Transcript Jake Baldwin Krista Hasling Maryam Moghaddam-Zadeh Jack Oakes Scott Wisdom Project Overview  S.C.A.D.A. system  Manna Energy Foundation , Rwanda  Water Purification  Project Objective  Remotely.

Jake Baldwin
Krista Hasling
Maryam Moghaddam-Zadeh
Jack Oakes
Scott Wisdom
Project Overview
 S.C.A.D.A. system
 Manna Energy Foundation , Rwanda
 Water Purification
 Project Objective
 Remotely determine system health
 Perform control operations based on use (autonomous
and supervisory)
 Report and record
Features
 This design goal:
 32 External ADC’s
 6 Relay/Valve controls
 4 Bus Power
 3 Bus Data
 GSM communication
 Memory SD card
 Demo will not include max number of sensors
Structural Setup
System Block Diagram
Supply
PV
Batteries
Power
Pumps,
UVs
Analog
MC
Base
Station
Antenna
GSM
Memory
Layout
System Block Diagram
Supply
PV
Batteries
Power
Pumps,
UVs
Analog
MC
Base
Station
Antenna
GSM
Memory
PCB Layout – Power Converters
Schematic for 3.3V buck
converter
 Uses LM3100 Chip
 Same as 5V and 10V buck
 Supplies max currents of 1.5 A
 Predicted max current needed is
<1 A
Schematic for 12 V Buck-Boost
 Uses LM5118
 Converter can supply a
max current of 3.5 amps
 Predicted Max current
< 1.5 Amps
Schematic for 24V Boost
 Uses LM3488
 Max current of 3.4 Amps
 Predicted max value <1 Amp
Progress
 Converters and PCB are designed and ordered
 No implemented circuit protection yet….
 Separating headers on current PCB will be removed
for finished project
System Block Diagram
Supply
PV
Batteries
Power
Pumps,
UVs
Analog
MC
Base
Station
Antenna
GSM
Memory
Sensors Progress
5 Vdc
5 Vdc
24 Vdc
240 Vac
12 Vdc
Pressure Meter 1
Pressure Meter 2
Flow Meter
UV light
Valve
0- 5 Vdc
0- 5 Vdc
ADC
2- 40 mA
ADS7828
0- 12 Vdc
0- 12 Vdc
3.3 Vdc
I2C
MC
ATxmega
64A1
Analog/Digital Converter
Sensors
Flow Meter
•Signet 2551
•No device due to cost ($1500 each)
•Using a direct current output to act as device in testing
•2 devices per system
•Output: 4 to 20 mA
•Temperature: -20° to 70° C
Pressure Meter
•Omega 209
•2 devices for testing
•6 devices per system
•Output: 0 to 5 V at .0125 V/division
•Temperature: -20° to 80° C
Sensors
UV lights
•Sterilight with ICE controller
•1 device for testing
•Water temperature: 2° to 40° C
•UV wavelength: 254 nm
•SP100-HO: 11 gpm
•9000 hours of use
Brass Actuated Ball Valve
•DynaMatic AP20DA
•1 device for testing
•Temperature: -15° to 300 ° C
Terminal Block
•PT 1935006
•PCB attachment for ADC to sensors
•16 connections
Current System
Our System
Pressure
Water
Collection
Tank
Pressure
Water Storage
Tank
Filter 1
UV light 1
UV light 2
Flow
Expo Demo Setup
Valve
UV light
“Flow”
Pressure
Pressure
Pump
*No Flow Meter due to cost
System Block Diagram
Supply
PV
Batteries
Power
Pumps,
UVs
Analog
MC
Base
Station
Antenna
GSM
Memory
Microcontroller – ATxmega64A1
 Calibration of internal 32 MHz RC DFLL oscillator
 Initialize and use communication modules
 SPI
 I2C
 UART
 Sample sensors with timer interrupt
 Log data to SD Card
 Parse and execute commands from cell module and
base-station
 Monitor and control using programmed algorithm
Buses and Connections
32kHz
XTAL
PDI
Port
Serial-toUSB IC
(to basestation)
RS-232
Debug
Port
Cell
Module
ATmega32
DMA
UART
UART
I2C
ADC
SD Card
SPI
I2C
Image source:
http://www.atmel.com/dyn/resources/prod_documents/doc8067.p
df
Code Flow
Power on
Initialize
modules
Idle
Timer 1 interrupt
Sample
sensors
Write
measurement
to SD Card
over DMA
Command from base-station or cell
WRITE
Parse
command
READ
Measurements No
satisfy algorithm
conditions?
Read
measurement
from SD Card
Yes
Perform
algorithm
results of
satisfied conditions
Send
Measurement
Over Cell
Return to Idle
XXXX
Other
basestation/cell
commands...
Monitor and Control
Algorithm
Structure of one software algorithm block
Condition 1
&
Condition 2
& …
Condition n
Result 1
&
Result 2
& …
Result n
…
With additional blocks, control is a “sum of products”
Monitor and Control
Algorithm
 Condition types:
Threshold(Value, Above/Below, SensorID)
True/False(Condition)
 Result types:
ChangeValve(Closed/Open)
ChangeRelay(On/Off)
SendAlert(AlertType, Method, Value)
Memory – SD Card
 Use 512-byte block size
 Microcontroller allocates 512-byte buffer that can be
read or written to
 SPI at 4MHz
 Hash table between time stamps and block addresses
(grouped by day and hour)
Memory: Schematic
Memory: Process Flows for
SD Card
SD Card Initialization:
SD Card Read Cycle:
SD Card Write Cycle:
GO_IDLE_STATE
trace
SEND_OP_COND
trace
System Block Diagram
Supply
PV
Batteries
Power
Pumps,
UVs
Analog
MC
Base
Station
Antenna
GSM
Memory
GSM Cellular
 AVR-GSM
 Calling card
 Embedded antenna
 Direct interface for USB
terminal communication
 Off board connectors for
power and buses
FBD: GSM Module
SIM300D
Serial
Interface
FTDI
SERIAL-USB
USB PORT
Serial
Interface
ATMEGA32
2 PIN Power
EXT I/O
I2C
Laptop
-DAQFactory
-Real Term
12Volt DC
-Prototype power
-’Wall’ power
I2C
6 pin ISP
XMega
26 Pin IO
Prototype Components
GSM Cellular
ATxmega64 /ATMega32
SIM300 Bus/ATMega32
 I2C with defined commands
 ‘Get’ and ‘Set’
 2 Buffers
 Data Transmit (~160 byte)
 Data Receive (~160 byte)
 100Khz ~ 400Khz
 UART commands
 ‘AT’ ASCII commands
 2 Buffers
 UART RX 256 bytes
 UART TX 256 bytes
 3x30 SIM300 Buffers
 External connections
 12V, GND, SCL, SDA
 ISP programmer
 Status buffer/byte
 115K2 desired
Code Flow
Peripheral
Init
(UART, I2C)
GSM Data
Received
Cellular Init
Monitor
Traffic
Status Byte
MCU
Command
Back to
Monitor Traffic
No
No
Data
Yes
MCU Send
Data
Update
Status
MCU Data
Request
Data Available
Update
Status
Forward
GSM Cellular - Progress
+ Text messaging works (AT&T)
+ Uart for ATmega32 works (interrupt)
+ I2C master configured for ATMega32 (interrupt)
- Needs to be slave
+ Fully defined status byte, bus protocol
- Perform simple Uart/I2C test via terminal
System Block Diagram
Supply
PV
Batteries
Power
Pumps,
UVs
Analog
MC
Base
Station
Antenna
GSM
Memory
Base Station
Base Station
 Two ways of communication:
 Serial to Microcontroller (and ADC)
 Serial to GSM module
 Two drivers on DAQFactory
 Two sets of Sequences
 GSM cell needs AT parsing
GSM Communication
 DAQFactory now communicates with GSM cell
MCU Communication
 Will Communicate with ADC through STK 500
 Dummy microcontroller Atmega 32
 Transmit commands and receive status
Interface Commands
Cmd Type
GET_Status
Commands
Sensor (ADC)
Cmd
0x01
Tx Parameters
Tx
Cmd,
\x01
Sensor ID (1\x02
32)
(0x01-0x20)
Rx Parameters
Cmd,
Sensor ID,
Data length (12 bits),
Data Measured
Relay State
0x02
Cmd,
\x02
Relay ID (0x01-0x04) \x04
Cmd,
Relay ID,
Data length (8 bits),
State
\x02
\x04
\x01
\x00 - Not Flipped
Valve State
0x03
Cmd,
Valve ID (0x1-0x2)
\x03
\x01
Cmd,
Valve ID,
Data length (8 bits),
State
\x03
\x01
\x01
\x01 - Open
Power Sensor
0x04
Cmd,
Sensor ID (0x1-0x4)
\x04
\x03
Cmd,
Sensor ID,
Data length (12 bits),
Data Measured
\x04
\x03
\x0F – Power Value
\x01
Memory
(Block)
0x05
Cmd,
Day (0x0-0x1F),
Beginning Hour,
Ending Hour
(00-23)(0x00-17)
\x05
\x10
\x11 – 11am
\x14
Cmd,
Day,
Beginning Hour,
Ending Hour,
Data length (512 Bytes),
Measurements
\x05
\x10
\x11 – 11am
\x14
\x200
\23….
Cmd,
\x06
Cmd,
Data length (64 Bytes),
Measurements
\x06
\x40
\x23….
Cmd,
MOD ID (0x1-0x3)
\x07
\x01
Cmd,
MOD ID,
Data length (8 bits),
Status
\x07
\x01
\x01
\x00
0x06
Memory
(Recent
Measurement)
0x07
MOD Status
Rx
\x01
\x02
\x02
\x0F – Pressure
\x65
Interface Commands
Cmd Type
Commands
Cmd
Tx
Rx Parameters
Rx
Cmd,
Log Mode ID (0x01-0x02)
\x11
\x01
Cmd,
Log Mode ID,
Data length (8 bits),
Confirmed State
\x11
\x01
\x01
\x01 – Was set! And
begins logging Data..
Relay State 0x12
Cmd,
Relay ID (0x01-0x06)
Relay State (00 or 01)
\x12
\x04
\x01
Cmd,
Relay ID,
Data length (8 bits),
Confirmed State
\x12
\x04
\x01
\x01 - Was Flipped!
Valve State 0x13
Cmd,
Valve ID (0x1-0x2)
\x13
\x01
Cmd,
Valve ID,
Data length (8 bits),
Confirmed State
\x13
\x01
\x01
\x01 – Was Opened!
SET_Status Data
Logging
Mode
0x11
Tx Parameters
ID
Sensor
Relay
Valve
Power Sensor MOD
Log Mod
0x01
0x02
Pressure 1
Pressure 2
Relay 1
Relay 2
Valve 1
Valve 2
PS 1
PS 2
Microcontroller
GSM Cell (Signal
Strength, etc.)
Keep logging
Stop logging until
requested!
0x03
0x04
0x05
0x06
0x07
AC Current 1
AC Current 2
Temperature
Relay 3
Relay 4
PS 3
PS 4
DAQFactory
…..
DAQFactory User Interface
Division of Labor
Sensors/
Power Relays Primary MCU Memory Cellular
Jack Oakes
X
X
X
Scott Wisdom
X
X
X
Krista Hasling
X
X
X
Maryam
Moghaddamzadeh
X
Jake Baldwin
X
Board
Layout
X
X
X
X
X
Base
station
X
X
X
X
Budget
Sub-Section
Component
Quantity Unit Cost
Power
Power Components
IC's
1
10
$
$
Sensors
ADS7828
MAX3377EEUD
TPIC2603
RELAY
Omegadyne
Phidgets
DynaMatic
5
2
2
2
2
2
1
$
$
$
$
2.50
$
100.00
$
30.00
expensive
Sample
Sample
Sample
$
5.00
$
200.00
$
60.00
memory card pin out board
USB
max3232
Serial db9
Header pins
atxmega
stk600
1
2
1
2
$
$
$
$
18.00
-
$
18.00
Sample
Capstone sample
Sample
1
$
102.00
$
102.00
Cellular
PIC-GSM
AVR-GSM
SIM CARD
PIC-DEV board
D-26 pin
Header 6-pin
Header 6-pin
1
1
2
1
2
2
2
$
$
$
$
$
$
$
275.00
250.00
15.00
107.00
-
$
$
$
$
$
$
$
275.00
250.00
30.00
107.00
-
BaseStation
PCB Orders
DAQ-FACTORY (Starter)
Proto PCB
Shipping
1
2
1
$
$
$
45.00
33.00
14.88
$
$
$
45.00
66.00
14.88
Memory
Main Processor
Running Total Cost
65.00
4.50
$
$
Date Purchased
65.00
45.00
9/21/2009
9/16/2009
9/19/2009
8/24/2009
9/15/2009
8/31/2009
8/24/2009
Packaging
Integration
Capstone DEMO
UROP Funding
EEF
Manna Energy
Running Totals
Total Available
$800.00
??
$2,000.00
$2,800.00
Currently Spent
$
292.88
Remaining
$507.12
$
$
$1,010.00
$1,517.12
990.00
1,282.88
Milestone 1
 Power Converters-efficiency numbers at different load conditions
 Physical Demo Constructed
 ADC and uC working together (with dummy test voltages)
 Physical connections for out-of-box items design completed
 GSM receiving text messages through serial port
 I2C slave functional – GSM module
 GSM module commands working
 Read/Write to SD card
 I2C functional
 Define Communications Protocol
 Retrieve sensor data
 Retrieve requested data in base module from remote module – on-site
 One-way communication between base station and uC – through text
Milestone 2
 Power circuit protection implemented
 Physical connection to battery and PCB designed
 All sensors connected to ADC
 AC power safely working
 Sensors and ADC working together
 ADC data written to SD card using timer interrupts
 Implementing Basic Set commands
 Hard-coded antonymous control algorithm
 GSM two-way functionality with uC
 Parse received commands and update status in DAQFactory
Questions?