Department of Electrical and Computer Engineering Lighting Tool Box Winter 2004 ECE 498 Team Members: Nick Sitarski Blaine Thompson Brandon Harris Dave Chronicle Vladi Gergov Advisor: Professor John W. Miller

Department of Electrical and Computer Engineering Project Summary The Lighting Tool Box is a collection of common machine vision lighting systems controlled locally or via the Internet The goal of this project is to design and implement three lighting controllers which interface with a GNU/Linux based embedded controller The embedded controller supports the Web Cam and Internet interface as well as PWM signal syntheses The Incandescent System can provide the 360 degree lighting for requirements such as structured lighting A fluorescent Lighting system was developed for applications that require a large aspect ratio An LED ring light was developed for applications requiring close proximity inspections Each lighting subsystem can be operated in a stand alone configuration All major functions of the three lighting systems were designed and implemented with the exception of the following features –No lamp voltage regulation on incandescent system –No computer controlled strobe only through local hardware –No remote health status detection

Department of Electrical and Computer Engineering Design Requirements The system was designed to be operated in a factory environment, thus size, ease of remote use, and construction was considered during design stages The whole system can be controlled via the internet / local network or through local operation Equipment should be portable, easy to connect / disconnect All systems are powered from 120 VAC Embedded computer used for remote operation Lighting parameters must be maintained at constant value once set Construction of equipment must comply with electrical safety codes to minimize hazards to user and risk of fire

Department of Electrical and Computer Engineering Technical Specifications Embedded Controller Enclosure Dimensions: 6.5”x4.5”x3.5” Processor Speed: 300 MHz Operating System: GNU/Linux Weight: 2 lbs. Power requirements 120 watts Incandescent System Enclosure Dimensions: 11”x17”x9.5” Lamp Enclosures: 4”x4”x8” Weight: 30 lbs. Power requirements 120 watts LED System Enclosure Dimensions: 11”x15”x9.5” Ring Light: 4”x4”x2” Weight: 10 lbs. Power requirements 120 watts Fluorescent System Enclosure Dimensions: 8”x10”x2.5” Tubular Light Enclosure: 48”x4”x4” Shadow Box Enclosure: 12”x12”x5” Weight: 5 lbs. Power requirements 120 watts with power factor of.99

Department of Electrical and Computer Engineering Subsystems LED Lighting System (Blaine Thompson) - The LED subsystem is a single channel system that controls a LED ring light. The intensity is controlled via a 40KHz PWM signal. This subsystem also contains a strobe feature that modulates the LED ring light output. This is ideally suited for close proximity viewing. Fluorescent Lighting System (Brandon Harris) – The fluorescent lighting system uses an electronic ballast to power and precisely control the intensity of a 32 W fluorescent bulb. This is used for large aspect-ratio viewing. Incandescent Lighting System (Nick Sitarski) – The Incandescent subsystem is a 4 channel system that powers and precisely controls the intensity of the 4 halogen lamps. This is typically used for 360° illumination applications. Embedded Computer (Vladi Gergov, David Chronicle) - The embedded computer uses a combination of microprocessors, I/O, and networking to control the lighting systems remotely via the internet or local network.

Department of Electrical and Computer Engineering Design Constraints Maximum power output is limited to 32 watts for fluorescent subsystem controller. Major circuit redesign is required to exceed this power restriction. The Incandescent subsystem controller is not regulated for remote operation due to time and economic constraints. A high performance A/D I/O card is required as well as extensive programming. Had to construct LED ring light due to cost constraints. Economic constraints limited transformer size for Incandescent subsystem allowing a maximum lamp size of 35 watts. Strobing features could not be implemented in software due to time constraints.

Department of Electrical and Computer Engineering Design Options PWM Signal is generated via an embedded computer as opposed to local hardware to reduce complexity of hardware design. Modular design of system components and website for easier maintenance and prototyping Built custom hardware for lighting subsystems as opposed to commercially available product to reduce cost Operating system (open source, commercial, or custom) –GNU/Linux was chosen due to its lack of licensing fees, open source, stability, and less resources required –PC/104 technology for compact, low power requirements, less heat dissipation, and greater heat tolerance.

Department of Electrical and Computer Engineering Logical Schematics

Department of Electrical and Computer Engineering Test Results Integrated system test was performed satisfactorily with minor exceptions Exceptions include –Limited range of control for incandescent lamp output due to biasing method for MOSFETs, in the future a scaling amplifier will be added to condition the PWM signal –Embedded computer safety ground must be disconnected when operating Fluorescent controller –Strobing test was not performed because software integration was not complete –Lamp voltage regulation test showed that the embedded computer’s A/D board and driver was not fast enough to regulate the lamp voltage

Department of Electrical and Computer Engineering Conclusions and Future Work Project scope was large Four systems total Both CE/EE skills required Main functions were implemented successfully Project cost were higher than expected Improvements/optimizations can be made Advisor has expressed interest in continuing project in future semester Advisor has expressed an interest in co-authoring a paper based on the Lighting Tool Box

Department of Electrical and Computer Engineering Acknowledgements Individuals Professor Miller –Support with electronic design –Donation of material –Providing us with a lab Professor Shridhar –Allowing a project this large with 5 members Companies Stancor – Donation of $ in power supply transformers Bud Industries – Donation of electronic enclosure for LED light controller GNU – For open source software Linux – For open source Kernel

Department of Electrical and Computer Engineering Data Flow Graphic Hardware Software Web Service lightingtoolbox.com Console void main() { Cout<<“Hello World”; Cout<<endl; Cout<<“GNU/Linux is good”; }

Department of Electrical and Computer Engineering Pictures