lighting tool box
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Department of Electrical and Computer Engineering
Lighting Tool Box
Winter 2004ECE 498
Team Members:Nick Sitarski
Blaine ThompsonBrandon HarrisDave Chronicle
Vladi Gergov
Advisor: Professor John W. Miller
Department of Electrical and Computer Engineering
Project Summary
• 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
• 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• Embedded Controller
Enclosure Dimensions: 6.5”x4.5”x3.5”Processor Speed: 300 MHzOperating System: GNU/LinuxWeight: 2 lbs.Power requirements 120 VAC @50 watts
• Incandescent SystemEnclosure Dimensions: 11”x17”x9.5”Lamp Enclosures: 4”x4”x8”Weight: 30 lbs. Power requirements 120 VAC @250 watts
• LED SystemEnclosure Dimensions: 11”x15”x9.5”Ring Light: 4”x4”x2”Weight: 10 lbs.Power requirements 120 VAC @50 watts
• Fluorescent SystemEnclosure 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• 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
Light 2 Out
Light 3 Out
Light 4 Out
Light 1 Out
PowerSupply
LPFs
SignalConditioners
Local/RemoteSwitch
Local PWMGenerator
MOSFETSRemote PWM 1
Remote PWM 2
Remote PWM 3
Remote PWM 4
Lamp 1 VoltageLamp 2 VoltageLamp 3 VoltageLamp 4 Voltage
Common toMicrocontroller
AC In
Incandescent LightingSystem
Strobe In
Ring LightOut
PowerSupply
TriggerCircuit
HealthStatus
Local/RemoteSwitch
Local PWMGenerator
MOSFETSRemote PWM
Common toMicrocontroller
AC In
LED Lighting System
Health Signals toMicro Controller
Light Out
PowerSupply
LPF forRemote Use
ElectronicBallast
Local/RemoteSwitch
Variable DCVoltage Source
Remote PWM
Common toMicrocontroller
AC In
Fluorescent LightingSystem
Department of Electrical and Computer Engineering
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
• 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
Hardware
Software
Web Service
lightingtoolbox.com
Console void main()
{Cout<<“Hello World”;Cout<<endl;Cout<<“GNU/Linux is good”;}
Department of Electrical and Computer Engineering
Pictures
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