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EZ Mash A.B.S.

EZ Mash A.B.S. Jason Galloway John Cox Justin Crandall. Georgia Institute of Technology 10/20/08. Project Overview. What: A batch process system to automatically convert grain starches into sugars, a critical component of beer production.

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EZ Mash A.B.S.

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  1. EZ Mash A.B.S. Jason Galloway John Cox Justin Crandall Georgia Institute of Technology 10/20/08

  2. Project Overview • What: A batch process system to automatically convert grain starches into sugars, a critical component of beer production. • Why: Will cut time from 3-4 hours to approx. one hour, better recipe repeatability. • Who: Home and commercial brewer. • Cost: $27,350 ($350.00+$27K)

  3. Design Objectives • Inputting brewing parameters, such as start time and mash temperature in GUI. • Implement PID loop to maintain set-point temperatures within 1 °F of target. • Designed to draw less than 12 Amps. • Strive to use materials that can withstand high temperatures up to 190 °F.

  4. Technical Approach – Hardware Design

  5. Technical Approach-Temperature Set-Points • Highest Mash Temp. = 170 °F. • Highest Water Temp. = 190 °F. • Water Temp. Range = 70 - 190 °F. • +/- 1 degree differential to target set-point temp. • Hold steady temperature in 149 - 156 °F, set by user in GUI.

  6. Technical Approach-Automation Controller • Basic Stamp • Quick prototyping • Easy DAQ for PID loop tuning • 15 pins available for I/O • I2C bus, allows extra I/O (temperature sensors) • 20 MHz ~ 4,000 instructions/sec

  7. Technical Approach-Temperature Control • DS1620-direct digital thermometer • PID Algorithm, programmed in BASIC • Heat exchange in liquid bath. • Electric element provides 1125 Watts. • Insulated Vessels

  8. Technical Approach-Volume Management • FlexiForce sensor to measure liquid volumes. • Magnetic drive pump with 7.2 gpm and maximum head 12.1 ft. • ½” nom. Copper and thermal plastic tubing. • Direct acting solenoid valves.

  9. Technical Approach - Connections

  10. Technical Approach-Power Management and Circuit I2C ControlModule Temp Sensors FlexiForce Sensor

  11. Technical approach – GUI interface • Allows user to input variables such as Mash time, set-point temperature, and start time. • Provides a tool for analysis of step-response in order to tune the PID algorithm for optimal performance.

  12. Technical Approach - Flowchart

  13. Demonstration Plan • Brew a non-alcoholic pre-boil sugar solution (wort). • Demonstrate GUI and temperature management via data-logging. • Success when pre-boil wort is produced by user input via GUI interface without off-flavors.

  14. Project Schedule • Build thermowell for DS1621 sensors: 10/22 • Complete FlexiForce volume sensor: 10/22 • Prototype Power Circuit: 10/29 • PID Loop and Tuning: 11/5 • Program StampPlot Macro: 11/12 • Test Run using water: 11/19

  15. Current Status of Project • Assembly of hardware, including recirculation system, insulated vessels, and solenoid valves complete. • Temperature sensors interfaced, pressure sensor reading linear voltage relationship to pressure. • Prototype control circuit assembled, power circuit near completion.

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