wireless user interface for variable frequency drives
DESCRIPTION
Sponsor: Lenze Advisor : Professor John Chandy. Wireless User Interface for Variable Frequency Drives. Team 168 Alex Shuster (EE) Michael Kloter (EE) Christopher Perugini (EE) Kevin Wei ( EngPhys - EE). Outline. Lenze Existing Problems Deliverables Solution Wireless Hardware - PowerPoint PPT PresentationTRANSCRIPT
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Wireless User Interface for Variable Frequency Drives
Team 168Alex Shuster (EE)Michael Kloter (EE)Christopher Perugini (EE)Kevin Wei (EngPhys - EE)
Sponsor: Lenze Advisor: Professor John Chandy
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Outline• Lenze
• Existing Problems
• Deliverables
• Solution▫Wireless▫Hardware
▫Network Topology
▫Transmission
▫Adaptation
• Budget
• Project Summary
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Lenze
Provide Motor Control Solutions• Automotive Construction• Robotics• Manufacturing and Packaging
Variable Frequency Drives• Speed and Control System for AC motor
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Existing Problems and Deliverables
Current Problems• Hardwired Communication• Manually Set Parameters• Limited Accessibility
Objectives • Develop VFD Wireless Interface• Maximize Transmission Distance• Multi VFD Operation• Industrial Grade
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Wireless SolutionCommunication Options:
• Wi-Fi• Bluetooth• ZigBee
Wireless Communication Choice: ZigBee• 10-100m / Node • Unlimited Range Extension• Low Cost• Industrial Operation
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Hardware Solution
B&B Electronics USOPTL4• USB Serial Converter• Transforms Serial
Signal to RS-485
Sparkfun ATMega128RFA1• MCU and ZigBee
Transceiver Combo• Cost Effective• Compact Size
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Hardware ConstraintsMCU/Transceiver:
• Communicates using TTL levels• VFD requires RS-485 levels
Reference Voltage Conflict: RS-485 vs TTL
Solution:• Breakout Board Switching• MCU Code Modification
RS-485 TTL
High Reference Level
+200mV Differential 3.3V
Low Reference Level
-200mV Differential 0V
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Software Stack Solution
• Basic Data Services
• Routing
• Power Management
• Network Management
• Data Failure Correction
• Message Payload Formatting
• Advanced Security
• MCU Power Management
• Hardware Peripheral Interface
Lightweight Mesh
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Transceiver Scheme SelectionOptions:• FIFO Byte by Byte
▫Buffer vectors inserted in payload frame as received• FIFO Message
▫Waits for full message before sent to payload frame
Framing Choice: FIFO Byte by Byte• Simplicity
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Transmission Options
Predefined Buffer Size•Transmits when buffer filled
Variable Buffer Size•Transmits when timer triggered
Real Time Transmission•Transmit data as received
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Real Time Transmission
Easiest Method:•Each data byte transmitted to the VFD
once received from the computer
Most Convenient Method:
•Easily adaptable to other applications
•Will not restrict the use for future products
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Indirect Adaptation
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Indirect Adaptation
Problems:
•Added Costs•RS232/RS485 Converter Bulky
Solutions:•Direct Adaptation•Modify Code to Half Duplex•Incorporate GPIO from MCU
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Direct Adaptation
Tx/Rx Control:•Tell RS485/TTL Transceiver when to
Send/Receive ▫ Incorporate GPIO from MCU
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Direct Adaptation
TX/RX Control
TX/RX Control
RS485 to TTL
MCU+
Transceiver
TTL toRS485
MCU+
Transceiver
Computer to USB to RS485
TX/RX
RX
TX
GPIO
TX/RX TX/RX
TX/RX
GPIO
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BudgetLenze Grant: $1000
Product Quantity Unit Price Price
Design Estimates
In System Programmer
1 $35.36 $35.36
Single Chip MCU and ZigBee Transceiver
3 $9.75 $29.25
RS-485 to TTL Transceiver
3 $2.70 $8.10
ZigBee Development Kit
1 $119.00 $119.00
RS-232 to RS-485 Converter
3 $80.11 $240.33
RS-232 to TTL Transceiver
3 $18.54 $55.62
Misc. Supplies $100.00
Total: $587.66
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Project Summary
ZigBee PCB Antenna:• Easy to tune• Reduces Costs
MCU Integration:• Eliminate External
Hardware• Wireless Upgrade Package
Future Implementation
• Communication Established
• Hardwired Connections Eliminated
• Cost Effective Implementation
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Questions