Transcript Lighting Tool Box Cost & Safety Analysis

Lighting Tool Box
Winter 2004
ECE 498
Team Members:
Nick Sitarski
Blaine Thompson
Brandon Harris
Dave Chronicle
Vladi Gergov
Advisor: Professor John W. Miller
Department of Electrical and Computer Engineering
Project Summary
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The Lighting Tool Box is a collection of
common machine vision lighting
systems controlled locally or via the
Internet
The goal of this project is to design and
implement three lighting controllers
which interface with a GNU/Linux based
embedded controller
The embedded controller supports the
Web Cam and Internet interface as well
as PWM signal syntheses
The Incandescent System can provide
the 360 degree lighting for requirements
such as structured lighting
A fluorescent Lighting system was
developed for applications that require a
large aspect ratio
An LED ring light was developed for
applications requiring close proximity
inspections
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Each lighting subsystem can be
operated in a stand alone
configuration
All major functions of the three
lighting systems were designed
and implemented with the
exception of the following features
– No lamp voltage regulation on
incandescent system
– No computer controlled strobe
only through local hardware
– No remote health status
detection
Department of Electrical and Computer Engineering
Design Requirements
• The system was designed to be operated in a factory
environment, thus size, ease of remote use, and construction
was considered during design stages
• The whole system can be controlled via the internet / local
network or through local operation
• Equipment should be portable, easy to connect / disconnect
• All systems are powered from 120 VAC
• Embedded computer used for remote operation
• Lighting parameters must be maintained at constant value
once set
• Construction of equipment must comply with electrical safety
codes to minimize hazards to user and risk of fire
Department of Electrical and Computer Engineering
Technical Specifications
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Embedded Controller
Enclosure Dimensions: 6.5”x4.5”x3.5”
Processor Speed: 300 MHz
Operating System: GNU/Linux
Weight: 2 lbs.
Power requirements 120 VAC @50 watts
Incandescent System
Enclosure Dimensions: 11”x17”x9.5”
Lamp Enclosures: 4”x4”x8”
Weight: 30 lbs.
Power requirements 120 VAC @250 watts
LED System
Enclosure Dimensions: 11”x15”x9.5”
Ring Light: 4”x4”x2”
Weight: 10 lbs.
Power requirements 120 VAC @50 watts
Fluorescent System
Enclosure Dimensions: 8”x10”x2.5”
Tubular Light Enclosure: 48”x4”x4”
Shadow Box Enclosure: 12”x12”x5”
Weight: 5 lbs.
Power requirements 120 VAC @50 watts with power factor of .99
Department of Electrical and Computer Engineering
Subsystems
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LED Lighting System (Blaine Thompson) - The LED subsystem is a
single channel system that controls a LED ring light. The intensity is
controlled via a 40KHz PWM signal. This subsystem also contains a
strobe feature that modulates the LED ring light output. This is ideally
suited for close proximity viewing.
Fluorescent Lighting System (Brandon Harris) – The fluorescent
lighting system uses an electronic ballast to power and precisely
control the intensity of a 32 W fluorescent bulb. This is used for large
aspect-ratio viewing.
Incandescent Lighting System (Nick Sitarski) – The Incandescent
subsystem is a 4 channel system that powers and precisely controls
the intensity of the 4 halogen lamps. This is typically used for 360°
illumination applications.
Embedded Computer (Vladi Gergov, David Chronicle) - The
embedded computer uses a combination of microprocessors, I/O, and
networking to control the lighting systems remotely via the internet or
local network.
Department of Electrical and Computer Engineering
Design Constraints
• Maximum power output is limited to 32 watts for fluorescent
subsystem controller. Major circuit redesign is required to
exceed this power restriction.
• The Incandescent subsystem controller is not regulated for
remote operation due to time and economic constraints. A high
performance A/D I/O card is required as well as extensive
programming.
• Had to construct LED ring light due to cost constraints.
• Economic constraints limited transformer size for Incandescent
subsystem allowing a maximum lamp size of 35 watts.
• Strobing features could not be implemented in software due to
time constraints.
Department of Electrical and Computer Engineering
Design Options
• PWM Signal is generated via an embedded computer as
opposed to local hardware to reduce complexity of hardware
design.
• Modular design of system components and website for easier
maintenance and prototyping
• Built custom hardware for lighting subsystems as opposed to
commercially available product to reduce cost
• Operating system (open source, commercial, or custom)
– GNU/Linux was chosen due to its lack of licensing fees,
open source, stability, and less resources required
– PC/104 technology for compact, low power requirements,
less heat dissipation, and greater heat tolerance.
Department of Electrical and Computer Engineering
Logical Schematics
LED Lighting System
Remote PWM
Health Signals to
Micro Controller
MOSFETS
Local PWM
Generator
Fluorescent Lighting
System
Ring Light
Out
Strobe In
Variable DC
Voltage Source
Remote PWM
Local/Remote
Switch
Common to
Microcontroller
Local/Remote
Switch
Electronic
Ballast
Health
Status
Common to
Microcontroller
AC In
LPF for
Remote Use
Trigger
Circuit
Power
Supply
AC In
Power
Supply
Incandescent Lighting
System
Remote PWM 1
Remote PWM 2
Remote PWM 3
Remote PWM 4
Lamp 1 Voltage
Lamp 2 Voltage
Lamp 3 Voltage
Lamp 4 Voltage
Common to
Microcontroller
AC In
MOSFETS
Local PWM
Generator
Local/Remote
Switch
Light 1 Out
Light 2 Out
Light 3 Out
Light 4 Out
Signal
Conditioners
LPFs
Power
Supply
Department of Electrical and Computer Engineering
Light Out
Test Results
• Integrated system test was performed satisfactorily with minor
exceptions
• Exceptions include
– Limited range of control for incandescent lamp output due
to biasing method for MOSFETs, in the future a scaling
amplifier will be added to condition the PWM signal
– Embedded computer safety ground must be disconnected
when operating Fluorescent controller
– Strobing test was not performed because software
integration was not complete
– Lamp voltage regulation test showed that the embedded
computer’s A/D board and driver was not fast enough to
regulate the lamp voltage
Department of Electrical and Computer Engineering
Conclusions and Future Work
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Project scope was large
Four systems total
Both CE/EE skills required
Main functions were implemented successfully
Project cost were higher than expected
Improvements/optimizations can be made
Advisor has expressed interest in continuing project
in future semester
• Advisor has expressed an interest in co-authoring a
paper based on the Lighting Tool Box
Department of Electrical and Computer Engineering
Acknowledgements
Individuals
• Professor Miller
– Support with electronic design
– Donation of material
– Providing us with a lab
• Professor Shridhar
– Allowing a project this large with 5 members
Companies
• Stancor – Donation of $150.00 in power supply transformers
• Bud Industries – Donation of electronic enclosure for LED light
controller
• GNU – For open source software
• Linux – For open source Kernel
Department of Electrical and Computer Engineering
Data Flow Graphic
Console
Software
void main()
{
Cout<<“Hello World”;
Cout<<endl;
Cout<<“GNU/Linux is good”;
}
Hardware
Department of Electrical and Computer Engineering
Web Service
lightingtoolbox.com
Pictures
Department of Electrical and Computer Engineering