Viking Pump Flow Manager - Phase 2

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

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

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

4. Definitions 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 Viscous: Having a relatively high resistance to flow QVGA: 4x6 inch high resolution touch screen, has onboard analog voltage inputs and outputs

5. Problem Statement Design a system to do the following 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 access to system through serial bus

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and error detection Inline meters to measure flow can hinder flow performance Problems with current system Hardware out of date User interface is outdated and difficult to use

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

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

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

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

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

12. System Overview

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

14. Previous Model Outdated User Interface

15. Previous Model

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

17. Updated Model Standardized equipment

18. Updated Model PC interface

19. Updated Interface Circuitry

20. Updated Graphical Interface The flow menu will allow the user to input and update the desired flow rate. This design is preliminary and should be modified to include greater functionality.The flow menu will allow the user to input and update the desired flow rate. This design is preliminary and should be modified to include greater functionality.

21. Initial Performance Measurement

22. Updated Flow Manager

23. Algorithm Performance

24. Schedule

25. Personal Effort

26. QVGA Repair $250 Provided by Senior Design Pump equipment $0 Donated by Viking Miscellaneous parts $175 Viking/Group members Poster $40 Group members Total material cost: $465 Total material cost Labor (839hrs @ $11.00) $9,229.00 Materials 465.00 Total cost of project: $9,694.00 7,525.50 Previous group Project Total thus far $17,219.50 Project Costs

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

28. What Didn’t Go Well Understanding the definition of the project Learning how to interface with the pump 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. Communication with sensors and QVGA

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

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

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

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

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

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

35. Questions?