Calvin College Senior Design Team 11 Aaron Maley Jeff Overweg Simeon Eisen Jacob VanderWall

T HE T EAM Simeon Eisen Jeff Overweg Aaron Maley Jacob VanderWall

A N ICHE IN THE M ARKET There are current pool care systems, but they are not created and marketed to the average residential pool owner. Current systems range in price from $1200-$7000 for just the controller alone A product with the features of the high end systems, at a price that residential pool owners can afford would be a very viable real world product

T HE P ROJECT To create an affordable chemical control system for the residential pool market. What Does it Do? Sample pool water at regular intervals Microprocessor controlled system Dispense chemicals into the pool pump system Granule feed system Broadcast pool data via website Wireless module

M ICROCONTROLLER S YSTEM Goal: Use an embedded microcontroller to control water testing, chemical dispersal, local display, and data being sent to web server. Major Components and Interfaces: Sensors and Related Circuits Chemical Dispersal Control Local Display/User Interface Analog Data to Web Server

M ICROCONTROLLER S YSTEM Full System Diagram

M ICROCONTROLLER S YSTEM Sensors and Related Circuits Three main sensor inputs Temp, pH, ORP How are the amounts of Chemicals Needed Calculated? pH, ORP, temperature readings and size of pool are used to calculate the required dosage Dosage precision can exceed 0.25 oz

F REE C HLORINE C ALCULATION

M ICROCONTROLLER S YSTEM Local Display/User Interface Graphic LCD Touch Screen Interface What does this allow the user to do? Directly view relevant information Calibrate probes and sensors Define parameters such as: Pool Volume Pump Cycle Time

M ICROCONTROLLER S YSTEM Data to Web Server Analog Level Created with: PWM signals passed through a low pass filter How does the Web Server Interpret Values? Varying Duty Cycles Form Different Voltage Levels Communication Specification for Analog Interpretation Defines Relationships

M ICROCONTROLLER S YSTEM Chemical Dispersal Control Digital Control Logic (Stepper Motor Control) Solenoid Valve Channel Control How the System Disperses the Chemicals

I NSTRUMENTATION S ETUP Sensor Chamber Design

D ISPENSER Goal: To create an interface that would utilize the existing pool pump and filter system to dispense and mix chemicals into the pool water. Two distinct elements Auger Based Dispenser Diverted Mixing Chamber

M ECHANICAL S ETUP Final Mechanical Implementation Pool Filter Pump Sensor Chamber Dispenser

M ECHANICAL S ETUP Dispenser System Design

M ECHANICAL S ETUP Dispenser Prototype

W ORKING C OMPONENTS

D ISPENSING C ALIBRATION

S TEPPER M OTOR AND S OLENOID C ONTROL

W IRELESS W EB S ERVER Goal: To create a basic web server in order to wirelessly broadcast system readings to the consumer. Main Components b Chip/Security Settings Analog Input/Calculations Website Design

W IRELESS W EB S ERVER b Chip/Security Settings Chip/Development Board Selection Arduino Development Kit Wishield Security Capabilities Compatible with modern b/g routers Can utilize 64bit WEP, WPA, WPA2 encryption

W IRELESS W EB S ERVER Analog Input Calculations Varying Duty Cycles + Low Pass Filter Analog Voltage 0V – 5V Communication Specification Determines pH, ORP, Chemical Status, Temperature Calculation of Free Chlorine PWM Volts Analog Low-Pass Filter

W IRELESS W EB S ERVER Page Design

W IRELESS W EB S ERVER System Block Diagram

C OMPETITIVE A NALYSIS Main Competitors: Chemtrol CAT Aquasol Competitor’s System FeaturesPrice Chemtrol 250pH and ORP Controller$ CAT 4000pH and ORP Controller + Web Monitoring $ Aquasol SPC Controller pH and ORP Controller$ Chemtrol PC2000pH, free Chlorine, Remote interface$

S ALES & M ARKETING Customer Base Existing( US alone) 5.1 million in-ground pools 3.7 million above-ground pools Growth( Based on 2007) 131,000 new in-ground pools 233,000 new above-ground pools Target Demographic Work with BUS 397 Advanced Marketing Class Middle-aged to Elderly in Average Middle to Upper Middle Class Homes

G OING B EYOND Different ways project could be enhanced or developed further. Expand Wireless Capability and Complexity Add Online Data Logging Add Wireless System Control Use Precision Designed Mechanical Parts Integrate onto single PCB Develop Business Plan as a Distributer and/or a Supplier

A CKNOWLEDGEMENTS Tim Theriault– Industrial Consultant Prof. VanderLeest – Team Advisor Brian Honeck, Eric Walstra, Darryl DeBruin – CEAC Reviewers Bob DeKraker – Parts Ordering Phil Jasperse – Shop Help

Q UESTIONS