Viking Pump Flow Manager - Phase 2 Senior Design May 06-12

People Team Members Team Members Dwayne Stammer - CprE Dwayne Stammer - CprE Francois Munyakazi – EE Francois Munyakazi – EE Dan Paulsen – CprE/EE Dan Paulsen – CprE/EE Faculty Advisor Faculty Advisor Nicola Elia Nicola Elia Client Info Client Info Viking Pump Inc. Viking Pump Inc.

Outline Introduction and problem statement – Dan Paulsen Introduction and problem statement – Dan Paulsen Design and implantation – Dwayne Stammer Design and implantation – Dwayne Stammer Schedule, financial, and closing – Francois Munyakazi Schedule, financial, and closing – Francois Munyakazi Future Work – Team Future Work – Team

Definitions Flow meter: An instrument used to measure pressure, flow rate, and discharge rate of a liquid, vapor, or gas flowing in a pipe Flow meter: An instrument used to measure pressure, flow rate, and discharge rate of a liquid, vapor, or gas flowing in a pipe Set point: The speed that a pump has to rotate in order to achieve a given flow or output pressure Set point: The speed that a pump has to rotate in order to achieve a given flow or output pressure Viscous: Having a relatively high resistance to flow Viscous: Having a relatively high resistance to flow QVGA: 4x6 inch high resolution touch screen, has onboard analog voltage inputs and outputs QVGA: 4x6 inch high resolution touch screen, has onboard analog voltage inputs and outputs

Problem Statement Design a system to do the following Design a system to do the following Control a pump to maintain a given flow using only speed, pressure, and temperature measurements Control a pump to maintain a given flow using only speed, pressure, and temperature measurements Provide an easier user interface to control flow rate and other working parameters Provide an easier user interface to control flow rate and other working parameters Provide access to system through serial bus Provide access to system through serial bus

Why? Why is this valuable? Why is this valuable? Measuring flow for viscous fluids is very hard Measuring flow for viscous fluids is very hard Less parts needed to build a pumping system Less parts needed to build a pumping system Has many other uses such as batch flow, and error detection Has many other uses such as batch flow, and error detection Inline meters to measure flow can hinder flow performance Inline meters to measure flow can hinder flow performance Problems with current system Problems with current system Hardware out of date Hardware out of date User interface is outdated and difficult to use User interface is outdated and difficult to use

System Use System will be configured and run by trained technicians System will be configured and run by trained technicians Will operate in harsh “factory floor” environments Will operate in harsh “factory floor” environments Temperatures ranging from 40° to 120°F Long periods of use

Assumptions Inputs from the system will be: Inputs from the system will be: Inlet pressure – input voltage Inlet pressure – input voltage Outlet pressure – input voltage Outlet pressure – input voltage Temperature of the fluid – input voltage Temperature of the fluid – input voltage Current pump speed – input voltage pulse - 60 pulses/revolution Current pump speed – input voltage pulse - 60 pulses/revolution Outputs to the system will be: Outputs to the system will be: 4-20mA signal to DC Drive 4-20mA signal to DC Drive

Limitations The controller must be able to operate in a real time environment The controller must be able to operate in a real time environment The software implementation must be portable The software implementation must be portable The controller solution must be economical The controller solution must be economical The controller must be able to control the actual flow within 0.25% of the set point The controller must be able to control the actual flow within 0.25% of the set point

End Product Implementation for basic prototype that properly controls pump system Implementation for basic prototype that properly controls pump system Documentation of controller and source code Documentation of controller and source code

Problem Definition Current flow manager is difficult to use and obsolete Current flow manager is difficult to use and obsolete User interface needs updated to a much more intuitive interface User interface needs updated to a much more intuitive interface Will be solved using a new touch screen interface Will be solved using a new touch screen interface Hardware used is no longer available because it was custom made to the application Hardware used is no longer available because it was custom made to the application Will be solved using over the shelf parts Will be solved using over the shelf parts Writing software with different hardware platforms in mind Writing software with different hardware platforms in mind

System Overview Pump Pressure Readouts Pressure Gauges Thermometer Flow meter Pressure Relief Valve Revolution CounterMotor Flow Flow Meter Readout

System Overview Four inputs Four inputs Inlet pressure Inlet pressure Output pressure Output pressure Fluid Temperature (to determine viscosity) Fluid Temperature (to determine viscosity) Pump RPM Pump RPM One output One output Desired motor speed Desired motor speed

Previous Model Outdated 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.

Previous Model

Updated Model Touch screen user interface Touch screen user interface Updated C code Updated C code Standardized equipment (not as much customized circuitry required) Standardized equipment (not as much customized circuitry required) PC interface with more advanced GUI features PC interface with more advanced GUI features

Updated Model Standardized 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.

Updated Model PC interface

Updated Interface Circuitry

Updated Graphical Interface

Initial Performance Measurement Violet: Output SignalRed: Flow Rate

Updated Flow Manager

Algorithm Performance Blue: Set PointGreen: Flow RateOrange: Pressure

Schedule

Personal Effort Total hours: 839

QVGA Repair$250Provided by Senior Design QVGA Repair$250Provided by Senior Design Pump equipment$0Donated by Viking Miscellaneous parts$175Viking/Group members Poster $40Group members Total material cost:$465 Total material cost Total material cost Labor $11.00) $9, Labor $11.00) $9, Materials Materials Total cost of project: $9, Total cost of project: $9, , Previous group 7, Previous group Project Total thus far $17, Project Total thus far $17, Project Costs

What Went Well Some part were easy to get from common store Some part were easy to get from common store Design of project was easy, important decisions already made by previous team Design of project was easy, important decisions already made by previous team Communication between components was fairly well Communication between components was fairly well Good Coordination between team members Good Coordination between team members

What Didn’t Go Well Understanding the definition of the project Understanding the definition of the project Learning how to interface with the pump Learning how to interface with the pump QVGA was damaged because we did not understand how the pieces should work together. QVGA was damaged because we did not understand how the pieces should work together. Dealt with odd behavior with parts which were out of the scope of our project. Dealt with odd behavior with parts which were out of the scope of our project. Communication with sensors and QVGA Communication with sensors and QVGA

Knowledge Gained Learned the control algorithms for pump flows Learned the control algorithms for pump flows Learned How to program the QVGA Learned How to program the QVGA Developed team communication Developed team communication Learned how to effectively distribute work loads among team members Learned how to effectively distribute work loads among team members Learned how to better work with clients while keeping a project on track Learned how to better work with clients while keeping a project on track

Risk Management Anticipated risks Anticipated risks Loss of code Loss of code Loss of team member Loss of team member Anticipated risks encountered Anticipated risks encountered Loss of team member Loss of team member John Taylor went to internship John Taylor went to internship Cliff Pinsent graduated Cliff Pinsent graduated Unanticipated risks encountered Unanticipated risks encountered Damage of the QVGA Damage of the QVGA

Work Completed Repair QVGA Repair QVGA Acquired model from Viking Acquired model from Viking Studied algorithm and controllers Studied algorithm and controllers Designed and prototyped GUI screens Designed and prototyped GUI screens Detected I/O of QVGA Detected I/O of QVGA Wrote C code and serial code Wrote C code and serial code Build pump interface between QVGA and pump Build pump interface between QVGA and pump Designed circuitry for sensor testing and QVGA Designed circuitry for sensor testing and QVGA

Work Completed Cont. Work Completed Cont. 80% Completed writing / debugging the C code to control flow 80% Completed writing / debugging the C code to control flow 80% write and implement the full GUI 80% write and implement the full GUI Created a methodology for the QVGA to be controlled via serial comm. Created a methodology for the QVGA to be controlled via serial comm.

Closing The previous version of the product The previous version of the product Pros: Has a very large success Pros: Has a very large success Cons: User interface Cons: User interface The lack of user friendliness of the device even thought it is still the best device on the market The lack of user friendliness of the device even thought it is still the best device on the market

Closing Cont. Closing Cont. Viking Pumps needs a well-designed flow control manager Viking Pumps needs a well-designed flow control manager To be used with already existing pumps. To be used with already existing pumps. Cost effective Cost effective Portability Portability Moving from one hardware to another without major software rework Moving from one hardware to another without major software rework

Questions?