Viking Pump Flow Manager - Phase 2 - Iowa State University

Viking Pump Flow Manager - Phase 2 - Iowa State University

Viking Pump Flow Manager Phase 2 Senior Design May 06-12 People Team Members Dwayne Stammer - CprE Francois Munyakazi EE Dan Paulsen CprE/EE

Faculty Advisor Nicola Elia Client Info Viking Pump Inc.

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

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 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 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Hardware out of date User interface is outdated and difficult to use System Use System will be configured and run by trained technicians Will operate in harsh factory floor

environments Temperatures ranging from 40 to 120F Long periods of use 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 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 End Product Implementation for basic prototype that properly controls pump system Documentation of controller and source code 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 System Overview Motor Revolution Counter Flow Meter Readout Pressure Gauges

Flow Thermometer Pressure Readouts Pump Flow meter Pressure Relief Valve System Overview Four inputs

Inlet pressure Output pressure Fluid Temperature (to determine viscosity) Pump RPM One output Desired motor speed

Previous Model Outdated User Interface The current Flow Manager provides the user with a lessthan-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 Model Updated Model

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

Circuitry Updated Graphical Interface Initial Performance Measurement Violet: Output Signal Red: Flow Rate Updated Flow Manager

Algorithm Performance Blue: Set Point Green: Flow Rate Orange: Pressure Schedule

Personal Effort John Taylor , Cliff Pisent, 35 104 Francois Munyakazi, 200 Dwayne Stammer, 275 Dan Paulsen, 225

Total hours: 839 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) Materials 465.00 Total cost of project: 7,525.50 Previous group Project Total thus far

$9,229.00 $9,694.00 $17,219.50 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 What Didnt 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

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 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

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 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. 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 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 Questions?

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