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ECE504 ST Project Jeff Rice

ECE504 ST Project Jeff Rice. Arduino Based Temperature Controller, Ethernet Enabled **Please Click on Icon to Hear Sound, then click On slide when sound over to advance**. Presentation Structure. Arduino Overview Review of Temperature Controller Project stages and results

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ECE504 ST Project Jeff Rice

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  1. ECE504 ST ProjectJeff Rice Arduino Based Temperature Controller, Ethernet Enabled **Please Click on Icon to Hear Sound, then click On slide when sound over to advance**

  2. Presentation Structure • Arduino Overview • Review of Temperature Controller Project stages and results • Microprocessors role in industrial & utility controllers

  3. Arduino Overview Pin connectors for I/O Serial port interface (SPI) Crystal Oscillator (clock source) USB port and onboard USB-serial chip allows easy programming in C language Volt Regulator – to allow wide input voltage range Brains – Atmel ATMega RISC microprocessor with pre-loaded bootloader Result - $30 microproc. Based dev. Development board with wide usage and many open source libraries.

  4. Arduino: Open Source Enabled Actuators: LEDs, Solenoids, Motors Peripherals: LCDs, remote I/O (I2C) Direct Inputs: Heat, Light, Motion Arduino Board • Libraries • LCD • I2C • PID • CapSense • LowPower • Modbus • Zigbee • X10 (PLC) • Servo • SD Card • Stepper Motor • Text Messaging • Printing • Tones PC or Mac running Arduino IDE

  5. Arduino History

  6. Thyristor Review • Thyristors are widely used three terminal power semiconductors – if you gate it the unit conducts until reversed biased. • Mature technology, mass produced and widely used for motor drives & inverters • Gate not isolated from Cathode

  7. Thyristor Trouble (continued) • 5v gate signal driven by micro and power supply, thyristor cathode and anode hooked to AC mains supply.

  8. Using a Solid State Relay • Duty cycle control over 1 second interval • 120 segment resolution (# of half sine waves)

  9. Image by Tony van Roon (http://www.sentex.ca/~mec1995/gadgets/relays/relays.html)

  10. Hardware Setup AC Breaker Digital Temperature Sensor Arduino Local LCD HMI Heating Element Solid State Relay

  11. PID Control Loops Overview • PID Loops: very common control loop • PID = Proportional, Integral, Derivative • Controlled Variable, Setpoint, Output Image source = Wikipedia http://en.wikipedia.org/wiki/File:PID_en.svg

  12. Simple Web Setup Any Computer with a Web Browser Web Browser Ethernet Ethernet Expansion Board with Wiznet 5100 TCP/IP Chip Arduino Unit PID Library Ethernet Library SSR Firing Routine One Wire Comm.

  13. Simple Web Result • Virtual Emulation of Local LCD Display with ability to change setpoint

  14. Full HMI Setup Inductive Automation Ignition Runtime and IDE Status Module HMI IDE and Runtime Historian Database & Drivers OPC Kepware I/O Server USB Arduino Unit PID Library Modbus Library Register Data SSR Firing Routine I2C Comm

  15. Kepware I/O Server • Handles communication to hardware, data concentration and status flagging

  16. Ignition HMI (Platform Monitor)

  17. Need for Local Control • Note that processor controls the process, not the HMI. • No critical process data routed through HMI. • LCD Serves as Backup indication • Typically a real critical process would have a “hard” backup to the controller

  18. Arduino Ethernet boardSecurity Issues • Based on Wiznet5100 chip • Found published errata on chip

  19. Bridge to PLCs • In Process Control we don’t hear people talk about • Microprocessors • Libraries and common code • Instead Industrial vendors either • Develop everything themselves • package chipsets and libraries in their own “wrappers”

  20. GE Fanuc VersaMaxMicroController One of the more common GE micro PLCs

  21. GE Versamax Micro PLC Innards IO Board RELAYS CPU/Comm Board Terminals

  22. GE Labeled, But Made By….Someone Else? Renesas microprocessor Hitachi manufactured PCB

  23. PLC Demolition Results • If we can extrapolate from this one example: • Although PLCs looks like custom built pieces of proprietary hardware and software… • The industry reuses technology and components. Use of such third party hardware and software can open the doors of information to mal – actors

  24. Presentation Conclusion • Learning / Research project • Gained experience with Arduino, Processing, Libraries and C language, Modbus protocol, GE PLCs, One Wire protocol, Thyristors and Solid State Relays and Ignition HMI platform. • Hopefully some of this was passed on in the presentation!

  25. Questions? • Jeffrey.wallace.rice@gmail.com • Thanks for listening!

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