Viking Pump Viking Pump Flow Manager - Flow Manager -

Phase 2 Phase 2 Senior DesignSenior Design

May 06-12May 06-12

PeoplePeople

Team MembersTeam Members Dwayne Stammer - CprEDwayne Stammer - CprE Francois Munyakazi – EEFrancois Munyakazi – EE Dan Paulsen – CprE/EEDan Paulsen – CprE/EE

Faculty AdvisorFaculty Advisor Nicola EliaNicola Elia

Client InfoClient Info Viking Pump Inc.Viking Pump Inc.

OutlineOutline Introduction and problem statement – Dan Introduction and problem statement – Dan

PaulsenPaulsen Design and implantation – Dwayne StammerDesign and implantation – Dwayne Stammer Schedule, financial, and closing – Francois Schedule, financial, and closing – Francois

MunyakaziMunyakazi Future Work – TeamFuture Work – Team

DefinitionsDefinitions Flow meter:Flow meter: An instrument used to measure An instrument used to measure

pressure, flow rate, and discharge rate of a pressure, flow rate, and discharge rate of a liquid, vapor, or gas flowing in a pipeliquid, vapor, or gas flowing in a pipe

Set point:Set point: The speed that a pump has to The speed that a pump has to rotate in order to achieve a given flow or rotate in order to achieve a given flow or output pressureoutput pressure

Viscous: Viscous: Having a relatively high resistance Having a relatively high resistance to flowto flow

QVGA: QVGA: 4x6 inch high resolution touch 4x6 inch high resolution touch screen, has onboard analog voltage inputs screen, has onboard analog voltage inputs and outputsand outputs

Problem StatementProblem Statement

Design a system to do the followingDesign a system to do the following Control a pump to maintain a given flow Control a pump to maintain a given flow

using only speed, pressure, and using only speed, pressure, and temperature measurementstemperature measurements

Provide an easier user interface to Provide an easier user interface to control flow rate and other working control flow rate and other working parametersparameters

Provide access to system through serial Provide access to system through serial busbus

Why?Why?

Why is this valuable?Why is this valuable? Measuring flow for viscous fluids is very hardMeasuring flow for viscous fluids is very hard Less parts needed to build a pumping systemLess parts needed to build a pumping system Has many other uses such as batch flow, and Has many other uses such as batch flow, and

error detectionerror detection Inline meters to measure flow can hinder flow Inline meters to measure flow can hinder flow

performanceperformance Problems with current systemProblems with current system

Hardware out of dateHardware out of date User interface is outdated and difficult to useUser interface is outdated and difficult to use

System UseSystem Use

System will be configured and run System will be configured and run by trained techniciansby trained technicians

Will operate in harsh “factory floor” Will operate in harsh “factory floor” environmentsenvironments Temperatures ranging from 40° to

120°F Long periods of use

AssumptionsAssumptions

Inputs from the system will be:Inputs from the system will be: Inlet pressure – input voltageInlet pressure – input voltage Outlet pressure – input voltageOutlet pressure – input voltage Temperature of the fluid – input voltageTemperature of the fluid – input voltage Current pump speed – input voltage pulseCurrent pump speed – input voltage pulse

- 60 pulses/revolution - 60 pulses/revolution Outputs to the system will be:Outputs to the system will be:

4-20mA signal to DC Drive4-20mA signal to DC Drive

LimitationsLimitations

The controller must be able to The controller must be able to operate in a real time environmentoperate in a real time environment

The software implementation must be The software implementation must be portableportable

The controller solution must be The controller solution must be economicaleconomical

The controller must be able to control The controller must be able to control the actual flow within 0.25% of the the actual flow within 0.25% of the set pointset point

End ProductEnd Product

Implementation for basic prototype Implementation for basic prototype that properly controls pump systemthat properly controls pump system

Documentation of controller and Documentation of controller and source codesource code

Problem DefinitionProblem Definition

Current flow manager is difficult to use Current flow manager is difficult to use and obsoleteand obsolete User interface needs updated to a much User interface needs updated to a much

more intuitive interfacemore intuitive interface Will be solved using a new touch screen Will be solved using a new touch screen

interfaceinterface Hardware used is no longer available Hardware used is no longer available

because it was custom made to the because it was custom made to the applicationapplication

Will be solved using over the shelf partsWill be solved using over the shelf parts Writing software with different hardware Writing software with different hardware

platforms in mindplatforms in mind

System OverviewSystem Overview

Pump

Pressure Readouts

Pressure Gauges

Thermometer

Flow meterPressure Relief Valve

Revolution CounterMotor

Flow

Flow Meter Readout

System OverviewSystem Overview

Four inputsFour inputs Inlet pressureInlet pressure Output pressureOutput pressure Fluid Temperature (to determine Fluid Temperature (to determine

viscosity)viscosity) Pump RPMPump RPM

One outputOne output Desired motor speedDesired motor speed

Previous ModelPrevious Model

Outdated User InterfaceOutdated 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 ModelPrevious Model

Updated ModelUpdated Model

Touch screen user interfaceTouch screen user interface Updated C codeUpdated C code Standardized equipment (not as Standardized equipment (not as

much customized circuitry required)much customized circuitry required) PC interface with more advanced PC interface with more advanced

GUI featuresGUI features

Updated ModelUpdated Model

Standardized equipmentStandardized 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 ModelUpdated Model

PC interfacePC interface

Updated Interface Updated Interface CircuitryCircuitry

Updated Graphical Updated Graphical InterfaceInterface

Initial Performance Initial Performance MeasurementMeasurement

Violet: Output Signal

Red: Flow Rate

Updated Flow ManagerUpdated Flow Manager

Algorithm PerformanceAlgorithm Performance

Blue: Set Point

Green: Flow Rate

Orange: Pressure

ScheduleSchedule

Personal EffortPersonal Effort

Dwayne Stammer, 275

Dan Paulsen, 225

Francois Munyakazi,

200

John Taylor , 104

Cliff Pisent, 35

Total hours: 839

QVGA RepairQVGA Repair $250$250 Provided by Senior DesignProvided by Senior DesignPump equipmentPump equipment $0$0 Donated by VikingDonated by VikingMiscellaneous partsMiscellaneous parts $175$175 Viking/Group membersViking/Group members

Poster Poster $40$40 Group membersGroup membersTotal material cost:Total material cost: $465$465

Total material costTotal material cost Labor (839hrs @ $11.00) $9,229.00Labor (839hrs @ $11.00) $9,229.00 MaterialsMaterials 465.00 465.00 Total cost of project:Total cost of project: $9,694.00 $9,694.00

7,525.50 Previous group7,525.50 Previous group Project Total thus farProject Total thus far $17,219.50 $17,219.50

Project CostsProject Costs

What Went WellWhat Went Well

Some part were easy to get from Some part were easy to get from common store common store

Design of project was easy, important Design of project was easy, important decisions already made by previous decisions already made by previous teamteam

Communication between components Communication between components was fairly wellwas fairly well

Good Coordination between team Good Coordination between team membersmembers

What Didn’t Go WellWhat Didn’t Go Well

Understanding the definition of the Understanding the definition of the projectproject

Learning how to interface with the Learning how to interface with the pumppump QVGA was damaged because we did not QVGA was damaged because we did not

understand how the pieces should work understand how the pieces should work together.together.

Dealt with odd behavior with parts which Dealt with odd behavior with parts which were out of the scope of our project.were out of the scope of our project.

Communication with sensors and QVGACommunication with sensors and QVGA

Knowledge GainedKnowledge Gained

Learned the control algorithms for Learned the control algorithms for pump flowspump flows

Learned How to program the QVGALearned How to program the QVGA Developed team communicationDeveloped team communication Learned how to effectively distribute Learned how to effectively distribute

work loads among team memberswork loads among team members Learned how to better work with Learned how to better work with

clients while keeping a project on clients while keeping a project on tracktrack

Risk ManagementRisk Management

Anticipated risksAnticipated risks Loss of codeLoss of code Loss of team memberLoss of team member

Anticipated risks encounteredAnticipated risks encountered Loss of team member Loss of team member

John Taylor went to internship John Taylor went to internship Cliff Pinsent graduatedCliff Pinsent graduated

Unanticipated risks encounteredUnanticipated risks encountered Damage of the QVGADamage of the QVGA

Work CompletedWork Completed

Repair QVGARepair QVGA Acquired model from VikingAcquired model from Viking Studied algorithm and controllersStudied algorithm and controllers Designed and prototyped GUI screensDesigned and prototyped GUI screens Detected I/O of QVGADetected I/O of QVGA Wrote C code and serial codeWrote C code and serial code Build pump interface between QVGA and Build pump interface between QVGA and

pumppump Designed circuitry for sensor testing and Designed circuitry for sensor testing and

QVGAQVGA

Work Completed Cont.Work Completed Cont.

80% Completed writing / debugging 80% Completed writing / debugging the C code to control flowthe C code to control flow

80% write and implement the full 80% write and implement the full GUIGUI

Created a methodology for the Created a methodology for the QVGA to be controlled via serial QVGA to be controlled via serial comm.comm.

ClosingClosing

The previous version of the product The previous version of the product Pros: Has a very large successPros: Has a very large success Cons: User interfaceCons: User interface The lack of user friendliness of the The lack of user friendliness of the

device even thought it is still the best device even thought it is still the best device on the marketdevice on the market

Closing Cont.Closing Cont.

Viking Pumps needs a well-designed Viking Pumps needs a well-designed flow control manager flow control manager To be used with already existing pumps. To be used with already existing pumps.

Cost effectiveCost effective PortabilityPortability

Moving from one hardware to another Moving from one hardware to another without major software reworkwithout major software rework

Questions?Questions?