Wireless Power Panel Meter (WPPM)
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1 Wireless Power Panel Meter (WPPM) Kyle Coan & Phil Perrigo Senior Project Description Western Washington University November 3, 2009 Prof. Todd Morton Page 1 of 13
2 Introduction With recent development in new green technologies, saving power has become an important issue. The big question is how? We are creating a wireless power panel meter (WPPM) for residential use. With the growing need for green technologies, ways for increasing the energy consciousness of the population will become a household necessity. Using a combination of current transformers and voltage transducers along with a MCU the WPPM will allow us to readout things such as voltage, current, and power. The current transformers will connect to the household wiring at the panel, which is 3-wire single phase also known as split phase. With this information we can calculate the power consumption of the whole household and estimated energy costs for the day, week, and month. We will implement a wireless LCD readout in kwh via the ZigBee board that will allow the consumer to place it in an area where everyone in the household can be aware of power usage. With all of the information that the system will provide, the user will be more in control of their power consumption and reduce it based on usage and cost. Hardware Description Figure 1 - System block diagram 3V BATTERY Page 2 of 13
3 Our power meter will be built around two microcontrollers, the MC13213 and the MC Figure 1 is the system level block diagram with the major components of our project. The Transceiver board, MCU1, will convert the analog signal from the CT s and VT to be used in calculations. It will also send and receive data via radio frequency. Figure 2 is the block diagram for MCU1. Figure 2 MCU1 block diagram The MCU on the transceiver (MCU 1) will be in charge of several tasks. Firstly, it will receive data from the 2 CT s and the VT. Both the CT s and VT will be outputting a proportional DC voltage based on the input. That data will then be fed into three A/D ports on MCU 1. MCU1 will be responsible for storing and calculating the data. It will also be responsible for sending the data to MCU 2 to be displayed on the LCD. To store our data we will not need a lot of memory, a maximum of 16 Kb of Flash and 1 Kb of RAM will be sufficient. To power this microcontroller we will use a power supply that will transform v AC down to 3v DC. A BDM connector will be attached to PTG0 and will be used during the development phase of this project for debugging. The BDM will not be included in the final product. We will use a 2 MHz crystal connected to XTAL1/XTAL2 for our clock frequency. MCU1 will use an antenna connected to the internal RF module for communication. Page 3 of 13
4 Figure 3 MCU2 block diagram Figure 3 is the block diagram for the Network board (MCU2). MCU 2 will be in charge of receiving the data from MCU 1 and displaying it to an LCD screen. MCU 2 will also be in charge of handing the user input for kwh cost. This will be accomplished by attaching a keypad running in 4-bit mode to the MCU on PORTD. 4-bit mode will reduce the amount of I/O pins need to connect the keypad to the MCU. A BDM connector will be attached to PTG0 and will be used during the development phase of this project for debugging. The BDM will not be included in the final product. We will use a 2 MHz crystal connected to XTAL1/XTAL2 for our clock frequency. MCU2 will use an antenna connected to the internal RF module for communication. On MCU2 we will have a button dedicated for a software reset. When the reset button is pressed on MCU2, it will send the reset signal to the transceiver board (MCU1) to clear all saved data. MCU 2, the LCD, and keypad will be powered by four AA batteries. This allows the unit to be mobile allowing for the consumer to be informed about power consumption anywhere in the house. To increase battery life we will sleep MCU2 for the majority of the time and have MCU1 calculate the data. Page 4 of 13
5 Software Description We will use the C programming language to write our code. For sending and receiving data we will use the SMAC (Simple Media Access Control) protocol housed within the Zigbee system. There will be two MCUs used. MCU1 is the transceiver connected to the power panel. The transceiver modules are listed in table 1. Table 1 Transceiver Modules Module Name Module Description Time Slice Kernel This will schedule tasks and calculate time to be used in KWh computation Wireless Communication This module will handle the SMAC protocol for sending and receiving data. Timer This will count seconds, minutes, and hours for real time calculations AtoD This will read analog inputs from CT s and VT Our system requires multiple simultaneous calculations that need to be run frequently, analog to digital conversion, and the ability to send data to the Network board. To achieve this we will use the time slice kernel to schedule the tasks. The AtoD module will read the analog inputs from the CT s and VT to be used in calculations. The equation for total cost includes the amount of time passed in relation to the power used. To calculate this we need a Timer module that will count time in seconds, minutes, and hours. While the transceiver is calculating data it needs to send information to the Network board when prompted. The Wireless Communication module will use the SMAC protocol to send and receive the data. The second MCU, MCU2, will consist of five modules that are defined in table 2 below. Page 5 of 13
6 Table 2 Module Name μc/os Wireless Communication Keypad LCD Display Button Network Board Modules Module Description This will be used to schedule tasks This module will handle the SMAC protocol for sending and receiving data. This will read the keypad data This module will handle displaying data on the LCD. This module will detect when the button is pressed and change states. For scheduling tasks in this MCU we will use μc/os kernel. The main functions of this unit are to display information, store the user defined cost constant, and navigate through the program. The Wireless Communication module will receive the information from the transceiver and send a reset signal using the SMAC protocol. The LCD Display module will take the information received from the transceiver and display it to the user. The Button module will detect a button press and move through the program states. The keypad module will read the cost constant from the keypad. RESET State Diagram Figure 4 State Diagram Page 6 of 13
7 Figure 5 depicts the state diagram for our user interface. It will have 4 different states with state one being the reset state. Our system has one navigation button that will take you to the next state when pressed. Continually pressing the button will loop through all the states. User Interface State 1: The above picture is what the home (reset) display should look like. The total kwh and total cost will be updated in real-time. When a button press is received in state 4 the program will return to state 1. State 2: The above picture is what should be displayed in state 2. The display should read kws and kws will be updated in real-time. When a button press is received in state 1 the program will change to state 2. State 3: The above picture is what the display should look like in state 3. The line current should be displayed in real time. When a button press is received in state 2 the program will change to state 3. State 4: The above picture is what the user input should look like in state 4. The user will then set the cost per kwh based on their local utilities rate using the keypad. When a button press is received in state 3 the program will change to sate 4. Page 7 of 13
8 A keypad similar to the one above should be used for the user input of state 4 (Set Cost). Since the cost per kwh is going to be in cents, there is no need for a keypad with letters in this situation. Communication Protocol ZigBee is targeted at radio-frequency (RF) applications that require a low data rate, long battery life, and secure networking. This product must comply with the standards for a Class B device described in 47 C.F.R. part 15 of the FCC rules and regulations. These regulations are in place to protect from interference by other household devices such as radio or television. The ZigBee protocol operates in the 2.4 GHz band and is based on the IEEE RF standard. For this project we will use the SMAC protocol, a simpler ZigBee protocol typically used for point to point networks. This communication will be bidirectional, so both units can send and receive information. The transceiver will send the calculated line current, real time kwh, and total cost to the network board. The network board will send the user cost constant to the transceiver board which will be stored in memory. The network board will also send the reset signal to the transceiver. This will allow them to be reset synchronously. By using the ZigBee communication standard, our project will inherently adhere to international standards of the FCC, ETSI, and ARIB. The combination of the radio and microcontroller in a small footprint package allows for a cost-effective solution. Development Plan In order for our project to be successful, it will be very important for us to continue to develop and test our project through winter and spring quarter. During winter quarter, our main goals are to get parts ordered and setup our ZigBee communication protocol. Selecting the proper channel for communication is essential because someone else s project will also be using ZigBee wireless. Initially we will focus our attention on finishing any research and then order all of our parts for our project. Once we receive the CT s and VT we will begin the testing process for them and make sure the microcontroller can properly read the data through the A/D port. Simultaneously, we will begin setting up the SMAC kernel to run the bidirectional communication between the boards. These are the primary tasks we have planned that we would like to complete during winter quarter, although we will likely work on any items that are similar to the work being done in ETEC 454 (such as LCD displays and key-pad interfacing). We would like to incorporate the key-pad from ETEC 454 into our project for the user input part of the user interface. Our approximate winter quarter schedule is as follows: Page 8 of 13
9 Table 3 Winter Quarter Week Task 1 Finish research on components 2 Order parts 3 Research ZigBee communication code 4 Design op amp circuit to give correct output levels for A/D converter 5 Test CT's and VT 6 Attach CT's and VT to panel 7 Write code for user input keypad 8 Finish code for input keypad 9 Attach keypad to ZigBee NIC board 10 Write code for display 11 Finish code for display Spring quarter will be focused on the software portion of our project. Our first task will be to finish the SMAC protocol on the transceiver MCU. Once this has been accomplished, we will be ready to implement the communication code within the SMAC interface. This will definitely be the most challenging part of our project. When the communication is setup, we can start working on creating the code to actually compute the power and display it to the LCD on the handheld. After the main programs and communication are written, we will focus on doing any final touches on the project (build mock wall and mount all hardware) to get it ready for demonstration. Throughout the quarter, we will also need to be sure to have everything completed for the hardware and code reviews during the quarter. Our spring quarter schedule is as follows: Table 4 Spring Quarter Week Task 1 Finish construction of power panel with outlets 2 Write code to collect data from CT's & VT 3 Complete last minute items needed for hardware review 4 Hardware Review 5 Work on ZigBee communication code 6 Finish ZigBee communication code data 7 Write code for received data and output to LCD 8 Finish code for code review 9 Code Review 10 Complete last minute demonstration details & demonstrate project Page 9 of 13
10 For this project there are many tasks and modules. We will divide them up between us as follows in table 5. While dividing up the things needed to be done by each of us, we will make sure that each of us have software and hardware development tasks. At the same time each of us will be responsible for building the demonstration wall for the final product. Table 5 Kyle Tasks to be completed: Task for displaying line current Task for calculating kwh total using cost Timer module for counting Keypad module for user input *Build demo wall Task for VT data to AD *Wireless module for RF communication Phil Task for CT's data to AD Task for displaying data on LCD Task for calculating kwh real time Task for storing user cost *Assemble electrical in demo wall *Wireless module for RF communication *Tasks to be worked on by both of us Development Hardware and Software We will be using the Freescale MC13213-SRB development kit. This kit comes with three boards (only using two), and all necessary development software. These boards have several built in advantages. First, they come equipped with bidirectional communication between the boards. Second, both units are designed to run off two standard AA batteries, which will be useful for our handheld board. Another nice capability of this board is that it has a built in antenna in the PCB. This will save us time from having to design an antenna. With all of the capabilities built into the board, we will only need to build and design the keypad module for the user input. We may encounter problems when we interface the keypad with the Zigbee Development kit. The keypad will be connected to PORTD, this port is general purpose I/O that shares a connection with the onboard LEDs. If we are unable to interface the keypad we will be forced to implement another way to input user cost. This can be achieved by adding two more buttons to the network board. Button 1 will cycle through digits (0 9), and button 2 will cycle through tens, ones, and tenths (##.# cents). We plan on interfacing the keypad through PORTD because adding more buttons would be costly. Page 10 of 13
11 Since the board has USB connectivity to the PC it will allow us to do development at home or in the lab. The use of the ETEC 340 digital oscilloscope will be used during the development process of our microcontroller software and hardware. We will also use other resources during the construction of our wall with the power panel. Prototype Description Figure 5 Prototype Sketch Figure 5 is a sketch of the power panel with the prototype. To demonstrate our project we are going to build a 4 x6 wall built to UL and NEC (National Electrical Code 2010) code specs to accommodate a power panel and two GFCI (ground fault circuit interrupter) outlets. The outlets will be mounted in J-boxes. Providing our CTs and all other components are small enough, we want them to fit inside the panel behind the cover. The wall will have vertical studs with sheetrock mounted to them similar to a real wall in a house. The panel will be mounted flush to the sheetrock. For cost and demonstration purposes we will use a 100A panel, the smallest size legal by code. We are making an extension cord that will power the panel from the 120v/208v plugs underneath the computer tables (see figure 5). Since we won t be able to have a full house load hooked up, two circuits should do for demonstration purposes. Connected to each circuit will be an appliance and or some other piece of electronic equipment that has a decent continuous amperage draw while it is on. We need two circuits because we want to demonstrate a load on each 120v leg of the 240v feed. Our system will monitor the current on each leg and add the total kwh usage into one kwh total. Users will be able view the output power on the handheld device. We will also have a poster or power point that will help visualize how the hardware is hooked up. This is because we can t have the cover off the panel to show people due to safety reasons. Page 11 of 13
12 Sustainability Design Our project is focused around reducing power consumption and in turn wasting less energy. During the development stages we will most likely use the power supplies provided for the boards to avoid creating waste in terms of used batteries. Once the project is finalized for demonstration purposes we will use standard AA batteries for the handheld which can be disposed of by recycling. If the consumer so chooses, rechargeable AA batteries could be used to reduce battery waste. The full load draw is 120 ma and the sleep mode draw is 40 ua. For worst case we assume that the user will look check the display on average 10 times a day. With the display time being one minute, we found the duty cycle to be 1.6% using full CPU load and 98.4% in sleep mode. With a 1.6% duty cycle we have an average draw of 1.95 ma. The network board will be powered by four AA Alkaline batteries. Under these conditions the batteries would last for approximately 213 days. Project Specifications: Accuracy: 1% for current & Voltage Resolution: 100mW Range: kW Maximum distance between display and panel: 40 meters Communication protocol: ZigBee (SMAC version) Requirements met: Part 15 of FCC rules and regulations (operating in 2.4 GHz band), ETSI, and ARIB. Power Requirements: Figure 6 input power Input source power: 120v/208v 3-phase y connection (only two phases of the 208v will be used with reference to the neutral to produce two 120v single phase combined to make 240v at the panel, see figure 6.) Sources: Wall wort (9v 0.56A) Battery Life: 213 days Worst-case power dissipation: ~460mW Worst-case sleep power dissipation: ~.152 mw Environmental Requirements: Temperature: 20 C (Room temperature) Vibration: All components will be secured in the panel to reduce risk of shorting. Development transceiver: 4 x2.5 x1.5 Development board w/lcd: 6 x4 x1.5 PCB Size Limits: Page 12 of 13
13 Parts List: Transceiver Board MCU1 Power Part Quantity Price Distributor Dissipation Lead Time Current Transformer 2 $ FLEX CORE 0mA 6 weeks Voltage Transducer 1 $ FLEX CORE 0mA 6 weeks MCU $3.50 Freescale 2.1 ma 6 weeks antenna 1 $5.00 Digikey 0mA 2 3 weeks 3V wall transformer 1 $4.94 Digikey N/A 2 3 weeks Capacitor 5 $1.80 Digikey 0mA 2 3 weeks Resistor 5 $0.27 Digikey 0mA 2 3 weeks Network Board MCU2 Part Quantity Price Distributor Power Dissipation Lead Time MCU $3.50 Freescale 2.1 ma 6 weeks Button 2 $0.41 Digikey 0mA 2 3 weeks antenna 1 $5.00 Digikey 0mA 2 3 weeks AA Batteries 4 $4.94 Duracel N/A 1 week Capacitor 5 $1.80 Digikey 0mA 2 3 weeks Keypad 1 $40.00 Digikey 0mA 2 3 weeks LCD Display 1 $8.50 Digikey 9 ma 2 3 weeks Resistor 5 $0.27 Digikey 0mA 2 3 weeks Page 13 of 13
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