MULLE World smalest mobile Internetserver Implementation and Manufacturing Challenges

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3 MULLE World smalest mobile Internetserver Implementation and Manufacturing Challenges Professor Jerker Delsing EISLAB, Luleå University of Technology, Luleå, Sweden

4 Vision Sensors on Internet Sensor talks TCP/IP Minimal size < 1 cm 3 Power life time > 2 year Wireless ad-hoc networking Roughed packaging Ad-hoc application integration Secure 1 cm 3

5 Hardware solution...

6 System Design Requirements On board Web server Wireless communication Real time clock Size target : 25 x 25 x 5 mm Battery supply 3.6V 4.8V nominal Low power Analog I/O Digital I/O Power supply output

7 Digital Core Renesas M16/62A 16 bit architechture 20 kb RAM, 256 kb flash ROM 8-10 bit analog I/O Bare die footprint 13x13 mm incl. pads No bootcode in bare die Xicor X1288 RTC, reset logic and 256 kbit serial memory Clocks 10 MHz resonator and 32 khz crystal

8 Analog interface A/D converter inputs 3 single ended and one differential input 8 bits resolution at 357 khz Monitoring of battery level D/A converter Two 8 bit D/A outputs References 1.2 V and 2.5 V references

9 External access I/O connector Serial, timer, and interrupts A/D and D/A converter and references Switchable supply voltage for sensors Bluetooth Mitsumi WML-C10AHR Class 2 BT with integrated antenna Serial comm. to M16, SPI for config. Power supply XC V linear regulator

10 MULLE Block Schema tic

11 Circuit board properties Glass fiber FR4 substrate 6 layer design Minimum conductor width 150 µm Copper thickness 35/18 µm Blind conical micro vias 75/127 µm and 125/400 µm Chemical Ni/Au surface layer Multi-Teknik, Gothenburg

12 Boot code programming Parallell programming 40 Programming lines Card edge connectors Used once, then not needed Implemented on break-off parts Wires to break-off parts only on outer layers Re-bonding and globtop of M16 after programming

13 L U L E Å U N I V E R S I T Y O F T E C H N O L O G Y The complete HW Instr. amplifier M16 (glob-topped) solution RTC / EEPROM Bluetooth antenna Main connector Bluetooth chipset 25 mm

14 Software solution...

15 Software OS functionality in assembler All user software written in ANSI C Compiler: IAR Embedded Workbench Code space: requires less than 20 kb of RAM and 200 kb of program ROM Hardware dependant functions are encapsulated by software libraries Low power design Bluetooth and CPU low power modes are available Possible to remotely switch on/off sensors

16 Bluetooth communication profiles BT CTRL Network application & data acquisition TCP IP NAT PPP UDP RFCOMM L2CAP HCI UART SDP Bluetooth module Software protocol stack DUN Profile Uses the dial-up services of the gateway (e.g. a cell phone) Wide area coverage LAN Access Profile LAN Access point (LAP) Provides Internet access for other nodes Data Terminal (DT) Uses the services of the LAP

17 IP communication BT CTRL Network application & data acquisition TCP IP NAT PPP UDP RFCOMM L2CAP HCI UART SDP Bluetooth module Software protocol stack NAT Provides IP addresses to peer nodes Address & port translation Multiplex traffic from many nodes over the cell phone TCP/IP Provides access by wide-spread tools/applications e.g. browsers

18 Connection to the Internet (Mobile) nodes Internet Networking sensors Host User... User

19 Performance and applications

20 L U L E Å U N I V E R S I T Y O F T E C H N O L O G Y Power consumption Various modes of operation Stop mode: 2.3 ma -> 20 ua Wait mode: 14 ma -> 150 ua Bluetooth mode: 35 ma Full system mode: 51 ma Li-poly cell for small size Varta LPP x20x4 mm, 3.7 V, 130 mah Li-Ion cell for low temperature Varta LIC CWC High performance operation at -20 C 3.7 V, 2200 mah

21 L U L E Å U N I V E R S I T Y O F T E C H N O L O G Y Application example Cross-county ski event Vasaloppet nodes, GPS & heart rate Prof. J. Delsing ~12 hours Nodes operational for 97 % - Sensor node - GPS receiver on shoulder - GPRS - Cell phone in pocket - Sensor node - Heart rate chest belt

22 L U L E Å U N I V E R S I T Y O F T E C H N O L O G Y Professor Puls Vasaloppet

23 L U L E Å U N I V E R S I T Y O F T E C H N O L O G Y Mulle today Light weight implementation of EIS Fully functional sensor networking and AmI On board Web server, BT and TCP/IP Total size 23x25x10 mm incl. supply Next step: reduce power consumption and unit size

24 Mulle tomorrow Encapsulation Building technology Energy excavation Service discovery Robust real time performance Tight integration with sensors

25 Encapsulation Cooperation with ProofCap AB EMC protection Environment protection Integration of antennas

26 Integrated antennas

27 Integrated antennas

28 Building technology Cooperation with Cuptronic AB Sequential build up of circuit boards, SBU Environment friendly Extremely small dimensions

29 Trad vs SBU traces

30 Energy excavation Cooperation with Monash University, Australia Prof. Y Bing Dye solar cell technology Painting a solar cell on the device

31 Service discovery What service does a sensor device provide to a system Automatic integration into governing systems

32 Tight integration with sensors The Tumb size ultrasonic measurement system MULLE-GPS MULLE-Acc MULLE-IR MULLE-T

33 L U L E Å U N I V E R S I T Y O F T E C H N O L O G Y The tumb size ultrasonic measurement system Ultrasound measurement system Miniature ultrasound system combined with MULLE to achieve complete stand alone measurement system

34 Robust real time performance Reactive approach to real time system and their programing The Timber tools

35 System models Today Timber Objects Events Reactions Deadlines Semantic gap! Objects Events Reactions Deadlines Threads Semaphores Monitors Priorities Machine code Liveness and state integrity by construction! Machine code

36 Today Modularity Timber Well understood in isolation Well understood in isolation A + B A + = B A B A B Race conditions Priority interference Conflicting eventloops Deadlocks Well understood in terms of its components!

37 Architecture Traditional Timber Typically C/C++ Provides abstractions Application Middleware Under compiler control All under compiler control! Application Language abstractions, compiles to C Generic, low-level features RTOS RT kernel Hardware Tailored to application! Hardware

38 Analysis - Predictability Today Timber Design Compile Test Test Test Test Test Test Test Test Deploy Deploy Deploy Functionality Robustness Response times Memory usage Power consumption Design Compile Analyze Analyze Analyze Test Deploy

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