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On-Site HotBox Calibration System

On-Site HotBox Calibration System . Team 2 Pourya Assem & Paul Lupas Prof. A.C.Singer ECE 445 – Fall 2012. Introduction. What is this about? IR Heat Sensor Transducer Calibration Device Where is it used? HotBox Monitoring System What is it used for? Analyze Heat Signature

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On-Site HotBox Calibration System

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  1. On-Site HotBox Calibration System Team 2 Pourya Assem & Paul Lupas Prof. A.C.Singer ECE 445 – Fall 2012

  2. Introduction • What is this about? • IR Heat Sensor • Transducer Calibration Device • Where is it used? • HotBox Monitoring System • What is it used for? • Analyze Heat Signature • Analyze Transducer timing • Prevent Derailment

  3. Motivation • Why is this needed? • Wheel inspection required by Federal Laws • Sensors often go out of calibration • Why is this better? • Switch from mechanical to electrical method • Time & Cost efficient • Introduce a standard calibration procedure

  4. Field Operations/Inspection

  5. System Features • Wireless Units: unreachable locations • SD Card: further data analysis • Graphical interface: user friendly • 9V battery powered: portable device

  6. High Level Block Diagram

  7. Low Level Amplifier

  8. Transducer Signals • Maximum train speed 65mph • Minimum transducer timing 26.5ms • Signal: 100-250mVpp, 10Hz sinusoid • Minimum train speed 20mph • Maximum transducer timing 2.8s • Signal: 100-250mVpp, 3Hz sinusoid

  9. Transformers + Fuses • Input: 100-250mV sinusoid 3Hz-10Hz • Output: 100-250mV sinusoid 3Hz-10Hz • Flat Frequency response • Minimum phase delay • Total isolation • Minimum drain current • High current protection

  10. Transformers + Fuses • Freq. Response • 1Hz to 2KHz Transducer 1 Transducer 2

  11. Transducer Amplifier • Input: 100-250mVpp sinusoid 3Hz-10Hz • Output: 2VDC rectified sinusoid 3Hz-10Hz • 30% Signal Saturation • Non-Inverting Config. • LNA • Low Freq. Gain: 41

  12. Transducer Amplifier • Amplification limited by internal power consumption • 30% saturation @ 2VDC • Level restorer required • Freq. Response 1Hz-20Hz

  13. Level Restorer • Input: 2VDC Rectified and Clipped 3Hz-10Hz Sinusoid • Output: 3.3VDC Inverted and Restored 3Hz-10Hz Signal • NPN Common Collector Amp. • Properly Invert and Restore signal from 2VDC to 3.3VDC

  14. Level Restorer • NPN Base Voltage • NPN Collector Voltage

  15. Slicer • Input: 2-3.3VDC Inverted and Restored 3Hz-10Hz Signal • Output: 3.3VDC Burst Wave 3Hz-10Hz • Trim-off the slow ramp (rise and fall) edges • Implemented using TTL Combinational LOGIC • Function as OR • Chain Inverters to increase noise immunity

  16. Slicer + OR function • Level Restorer Signals Sliced • Transducers • Sliced/OR-ed signals

  17. IR Heat Sensor Signal • Signal: 2Vpp with BW of 5-100Hz @ 1VDC offset • Bad timing • Uncalibrated IR Heat Sensor

  18. Active Filter • Ideal Input: 2Vpp signal with BW of 5-100Hz 1VDC offset • Output:2Vpp signal with BW of 5-100Hz 1VDC offset • Cut-off Freq. 1KHz 20dB • Minimum phase delay • LNA Gain:1

  19. Active Filter • Frequency Response 1Hz-3KHz • VTC and Phase for 10Hz sinusoid 2Vpp 1VDC offset

  20. Active Filter • Noise Handling • Input: 800Hz Square Wave • Output: Higher Harmonics Rejection

  21. TX Microprocessor • Adaptive algorithm • Collects 16 sample points for all speeds

  22. XBEE Transceivers • Input: • 115200 baud rate from TX Microprocessor • Packaged heat samples • 2.4GHz Transceiver • unlicensed frequency band • 1mW – up to 100feet • Series 1XBEE

  23. RX Microprocessor

  24. Dual 4 to 1 Mux • Both RX XBEE and GLCD require Serial Port of RX Microprocessor • Train is present: • Serial Port connected to RX XBEE • Train has passed: • Serial Port connected to GLCD • Room to add more subsystems

  25. SD Card • Powered by 3.3V • SPI communication • Further data analysis • Connect to PC • Data saved in memory #434,364,289,213,143,82,36,7,0,10,41,90,152,224,300,375,#467,518,552,566,558,532,491,432,363,287,212,141,81,35,7,0,#*

  26. GLCD • 115200 baud rate • Display signal waveforms • Show signal average • Indicate if above alarm level • Receives data from ATMEL 328 Serial Port through the Dual 4 to 1 Mux • Data from SD Card mapped to 128x128 pixels

  27. User Interface • “Reset” button: reset both TX and RX Units • “Next” button: navigate through data collected

  28. Power Supply • 3.3V required for: • XBEE • SD Card • Amplifiers • 5V required for: • Microcontroller • GLCD

  29. Power Supply • Input Voltage: 9V • Output Voltage: 3.32V • Voltage ripples: 50mV • Tolerance < 2%

  30. System Testing • All Components are chosen from Low Power versions • 9V 250mAh Battery: • 2 hours continuous use • Inspect 6 long freight trains

  31. System Testing • Transducer + Heat Signature Signals

  32. System Testing 301,237,176,120,72,35,10,0,2,19,50,91,143,201,264,329,#417,47542,563,565,546,508,453,387,313,237,164,100,48,14,0,4,29,#198,273,349,420,481,528,557,567,556,525,477,415,343,267,193,123,#3,0,17,52,105,170,244,320,394,460,512,548,566,563,539,495,#298,222,151,88,41,10,0,8,37,83,144,215,291,366,435,491,#566,551,517,465,400,327,251,177,111,57,19,0,2,24,64,118,#336,409,472,521,554,567,559,532,487,427,356,281,205,135,76,31,#12,45,95,159,231,307,381,449,504,543,564,564,544,506,451,382,#162,98,47,14,0,5,30,74,133,203,277,353,424,484,530,555,#523,475,412,264,190,121,65,24,2,0,18,55,108,174,247,#*

  33. PCB TX Unit Bottom

  34. PCB TX Unit Top

  35. PCB RX Unit

  36. Connection Ports • Connection Ports for Transducer + IR Heat Sensor Signals

  37. Accomplishments • Detect train at different speeds • Correct detection of corresponding heat signature • Wireless Functionality • Graphical Display • SD Card data storage • Portable RX Unit, battery powered • Tested under extremes

  38. Difficulties • Power Management • Establish working link between all modules • Control of data flow • Simulating Transducer Signals • Correct data analysis • Calculations/Scaling of real world problem into a working system

  39. Further Improvements • Improve wireless range (50mW TX XBEE) • Change user interface to touchscreen • Replace GLCD and avoid pushbuttons • Time stamp the data collected • Collect data from multiple tracks: one TX Unit • Implement Bluetooth Module • Read data collected using an Android App • Software add-ons

  40. THANK YOU • Questions? • Comments? • Tomatoes?

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