Viking Pump Flow Manager - Phase 2

1. Viking Pump Flow Manager - Phase 2 Senior Design May 06-12

2. People • Team Members • Dwayne Stammer - CprE • Francois Munyakazi – EE • Dan Paulsen – CprE/EE • Faculty Advisor • Nicola Elia • Client Info • Viking Pump Inc.

3. Outline • Introduction and problem statement – Dan Paulsen • Design and implantation – Dwayne Stammer • Schedule, financial, and closing – Francois Munyakazi • Future Work – Team

4. Definitions • Flow meter: An instrument used to measure pressure, flow rate, and discharge rate of a liquid, vapor, or gas flowing in a pipe • Set point: The speed that a pump has to rotate in order to achieve a given flow or output pressure • Viscous: Having a relatively high resistance to flow • QVGA: 4x6 inch high resolution touch screen, has onboard analog voltage inputs and outputs

5. Problem Statement • Design a system to do the following • Control a pump to maintain a given flow using only speed, pressure, and temperature measurements • Provide an easier user interface to control flow rate and other working parameters • Provide access to system through serial bus

6. Why? • Why is this valuable? • Measuring flow for viscous fluids is very hard • Less parts needed to build a pumping system • Has many other uses such as batch flow, and error detection • Inline meters to measure flow can hinder flow performance • Problems with current system • Hardware out of date • User interface is outdated and difficult to use

7. System Use • System will be configured and run by trained technicians • Will operate in harsh “factory floor” environments • Temperatures ranging from 40° to 120°F • Long periods of use

8. Assumptions • Inputs from the system will be: • Inlet pressure – input voltage • Outlet pressure – input voltage • Temperature of the fluid – input voltage • Current pump speed – input voltage pulse - 60 pulses/revolution • Outputs to the system will be: • 4-20mA signal to DC Drive

9. Limitations • The controller must be able to operate in a real time environment • The software implementation must be portable • The controller solution must be economical • The controller must be able to control the actual flow within 0.25% of the set point

10. End Product • Implementation for basic prototype that properly controls pump system • Documentation of controller and source code

11. Problem Definition • Current flow manager is difficult to use and obsolete • User interface needs updated to a much more intuitive interface • Will be solved using a new touch screen interface • Hardware used is no longer available because it was custom made to the application • Will be solved using over the shelf parts • Writing software with different hardware platforms in mind

12. System Overview Motor Revolution Counter Flow Meter Readout Pressure Gauges Flow Thermometer Pressure Readouts Flow meter Pump Pressure Relief Valve

13. System Overview • Four inputs • Inlet pressure • Output pressure • Fluid Temperature (to determine viscosity) • Pump RPM • One output • Desired motor speed

14. Previous Model Outdated 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.

15. Previous Model

16. Updated Model • Touch screen user interface • Updated C code • Standardized equipment (not as much customized circuitry required) • PC interface with more advanced GUI features

17. Updated Model Standardized 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.

18. Updated Model PC interface

19. Updated Interface Circuitry

20. Updated Graphical Interface

21. Initial Performance Measurement Violet: Output Signal Red: Flow Rate

22. Updated Flow Manager

23. Algorithm Performance Blue: Set Point Green: Flow Rate Orange: Pressure

24. Schedule

25. Personal Effort Total hours: 839

26. Project Costs • QVGA Repair $250 Provided by Senior Design Pump equipment $0 Donated by Viking Miscellaneous parts $175 Viking/Group members Poster $40 Group members Total material cost: $465 • Total material cost Labor (839hrs @ $11.00) $9,229.00 Materials 465.00 Total cost of project: $9,694.00 7,525.50 Previous group Project Total thus far $17,219.50

27. What Went Well • Some part were easy to get from common store • Design of project was easy, important decisions already made by previous team • Communication between components was fairly well • Good Coordination between team members

28. What Didn’t Go Well • Understanding the definition of the project • Learning how to interface with the pump • QVGA was damaged because we did not understand how the pieces should work together. • Dealt with odd behavior with parts which were out of the scope of our project. • Communication with sensors and QVGA

29. Knowledge Gained • Learned the control algorithms for pump flows • Learned How to program the QVGA • Developed team communication • Learned how to effectively distribute work loads among team members • Learned how to better work with clients while keeping a project on track

30. Risk Management • Anticipated risks • Loss of code • Loss of team member • Anticipated risks encountered • Loss of team member • John Taylor went to internship • Cliff Pinsent graduated • Unanticipated risks encountered • Damage of the QVGA

31. Work Completed • Repair QVGA • Acquired model from Viking • Studied algorithm and controllers • Designed and prototyped GUI screens • Detected I/O of QVGA • Wrote C code and serial code • Build pump interface between QVGA and pump • Designed circuitry for sensor testing and QVGA

32. Work Completed Cont. • 80% Completed writing / debugging the C code to control flow • 80% write and implement the full GUI • Created a methodology for the QVGA to be controlled via serial comm.

33. Closing • The previous version of the product • Pros: Has a very large success • Cons: User interface • The lack of user friendliness of the device even thought it is still the best device on the market

34. Closing Cont. • Viking Pumps needs a well-designed flow control manager • To be used with already existing pumps. • Cost effective • Portability • Moving from one hardware to another without major software rework

35. Questions?