EZ Mash A.B.S. Jason Galloway John Cox Justin Crandall Georgia Institute of Technology 10/20/08

Project Overview What: A batch process system to automatically convert grain starches into sugars, a critical component of beer production. What: A batch process system to automatically convert grain starches into sugars, a critical component of beer production. Why: Will cut time from 3-4 hours to approx. one hour, better recipe repeatability. Why: Will cut time from 3-4 hours to approx. one hour, better recipe repeatability. Who: Home and commercial brewer. Who: Home and commercial brewer. Cost: $27,350 ($ $27K) Cost: $27,350 ($ $27K)

Design Objectives Inputting brewing parameters, such as start time and mash temperature in GUI. Inputting brewing parameters, such as start time and mash temperature in GUI. Implement PID loop to maintain set-point temperatures within 1 °F of target. Implement PID loop to maintain set-point temperatures within 1 °F of target. Designed to draw less than 12 Amps. Designed to draw less than 12 Amps. Strive to use materials that can withstand high temperatures up to 190 °F. Strive to use materials that can withstand high temperatures up to 190 °F.

Technical Approach – Hardware Design

Technical Approach- Temperature Set-Points Highest Mash Temp. = 170 °F. Highest Mash Temp. = 170 °F. Highest Water Temp. = 190 °F. Highest Water Temp. = 190 °F. Water Temp. Range = °F. Water Temp. Range = °F. +/- 1 degree differential to target set-point temp. +/- 1 degree differential to target set-point temp. Hold steady temperature in °F, set by user in GUI. Hold steady temperature in °F, set by user in GUI.

Technical Approach- Automation Controller Basic Stamp Basic Stamp Quick prototyping Quick prototyping Easy DAQ for PID loop tuning Easy DAQ for PID loop tuning 15 pins available for I/O 15 pins available for I/O I2C bus, allows extra I/O I2C bus, allows extra I/O (temperature sensors) (temperature sensors) 20 MHz ~ 4,000 instructions/sec 20 MHz ~ 4,000 instructions/sec

Technical Approach- Temperature Control DS1620-direct digital thermometer DS1620-direct digital thermometer PID Algorithm, programmed in BASIC PID Algorithm, programmed in BASIC Heat exchange in liquid bath. Heat exchange in liquid bath. Electric element provides 1125 Watts. Electric element provides 1125 Watts. Insulated Vessels Insulated Vessels

Technical Approach- Volume Management FlexiForce sensor to measure liquid volumes. FlexiForce sensor to measure liquid volumes. Magnetic drive pump with 7.2 gpm and maximum head 12.1 ft. Magnetic drive pump with 7.2 gpm and maximum head 12.1 ft. ½” nom. Copper and thermal plastic tubing. ½” nom. Copper and thermal plastic tubing. Direct acting solenoid valves. Direct acting solenoid valves.

Technical Approach - Connections

Technical Approach- Power Management and Circuit I2C Temp Sensors Control Module FlexiForce Sensor

Technical approach – GUI interface Allows user to input variables such as Mash time, set- point temperature, and start time. Allows user to input variables such as Mash time, set- point temperature, and start time. Provides a tool for analysis of step-response in order to tune the PID algorithm for optimal performance. Provides a tool for analysis of step-response in order to tune the PID algorithm for optimal performance.

Technical Approach - Flowchart

Demonstration Plan Brew a non-alcoholic pre-boil sugar solution (wort). Brew a non-alcoholic pre-boil sugar solution (wort). Demonstrate GUI and temperature management via data-logging. Demonstrate GUI and temperature management via data-logging. Success when pre-boil wort is produced by user input via GUI interface without off- flavors. Success when pre-boil wort is produced by user input via GUI interface without off- flavors.

Project Schedule Build thermowell for DS1621 sensors: 10/22 Build thermowell for DS1621 sensors: 10/22 Complete FlexiForce volume sensor: 10/22 Complete FlexiForce volume sensor: 10/22 Prototype Power Circuit: 10/29 Prototype Power Circuit: 10/29 PID Loop and Tuning: 11/5 PID Loop and Tuning: 11/5 Program StampPlot Macro: 11/12 Program StampPlot Macro: 11/12 Test Run using water: 11/19 Test Run using water: 11/19

Current Status of Project Assembly of hardware, including recirculation system, insulated vessels, and solenoid valves complete. Assembly of hardware, including recirculation system, insulated vessels, and solenoid valves complete. Temperature sensors interfaced, pressure sensor reading linear voltage relationship to pressure. Temperature sensors interfaced, pressure sensor reading linear voltage relationship to pressure. Prototype control circuit assembled, power circuit near completion. Prototype control circuit assembled, power circuit near completion.