Upload
kory-banks
View
214
Download
0
Tags:
Embed Size (px)
Citation preview
Viking Pump Viking Pump Flow Manager - Flow Manager -
Phase 2 Phase 2 Senior DesignSenior Design
May 06-12May 06-12
PeoplePeople
Team MembersTeam Members Dwayne Stammer - CprEDwayne Stammer - CprE Francois Munyakazi – EEFrancois Munyakazi – EE Dan Paulsen – CprE/EEDan Paulsen – CprE/EE
Faculty AdvisorFaculty Advisor Nicola EliaNicola Elia
Client InfoClient Info Viking Pump Inc.Viking Pump Inc.
OutlineOutline Introduction and problem statement – Dan Introduction and problem statement – Dan
PaulsenPaulsen Design and implantation – Dwayne StammerDesign and implantation – Dwayne Stammer Schedule, financial, and closing – Francois Schedule, financial, and closing – Francois
MunyakaziMunyakazi Future Work – TeamFuture Work – Team
DefinitionsDefinitions Flow meter:Flow meter: An instrument used to measure An instrument used to measure
pressure, flow rate, and discharge rate of a pressure, flow rate, and discharge rate of a liquid, vapor, or gas flowing in a pipeliquid, vapor, or gas flowing in a pipe
Set point:Set point: The speed that a pump has to The speed that a pump has to rotate in order to achieve a given flow or rotate in order to achieve a given flow or output pressureoutput pressure
Viscous: Viscous: Having a relatively high resistance Having a relatively high resistance to flowto flow
QVGA: QVGA: 4x6 inch high resolution touch 4x6 inch high resolution touch screen, has onboard analog voltage inputs screen, has onboard analog voltage inputs and outputsand outputs
Problem StatementProblem Statement
Design a system to do the followingDesign a system to do the following Control a pump to maintain a given flow Control a pump to maintain a given flow
using only speed, pressure, and using only speed, pressure, and temperature measurementstemperature measurements
Provide an easier user interface to Provide an easier user interface to control flow rate and other working control flow rate and other working parametersparameters
Provide access to system through serial Provide access to system through serial busbus
Why?Why?
Why is this valuable?Why is this valuable? Measuring flow for viscous fluids is very hardMeasuring flow for viscous fluids is very hard Less parts needed to build a pumping systemLess parts needed to build a pumping system Has many other uses such as batch flow, and Has many other uses such as batch flow, and
error detectionerror detection Inline meters to measure flow can hinder flow Inline meters to measure flow can hinder flow
performanceperformance Problems with current systemProblems with current system
Hardware out of dateHardware out of date User interface is outdated and difficult to useUser interface is outdated and difficult to use
System UseSystem Use
System will be configured and run System will be configured and run by trained techniciansby trained technicians
Will operate in harsh “factory floor” Will operate in harsh “factory floor” environmentsenvironments Temperatures ranging from 40° to
120°F Long periods of use
AssumptionsAssumptions
Inputs from the system will be:Inputs from the system will be: Inlet pressure – input voltageInlet pressure – input voltage Outlet pressure – input voltageOutlet pressure – input voltage Temperature of the fluid – input voltageTemperature of the fluid – input voltage Current pump speed – input voltage pulseCurrent pump speed – input voltage pulse
- 60 pulses/revolution - 60 pulses/revolution Outputs to the system will be:Outputs to the system will be:
4-20mA signal to DC Drive4-20mA signal to DC Drive
LimitationsLimitations
The controller must be able to The controller must be able to operate in a real time environmentoperate in a real time environment
The software implementation must be The software implementation must be portableportable
The controller solution must be The controller solution must be economicaleconomical
The controller must be able to control The controller must be able to control the actual flow within 0.25% of the the actual flow within 0.25% of the set pointset point
End ProductEnd Product
Implementation for basic prototype Implementation for basic prototype that properly controls pump systemthat properly controls pump system
Documentation of controller and Documentation of controller and source codesource code
Problem DefinitionProblem Definition
Current flow manager is difficult to use Current flow manager is difficult to use and obsoleteand obsolete User interface needs updated to a much User interface needs updated to a much
more intuitive interfacemore intuitive interface Will be solved using a new touch screen Will be solved using a new touch screen
interfaceinterface Hardware used is no longer available Hardware used is no longer available
because it was custom made to the because it was custom made to the applicationapplication
Will be solved using over the shelf partsWill be solved using over the shelf parts Writing software with different hardware Writing software with different hardware
platforms in mindplatforms in mind
System OverviewSystem Overview
Pump
Pressure Readouts
Pressure Gauges
Thermometer
Flow meterPressure Relief Valve
Revolution CounterMotor
Flow
Flow Meter Readout
System OverviewSystem Overview
Four inputsFour inputs Inlet pressureInlet pressure Output pressureOutput pressure Fluid Temperature (to determine Fluid Temperature (to determine
viscosity)viscosity) Pump RPMPump RPM
One outputOne output Desired motor speedDesired motor speed
Previous ModelPrevious Model
Outdated User InterfaceOutdated User Interface
The current Flow Manager provides the user with a less-than-intuitive interface. Certain combinations of button presses will change its operational state. Our primary goal is to develop a user interface that is easier to use and incorporates all warning lights into the touch screen.
Updated ModelUpdated Model
Touch screen user interfaceTouch screen user interface Updated C codeUpdated C code Standardized equipment (not as Standardized equipment (not as
much customized circuitry required)much customized circuitry required) PC interface with more advanced PC interface with more advanced
GUI featuresGUI features
Updated ModelUpdated Model
Standardized equipmentStandardized equipment
The QVGA controller card provides touch screen capabilities delivered through a C library. It also supports digital and analog I/O. This eliminates the need for fully customized circuits, thus reducing production cost.
Personal EffortPersonal Effort
Dwayne Stammer, 275
Dan Paulsen, 225
Francois Munyakazi,
200
John Taylor , 104
Cliff Pisent, 35
Total hours: 839
QVGA RepairQVGA Repair $250$250 Provided by Senior DesignProvided by Senior DesignPump equipmentPump equipment $0$0 Donated by VikingDonated by VikingMiscellaneous partsMiscellaneous parts $175$175 Viking/Group membersViking/Group members
Poster Poster $40$40 Group membersGroup membersTotal material cost:Total material cost: $465$465
Total material costTotal material cost Labor (839hrs @ $11.00) $9,229.00Labor (839hrs @ $11.00) $9,229.00 MaterialsMaterials 465.00 465.00 Total cost of project:Total cost of project: $9,694.00 $9,694.00
7,525.50 Previous group7,525.50 Previous group Project Total thus farProject Total thus far $17,219.50 $17,219.50
Project CostsProject Costs
What Went WellWhat Went Well
Some part were easy to get from Some part were easy to get from common store common store
Design of project was easy, important Design of project was easy, important decisions already made by previous decisions already made by previous teamteam
Communication between components Communication between components was fairly wellwas fairly well
Good Coordination between team Good Coordination between team membersmembers
What Didn’t Go WellWhat Didn’t Go Well
Understanding the definition of the Understanding the definition of the projectproject
Learning how to interface with the Learning how to interface with the pumppump QVGA was damaged because we did not QVGA was damaged because we did not
understand how the pieces should work understand how the pieces should work together.together.
Dealt with odd behavior with parts which Dealt with odd behavior with parts which were out of the scope of our project.were out of the scope of our project.
Communication with sensors and QVGACommunication with sensors and QVGA
Knowledge GainedKnowledge Gained
Learned the control algorithms for Learned the control algorithms for pump flowspump flows
Learned How to program the QVGALearned How to program the QVGA Developed team communicationDeveloped team communication Learned how to effectively distribute Learned how to effectively distribute
work loads among team memberswork loads among team members Learned how to better work with Learned how to better work with
clients while keeping a project on clients while keeping a project on tracktrack
Risk ManagementRisk Management
Anticipated risksAnticipated risks Loss of codeLoss of code Loss of team memberLoss of team member
Anticipated risks encounteredAnticipated risks encountered Loss of team member Loss of team member
John Taylor went to internship John Taylor went to internship Cliff Pinsent graduatedCliff Pinsent graduated
Unanticipated risks encounteredUnanticipated risks encountered Damage of the QVGADamage of the QVGA
Work CompletedWork Completed
Repair QVGARepair QVGA Acquired model from VikingAcquired model from Viking Studied algorithm and controllersStudied algorithm and controllers Designed and prototyped GUI screensDesigned and prototyped GUI screens Detected I/O of QVGADetected I/O of QVGA Wrote C code and serial codeWrote C code and serial code Build pump interface between QVGA and Build pump interface between QVGA and
pumppump Designed circuitry for sensor testing and Designed circuitry for sensor testing and
QVGAQVGA
Work Completed Cont.Work Completed Cont.
80% Completed writing / debugging 80% Completed writing / debugging the C code to control flowthe C code to control flow
80% write and implement the full 80% write and implement the full GUIGUI
Created a methodology for the Created a methodology for the QVGA to be controlled via serial QVGA to be controlled via serial comm.comm.
ClosingClosing
The previous version of the product The previous version of the product Pros: Has a very large successPros: Has a very large success Cons: User interfaceCons: User interface The lack of user friendliness of the The lack of user friendliness of the
device even thought it is still the best device even thought it is still the best device on the marketdevice on the market
Closing Cont.Closing Cont.
Viking Pumps needs a well-designed Viking Pumps needs a well-designed flow control manager flow control manager To be used with already existing pumps. To be used with already existing pumps.
Cost effectiveCost effective PortabilityPortability
Moving from one hardware to another Moving from one hardware to another without major software reworkwithout major software rework