Lighting Tool Box Machine Vision Lighting Team Members: B. Thompson N. Sitarski B. Harris D. Chronicle V. Gergov Advisor: J. W. Miller University of Michigan-Dearborn

Introduction to Lighting Tool Box Lighting Tool Box system function and purpose Lighting Tool Box components LED Light Controller Incandescent Light Controller Florescent Lamp Controller Computer

Design Objectives The goal is to design and implement three lighting systems that can be remotely controlled via the internet or locally in a stand alone configuration.

Implementation Choices Linux/GNU Operating System Stability Cost Scalability Open Source PC104 Embedded System Size Heat-load No moving parts

Implementation Choices cont. Custom hardware for lighting controllers Off the shelf products are non-existent Flexibility to make changes Cost

High Level System Block Diagram Incandescent Server (PC104) Incandescent Light System Web Cam LED Ring Light Internet Light System Fluorescent Fluorescent Light System Client

High Level Block Diagram Incandescent Lighting controller 120V AC Power Supply Light GND MOSFET LPF Driver PWM Local/Remote

Low Level Block Diagram Power Supply Vin 120 V RMS Vout 12 Volts to 18 Volts Unregulated Rectifier Circuit has a PIV of 36 Volts Diodes Rated at 50 Volts Maximum Current of Circuit is 20 Amps Capacitor was Calculated with I=C*(dv/dt) , C = (20 (amps) * 8 (ms)) / 6 (V) = 27,000 uF 68,000 uF Electrolytic was the value closest to the calculated value

Low Level Block Diagram Signal Conditioner Differential Amplifier measures voltage across lamp Scales voltage to level compatible with computer input Provides Isolation between lamp circuit and computer

Low Level Block Diagram MOSFET Driver MOSFET operated in saturation region of curve Provides efficient switching to lamp load Low heat dissipation

High Level Block Diagram LED Light Controller System Health Power Supply 12 VDC 5 VDC PWM Oscillator Select Logic MOSFET Driver LED Light Ring Remote PWM External Sync

Schematic Diagram Power Supply

Schematic Diagram Select Logic

Over Voltage Alarm Circuit

PWM Oscillator 40 KHz

Commercially Available Ring Lights

Bright Field vs. Dark field Bright Field - Light is aimed directly at an object, often creating distinct shadows. Effective for high degrees of contrast, but can creates specular reflections Dark Field – Light is projected at an angle to the surface, causing any variations to deflect light up into the camera. Nothing is seen by the vision system if there are no aberrations on the surface.

High Level Block Diagram Fluorescent Lighting Controller Circular Fluorescent Lamp Server (PC104) Fluorescent Controller

Fluorescent Lamp Intensity control circuit schematic

Project Changes Lighting controllers will have the capability of being controlled in stand alone configuration.

Dave And Vladi’s Completed Tasks Acquired all needed parts (PC104, I/O Board, 2.5” HDD, Flash, Web Cam, Enclosures, Misc.) Assembled PC104 and Modules Installed/Streamlined Debian GNU/Linux OS on PC104 (under 100 MB compared with ~1.2 GB min Windows install ) Custom Linux Kernel 2.4.23 configured and compiled with i586 optimization, preemptive task scheduler, and low latency patches Web Cam Installed and configured with our kernel Web Site code completed in PHP, XHTML 1.0 Strict, and CSS 2.0 in accordance with W3C standards Web Site daemon control module Coded Web Cam Snapshot BASH Script Coded

Dave and Vladi’s Remaining Tasks Digital I/O Card integration into our kernel Digital I/O daemon control code Testing of code with actual lighting systems Achieve system boot time of ~ 3 sec Miscellaneous enhancements of code and Operating System

Nick’s Completed Tasks Power Supply design, test, and construction MOSFET Driver Circuit design, test, and construction Lamp Filter design, test and construction Lamp Head design and construction Heat sinks have been sized and installed on high temperature components All components have been installed and tested in a commercially available electronics cabinet, unit is fully functional in local mode of operation

Nick’s Remaining Tasks Implement computer interface circuit Integrated test of finished product

Blaine’s Completed Tasks Regulated Power Supply design, test, and construction MOSFET Driver Circuit design, test, and construction Strobe circuit design, test and construction Remote/ Local select logic design, test, and construction LED Ring Light Head design and construction Heat sinks have been sized and installed on high temperature components Computer interface circuit All components have been installed and tested in a commercially available electronics cabinet, unit is fully functional in local mode of operation

Blaine’s Remaining Tasks Integrated system test Possible additional Ring Light configurations

Brandon’s Completed Tasks Dimmable (from 1 to 100%) 32 watt fluorescent lamp dimmer circuit assembled on board 0-5VDC intensity control circuit System test with 32 watt lamp

Brandon’s Remaining Tasks Install components in cabinet Construct shadow box for transmitted lighting applications Research circuit modification requirements to operate a 40 watt lamp Integrated system test

Timeline for Remaining Tasks February 1-14 15-28 March 1-15 March 16-31 April 1-25 Implement computer interface hardware Debug computer interface hardware Develop PWM code Integrated System Test Refine and debug computer interface software Prepare for demonstration Give Demonstration Complete Final Report

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