub
Thermal management IC: Maxim temperature sensor hub
$1.50
$1.50
$1.50
$0.10
$0.10
$3.10
Competitor
Thermal management IC
BOM Integration Value
Reduced engineering effort
Total Additional Value
Total Value Delivered
Target PSoC Solution: Total Cost:
33% Total Savings:
CY8C4245AXI-483$2.091
$1.01
1 Digikey website 1ku pricing on 7/7/2014 man-week; amortized over an assumed production volume of 100ku
2 Supplier website 1ku pricing on 7/7/20143 Savings of two man-weeks of engineering effort at the rate of $5K per
EVC Slide: To clearly define the value of the Cypress solution, including BOM integration and unique functionality.
PSoC 4 Thermal Management Solution Value
9c
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
Competitor EMC2302-1-AIZL-TR EMC2302-1-AIZL-TR hub EMC1074-1-AIZL-TR
Price: $0.742
Additional Value
Reduced engineering effort: PSoC 4 saves two man-weeks of effort to customize the thermal algorithmValue added: $0.103Price: $0.802
Temperature sensor hub: MCHP/SMSC temperature sensorPrice: $0.802
BOM Integration
Fan controller IC: MCHP/SMSC two-fan controller
Fan controller IC: MCHP/SMSC two-fan controller
$0.80
$0.80
$0.74
$1.54
$0.10
$0.10
$2.44
Competitor
Fan controller IC
Temperature sensor hub
BOM Integration Value
Reduced engineering effort
Total Additional Value
Total Value Delivered
Target PSoC Solution: Total Cost:
14% Total Savings:
CY8C4245AXI-483$2.091
$0.35
1 Digikey website 1ku pricing on 7/7/2014 man-week; amortized over an assumed production volume of 100ku
2 Supplier website 1ku pricing on 7/7/20143 Savings of two man-weeks of engineering effort at the rate of $5K per
EVC Slide: To clearly define the value of the Cypress solution, including BOM integration and unique functionality.
PSoC 4 Thermal Management Solution Value
9d
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
PSoC Thermal Management Solutions
Feature PSoC 1 PSoC 3 PSoC 4 PSoC 5LP
Core M8C 8051 ARM Cortex-M0 ARM Cortex-M3
No. of Fans 2 to 8 8 to 16 2 to 4 8 to 16
No. of Temp. Sensing Channels
8 to 24 16 to 32 10 to 14 16 to 32
Sensor Types Diode, RTD, Thermistor
Diode, RTD, Thermistor
Diode, RTD, Thermistor
Diode, RTD, Thermistor
I2C Sensors Yes Yes Yes Yes
Price Range1 $1.53 to $3.22 $3.48 to $4.73 $1.74 to $1.92 $5.00 to $5.59
PSoC Solutions Portfolio: To show the capabilities of CY solutions.To enable customers to select the appropriate CY solution for their requirements.
1 1ku pricing from Cypress website on 7/31/2014
9e
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
1. Watch our demo video: www.cypress.com/go/ThermalManagement
2. Buy the Thermal Management Kit ($129), the PSoC 4 Pioneer Kit ($25) and the PSoC Shield Adapter Kit ($25):
CY8CKIT-036: www.cypress.com/go/CY8CKIT-036
CY8CKIT-042: www.cypress.com/go/CY8CKIT-042
CY8CKIT-019: www.cypress.com/go/CY8CKIT-019
3. Install PSoC Creator software:
www.cypress.com/PSoCCreator
Here’s How to Get Started
Call to Action: To tell customers how to start their design process. 11
Infant Incubatorby Ningbo David Medical
Each incubator has one fan and two Temperature Sensors to measure body and air temperatures
Automated Teller Machine
Each machine has up to two fans and two Temperature Sensors
Each unit has up to four fans and one Temperature Sensor
Spectrum Analyzer
Engineering Presentation Owner: JHNWRev *F Tech lead: VVSK
References and LinksDemo video: www.cypress.com/go/ThermalManagement Demonstrates the CY8CKIT-036 Thermal Management Kit
Thermal Management Kit (CY8CKIT-036): www.cypress.com/go/CY8CKIT-036 Contains the kit documentation
PSoC 4 Pioneer Kit (CY8CKIT-042): www.cypress.com/go/CY8CKIT-042
PSoC Shield Adapter Kit (CY8CKIT-019): www.cypress.com/go/CY8CKIT-019
Component datasheet for Fan Controller: www.cypress.com/go/FanControllerComponent
Fan Controller Application Note (AN89346): www.cypress.com/go/AN89346Contains the Thermal Management Example Project
Diode Application Note (AN60590): www.cypress.com/go/AN60590
Cypress Platform PSoC Product Roadmap: www.cypress.com/go/PSoCRoadmaps
References and Links: Provide a comprehensive view of resources to assist in learning about and adopting the solution. 13