Lighting Tool Box Lighting Tool Box

Machine Vision LightingMachine Vision Lighting Team Members:Team Members: B. ThompsonB. Thompson

N. SitarskiN. Sitarski

B. HarrisB. Harris

D. ChronicleD. Chronicle

V. GergovV. Gergov

Advisor: Advisor: J. W. MillerJ. W. Miller

University of Michigan-DearbornUniversity of Michigan-Dearborn

Introduction to Lighting Tool BoxIntroduction to Lighting Tool Box

Lighting Tool Box system function and Lighting Tool Box system function and purposepurpose

Lighting Tool Box componentsLighting Tool Box components– LED Light ControllerLED Light Controller– Incandescent Light ControllerIncandescent Light Controller– Florescent Lamp ControllerFlorescent Lamp Controller– ComputerComputer

Design ObjectivesDesign Objectives

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

Implementation ChoicesImplementation Choices

Linux/GNU Operating SystemLinux/GNU Operating System– StabilityStability– CostCost– ScalabilityScalability– Open SourceOpen Source

PC104 Embedded SystemPC104 Embedded System– SizeSize– Heat-loadHeat-load– No moving partsNo 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 DiagramHigh Level System Block Diagram

Server(PC104)

Incandescent

LED

Fluorescent

Light System

Light System

Light SystemClient

Internet

Web Cam

Incandescent

RingLight

Fluorescent

High Level Block Diagram Incandescent High Level Block Diagram Incandescent Lighting controllerLighting controller

Power Supply

120V ACLight

MOSFET

PWM

Local/Remote

LPFGND

Driver

Low Level Block Diagram Low Level Block Diagram Power SupplyPower 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 Low Level Block Diagram Signal ConditionerSignal 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 Low Level Block Diagram MOSFET DriverMOSFET Driver

MOSFET operated in saturation region of curve

Provides efficient switching to lamp load

Low heat dissipation

High Level Block Diagram LED Light Controller

LED Light Ring

PWMOscillator

MOSFETDriver

PowerSupply

12 VDC5 VDC

SelectLogic

Remote PWM

ExternalSync

System Health

Schematic Diagram Schematic Diagram Power SupplyPower Supply

Schematic Diagram Schematic Diagram Select LogicSelect 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

CircularFluorescentLamp

FluorescentController

Server(PC104)

Fluorescent Lamp Intensity control circuit schematic

Project ChangesProject Changes

Lighting controllers will have the capability of Lighting controllers will have the capability of being controlled in stand alone configuration.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 TasksTimeline for Remaining Tasks

February February

1-141-14

February February

15-2815-28

MarchMarch1-151-15

MarchMarch

16-3116-31

AprilApril

1-251-25

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

FeedbackFeedback

Any questions, comments, or suggestions?Any questions, comments, or suggestions?