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CLEANROOM PARAMETERS MONITORING SYSTEMS (CPMS)

MOHAMAD SYAHIR BIN JAPAR

This report is submitted in partial fulfillment of requirement for the Bachelor of

Electronic engineering (Industrial Electronics) with Honors

Faculty of Electronics & Computer Engineering

University technical Malaysia Melaka

June 2014

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UNIVERSTI TEKNIKAL MALAYSIA MELAKA

FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER

BORANG PENGESAHAN STATUS LAPORAN

PROJEK SARJANA MUDA II

Tajuk Projek : Cleanroom Parameters Monitoring System (CPMS)

Sesi Pengajian : 1 3 / 1 4

Saya MOHAMAD SYAHIR BIN JAPAR (HURUF BESAR) mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi

pengajian tinggi.

4. Sila tandakan ( √ ) :

SULIT*

*(Mengandungi maklumat yang berdarjah keselamatan atau

kepentingan Malaysia seperti yang termaktub di dalam AKTA

RAHSIA RASMI 1972)

TERHAD**

**(Mengandungi maklumat terhad yang telah ditentukan oleh

organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh:

__________________________ ___________________________________

(TANDATANGAN PENULIS) (COP DAN TANDATANGAN PENYELIA)

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“I hereby, declare this report is the result of my own research except as cited of the

reference”

Signature :

Author Name : MOHAMAD SYAHIR BIN JAPAR

Date : ……………………………………………………

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“I / we acknowledge that I have read this piece in my / our this work is sufficient in

scope and quality for the award of Bachelor of Electronic Engineering (Industrial

Electronics) With Honors"

Signature : ……………………………….

Name : MUHAMMAD NOORAZLAN SHAH BIN ZAINUDIN

Date : ………………………………..

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Dedicated to my beloved family especially my father and mother, lecturer and to all my

friends

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ACKNOWLEDGEMENTS

Alhamdullilah, I would like to express my deepest appreciation to my supervisor,

En. Muhammad Noorazlan Shah Bin Zinudin who have helped me making this project

possible. His support,guidance and advice throughout this project are greatly

appreciated. Indeed without his guidance, i would not complete this project successfully.

In addition, thenks to all my friends that helping me to complete this project and

make my dream come. The guidance and support received my friends who are

contributing to this project, was vital for the succes of the projects

Finally, first in my heart, I would also like to thanks especially my parents for

their continued moral and financial support throughout my studies and project. Without

them, I would not to be here and finish my degree.

Thank You.

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ABSTRACT

Cleanroom Parameters Monitoring System (CPMS) is a device that can display

the critical parameters inside the sensitive area. These project refer to monitoring inside

the cleanroom area because this place need to protect the products and also the

equipments from contamination. Contamination can generated from the facilities,

people, tools and fluids inside the cleanroom environment. By monitoring the critical

parameters such as temperature, humidity, dew points, particle count and light intensity

it can reduce and prevent these contaminants. These projects will show the actual

parameters inside the cleanroom area and give an indicator to the parameters that exceed

the specifications based on the cleanroom standard. Parameters that will be measured for

this project is temperature, dew points, relative humidity, particle count and light

intensity.

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ABSTRAK

Cleanroom Parameters Monitoring Sytem (CPMS) merupakan alat yang akan

memaparkan parameter yang kritikal di dalam kawasan sensitif. Projek ini merujuk

kepada pemantauan didalam kawasan bilik bersih (cleanroom) kerana kawasan ini perlu

melindungi produk dan peralatan daripada pencemaran. Pencemaran boleh terhasil

daripada manusia, peralatan dan cecair di dalam persekitaran bilik bersih. Dengan

pemantauan suhu, kelembapan, bilangan habuk dan kecerahan cahaya, ianya dapat

melindungi dan mengurangkan pencemaran. Projek ini akan memaparkan keadaan

sebenar parameter di dalam persekitaran bilik bersih dan memberikan petunjuk

sekiranya parameter melebihi daripada spesifikasi bilik bersih yang telah ditetapkan.

Parameter yang akan di ukur bagi projek ini adalah suhu, kelembapan, titik embun,

kiraan habuk dan kecerahan cahaya.

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TABLE OF CONTENTS

CHAPTER CONTENTS PAGE

PROJECT TITLE i

PROJECT STATUS FORM ii

DECLARATION iii

APPROVAL iv

DEDICATION v

ACKNOWLEDGEMENT vi

ABSTRACT vii

ABSTRAK viii

CONTENTS ix

LIST OF TABLES xii

LIST OF FIGURES xiii

LIST OF ABBREVIATIONS xvi

1.0 INTRODUCTION 1

1.1 Project Overview 1

1.2 Objectives of Project 2

1.3 Problem Statement 3

1.4 Scopes of Work 3

1.5 Project Planning 3

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1.6 Thesis Outline 4

2.0 LITERATURE REVIEW 5

2.1 Background Study 5

2.2 Software Overview 6

2.2.1 Arduino IDE 6

2.3 Hardware Overview 7

2.3.1 Arduino UNO Rev 3 7

2.3.2 DHT 11 Sensor 8-12

2.3.3 Dust Sensor 13-14

2.3.4 Light Dependent Resistor (LDR) 15-16

2.3.5 Real Time Clock DS 1307 17-18

2.3.6 2.4” TFT LCD Touch Shield 18-19

2.4 Related Project 20-22

2.4.1 Reading DS1820 temperature sensor with PIC16F628A 20

2.4.2 Temperature Alarm Using PIC16C84 Microcontroller 21

2.4.3 Temperature and Humidity Display with Adaptive

Brightness Control Using PIC12F683

22

2.5 Comparison Projects 23

3.0 METHODOLOGY 24

3.1 Project Methodology 24-25

3.2 Data Collection Method 26

3.3 Flow Chart Methodology 27

3.4 Block Diagram 28

3.5 Gantt Chart 29

3.6 Project Planning 30

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3.7 Setup an Arduino UNO Board 31-34

3.7.1 USB cable 32

3.7.2 Arduino IDE 33

3.7.3 Arduino Main Board to Computer 34

4.0 RESULT AND DISCUSSION 38

4.1 Overview 38

4.2 Testing The Sensors On Arduiono Board 39

4.2.1 Dust Sensor 39

4.2.2 DHT 11 Sensor 40

4.2.3 LDR Sensor 41

4.2.4 Test The Display 42

4.2.5 Displaying Sensor Data On TFT LCD Shield 43

4.3 Installation 44

4.4 Product Features 45

4.4.1 Sensor supply for Temperature, Humidity, Dew Points,

Light Intensity and Dust.

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4.4.2 Accurate and user friendly. 46-47

4.4.3 Parameter Limit Indicator 48

4.4.4 Large Color Display 48

4.5 FS209E and ISO Cleanroom Standards 49

5.0 CONCLUSION AND RECOMMENDATION 50

5.1 Overview 50

5.2 Project Conclusion 51

5.3 Recommendations 52

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REFERENCES 53-54

APPENDICES A 55

APPENDICES B 56

APPENDICES C 57

APPENDICES D 58

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LIST OF TABLES

NO TITLE PAGES

1 Table 2.1 : DHT 11 Specifications 9

2 Table 2.2 : Electrical Characteristics for Dust Sensor 14

3 Table 2.3: TFT LCD Specifications 19

4 Table 2.4 : Comparison with others project 23

5 Table 4.1: Accuracy of DHT 11 48

6 Table 4.2: Accuracy of Dust Sensor 48

7 Table 4.3: Sensitivity of LDR sensor 49

8 Table 4.4: Class Limit for FS209E and ISO 51

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LIST OF FIGURES

NO TITLE PAGES

1 Figure 2.1: Arduino IDE Software 6

2 Figure 2.2: Arduino UNO Rev 3 Main Board 7

3 Figure 2.3: DHT 11 Sensor 8

4 Figure 2.4: Communication Process 11

5 Figure 2.5: Data “0” indication 12

6 Figure 2.6: Data “1” indication 12

7 Figure 2.7: Grove Dust Sensor 13

8 Figure 2.8: Grove Dust Sensor Block diagram 14

9 Figure 2.9: Light Dependant Resistor (LDR) 15

10 Figure 2.10: Resistance versus Luminance Graph 16

11 Figure 2.11: Real Time Clock DS1307 (RTC) 17

12 Figure 2.12: Operating Circuit And Pin Configuration for RTC

DS1307 17

13 Figure 2.13: TFT LCD Touch Shield 18

14 Figure 2.14: Project 1 20

15 Figure 2.15: Project 2 21

16 Figure 2.16: Project 3 22

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17 Figure 3.1: Steps of Methodology 25

18 Figure 3.2: System Flow Chart 27

19 Figure 3.3: Block Diagram 28

20 Figure 3.4: Gantt Chart fpr Semester 1 30

21 Figure 3.5: Arduino UNO Rev.3 31

22 Figure 3.6: USB Cable B Type 32

23 Figure 3.7: Arduino IDE 33

24 Figure 3.8: Found New Hardware 34

25 Figure 3.9: Found New Hardware Wizard 34

26 Figure 3.10: Found New Hardware Wizard 35

27 Figure 3.11: Browse for Folder 35

28 Figure 3.12: Hardware Installation 36

29 Figure 3.13: Found New Hardware Wizard 36

30 Figure 3.14: Device Manager 37

31 Figure 4.1: Dust Sensor Result on Serial Monitor 39

32 Figure 4.2: DHT 11 Result on Serial Monitor 40

33 Figure 4.3: LDR Result on Serial Monitor 41

34 Figure 4.4: Testing LCD Display 42

35 Figure 4.5: Displaying Sensor Data on LCD 43

36 Figure 4.6: Assembling Cleanroom Parameters Monitoring System

(CPMS) 44

37 Figure 4.7: DHT 11 Parameters 45

38 Figure 4.8: LDR Parameter 45

39 Figure 4.9: Particle Count Parameter 46

40 Figure 4.9: Resistance as Function of Illumination 47

41 Figure 4.10: Limit Indicator for Parameters 48

42 Figure 4.11: Large LCD Color Display 48

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LIST OF ABBREVIATIONS

CPMS - Cleanroom Parameter Monitoring System

OTP - One Time Programmable

TFT - Thin Film Transistor

ICSP - In Circuit Serial Programming

FTDI - Future Technology Devices International

USB - Universal Serial Bus

DC - Direct Current

LDR - Light Dependent Resistor

LCD - Liquid Crystal Display

LPO - Low Pulse Occupancy

RH - Relative Humidity

PM - Particulate Matter

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CHAPTER I

INTRODUCTION

1.1 Project Overview

Clean room is a strictly area where critical parameters need to be monitor

for protect sensitive equipment or manufacturing products from contamination.

There are several designs why the clean room needs to be monitor which are

verify the process environment inside the critical area is perform according to

the require specifications[1]. The others reason is for document the data of the

process environment conditions. Clean room environment is sensitive with

product and personnel moving and changing where contamination can be happen.

By monitoring this critical parameter, it can trend charts and records of event that

can help to define maintenance cycles of cleaning.

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1.2 Objectives of Project

The specific objectives of this project are to:

1. Monitor the actual parameters of clean room environment.

2. Alerts the conditions that exceeding classification.

The first objective is to monitor and analyze the actual parameter of

cleanroom environment. By using DHT 11 (temperature & humidity sensor) and

air contaminant sensor environment inside the cleanroom can be monitor and will

be display out on the TFT LCD color display. The he data of the temperature,

humidity, dew points and dust can be monitor and analyze every hour by the

employee. The reasons why the cleanroom should be monitor is to verify either

the process environment is perform according to the requires specifications

because this areas are built to the specific requirements of the product that to be

built.

The second objective is alerts the conditions that exceeding

classifications. This is to alert the people of the actual parameters inside that area.

The parameters that exceed the specifics requirement becomes red font color to

show that the parameters is not on the requirement. By that it can help to records

the data and define maintenace cycles of cleaning process.

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1.3 Problem Statement

The purpose of this project is to monitor the quality of environment in

clean room area where the products are manufactured which the concentration of

airborne particles is controlled to the specified limits. The contaminants inside

the clean room are produced by the people, process, facilities and equipment.

The way to control the contamination is by control the overall

environment inside that area where temperature, humidity, dew points,light

intensity and dust need to be tightly controlled. In this project, it will show the

current value of temperature, humidity, dew points, dust and light intensity.

1.4 Scopes of Work

The scopes of works in this project are:

1. The design of this CPMS is to minimal the device for portable user inside

the clean room area.

2. The implemented of CPMS will consists of totally 3 sensor in 1 device

which are humidity and temperature sensor, air contaminant sensor , dew

points and light intensity sensor.

3. The coding software that will be used for this project is Arduino.

1.5 Project Planning

This project is implemented based on the project planning schedule. It

was started from September 2013 and finish May 2014.

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1.6 Thesis Outline

This thesis report contains 5 chapters that will explain more details on

each chapter to give an understanding about the whole project.

Chapter one will explain detail on the introduction of this project. In this

chapter, it presents an overview of quality environment for the cleanroom,

objective project, scope of works and project planning.

Chapter two will covers more about the literature review on the software

and hardware that will be used in this project. This chapter will discuss about the

source and article that related to this project. It will also relate the theory of

components and programming language by using Arduino Uno Rev.3. So this is

important to understand more about the overall concepts.

Chapter three will explain more about the project methodology, project

planning and project finishing. It will show the progress of this project according

to the due date which had been set before the project is in progress. In this

chapter also will include the flow chart and block diagram that will explain more

about the project system and it will also include Gantt chart for Semester I and II.

Chapter four is about the result and discussion for final year project. In

this chapter it will show how to set up the arduino software connect with

Windows and installation of arduino libraries. Other than that, this chapter will

discuss about how to troubleshoot the problems if anything happen to the

software and hardware.

Chapter five is the last chapter in this project that will represent the

conclusion based on the objective that had been specified in introduction part.

Next, this chapter also will discuss about the future planning of this project

which are suggestion for improvement on this project.

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CHAPTER II

LITERATURE REVIEW

2.1 Background Study

This chapter desribres and discusses the sources and articles that has been

studied and related to the project. This chapter also will describe the theory of

software and hardware overview that is used in this project. The literature review

must be done to comprehend the whole system and decide the best inputs,

outputs and devices. The project will be compared with the others project that

was designed. In addition, this chapter also describes all equipment, components

and programming languages that are used in the project.. All information such as

operation and specification of project also stated.

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2.2 Software Overview

2.2.1 Arduino IDE

Figure 2.1: Arduino IDE Software

Arduino software is one of the software that will be use for this project.

This software is an open source based on the simple microcontroller board and

writing software for the board. By using this software, it can develop interactive

objects, taking inputs from the variety of swithces or sensors and control the

outputs such as lights, motors and others physical outputs[3]. This software also

can communicate with software that running on the computer. In writing the

sketch code and load to the arduino, arduino IDE is the software tool.

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2.3 Hardware Overview

2.3.1 Arduino UNO Rev.3

Figure 2.2: Arduino UNO Rev 3 Main Board

Arduino UNO is the main board for this project. This main board consists

of microcontroller board based on Atmega328 and 14 digital input/output pins.

Arduino uno also has 6 analog inputs, 16 MHz crystal oscillator, USB

connection, power jack, ICSP header and reset button. This board contains

everything needed to support microcontroller and connect to USB cable. It can

also power it with AC to DC adapter or battery for get started. This board are

differs from all boards because it does not use FTDI USB to serial driver chip

and the features Atmega8U2 are programmed as USB to serial converter[3].

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2.3.2 DHT 11 Sensor

Figure 2.3: DHT 11 Sensor

DHT 11 is the sensor used for this project. This sensor will display the

current parameters for temperature, humidity and dew points where the sensor

complex are calibrated with digital signal output[2]. To ensures high reliability and

long term stability, this sensor is using exclusive digital signal acquisition technique

and sensing technology. It consists of resistive type humidity measurement

component and NTC temperature component. This sensors is connected with high

performance of 8 bit microcontroller that offering excellent quality, cost

effectiveness, fast response and anti interference ability.

The DHT 11 is calibrated in the laboratory that haas extremely accurate for

humidity calibration. It is stores as programs in OTP memory that used by the sensor

internal signal detecting process[9]. To make the system integration quick and easy,

this sensor using single wire serial interface. The DHT 11 convenient to connect and

special packages can be provided according to the users.