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Wireless User Interface for Variable Frequency Drives

Sponsor: Lenze Advisor : Professor John Chandy. Wireless User Interface for Variable Frequency Drives. Team 168 Alex Shuster (EE) Michael Kloter (EE) Christopher Perugini (EE) Kevin Wei ( EngPhys - EE). Outline. Lenze Existing Problems Deliverables Solution Wireless Hardware

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Wireless User Interface for Variable Frequency Drives

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  1. Sponsor:Lenze Advisor: Professor John Chandy Wireless User Interface for Variable Frequency Drives Team 168 Alex Shuster (EE) Michael Kloter (EE) Christopher Perugini (EE) Kevin Wei (EngPhys - EE)

  2. Outline • Lenze • Existing Problems • Deliverables • Solution • Wireless • Hardware • Network Topology • Transmission • Adaptation • Budget • Project Summary

  3. Lenze Provide Motor Control Solutions • Automotive Construction • Robotics • Manufacturing and Packaging Variable Frequency Drives • Speed and Control System for AC motor

  4. Existing Problems and Deliverables Current Problems • Hardwired Communication • Manually Set Parameters • Limited Accessibility Objectives • Develop VFD Wireless Interface • Maximize Transmission Distance • Multi VFD Operation • Industrial Grade

  5. Wireless Solution Communication Options: • Wi-Fi • Bluetooth • ZigBee Wireless Communication Choice: ZigBee • 10-100m / Node • Unlimited Range Extension • Low Cost • Industrial Operation

  6. Hardware Solution B&B Electronics USOPTL4 • USB Serial Converter • Transforms Serial Signal to RS-485 Sparkfun ATMega128RFA1 • MCU and ZigBee Transceiver Combo • Cost Effective • Compact Size

  7. Hardware Constraints MCU/Transceiver: • Communicates using TTL levels • VFD requires RS-485 levels Reference Voltage Conflict: RS-485 vs TTL Solution: • Breakout Board Switching • MCU Code Modification

  8. Software Stack Solution Lightweight Mesh • Basic Data Services • Routing • Power Management • Network Management • Data Failure Correction • Message Payload Formatting • Advanced Security • MCU Power Management • Hardware Peripheral Interface

  9. Transceiver Scheme Selection Options: • FIFO Byte by Byte • Buffer vectors inserted in payload frame as received • FIFO Message • Waits for full message before sent to payload frame Framing Choice: FIFO Byte by Byte • Simplicity

  10. Transmission Options Predefined Buffer Size • Transmits when buffer filled Variable Buffer Size • Transmits when timer triggered Real Time Transmission • Transmit data as received

  11. Real Time Transmission Easiest Method: • Each data byte transmitted to the VFD once received from the computer Most Convenient Method: • Easily adaptable to other applications • Will not restrict the use for future products

  12. Indirect Adaptation

  13. Indirect Adaptation Problems: • Added Costs • RS232/RS485 Converter Bulky Solutions: • Direct Adaptation • Modify Code to Half Duplex • Incorporate GPIO from MCU

  14. Direct Adaptation Tx/Rx Control: • Tell RS485/TTL Transceiver when to Send/Receive • Incorporate GPIO from MCU

  15. Direct Adaptation

  16. Budget

  17. Project Summary • Communication Established • Hardwired Connections Eliminated • Cost Effective Implementation ZigBee PCB Antenna: • Easy to tune • Reduces Costs Future Implementation MCU Integration: • Eliminate External Hardware • Wireless Upgrade Package

  18. Questions

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