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ECE504 ST Project Jeff Rice Arduino Based Temperature Controller, Ethernet Enabled **Please Click on Icon to Hear Sound, then click On slide when sound.

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Presentation on theme: "ECE504 ST Project Jeff Rice Arduino Based Temperature Controller, Ethernet Enabled **Please Click on Icon to Hear Sound, then click On slide when sound."— Presentation transcript:

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2 ECE504 ST Project Jeff Rice Arduino Based Temperature Controller, Ethernet Enabled **Please Click on Icon to Hear Sound, then click On slide when sound over to advance**

3 Presentation Structure Arduino Overview Review of Temperature Controller Project stages and results Microprocessors role in industrial & utility controllers Arduino Overview Review of Temperature Controller Project stages and results Microprocessors role in industrial & utility controllers

4 Arduino Overview Brains – Atmel ATMega RISC microprocessor with pre- loaded bootloader Volt Regulator – to allow wide input voltage range Pin connectors for I/O Serial port interface (SPI) Crystal Oscillator (clock source) Result - $30 microproc. Based dev. Development board with wide usage and many open source libraries. USB port and onboard USB-serial chip allows easy programming in C language

5 Arduino: Open Source Enabled Arduino Board Peripherals: LCDs, remote I/O (I2C) Actuators: LEDs, Solenoids, Motors Direct Inputs: Heat, Light, Motion Libraries LCD I2C PID CapSense LowPower Modbus Zigbee X10 (PLC) Servo SD Card Stepper Motor Text Messaging Printing Tones Libraries LCD I2C PID CapSense LowPower Modbus Zigbee X10 (PLC) Servo SD Card Stepper Motor Text Messaging Printing Tones PC or Mac running Arduino IDE

6 Arduino History Processing Ben Fry & Casey Reyes create Processing, programming language for Artists (MIT, 2001) WIRING Wiring IDE, development board & language created (Ivrea Italy, 2003) ARDUINO Arduino developed for low cost student development (Ivrea Italy, 2005)

7 Thyristor Review Thyristors are widely used three terminal power semiconductors – if you gate it the unit conducts until reversed biased. Mature technology, mass produced and widely used for motor drives & inverters Gate not isolated from Cathode

8 Thyristor Trouble (continued) 5v gate signal driven by micro and power supply, thyristor cathode and anode hooked to AC mains supply.

9 Using a Solid State Relay Duty cycle control over 1 second interval 120 segment resolution (# of half sine waves)

10 Image by Tony van Roon (http://www.sentex.ca/~mec1995/gadgets/relays/relays.html)http://www.sentex.ca/~mec1995/gadgets/relays/relays.html

11 Hardware Setup Digital Temperature Sensor Solid State Relay Heating Element Local LCD HMI AC Breaker Arduino

12 PID Control Loops Overview PID Loops: very common control loop PID = Proportional, Integral, Derivative Controlled Variable, Setpoint, Output Image source = Wikipedia

13 Simple Web Setup Any Computer with a Web Browser Web Browser Arduino Unit Ethernet Library Ethernet One Wire Comm. SSR Firing Routine PID Library Ethernet Expansion Board with Wiznet 5100 TCP/IP Chip

14 Simple Web Result Virtual Emulation of Local LCD Display with ability to change setpoint

15 Full HMI Setup Kepware I/O Server Inductive Automation Ignition Runtime and IDE Status Module HMI IDE and Runtime Historian Database & Drivers Arduino Unit Modbus Library Register Data USBUSB OPCOPC I2C Comm SSR Firing Routine PID Library

16 Kepware I/O Server Handles communication to hardware, data concentration and status flagging

17 Ignition HMI (Platform Monitor)

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19 Need for Local Control Note that processor controls the process, not the HMI. No critical process data routed through HMI. LCD Serves as Backup indication Typically a real critical process would have a “hard” backup to the controller

20 Arduino Ethernet board Security Issues Based on Wiznet 5100 chip Found published errata on chip

21 Bridge to PLCs In Process Control we don’t hear people talk about – Microprocessors – Libraries and common code Instead Industrial vendors either – Develop everything themselves – package chipsets and libraries in their own “wrappers”

22 GE Fanuc VersaMax MicroController One of the more common GE micro PLCs

23 GE Versamax Micro PLC Innards RELAYS Terminals IO Board CPU/Comm Board

24 GE Labeled, But Made By…. Someone Else? Renesas microprocessor Hitachi manufactured PCB

25 PLC Demolition Results If we can extrapolate from this one example: Although PLCs looks like custom built pieces of proprietary hardware and software… The industry reuses technology and components. Use of such third party hardware and software can open the doors of information to mal – actors

26 Presentation Conclusion Learning / Research project Gained experience with Arduino, Processing, Libraries and C language, Modbus protocol, GE PLCs, One Wire protocol, Thyristors and Solid State Relays and Ignition HMI platform. Hopefully some of this was passed on in the presentation! Learning / Research project Gained experience with Arduino, Processing, Libraries and C language, Modbus protocol, GE PLCs, One Wire protocol, Thyristors and Solid State Relays and Ignition HMI platform. Hopefully some of this was passed on in the presentation!

27 Questions? Thanks for listening!


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