Transcript Viking Pump Flow Manager - Phase 2

Viking Pump Flow
Manager - Phase 2
Senior Design
May 06-12
People
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Team Members
Dwayne Stammer - CprE
 Francois Munyakazi – EE
 Dan Paulsen – CprE/EE
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Faculty Advisor
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Nicola Elia
Client Info
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Viking Pump Inc.
Outline
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Introduction and problem statement – Dan Paulsen
Design and implantation – Dwayne Stammer
Schedule, financial, and closing – Francois Munyakazi
Future Work – Team
Definitions
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Flow meter: An instrument used to measure pressure,
flow rate, and discharge rate of a liquid, vapor, or gas
flowing in a pipe
Set point: The speed that a pump has to rotate in order
to achieve a given flow or output pressure
Viscous: Having a relatively high resistance to flow
QVGA: 4x6 inch high resolution touch screen, has
onboard analog voltage inputs and outputs
Problem Statement
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Design a system to do the following
Control a pump to maintain a given flow using only
speed, pressure, and temperature measurements
 Provide an easier user interface to control flow rate
and other working parameters
 Provide access to system through serial bus
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Why?
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Why is this valuable?
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Measuring flow for viscous fluids is very hard
Less parts needed to build a pumping system
Has many other uses such as batch flow, and error detection
Inline meters to measure flow can hinder flow performance
Problems with current system
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Hardware out of date
User interface is outdated and difficult to use
System Use
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System will be configured and run by trained
technicians
Will operate in harsh “factory floor”
environments
Temperatures ranging from 40° to 120°F
 Long periods of use
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Assumptions
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Inputs from the system will be:
Inlet pressure – input voltage
 Outlet pressure – input voltage
 Temperature of the fluid – input voltage
 Current pump speed – input voltage pulse
- 60 pulses/revolution
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Outputs to the system will be:
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4-20mA signal to DC Drive
Limitations
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The controller must be able to operate in a real
time environment
The software implementation must be portable
The controller solution must be economical
The controller must be able to control the actual
flow within 0.25% of the set point
End Product
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Implementation for basic prototype that
properly controls pump system
Documentation of controller and source code
Problem Definition
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Current flow manager is difficult to use and
obsolete
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User interface needs updated to a much more
intuitive interface
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Will be solved using a new touch screen interface
Hardware used is no longer available because it was
custom made to the application
Will be solved using over the shelf parts
 Writing software with different hardware platforms in
mind
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System Overview
Motor
Revolution Counter
Flow Meter Readout
Pressure Gauges
Flow
Thermometer
Pressure Readouts
Pump
Flow meter
Pressure Relief Valve
System Overview
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Four inputs
Inlet pressure
 Output pressure
 Fluid Temperature (to determine viscosity)
 Pump RPM
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One output
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Desired motor speed
Previous Model
Outdated User Interface
The current Flow Manager
provides the user with a lessthan-intuitive interface. Certain
combinations of button presses
will change its operational state.
Our primary goal is to develop a
user interface that is easier to
use and incorporates all warning
lights into the touch screen.
Previous Model
Updated Model
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Touch screen user interface
Updated C code
Standardized equipment (not as much
customized circuitry required)
PC interface with more advanced GUI features
Updated Model
Standardized equipment
The QVGA controller card
provides touch screen
capabilities delivered
through a C library. It also
supports digital and analog
I/O. This eliminates the
need for fully customized
circuits, thus reducing
production cost.
Updated Model
PC interface
Updated Interface Circuitry
Updated Graphical Interface
Initial Performance Measurement
Violet: Output Signal
Red: Flow Rate
Updated Flow Manager
Algorithm Performance
Blue: Set Point
Green: Flow Rate
Orange: Pressure
Schedule
Personal Effort
John Taylor , Cliff Pisent,
35
104
Francois
Munyakazi,
200
Dwayne
Stammer, 275
Dan Paulsen,
225
Total hours: 839
Project Costs
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QVGA Repair
Pump equipment
Miscellaneous parts
Poster
Total material cost:
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Total material cost
Labor (839hrs @ $11.00)
Materials
Total cost of project:
Project Total thus far
$250
$0
$175
$40
$465
Provided by Senior Design
Donated by Viking
Viking/Group members
Group members
$9,229.00
465.00
$9,694.00
7,525.50 Previous group
$17,219.50
What Went Well
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Some part were easy to get from common store
Design of project was easy, important decisions
already made by previous team
Communication between components was fairly
well
Good Coordination between team members
What Didn’t Go Well
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Understanding the definition of the project
Learning how to interface with the pump
QVGA was damaged because we did not understand
how the pieces should work together.
 Dealt with odd behavior with parts which were out
of the scope of our project.
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Communication with sensors and QVGA
Knowledge Gained
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Learned the control algorithms for pump flows
Learned How to program the QVGA
Developed team communication
Learned how to effectively distribute work loads
among team members
Learned how to better work with clients while
keeping a project on track
Risk Management
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Anticipated risks
Loss of code
 Loss of team member
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Anticipated risks encountered
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Loss of team member
John Taylor went to internship
 Cliff Pinsent graduated
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Unanticipated risks encountered
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Damage of the QVGA
Work Completed
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Repair QVGA
Acquired model from Viking
Studied algorithm and controllers
Designed and prototyped GUI screens
Detected I/O of QVGA
Wrote C code and serial code
Build pump interface between QVGA and pump
Designed circuitry for sensor testing and QVGA
Work Completed Cont.
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80% Completed writing / debugging the C code
to control flow
80% write and implement the full GUI
Created a methodology for the QVGA to be
controlled via serial comm.
Closing
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The previous version of the product
Pros: Has a very large success
 Cons: User interface
 The lack of user friendliness of the device even
thought it is still the best device on the market
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Closing Cont.
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Viking Pumps needs a well-designed flow
control manager
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To be used with already existing pumps.
Cost effective
Portability
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Moving from one hardware to another without
major software rework
Questions?