Cool O2 Automatic Sensor Fan
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1 Cool O2 Automatic Sensor Fan A report on a project performed for ME Mechatronics San Jose State University Department of Mechanical and Aerospace Engineering By: Yan Kin Chan Peter Vuong Andy Yip Saurabh Gupta May 16, 2006
2 Table of Contents Summary... 2 Introduction... 3 Design Details... 4 Results & Recommendations References Appendices
3 Summary An auto on/off fan was built based on a temperature sensor, two motion sensors, a fan, and a servo. The fan turns on when the ambient temperature reaches a certain degree. The motion sensors are used to track a person s movement which then the servo will rotate the fan toward that movement accordingly. A microcontroller was used to control the overall operation of this fan. A program has been written and downloaded into the microcontroller to control the temperature for powering on/off, and to control the degree of rotation of the servo as it receives signals from the motion sensors. The temperature sensor and the motion sensors send out a voltage to the microcontroller which then we regulated so that it would not overload the microcontroller. These voltages are then used as signals for giving commands to the microcontroller. Then, the microcontroller, which is also connected to the fan and the servo, sends out voltages (signals) back to the fan and servo allowing it to power on and off. The fan turns on only when there is a signal sent to the fan. From this project, we learned the difficulty in programming the microcontroller, the time and effort professional engineers spent on producing a quality satisfactory product. When programming the microcontroller, we encountered many problems such as debugging, setting the servo to run, letting the motion sensor to run smoothly, and etc. In addition, we learned more about servos, sensors, and other mechanical interfacing devices. 2
4 Introduction Mechatronics is one of the fastest growing fields in the engineering industry. Mechatronics is the combination of the fundamental mechanical engineering knowledge of mechanical as well as electrical engineering. We can see this great engineering application almost everywhere and everyday. For example, on washing and drying machine, there are temperature sensors, timer, and other devices that are all connected and controlled by a micro-controller that allows users to adjust the time, speed, and even the temperature at which the machine operates. On HVAC designs, air conditioners have implemented sensors that detect the temperature of the surrounding which send signals to a controller that regulate the powering of the machine. Our objective of this project is to build a device that has at least one sensor and one actuator that is controlled and operated by a microcontroller. The main concept of our project is to design a fan which power on itself as the it detects movement and if the surrounding temperature has reach a certain degree. It also has two motion sensors that track the person s movement. The overall design operates under a microcontroller that controls a servo, a fan, two motion sensors, and one temperature sensor. The temperature sensor is actually a thermal resistor which changes its resistance according to the surrounding temperature. The two motions sensors that we used were the SonaSwitch Ultrasonic sensors. The sensors act as a speaker as well as a microphone. It sends out signal up to a range of 7 feet, and as the signal bounces back as it detects an object, the microphone receive that signal and sends out a voltage to the microcontroller. The Futaba S3003 standard servo is used in conjunction with the motion sensors to direct the fan towards the moving object. Again, the whole functionality of the fan is controlled by a microcontroller where a program code has been downloaded into. 3
5 Design Details The two key components of the design were the temperature sensor and the motion sensor. The temperature sensor allowed for the fan to turn on automatically when the ambient temperature reached greater than the threshold temperature. The motion sensor detected motion within a vicinity of six feet allowing the fan base to rotate and point towards the user. Figure 1 shows the prototype that was presented. Shown in the figure is a 60 mm fan attached on top of the Futaba FP-S148 servo. Two Sonaswitch motion sensors were placed in plastic sensor holders which were fastened to the wooden base. The wooden base housed the breadboard and the Atmega 128 microcontroller. The NTC thermistor which is not shown in the figure was located at the other end of the wooden base. Detailed schematic diagrams of each of the subsystems are described below. Figure 1. Prototype of Cool O2 Automatic Sensor Fan Prototype of the project that was presented during the fair. A 60 mm fan was attached on top of the Futaba FP-S148 servo. Two Sonaswitch motion sensors were placed in plastic sensor holders which were fastened to the wooden base. The wooden base housed the breadboard and the Atmega 128 microcontroller. The thermistor which is not shown in the figure was located at the other end of the wooden base. 4
6 A temperature sensor circuit was constructed on the breadboard. The key component used in the construction of the temperature circuit was the NTC thermistor. The thermistor is a temperature sensitive resistor. A negative temperature coefficient unit was used, that is, the resistance decreased with an increase in temperature. The datasheet for the NTC thermistor is attached in Appendix B. The temperature sensor circuit was built such that the temperature and resistance had a relationship of 1 F = 0.1V. Thus, the circuit output a voltage of 7.5 V at a temperature of 75 F. The NTC thermistor does not have a linear relationship with temperature. However, for the narrow range of 75 F to 95 F required for this application, the relationship was sufficiently linear. At room temperature of 70 F, the thermistor had a resistance of 50kΩ. At body temperature of 98.6 F, the thermistor had a resistance of 36 kω. The schematic of the temperature sensor is shown in Figure 2. The circuit can be divided into two main sections of opamp 1 and op-amp 2. The op-amp 1 section contained an inverting amplifier which converted the variable resistance of the thermistor to a variable voltage. The op-amp 2 section contained an inverting summing op-amp which provided a voltage offset allowing for the output voltage to be proportional to temperature. An increase in ambient temperature caused a decrease in resistance of the thermistor, resulting in an increase in V out of the circuit. 5
7 Figure 2. Temperature Sensor Schematic The temperature sensor consisted of a thermistor which changed its resistance as a function of ambient temperature. An increase in temperature caused a decrease in the resistance of the thermistor and subsequently an increase in V out. A threshold temperature circuit was built to allow the user to set the temperature at which the fan would automatically turn on. Figure 3 shows the schematic of the threshold temperature circuit. In this case, the feedback resistor was set at 1KΩ and a trimpot resistor was used as a R 1. A trimpot resistor is a resistor with an adjustable resistance. Using a trimpot for R 1 allowed the user to adjust the threshold temperature to their liking. The gain of an non-inverting op-amp is given as follows: V out = V in [1 + R f /R 1 ]. Thus, if a user wanted the fan to turn on at a higher temperature, he or she would simply decrease the trimpot resistance resulting in an increase in V out. Alternatively, if the user wanted the fan to turn on at a lower temperature, he or she would increase the resistance of the trimpot resistance resulting in a decrease in V out. 6
8 Figure 3. Threshold Temperature Circuit Schematic A threshold temperature circuit set the temperature at which the fan would automatically turn on. The circuit consisted of a non-inverting amplifier. A trimpot was used as R 1 which allowed the user to adjust the threshold temperature. Increasing the resistance of the trimpot will decrease the value of V out causing a lower threshold temperature. Alternatively, decreasing the resistance of the trimpot will increase the value of V out causing a higher threshold temperature. The next circuit that was constructed was the comparator circuit. The comparator compared the output voltage from the temperature sensor and the output voltage from the threshold temperature circuit and switched its output to indicate the larger value. A standard LF741 opamp was used as a comparator. When the output voltage from the temperature sensor circuit was greater than the output voltage from the threshold temperature circuit, the op-amp output +5 V. When the output voltage from the temperature sensor circuit became smaller than the output voltage of the threshold temperature circuit, the op-amp output -5 V. The output of the comparator was connected to the power supply of the 60 mm fan. A diode was connected between the output of the op-amp and the fan which allowed the current to flow in only one direction. Thus, the fan would automatically power on with +5 V when the output voltage of temperature sensor circuit was higher than the threshold temperature circuit. 7
9 Figure 4. Comparator Circuit The comparator circuit compared the two output voltages from the temperature sensor and threshold temperature circuit and returned the higher output. The output of the comparator was connected to the power of the fan. When the voltage of the output temperature reached higher than the threshold temperature circuit, the fan automatically powered on with 5V. The prototype also incorporated two SonaSwitch Mini S motion sensors which detected motion within a vicinity of six feet and rotated the servo motor accordingly. The SonaSwitch motion sensor consists of a transmitter and a receiver. The transmitter sends out ultrasonic waves which are either reflected back to the receiver or depart from the sensor range. The datasheet of the SonaSwitch motion sensor is attached in Appendix B. Figure 5 shows the schematic of the SonaSwitch Mini S motion sensor [1]. 5 V was supplied to pin 7 and pin 6 was held to ground. Pin 2, the NPN open collector output was connected to the microcontroller. As the motion sensor detected motion, a 20mV signal was sent to the microcontroller which made the connected pin low. Alternatively, when no motion was detected, a 5 V signal was sent to the microcontroller which made the pin high. A program was downloaded to the Atmega 128 microcontroller allowing the servo to rotate when a 5 V signal was returned to the microcontroller. The copy of the programming code is attached in Appendix A. 8
10 Figure 5. Sonaswitch Mini S Motion Sensor Schematic of the Sonaswitch Mini S motion sensor is shown. Pin 2, the NPN open collector output was connected to the microcontroller. A 5 V signal was returned to the microcontroller when the motion senor did not detect any motion. The sensor returned a 20mV signal to the microcontroller when the sensor detected motion. Pin 6 was held to ground and a 5V power supply was supplied to pin 7. The servo motor served as the base of the fan as the 60 mm fan was attached on top of the servo. As the motion sensor detected motion, the servo motor and fan rotated to point in the direction of the user. The Atmega 128 microcontroller sent a stream of pulse-width modulated control signals in order to rotate the servo. In order to keep the servo from jittering, the 74HC4017 decade counter was used. The schematic of the 74HC4017 decade counter is shown in Figure 6 [2]. The yellow wire attached to the servo carried the control signal and was connected to pin 2 on the decade counter. +5 V was supplied to the red wire on the servo while the black wire was held to ground. Figure 6. 74HC4017 Decade Counter The 74HC4017 decade counter was wired between the servo and the microcontroller connection. The signal line of the servo was connected to pin 2. Pin 14 was connected to PB6 (OC1B) and pin 15 was connected to PB2. Pin 13 was held to ground and +5 volts was applied to pin 16. 9
11 Figure 7 shows the block diagram of the prototype. The comparator compared the two output voltages from the temperature sensor and threshold temperature circuit and output a voltage to indicate the higher value. If the voltage form the temperature sensor circuit was greater than the threshold voltage, the fan would be automatically powered on with +5 volts. The SonaSwitch Mini S motion sensor was used to for the rotating of the fan base to point towards the user. When no motion was detected, a 5 volt signal was sent from the SonaSwitch sensor to the microcontroller which made the pin high. While the pin was kept high, the program downloaded onto the microcontroller sent a pulse width modulation signal to rotate the servo. Figure 7 Block Diagram of the Prototype The block diagram of the prototype is shown. The two main components of the project were the temperature and motion sensors. The block diagram shows that the servo motor 10
12 rotated even when the ambient temperature was below the threshold temperature. Further improvements can be made to the system such that the servo motor only rotates when the ambient temperature is greater than the threshold temperature. Results & Recommendations The prototype of the Cool O2 Automatic Sensor Fan did perform as planned. The temperature sensor worked flawlessly. The threshold temperature was set at 95 F in order to show the operation of the temperature sensor. When the thermistor was touched and a body heat of 98.6 F was applied, the fan automatically powered on with +5 volts from the output of the comparator circuit. The motion sensor design worked as well, but had a few quirks. The original design was that the servo motor would rotate and the fan would point towards the user as soon as the motion sensor detected motion. However, the prototype that was produced was setup such that the servo motor would rotate when the user walked outside of the motion sensor range. When the pin on the microcontroller went high, the servo would rotate to point the fan towards the user. Ideally, the servo should have rotated when the pin on the microcontroller went low. Another problem was rotation of the servo motor. The servo would rotate between the two sensors six times before turning off for 20 seconds. After the 20 seconds, the servo would function normally for six more rotations. Due to the lack of time, this problem could not be investigated. Future improvements can be made to the project. The project was built such that the servo motor rotated when the motion sensors did not detect any motion. The design could be modified so that the servo motor rotates as soon as the motion sensors detect motion. If the block diagram is reviewed, it can be seen that the temperature sensor circuit and motion sensor circuit are not connected. This means that the servo currently rotates as long as the motion sensors are active 11
13 even if the ambient temperature is below the threshold voltage. For future work, the output signal of the comparator should be sent to a pin on the microcontroller which activates the motion sensor only when the ambient temperature is greater than the threshold voltage. Currently, the servo rotates between two positions to point the fan towards the user. An improvement that can be made is to have the servo rotate between three positions. Thus, when both the sensors detect motion, the servo would point towards the center position. Another simple yet effective improvement could be to implement an LCD thermometer. The output of the temperature sensor circuit could be sent to a LCD digital voltage readout and converted to the corresponding temperature to display the ambient temperature. This would allow the user to read the current temperature and know when the fan will automatically power on. 12
14 References 1. EDP Company, SonaSwitch (n.d.). Retrieved May 10, 2006 from: 2. Furman, B.J., Interfacing a Servo (2005). Retrieved May 10, 2006 from: 13
15 Appendices Appendix A Programming Code Shown below is the programming code downloaded onto the microcontroller that allowed the servo motor to rotate depending on the state of the pins. #include <avr/io.h> #include <avr/signal.h> #include <avr/interrupt.h> #include <avrlibdefs.h> #include <avrlibtypes.h> #define RC_Reset PB2 uint16_t RCpulse[10], *irc; void InitRCout(void); void StartRCout(void); void SetServo(int,int); int main(void) { DDRA=0x00;//set input PORTA=0xff;//ultrasonic sensor DDRB=0xff;//set output PORTB=0xff;//servo PORTB=PINA; while(1) { switch(pina) { case 0xfe://if it detects the one on left sei();//servo turns left InitRCout(); StartRCout(); SetServo(0,1000); break; case 0xfd: //if it detects the one of right sei();//servo turns right InitRCout(); StartRCout(); SetServo(0,2000); break; 14
16 } } return 0; } // Servos are connected to pins 1,3,5,7,9 // Dead time on pins 2 (after 1),4 (after 3),6 (after5), 8 (after 7), 0 (after 9) // Channel must be 0-4 maps to 1,3,5,7,9 // value is from approx 500 (0.5 ms) to approx 2500(2.5 ms) void SetServo(int channel, int value) { int period= 5000; int index= channel*2+1; // Temporarily disable interrupts unsigned char tmp = SREG; cli(); RCpulse[index]= value; index++; if (index == 10) index= 0; RCpulse[index]= period - value; // Reenable interrupts if they were on before SREG = tmp; } void InitRCout(void) { unsigned char i; // // High Speed Counter settings: CLK/8 normal.5us resolution // TCCR1A = (1<<COM1B1); TCCR1B = (1<<CS11); sbi(ddrb,2); sbi(ddrb,6); for (i= 0; i< 5; i++) SetServo(i, 1500); // Puteveryone at neutral (1.5 ms). } void StartRCout(void) { unsigned char tmp = SREG; cli(); PORTB = BV(RC_Reset); // Reset counter (set out0 high) OCR1B = TCNT1; // Capture our start time reference PORTB &= (char)~bv(rc_reset); SREG = tmp; irc = &RCpulse[0]; // Point to firstentry TIMSK = BV(OCIE1B); // Enable Compare on match interrupt 15
17 } SIGNAL(SIG_OUTPUT_COMPARE1B) { // PORTC++; if( (irc == &RCpulse[0]) ) { PORTB = BV(RC_Reset); PORTB &= (char)~bv(rc_reset); } TCCR1A &= (char)~_bv(com1b0); // Clear on match TCCR1C = _BV(FOC1B); // Force OCR1B += *irc++; // Calculate time to next compare. TCCR1A = _BV(COM1B0); // Set on match if (irc > &RCpulse[9]) { irc = &RCpulse[0]; } } 16
18 Appendix B Datasheets Datasheet of the NTC thermistor: 17
19 Datasheet of the SonaSwitch Motion Sensor: 18
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