Grindmaster Drink Dispenser Controller Grindmaster-Cecilware Corp. Nick Kitsos (ECE), Shaun Morris (ECE), Sean Caproon (ECE), Joe Pierce (ECE)

Background Information The Grindmaster-Cecilware Corp. (GMCW) Drink Dispensers Coffee Grinders Powdered Drinks Hot and Cold liquids Frozen liquids Capstone Project: Design a configurable, smart, prototype controller for their drink dispensers

Project Goals Add software configurable features to the dispensers Improve the user interface – Touchscreen LCD display – Keypad vs. dials internal to the dispenser Add network connectivity – IEEE g (Wi-Fi) interface – USB management interface Improve intelligence for energy conservation – Requires a real-time clock to turn heating element off during times that the shop is closed Create a universal controller for all dispensers (all-in-one) Increase user satisfaction – Easy-to-use interfaces for customers – Easily programmed by the business owner – Future capability to remotely manage the unit

Operational Concept Maintain suitable temperature of cold/hot media – Media is the liquid in which the drink powder is mixed, ie. water, syrup, etc. – Power up the compressor/heater in response to the temperature sensor Frozen drinks require a compressor – 6.0 KW Hot drinks require a heating element – 6.0 KW Controllable motor speeds – Auger to dispense powder into the mixer Power saving mode – Utilize real-time clock to determine when usage is low Widen acceptable temperature ranges

Operational Concept (cont’d) Wireless Ethernet (IEEE g) interface – System programming – Display diagnostics and usage information – Change dispense settings Touchscreen LCD interface – System programming – Change dispense settings – Display alerts – Advertising – Thank customers for purchase

Operational Concept (cont’d) Customer Selects drink size/type on the keypad – Receive feedback/guidance on LCD Machine Owner Program temperature ranges, motor speeds – Wireless Ethernet user interface – Touchscreen LCD interface Receive diagnostic/usage information

System Description

Major Components Microcontroller For this prototype, the group will use an Arduino development kit to demonstrate system functionality This development kit uses the same microprocessor that is currently used by Grindmaster ATmega microcontroller features: – 54 digital I/O (14 of which provide PWM) – 16 analog inputs – 4 hardware UARTs for TTL (5V) serial communication – Input voltage of 7-12V Motors and Valves The controller board must be capable of driving a large number of valves and motors For demonstration purposes, the group will switch one of each motor and valve.

Major Components (cont’d) Power Supply The power supply will run on VAC 60Hz, and should power the entire system. Real-time Clock The real-time clock will be used to provide time/date to the microprocessor, which will automatically change the settings on the machine when it is not in use

External Interfaces Touchscreen LCD Graphical feedback Programming mode Keypad Drink selection Wi-Fi Interface Diagnostics Programmability USB Interface Management

Internal Interfaces Contactors/Relay Outputs Multiple relays are required to actuate valves/motors – Two relays will be used to demonstrate switching one each of a 24W 120 VAC and 24 VAC valve and motor. – One relay will be used to demonstrate switching and speed control of a 24W 24 VDC motor. – One high power relay will be used to demonstrate switching of the relay that controls either the heater element or the compressor in the dispenser Sensor Inputs Two sensors: – A level sensor will determine when to open the main tank valve that refills the water tank. – A thermistor temperature sensor will be used to determine when the heater/compressor must be turned on

Functional Requirements Monitor and Control Temperature The heater must keep the temperature of the hot media between +75°C and +96°C. The compressor must keep the temperature of the cold media between -3°C and -5°C. For the prototype, simply switch the relay on/off in order to demonstrate powering heater/compressor – Since the relay must power 6,000 Watts, the solenoid requires significant current to pull the contacts closed – Additional circuitry is required

Functional Requirements (cont’d) Wireless Internet Access IEEE g protocol (Wi-Fi) – Wireless access security must also be implemented The interface will be used for: ―Programming ―Diagnostics To allow customers who do not have wireless access to the dispenser, the LCD can be used in the programming mode – Additional security features are required

Functional Requirements (cont’d) Real-Time Clock The RTC will be used to set the controller to power down the heater or compressor when the machine is not in use ―The user will provide the inputs to determine when the machine will go into power-saving mode Non-Volatile Settings Storage In case of power failure, previously saved settings will be restored once power comes back up ―This eliminates the need to re-configure the settings after a power failure

Current Status Microcontroller Development Familiarization with software and language Begun implementation of the wireless card – Successful communication between controller and WiFly board – Successful connection to “ulopen” network Wi-Fi DaughtercardArduino Development Board

Current Status Power System Need to power motors, valves, processor Provided a power supply which takes 120VAC to 24 VDC – Still require voltage reduction for powering processor board Relay System Multiple relays must be switched to demonstrate functionality – Problem: Low power output from processor, high power needed for switching relays

Current Status (cont’d) Wi-Fi Interface The IEEE g daughter card is operational – Programmed via the USB interface to the Arduino board – Software libraries obtained through Sparkfun We have been able to get the daughter card to obtain an IP address from the Ulopen network and can remotely ping the Wi-Fi interface – Next step is to develop the web-based UI

Ping Test Results

Open Issues Microcontroller will only output 5VDC at 40 mA – Requires relay board – This is under investigation. We may require additional, smaller relays or solid state relays to switch the large relays – Our preference is to use the existing components and circuits Software Logic – Dispensed drinks require precise timing of auger, mixer, and valves which has not been provided – If we can obtain the logic diagram of the existing software this will speed up the firmware development process

Future Development Activities Develop the User Interfaces – Keypad/LCD Touchscreen – USB GUI – Wi-Fi GUI Requires web client/server application development Build and test the power/relay system Incorporate Real-time clock data – Low power consumption standby mode

Extras Pictures – Components inside display machine

Water Tank – Top View

Water Dispense Valves – Side View

Whipper Motors – Side View

Auger Motors – Side View