team 14 joe grady james crow hongyu chen prakalp sudhakar victor villagomez client/faculty advisor:...
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Diffusion Furnace Controller Design
Team 14 Joe Grady
James CrowHongyu Chen
Prakalp SudhakarVictor Villagomez
Client/Faculty Advisor: Dr. Gary Tuttle
Problem StatementThe objective of the senior design project is to design a new
set of temperature controllers to use on a set of diffusion
furnaces located at the Microelectronics Research Center.
The project goals include:
• Temperature calibration of the furnaces
• Implementing of new temperature controllers into the
current furnace system
• Providing a computer interface so that temperature of the
furnaces can be controlled and monitored remotely.
• Providing extended remote control of the valves that
control the gases released in the furnace, if time and funds
permit.
System OverviewSystem Overview
Functional Requirements• Controller must have a temperature tolerance within
+/- 1 degree Celsius
• Controller must be digital and programmable (∆T/ ∆t)
• Controller must have communication capability
• Controller must be able to sample and store information for every cycle
• Controller must be able to control temperatures independently of each section
Functional Requirements• Software must be able to monitor and control the
parameters of the temperature controller
• Software must be able to support simultaneous use
by multiple students
• Software must be able to display graphs of the
process and of chemical flow
• Software needs to be accessed online via web
browser
• Graphical interface of the software must be user-
friendly
• Error checking and deviation
Non-functional Requirements• The new controllers need to be placed
where the old ones were so they need to able to fit within a certain space
• Connectors must be compatible with the new controller
Schedule – 1st Semester
Schedule – 2nd Semester
RS-232 Serial Communication
RS-232 Serial Communication• Baud Rate = 4800• Data Bits = 8• Parity = N• Stop = 1
Operating Protocol• Controllers do not initiate
communication, Command Module does.
• All communication is in ASCII format
• To start communication Command Module sends alert code followed by ID
Software Architecture
Software Architecture – Sequence Diagram
Software Architecture – Use Cases
BudgetParts and Materials: a) Suitable controller(s) b) Miscellaneous parts c) Poster
Without Labor$1,250.00$50.00$50.00
With Labor$1,250.00$50.00$50.00
Services:a)Website Upkeep (for 1 year) $60.00 $60.00
Labor ($12.50 per hour):a)Crow, James b)Villagomez, Victorc)Sudhakar, Prakalpd)Grady, Joee)Chen, Hongyu
$1125.00$1125.00$1125.00$1125.00$1125.00
Parts and Materials: a) Suitable controller(s) b) Miscellaneous parts c) Poster
Without Labor$620.00$0.00$0.00
With Labor$620.00$0.00$0.00
Services:a)Website Upkeep (for 1 year) $0.00 $0.00Labor ($12.50 per hour):a)Crow, James b)Villagomez, Victorc)Sudhakar, Prakalpd)Grady, Joee)Chen, Hongyu
$375.00$375.00$375.00$375.00$375.00
Current Expenses
Total Expected Expenses
Schematic – Old Controller
Hardware Interface Issues
• The existing controller/oven has the thermocouple’s negative (-) leads connected internally to the oven, but the new controller’s require them to be directly connected.
• The existing SCR firing circuits are 0-5 mA current controlled devices, but the new controller’s output to the SCR firing circuit is designed to operate a 0-5 V voltage controlled device.
ResourcesProfessor• Thorough knowledge about current
microcontrollers, and advice for digital microcontrollers
User Manuals• Manual for current analog microcontrollers• Manual for new digital microcontroller.Manufacturers• Websites to purchase new digital
microcontrollers• Omega.com – New microcontroller• Easysw.com – Serial Programming Guide
Questions ?
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