Long Range Wireless Mesh Network System Team 4B Kyle Sparger Jason Easterlund Francis Koskei Sponsors: Ryan Ashbaugh Paul Heerwagen from Red River Automation

Project Description Wireless mesh network which will interface with a Yaskawa F7 VSD (Variable Speed Drive), which controls a pumping unit. The VSDs will be scattered across large fields with distances up to 20 miles between them. The VSDs will be monitored and controlled from a central station (head-in unit). This station will have a high speed internet connection to allow remote monitoring of the site.

Requirements Wireless Unit – Free non-licensed frequency range (900MHz) – Temperature up to 70° C – Range up to 20 miles – $100 per unit – Ideally VAC 50/60Hz or 24VDC – Use RS485 for serial communication with VSD – Use FHSS for security – Support up to 300 devices – Peer-to-peer networking Software – Intuitive GUI interface – Capable of controlling all VSDs – Capable of monitoring all VSDs – Show alerts if a VSD shuts down (within 10 min) – Programmable data collection rate – Remote Accessibility (over Internet) – Run on Windows machines

Flowchart I (uP)

Flowchart II (PC)

Functional Block Diagram

Labor Costs With a Yearly Salary $60,000 And an Overhead Rate of 85% The Effective Cost is $53.37 per hour Estimated Overall Labor Cost: $25, Actual Overall Labor Cost: $ The Cost Difference is: -$ The Hour Difference is: 5 hours MemberTotal Working Hours (Projected)Total Working Hours (Actual) Kyle Sparger155 hours235 hours Jason Easterlund178 hours198 hours Francis Koskei143 hours38 hours Team Total Hours476 hours471 hours

Parts Cost for Development The total cost of parts for development was $ The breakdown of the cost per part can be seen in the table to the left ItemCost ($)QuantityTotal ($) AC4790 (200mW) Dev Kit+ CL4790 (1W) M68HC12 Dev Boards020 PC w/serial port020 Miscellaneous (PCB, other electronics) Power Supply (Test model) (see table below) VSD plus Power Converter010 Grand Total Voltage Supply Parts Cost Breakdown (different Quantities) PartPart NumberDist.Distributor Part # V reg.KA7805ATUMouser512-KA7805ATU V reg.KA278R33CTSTUMouser512-KA278R33CTSTU TransformerVPP Mouser553-VPP RectifierRS402LMouser583-RS402L uF CapKME35VB101M8X11LLMouser661-KME35VB101MLL uF CapKME25VB47RM5X11LLMouser661- KME25VB47RMLL uF CapSME16VB22RM5X11LLMouser661- SME16VB22RMLL Total ($)

Maximum Configuration Parts Cost per Wireless Unit (20 mile range / AC or DC input voltage) PartPart NumberDist.Distributor Part # TransceiverAC MMouser814-AC M HC12MC9S12C32MFU25Digi-keyMC9S12C32MFU25-ND RS-485 Chip MAX488CPA Digi-key MAX488CPA-ND Antenna Mouser PCB Board12 sq. inexpressPCBN/A Power Circuit See Table 2 N/A Total ($) Parts Cost for Maximum Configuration

Minimum Configuration Parts Cost per Wireless Unit (2 mile range / DC input voltage) PartPart NumberDist.Distributor Part # TransceiverAC MMouser814-AC M HC12MC9S12C32MFU25Digi-keyMC9S12C32MFU25-ND RS-485 Chip MAX488CPA Digi-key MAX488CPA-ND PCB Board12 sq. inexpressPCBN/A Power Circuit See Table 2 N/Aminus trans. and rectifier Total ($) Parts Cost for Minimum Configuration

Schedule (Gantt Chart)

Results Ability to read and write (local) the VSD registers Communication over wireless link using AC4790 transceivers GUI interface monitors VSD register values over the wireless link Does not send alert if value is out of range – Code in place, but not tested (time issue) No Mesh networking (time issue) – Only point-to-point

Recommendations Program uP with C – Easier to debug – Faster to develop – Better portability Add better error handling – Timeout feature for sending/receiving – Send error message if communication with VSD stops Develop a PCB for the project Develop routing protocol for mesh networking capability. Be aware of misleading documentation for AC4790