Home Automation Control over Powerline

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1 Western Washington University Home Automation Control over Powerline Electronics Engineering Technology Project Description Michael Nist ETEC 471 December 8 th, 2010 Page 1

2 Table of Contents Functional Description 2 Introduction 2 Physical Description 2 Functional Description 4 Software Requirements 7 User Interface 8 Communication Protocols 10 Development Plan 10 Development Schedule 10 Development Hardware and Software 11 Demonstration Prototype 11 Sustainability Considerations 11 Electrical Specifications 12 Project Specifications 12 Environmental Requirements 12 Power Requirements 12 PCB Size Limits 12 Preliminary Parts List 13 Functional Description Introduction The purpose of this project is give the end used the ability to control the power to many items in their home. This could include lighting, appliances, heating/air conditioning, or anything else that you would like to control. The communication between the controllers will use the power lines themselves to communicate. This system could be expanded upon to include power measurement and management as well as security system communication. For the purpose of this project, I will be focusing on power control and monitoring. I will be assembling a plug in outlet controller that also monitors the power used by the appliance plugged into it, and then a main control unit. Physical Description The hardware for this project will be split among two main units; the main controller and the plug in outlet controller. The main controller will be what the user interfaces with to remotely control the other units in the system (see Figure 1). It will contain a LCD display as well as direction buttons that the user will interface with. The main unit will also receive power usage data from the remote unit and display it on the LCD. The second unit in this project is a plug in outlet controller (see Figure 2). This will be a box that can plug into any standard home Page 2

3 outlet, and then control whatever is plugged into it. This unit will have on/off switches to both operate the item that is plugged into it, and to turn on or off the remote control functionality. This controller will also have power monitoring circuitry that will monitor the power usage of the item that is plugged into it. It will then transmit this information back to the main control unit. These units will both communicate with each other directly over the power lines they are plugged into. This will allow the units to communicate without the needing to run any extra wires or deal with any potential interference associated with wireless. The units will communicate via the medium that they are already attached to. The result will be a system where lighting and other power loads in the home can be controlled from one central location. The main control unit will also have the option of setting timers that would turn on/off the power to items at specified times. Lighting 1 On/Off Power Cord l 0 Figure 1: Picture of the main control unit. Dimensions: The main control unit should have a maximum height of 4 inches, a maximum width of 6 inches, and a maximum length of 10 inches. Power Cord Remote l 0 Outlet Power l 0 Figure 2: Picture of the plug in outlet controller. Dimensions: The plug in outlet controller should have a maximum height of 4 inches, a maximum width of 4 inches, and a maximum length of 8 inches. Page 3

4 Functional Description This system will require several microcontrollers to function (see figure 3). I have chosen to implement this system using power line communication hardware made by Cypress Semiconductor. The system will require a Cypress CY8CPLC20 microcontroller for use as the master controller in the main control unit (see figure 4). A LCD and user buttons will be attached to this microcontroller so that the user may interface with the system. This main control unit will communicate via the power line medium to the plug in outlet controller. The plug in outlet controller will utilize a Cypress CY8CPLC10 Power Line Commutation microcontroller to communicate with the main controller (see figure 5). This microcontroller provides only the means by which to communicate to the main controller, thus outlet controller will require an additional microcontroller to complete the task of power control. The microcontroller selected for this task will be a Cypress PSoC 1 CY8C The resources used on each of the microcontrollers will be fairly minimal. The Cypress power line microcontrollers will communicate with each other via Cypress Powerline Network Protocol. The Cypress powerline microcontroller in the outlet controller will communicate to the Cypress PSoC 1 microcontroller via the I 2 C bus. On the Cypress PSoC 1 chip, the actual manipulation of the power to the output outlet will be controlled via General Purpose IO (GPIO). This manipulation of the power should only require one port. Two GPIO ports will be used to accept the incoming signal from the power monitoring circuitry; this will then be fed into the analogue to digital converters (ADC). Finally, one more GPIO port will be used to detect the state of the user switch that will be used to override the network control of the outlet. The Cypress CY8C29466 chosen for this project has a total of 24 free GPIO lines, thus it should have plenty for our application. On the Cypress powerline microcontroller in the main control unit, there will be several GPIO ports utilized. The user LCD and user buttons will be attached via GPIO. The LCD will require 8 GPIO lines, thus a full port. The user buttons will require one line each, thus a total of 5 lines, one for each user button. The CY8CPLC20 microcontroller utilized for the main controller has a total of has a total of 18 free GPIO lines, as well as 8 lines dedicated for an LCD. Thus there should be enough ports for this application. Besides the microcontrollers, some other major components will be required. These will include switches, housings, user buttons, LCD, power supply circuitry, some form of circuitry to act as a relay to turn the power on and off to the controlled outlet, and circuitry to measure the power usage of the controlled outlet. Switches will be used in several places in the system. On the main controller unit, there will be a switch to turn the controller on and off. On the plug in outlet controller, there will be two switches, one switch will allow the user to manually toggle the power to the outlet, bypassing the powerline communication control. The other switch will be used to simply turn off the power line networking, so that the appliance can be controlled locally by the first switch. Page 4

5 The user buttons will be installed on the main control unit and will be used by the user to interface with it. This project will require the use of five user buttons, one for each direction, and one for ''. The directional buttons, 'UP', 'DOWN', 'LEFT', 'RIGHT', will be used for navigating around in the user interface. The '' button will be used for selecting the current item displayed on the screen. These five buttons will be provided by the use of a D Pad. This will allow all five buttons to be purchased and connected as a single unit. The housings will be of sufficient size to hold all the necessary components of the system. The housings will also provide necessary protection to the user from the possibility of electrical shock. The LCD will allow the user to view what is currently happening on the main controller. The LCD will be required to be able to display a sufficient number of characters for the user interface. The power supply circuitry will allow power to for the microcontrollers to be pulled directly from the 120v power lines that are being used for communication. All three microcontrollers will derive their power in this way. The communication/power supply circuitry must be able to convert the voltage down to 5v used by the microcontrollers and rectify it into DC. The circuitry must also provide all of the amplification, filtering, and isolation necessary to communicate over the power line networking. Plug In Outlet Controller Cypress PLC Slave Controller CY8CPLC10 I 2 C PSoC 1 MCU Power Control Circuitry Switc Appliance Being Controlled Power Line Controller Unit Cypress PLC MCU Master Controller CY8CPLC20 LCD HID Figure 3: Overall System Diagram Page 5

6 120V Powerline Power Switch 120V Powerline Power Line Circuitry (Data and Power) Power, 5v Data, TX RX GPIO P40 P46 Cypress PLC MCU Master Controller CY8CPLC20 GPIO P30 P34 LCD Display D Pad User buttons Figure 4: Block Diagram of Main Control Unit 120V Powerline Power Switch 120V 120V Power Line Circuitry (Data and Power) Power, 5v Cypress PSoC 1 CY8CPLC10 Data, TX RX Power 5v I 2 C GPIO P00 Power Control Circuitry 120V Enable Switch GPIO P01 Cypress PSoC 1 CY8C29466 GPIO P10 P11 Power Monitoring Circuitry 120V Outlet Figure 5: Block Diagram of Plug In Outlet Controller Page 6

7 Software Requirements The Cypress microcontrollers will require programming to perform their respective tasks. The programming language to be used for all three microcontrollers will be C, as this is a common language to all of the microprocessors and will simplify development. Below is a list of the modules that will be required for each of the microcontrollers in this system. CY8CPLC20 Modules CY8CPLC10 Modules CY8C29466 Modules PLC PLC I 2 C LCD I 2 C Toggle Power User Input Kernel Power Monitoring User Interface Kernel Timer Power Usage Kernel Table 1 CY8CPLC20 Modules PLC: Contains all the functions necessary to transmit and receive data over the power line communication medium. This will be used to communicate with all of the remote power controllers. LCD: Contains all the functions necessary to display data on the LCD display. User Input: Contains all the necessary functions to acquire button presses from the D pad and pass them on to the rest of the program. User Interface: Contains all the necessary functions to implement the user interface, including all the possible states. Timer: Contains all the necessary functions to set, clear, and view timers. This will allow the user to set a timer to control the power. Power Usage: Contains the functions necessary to keep track and calculate the power usage by the remote controlled outlets. Kernel: The kernel will be the central component of the microcontroller's programming. It will allow all of the other modules and functions to communicate. CY8CPLC10 Modules I 2 C: Contains all the functions necessary to transmit and receive data over the I2C bus. This will be used to communicate with the CY8C Kernel: The kernel will be the central component of the microcontroller's programming. It will allow all of the other modules and functions to communicate. CY8C29466 Modules Page 7

8 PLC: Contains all the functions necessary to transmit and receive data over the power line communication medium. This will be used to communicate with the main control unit. I 2 C: Contains all the functions necessary to transmit and receive data over the I2C bus. This will be used to communicate with the CY8CPLC10. Power Monitoring: Contains the functions necessary to measure and calculate current power usage, then pass it on to be transmitted back to the main controller. Kernel: The kernel will be the central component of the microcontroller's programming. It will allow all of the other modules and functions to communicate. User Interface The user interface for this system will consist of a LCD display and several buttons and switches. The plug in outlet controller will have two switches on it. One switch will be used to cycle the power to the outlet, overriding the current state that the controller had set it to. The controller will still be able to change the state again if instructed to by the main controller. The second switch will be used to disable the outlet controller, such that the power to the outlet is only controlled by the first switch. The main control unit will have the most in the way of user interface. It will contain the LCD display as well as several buttons and a switch. The switch will simply be used to turn the controller on and off. There will be a total of five buttons; up, down, left, right, and. These buttons will allow a user to navigate around the user interface and to select items and change the states of the remote controllers. The actual user interface will be displayed on an LCD module connected to the CY8CPLC20 microcontroller. The state diagram for the user interface of the main controller is detailed below in figure 6. The user interface of the main control unit will be required to perform several tasks. First it must be able to cycle through each of the remote controllers it is to talk to. In this case the plug in outlet controller. This will simply be called Controller 1. For any remote controllers, the user interface must be able to toggle the power state of the remote item to be controlled, set a timer, view the timer, and clear the timer, view instantaneous power usage, view 1hr power usage (in KWh), and view 24hr power usage (in KWh). Page 8

9 Next controller up Switch? Set Start +5min Set End +5Min Reset Set Timer? Set Start 00:00 Set End 00:00 Controller 1 Set Start 5Min Set End 5Min View Timer? Current Timer 00:00 12:00 Next controller down Clear Timer? Timer Cleared! View Power Usage? Instantaneous Watts Last 1Hr KWh Last 24 Hr KWh Clear Power Usage? Power Usage Cleared! Figure 6: User Interface State Diagram The above diagram shows all the states of the user interface as well as what the user interface LCD screen will look like on each step. Page 9

10 Communication Protocols In this project, there will be one communication protocol that will be external to the devices. This will be the Cypress Powerline Network Protocol, it is a communication protocol developed by Cypress to communicate over standard home power lines. It allows for addressing multiple nodes on the network enabling point to multipoint communication. The actual communication is completed using a FSK modem connected through an AC/DC power line coupling circuit to the power lines. The protocol supports bidirectional communication with acknowledgment based signaling. The protocol utilizes an eight bit packet CRC with a four bit CRC header for error detection and packet transmission. The result is a communication link utilizing the power lines as the connection medium that is capable of achieving up to 2400 bps. Development Plan Development Schedule Winter Quarter Date Week Task 1/3 1 Work on securing Cypress development boards 1/10 2 Design power control circuitry/ simulate 1/17 3 Design power monitoring circuitry/ simulate 1/24 4 Research necessary parts and chassis/ order 1/31 5 Write preliminary code for CY8C29466, get I 2 C working 2/7 6 Assemble power control and monitoring circuitry/test 2/14 7 Write code for CY8C29466/test with power control and monitoring circuitry 2/21 8 Test interfacing between CY8C29466 and CY8CPLC10 2/28 9 Test fit components in chassis 3/7 10 Correct any outstanding issues, wrap up loose ends 3/14 11 Finals Week, No work scheduled 3/28 12 Spring Break, No work scheduled Spring Quarter Date Week Task 4/4 1 Write code for CY8CPLC20, begin testing powerline network protocol 4/11 2 Continue coding CY8CPLC20, nail down powerline networking 4/18 3 Begin writing user interface, Hardware review: 4/19/2011 4/25 4 Work on user interface/begin integrating code, Software presentations: 4/29 5/2 5 Continue integrating code/debugging, Software presentations continued 5/9 6 Final assembly of all system components/ Begin final testing 5/16 7 Continue final testing/ improve performance 5/23 8 Build demonstration rig, wrap up loose ends, Code review: 5/24/2011 5/30 9 Prepare for demonstration, Demonstration: 6/2/2011 Page 10

11 Development Hardware and Software The design and development of this system will require the use of lab space and equipment. During the design phase, lab computers will be primarily utilized. Circuit design and simulation will be done using National Instruments MultiSim program available on the lab computers. Software development for all three of the Cypress microcontrollers will be performed using Cypress PSoC designer software utilizing both my own personal computer as well as the lab computers. Hardware testing will mostly be performed in the ET 340 lab where most of the specialized equipment is located. The equipment to be utilized will include the mixed signal oscilloscope, signal generator, multimeters, and other equipment as necessary. Demonstration Prototype To demonstrate this system, several development boards will be used. The Cypress CY3274 development board will be used for the CY8CPLC20 microcontroller. The Cypress CY3272 development board will be used for the CY8CPLC10 microcontroller. Finally, the Cypress CY3210 PSoCEval1 development board will be used for the CY8C29466 microcontroller. All of the electrical components will be housed in two separate project boxes; one for the main controller and one for the plug in outlet controller. Any electrical construction will be done with either soldering or prototyping boards. The main control unit and the plug in outlet controller will simply be plugged into separate outlets available on the lab bench. The system will communicate over the power line that they are both connected to. The plug in outlet controller will have a fan, lamp, or some other small appliance plugged into it for the control demonstration. When the controlled outlet is activated and power is supplied to the outlet, the power monitoring circuitry will measure and calculate the current power usage of the outlet and transmit this information back to the main control unit for display. A poster board will be included in the demonstration to display some of the concepts behind the system. Sustainability Considerations The overall power consumption of this system will be fairly low. Especially when contrasted against the amount of power you may potentially save by using this system to conserve energy. Care should still be taken in the design process to minimize the power consumed by the product and to eliminate as much wasted energy as possible. To help reduce any potential hazardous material usage in this system, only RoHS compliant parts and components will be used. Page 11

12 Electrical Specifications Project Specifications Accuracy: +/ 5% Resolution: 0.1W Range: W Data Rate: 1200bps Sampling Rate: At least every 500ms Communications Protocol: Cypress Powerline Network Protocol Environmental Requirements Operating temperature: 32 F 120 F Moisture requirements: N/A Vibration requirements: N/A Power Requirements Source: 120V AV Type: Internal Transformer Main Control Unit Worst Case Power Dissipation: 4.749W Plug in outlet controller Worst Case Power Dissipation: W PCB Size Limits Main Control Unit PCB Max Size: 5 in. x 6 in. Plug in outlet controller PCB Max Size: 6 in. x 4 in. The size of the PCB must be able to be accommodated within the overall maximum dimensions of the chassis described earlier in the document. Page 12

13 Preliminary Parts List Main Control Unit Item quantity Cost Max. Power Dis. Source Cypress CY8CPLC mW Cypress CH761 ND SPST Switch n/a Digikey P12330SDKR ND D Pad Switch n/a Digikey ND 32 Character LCD Module mW Digikey 8 x6 x4 Project Box n/a DigiKey WK6278TB ND 2A Fuse n/a DigiKey DF10S TDITR ND Rectifier n/a DigiKey PLK1185 ND common mode choke n/a DigiKey Flyback Transformer n/a DigiKey IW AC/DC power controller mW cdiweb 5V voltage regulator mW Digikey lmh6639mf Op Amp mW Digikey FCX591ATA Transistor mW Digikey Isolation transformer n/a Digikey 0.15uF Cap n/a Digikey Totals W Plug in outlet controller Item quantity Cost Max. Power Dis. Source CY8C mW Cypress Cypress CY8CPLC mW Cypress RELAY SPDT 10A 5V mW Digikey CH761 ND SPST Switch n/a Digikey SW318 ND SPDT Switch n/a Digikey 8 x3 x3 Project Box n/a DigiKey WK6278TB ND 2A Fuse n/a DigiKey DF10S TDITR ND Rectifier n/a DigiKey PLK1185 ND common mode choke n/a DigiKey Flyback Transformer n/a DigiKey IW AC/DC power controller mW cdiweb 5V voltage regulator mW Digikey lmh6639mf Op Amp mW Digikey FCX591ATA Transistor mW Digikey Isolation transformer n/a Digikey 0.15uF Cap n/a Digikey 50mΩ Resistor, 30W ,000mW Digikey 1MΩ Resistor, ¼ W mW Digikey Totals W Page 13

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