Electrical Design


Galvanically Isolated Smart Sensor

 
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Process

 

When beginning the electrical design process, TALOS reviews all requirements to identify the critical pathway and potential design problems. If the design requires a software interface component, collaboration between the electrical and software teams will commence to identify potential conflicts and an interface design document (IDD) will be generated. Once hardware parts have been selected, software and hardware design can begin. Altium Designer and SolidWorks seamlessly integrate for mechanical package verification and, when necessary, simulation for thermal analysis.

For this study, TALOS designed and produced smart sensors which allow configuration of up to eight smart sensors. These sensors interface with our smart metering system in a plug-and-play fashion. This sensor is galvanically isolated, features a link verification LED, and includes NVRAM to store calibration and sensor data.

 
 
 

Design

 

Design requirements included size, weight, power, measurement range, resolution, sensitivity, and thermal, shock, vibration and chemical compatibility constraints. This application required the sensor to be galvanically isolated from the data acquisition unit and transmit data accurately over 100 meters without requiring a custom cable assembly.

The primary feature of the smart sensor is the implementation of on-board memory for logging, calibration, and storing identifying information. This feature allows the smart metering system to detect if the sensor has been replaced or moved. The sensor communicates its type to the smart metering system allowing the correct interface drivers to be automatically selected.

Click image to view enlarged schematic

 
 
 
 

Implementation

 
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All systems at TALOS are validated prior to production. This validation phase typically includes, design rule validation, shock, vibration, thermal, and MTBF. Requirements are verified during this phase, and all high-risk requirements are captured and reassessed for risk mitigation and limitation.

Once the design has completed our verification and validation process, the prototype is ordered, assembled, and tested.

Every TALOS design goes through multiple inspections, starting with components that arrive from suppliers. These components are verified to meet required IPC inspection criteria, WHMA specification for harnesses. All systems undergo a burn-in test, inspection, and are shipped with a certificate of conformance and test report.