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MICHIGAN STATE UNIVERSITY COLLEGE OF ENGINEERING

Smart Gate Security ECE 480 Senior Design Project Final Report

Team 7

Trevor Emerick |Lauren Poole | Jazmine Gaymon | Bingyang Wu

Sponsor: ArcelorMittal

Sponsor Liaison: Cliff Barnett

Facilitator: Nihar Mahapatra

4/29/2015

ECE 480 – Design Team 7

1 Smart Gate Security

Executive Summary ArcelorMittal requested a new entry gate that will aid traffic flow, improve security, and reinforce safety on their Indiana Harbor Long Carbon (IHLC) Plant. During the visit to ArcelorMittal the team noticed the current plant entrance was very outdated and not secure. The current system consists of only two guards that monitor the incoming and outgoing traffic flow. Employees were granted access simply by waving their badge to the guards. This method was deemed inadequate because with this system an unauthorized person could easily wave a false card to the guard and gain entrance to the facilities. To improve the security of the front entrance employees will utilize the RFID tags currently installed in their employee IDs to grant them access through our “smart” gate. The hardware used to complete the small scale design, was an Arduino Yun microcontroller, serving as the processing unit. A servo motor and a Parallax RFID Card Reader were attached to the Arduino Yun as Input and Output devices. The required software for this project is Arduino Software, which makes it easy to write and upload code to the microcontroller through a serial port connection. After the hardware and software were configured and uploaded, two cards with RFID tags were used to test the functionality of the design. Only one tag was embedded in the microcontroller code as “having access.” While the RFID reader acknowledged both cards, only the card with the tag embedded in the system would initiate the servo motor. This is what ArcelorMittal is looking to implement as a solution at their plant.



Acknowledgments Cliff Barnett: Sponsor, for providing us with insight to what ArcelorMittal was looking for. As a result of our countless emails and meetings the team was able to jump into the project with a clear understanding and game plan. This made it easy to adjust the design as needed. Dr. Nihar Mahapatra: Facilitator, for his help and mentoring through the various stages of the project. His advice and feedback contributed greatly to our project and helped us come together as a team. Dr. Timothy Grotjohn and Dr. Latlia Udpa: ECE 480 professors, for their help and insight throughout the semester. Gregory Racich: ArcelorMittal Contact, for providing us with in depth knowledge of some of the infrastructure resources and policies at ArcelorMittal. This helped us jump into a designing a cost effective large scale budget. Mechanical Engineering Team: Partners, for providing us with layouts of the new entrance designs and mounting points for our hardware.



Table of Contents Executive Summary ...................................................................................................................... 1

Acknowledgements ...................................................................................................................... 2

Chapter 1 -‐ Introduction & Background ....................................................................................... 5

1.1 Introduction ....................................................................................................................................... 5

1.2 Background ....................................................................................................................................... 5

Chapter 2 -‐ Finding a Solution ...................................................................................................... 6

2.1 FAST Diagram ................................................................................................................................... 6

2.2 House of Quality ................................................................................................................................. 7

2.3 Conceptual Design Matrix ................................................................................................................. 8

2.4 Chosen Solution ................................................................................................................................. 9

2.5 Estimated Cost ................................................................................................................................. 10

2.6 GANTT Chart .................................................................................................................................... 11

Chapter 3 -‐ Final Design ............................................................................................................. 12

3.1 Hardware Setup ............................................................................................................................... 12

3.1.1 Setup Arduino Yun .................................................................................................................... 12

3.1.2 Setup RFID Reader .................................................................................................................... 13

3.1.3 Setup Servo Motor .................................................................................................................... 14

3.2 Software Setup ................................................................................................................................. 14

3.2.1 Arduino Software ...................................................................................................................... 14

3.3 Software Design ........................................................................................................................... 15

3.3.1 Built-‐in Database ...................................................................................................................... 16

3.3.2 Checking Database for Access .................................................................................................. 16

3.3.3 Brute Force Attack Protection .................................................................................................. 16

3.4 Design Issues and Solutions ............................................................................................................. 17

Chapter 4 -‐ Assembling & Testing .............................................................................................. 17

4.1 Assembling the Prototype ................................................................................................................ 17

4.2 Testing & Proof of Functionality ..................................................................................................... 19

Chapter 5 -‐ Summary and Conclusion ........................................................................................ 20

5.1 Summary and Conclusions .............................................................................................................. 20

5.2 Success and Failures ........................................................................................................................ 20



5.3 Suggestions for the Future .............................................................................................................. 21

5.4 Small Scale Final Costs .................................................................................................................... 21

5.5 Final Budget ..................................................................................................................................... 22

5.5.1 Small Scale (Team 7 Design) .................................................................................................... 22

5.5.2 ArcelorMittal Budget ................................................................................................................ 22

5.6 Final Schedule .................................................................................................................................. 23

Appendix 1 -‐ Individual Contributions ....................................................................................... 24

Lauren Poole .......................................................................................................................................... 24

Trevor Emerick ...................................................................................................................................... 25

Jazmine Gaymon .................................................................................................................................... 25

Bingyang Wu ......................................................................................................................................... 26

Appendix 2 – References ............................................................................................................. 28

Appendix 3 -‐ Technical Documents ............................................................................................ 29

Final Code (Entering Gate) ................................................................................................................... 29

Final Code (Exit Gate) ........................................................................................................................... 33



Chapter 1 -‐ Introduction & Background

1.1 Introduction ArcelorMittal is in need of a new updated electrical and mechanical design for the front gate entrance at the Indiana Harbor Long Carbon plant. According to many of the ArcelorMittal personnel, safety and security are two major concerns on and off the job. The current gate entrance is very outdated with little to no security. This means that anyone wanting to gain entrance has a significantly high chance of being able to do so with the current design. The goal is to modify the current entrance to ensure all personnel entering the facilities is supposed to be there. This is very important in meeting the objectives that ArcelorMittal has set in creating a safer and secure entrance. In order to create a solution to their problem we will need to design an entrance with the following: a Radio Frequency Identification card reader, and security cameras at the entrance. Due to the nature of the project there is both a small scale and large scale model. The small scale model will be what is presented on design day and will simulate aspects of the large scale model. The small scale model will also be connected to the Mechanical Engineering team’s prototype, giving the prototype life like characteristics. The large scale model however will consist of a mechanical model and a budget for ArcelorMittal to implement or contract out to another company.

1.2 Background Cliff Barnett, Environmental Engineering Manager, Project Sponsor, and receiving customer of the finished product provided the team with a tour and technical information on the card readers used currently throughout the ArcelorMittal IHLC Plant during our site visit. From this visit design specifications were established. The plant currently used the Matrix Systems card readers to assist in access control to their buildings. The Matrix systems had been proven to be efficient, familiar, and effective for the customer in the past. Since the card reader use Power over Ethernet (PoE), the customer will have a streamlined and easy installation process. The Matrix System card reader that was chosen for this project is the MXProx2. This card reader is capable of controlling a gate entrance using a built in microcontroller; as well as being capable of reading cards from 3 to 4 inches away, providing a secure entrance from the business standpoint. The next step consists of making sure that everyone entering the facility is doing so with their own credentials. This can be accomplished with the use of a security camera. The security camera aspect of the project was left open ended for the group to explore. After speaking with Greg Racich, Manager of Emergency & Security Services, the ArcelorMittal security infrastructure technology stack was more understood. The technology stack consisted of a ExacqVision video server which was used to record security cameras at different ArcelorMittal Plants. These servers are configured to record up to the 80 gigabyte capacity and then overwrite the oldest files. The compatible Internet Protocol (IP) cameras that ArcelorMittal uses with the ExacqVision server



are Axis, Samsung, and Arecont. After careful consideration, it was decided to go with is an Axis Q1604-E, an outdoor IP camera that utilizes PoE. Several requirements are met with this model including day and night functionality, a proven and reliable product that has been implemented before in ArcelorMittal’s security infrastructure, and capable of surviving the harsh weather changes in the midwest region. The camera itself has a very small footprint in the grand scheme of the overall design, as seen in figure 1 below.

Figure 1: Specification Design of the Axis Q1604-e camera.

Gate security designs in today’s society fall into two categories. Those that are manually controlled, which are typically toll based, and those that are automatic which are automatic. The latter has started to slowly grow and become a standard within the industry instead of the use of tags that hang from employee’s mirrors. The limits in today’s society are typically the cost to upgrade to this new standards. There are many companies that do not have problems with their current method and do not have the capital readily available to upgrade parking lot entrances, exits, or technology infrastructure. The companies that have accepted and implemented this new business model are typically using only RFID readers at the entrances. Therefore, we are proposing the new idea of recording the traffic flow, using security cameras, for each lane of traffic. This will provide a new and successful method of entrance because in the case of emergency, an emergency/security employee can look at the entrance footage and see what the person was wearing on that given day. This does not only protect the company but improves employee safety under extreme circumstances. Overall, this new technique will provide peace of mind not only for the business as a whole, but employees alike.

Chapter 2 -‐ Finding a Solution

2.1 FAST Diagram The overall goal of the project, as shown in the fast diagram, was to create a gate entrance that was “smart”. The fast diagram below is for the theoretical small scale model. However there are many similarities to the large scale model, which would be simpler and can be broken down into two main tasks. A RFID tag needs to be read, compared to an active database, and cause a visual of the individual to be recorded. This can be accomplished by using an Matrix System MXProx2 card reader, which will obtain the tag code from the employees identification card. This will be sent over the PoE connection that is used also to provide power to the card reader. During this time the IP camera will record the employee so there is a visual representation of every employee on site for that day. However if a visitor, contractor or trucker arrives to the plant, they will go through a similar process except instead of a RFID card being read, they will receive a Quick



Response code or have to register with the guards. After these steps have been completed, the respective individual will be given the grant or deny access message. Upon exiting the plant, each individual will scan their identification card, quick response code, or make contact with the guard so they can be removed from the onsite table. Given the circumstances, removing them from the table will provide a very accurate list of who is on site during an emergency. If there is an incident, like theft or unauthorized entry, the emergency and security team will have time stamps to narrow down who they should question. This can be seen in the fast diagram, and is important in the successful implementation at the ArcelorMittal Indiana Harbor Long Carbon plant.

Figure 2: FAST Diagram

2.2 House of Quality In order to determine the most critical customer requirements the house of quality approach was used. These requirements are as follows:

1. Improvement of Entrance Security a. The use of the RFID reader will provide additional security to the plant entrance.

This will replace the waving of identification cards to the guards without contact. Now there will be a virtual contact point between the employee and the matrix server, which will verify the employee's identification.

2. Improve Employee Safety a. With the ability to track when employees are entering and leaving the plant,

employees will be working in a safer environment. If anything were to happen, security would be able to compile a list of personnel still on the premises very quickly.

3. Increase Entrance Efficiency



a. The overall efficiency will be both for employees and visitors. Instead of a truck driver, contractor, or visitor having to get out of there car and check in with the guards, they can scan the quick response code, sent prior to their arrival, and be granted access fast.

2.3 Conceptual Design Matrix The below table was used to determine which method should be pursued for designing a small scale prototype.

Criteria Weight (%)

Arduino/Wireless IP Camera Raspberry Pi/Bus Camera

Operational Functional: A description of how the proposed device will benefit the company and how well it would interface. Acceptance: A validation for how well the solution would be received by the company, user, and the public's’ perspective.

30 This system will work very well since it will use many devices that are used widely in today’s society by both home and business owners. The system will be user friendly since it will be able to be accessed remotely and the camera will be more robust. Score: 30

This system will not work as well since the Raspberry Pi and Bus Camera are more limited in overall operation. This system would not be accepted very well since the user experience would be challenging for a person with average technical skills. Score: 26

Technical Technology: The amount of technology and support needed. The practical use of the proposed technology within the company Knowledge: Evaluation of the

30 The technology used in this design would be considered “state of the art” currently. The Arduino is very robust in customization and accessibility. While the IP camera has an infrared interface allowing for better night vision. The expertise that will be needed will be very minute. Many of the small problems that could be faced

The technology used in this design is older since the camera is recorded off the bus. When the camera is connected to the bus there is no opening for other devices to be interfaced. Making the design not only limited, but will be much larger to accomplish the task. The expertise to fix a problem with this design will be much more technical because the manager will need to track



needed expertise for each step of the project, as well as maintenance.

will be able to be fixed with a quick reboot. Score: 26

down which microcontroller is experiencing the problem in order to fix it Score: 20

Economic The overall cost for the proposed design and the amount the business will recoup.

30 300+ Score: 25

350+ Score: 23

Timeline Amount of time to deliver the proposed solution effectively.

10 5 to 7 weeks Score: 10

6-8 weeks Score: 9

Rank 100 x> 91 x> 78

Table 1 - Design Feasibility Matrix

2.4 Chosen Solution The team decided that the best solution was to use an Arduino Yun microcontroller as the processing unit for the gate controller and an IP Camera. This will then be connected to the input and output hardware. The computer will be used for code development and serial command window to track when RFID card is scanned. This solution is very unique in that it is a very small replica compared to the current solutions used in society. Many of the current gate security solutions utilize PoE for powering the device and connecting it to a network. Unlike these commonly used technologies, the new prototype will process almost everything on board except a USB connection for power and serial monitoring. There are a few reasons that the Arduino Yun was ideal for this application. Compared to the Raspberry Pi, the Arduino Yun was more robust and business oriented compared to the Raspberry Pi that was more homeowner oriented. Secondly, the Arduino Yun has an onboard wireless card which allows it to be connected to a network without sacrificing a USB port for a wireless adapter. Additionally, the design was chosen due to the use of a wireless camera. A wireless camera uses the IP protocols instead of the typical USB connection. This allows for the camera to be configured to write data to a central server. This enables videos to be stored centrally instead of a limited amount locally, leading to more storage availability. One of the benefits of this solution



architecture is the end user can choose how much storage to use and have the option to expand the storage volumes as needed. The next part of the solution is to receive an input to us for authentication. The Parallax RFID reader will be connected to the Arduino Yun. The RFID reader will read the code embedded in the identification card and will be fed into the overall program uploaded to the microcontroller. Depending on the user’s access restrictions, they will either be allowed to drive onto the premise or they will be unauthorized and not allowed to enter. As stated before, the serial viewer will also show the string that is tied to the RFID card for any logistics that need to be analyzed for the addition of users to the authentication list. After an individual is authorized to access the premise, it is important that the motor works effectively so one can get onsite efficiently. This aspect of the prototype will control the movement of the gate. This action is built into the code, if the card is in the database, the pin is activated and rotates the motor to an open position, wait and then close it to its starting position. A program will be written to combine all aspects of the design and provide an effective solution. The program will be developed on a Windows 7 laptop and the Arduino Yun software which is readily available on the manufacturer’s website. In order to obtain a string to use for authentication, the program will take the read value and store it in a temporary variable. The program will also have the desired pins set for controlling each hardware device. Once the value has been obtained it will check to see if it is valid. If it is valid, the motor will then activate and the car would be able to drive through. However, if it is not valid the RFID reader LED will flash and nothing will happen symbolizing an unauthorized card. The final working code can be seen in Appendix 3. Though the solution is very effective in the way it operates, there are some downsides when addressing it for use in industry. Many of today’s gate designs are not managed locally at the gate. The devices are networked using PoE and access off site information. After accessing this information the gate then can open or close depending on the received information. Unfortunately the constraints limited us our design prototype however, for this reason, an industry budget was created.

2.5 Estimated Cost During the building of this prototype there were limited costs to the MSU ECE department. Some of the resources used during the design process had no associated cost. These consisted of a dell laptop computer and the Arduino Yun Software. With these two systems coupled together, the team had the means to develop a working program. Since all of the team members are students, the additional man hours needed for development are not billable. However, there were some costs in designing the prototype which are listed in the table below with the product name,



cost, and reason for purchase. These costs are those associated to MSU and not to mass produce the design. Since it cannot be directly implemented, there is no budget for mass production of this prototype.

Product Cost Reasoning

Arduino Yun $75.95 Processing Unit

Servo Motor $13.99 Gate Motor

Logitech HD Webcam C310 $32.12 Safety Monitoring

RFID Reader $44.99 Input Device

Total: $167.06

Table 2 - Estimated Cost (Small Scale)

For the planned design, the team will be within the five hundred dollar budget that was previously set forth by the MSU ECE department.

2.6 GANTT Chart The GANTT Chart below, in Figure 3, is what the team was aiming to meet in the final design. This included a database, RFID reader, servo motor, webcam, and Arduino Yun microcontroller. Each aspect of the overall prototype would have been met from security to safety. The path in red is the immediate path for the success in designing a prototype. Unfortunately the first project plan was not met due to some design constraints that we could not address with the timespan given.

Figure 3: GANTT Chart



Many challenges were faced during the course of the semester which hindered the teams desired prototype. First, when trying to implement the python database, many errors were encountered. Initial troubleshooting was done but was unsuccessful. This could be due to newer versions of python with different libraries. The team decided that it would be more advantageous, for the sake of time, to create a local database within the program. This was part of the RFID code development to recognize which RFID card was valid. Once the RFID code was recognized the program would call the servomotor program to activate the servo motor. In the eyes of the team, this was a large success considering the frustration that was faced during the initial coding with an online database. Since the database for ArcelorMittal would be the Matrix Security Server which manages permissions and card readers, this was an acceptable solution for a design prototype. Under the given time constraints the team was unable to order and implement a security webcam to simulate the security aspect of the project. With the different business projects and struggles faced with getting the RFID and motor to work, it was not feasible to get the security camera to work. There however was research put into finding how the camera should operate. It would be a continuous stream of video and then capture snapshots, similar to the computer software LoJack, when motion was detected. The revised GANTT chart can be seen below in figure 4. This is the most recent and relevant GANTT chart for the teams efforts in designing the prototype.

Figure 4: Revised GANTT Chart

Chapter 3 -‐ Final Design

3.1 Hardware Setup

3.1.1 Setup Arduino Yun The Arduino Yun is a microcontroller board that has not only Input and Output pins but is also capable of being networked wirelessly or through an ethernet port. Initially the plan was to incorporate and use the networking capabilities to communicate with a python database hosted



on a separate laptop. Unfortunately due to the circumstances stated above, an alternative solution had to be sought. The new design used the Input and Output pins, along with the micro USB port. Each piece of the prototype would be assigned a pin which corresponded with the commands in the software. Similar to the input and output pins, the Arduino Yun has onboard ground, 3.3V and 5V connections to power the additional hardware implemented in the prototype. These pins can be seen in the image below on both sides of the board.

Figure 5: Arduino Yun

3.1.2 Setup RFID Reader The RFID reader must be powered and connected to the Arduino Yun microcontroller in order to pass through a RFID tag number. This tag number is extremely important to the success of the prototype. The Parallax RFID reader has four wires that that are used for power and passing data. The card reader schematic can be seen in figure 6 below. The Vcc is connected to the 5V on board supply and GND to ground. Connecting the wires as stated will provide the reader with power to work. Next the Enable pin and Sout pin can be connected to two different pins on the microcontroller board. These will be set to input pins. Setting the enable pin will allow for the reader remain active and in standby for a card to be swiped. The Sout pin is then used to transport the received tag into the program. From here the program is responsible for manipulating this string of characters to verify whether or not it is authenticated to activate the gate motor.



Figure 6: Parallax RFID Card Reader

3.1.3 Setup Servo Motor Once the RFID card has been read and verified, the next step is to activate the motor if authorized to do so. This can be done on the same board using the same program. The servo motor has three pins for connection to the microcontroller. Similar to the RFID reader two of these are power and ground. The power pin will be connected from the motor power pin (Red Wire) to the 3.3V on the microcontroller. Next the GND connection (Black Wire) will be connected to another GND connection on the microcontroller. The last pin that is on the servo motor is one that is thought of as an enable pin (White Wire). When the pin is set to active, the motor will be operational. If it is not active then the motor will not work. These constraints will be addressed in the next section which deals with writing the software and then assembling the working device.

Figure 7: Servo Motor

3.2 Software Setup

3.2.1 Arduino Software Arduino has software that works across all operating system, for developing and implementing code, while being very simple to install. The software is open source with an integrated



development environment (IDE) allowing programmers to have a vast majority of tools. The built in tools include a source code editor, automation tools, and a debugger. Having these resources available makes it easy to write a code and upload it to the microcontroller board. During the course of developing a working prototype, the team utilized the source code editor and debugger. The goal was to use the python library with the python database server, but was unsuccessful during implementation. Therefore, the libraries that were available from Arduino were not widely used. The software was very intuitive in aiding in the successful design of the working Gate Security prototype.

3.3 Software Design Below if a workflow of how the software was designed. The first thing it does is enable to RFID reader so a card can be read immediately if presented. The next step is to read the tag information off the card and check whether the person is valid or not. If they are valid, the program will cycle the motor up, wait and then down. Once completed there is a built in time delay to protect against brute force hacks and multiple access attempts. If someone tries to cycle different RFID cards, it will become very time consuming and obvious to the on duty security personnel. However, if it is not in the database, the program cycles through the wait time and then the RFID reader goes back to the ready and waiting state.

Figure 8: Program Workflow



3.3.1 Built-‐in Database The security gate system is expected to be capable of storing all the personal information of the individuals possessing an RFID tag or card. Thus, a database is needed. The team tried to establish an external database. We attempted to implement a database using an online server but technical issues were raised and the team was unable to pull it off within the given time frame. Instead of using an online database, the alternative solution was to have all the tag information built into the main program. The method of how to implement the built-in database and its drawbacks will be discussed in detail in the following session.

3.3.2 Checking Database for Access Each of the RFID tags have been pre-programmed with a unique 10-digit character string. Once a tag is scanned, the unique character string is read and compared with the information stored in the database. If the tag’s string matches one of the valid strings in the database, access will be granted and the servo motor will be activated. Similarly, access is denied if the scanned tag has a character string that cannot be found in the database and the servo motor will not activate. Specifically, this is achieved by an if statement that executes string comparison as the following:

if(strcmp(rfid,"02006E218CC") == 0 || strcmp(rfid,"02006E2C311") == 0 ); The declared variable “rfid” holds the 10-digit character string of a scanned tag. The string “strcmp(a, b) == 0” is a comparison command that compares the a and b strings. For demonstration purposes, the logic and layout of the example above is valid for two strings which were put into the built-in database. However, one strcmp directive serves only one tag string. Foreseeably, the code could go extremely wrong if the tag information of all the employees and visitors were to be included.

3.3.3 Brute Force Attack Protection One of the hot topics with any network or communication device is security. If there is a lack in security, the device may not serve its intended purpose. In security devices that use authentication, a hacker can use multiple devices to attempt to gain entry. With the gate security device, hackers can try a stack of predefined RFID cards, or a program that cycles RFID possibilities. In both of these cases the more options they have, the more vulnerable the system becomes. The team has decided to remediate this problem by adding a time delay that occurs once the motor is deactivated or the card is denied, which can be seen in figure 8 above. This delay creates a waiting time for any person trying to hack the system. The benefit of this waiting tactic is that the on duty guard will notice the strange activity and approach the unauthorized individual. The time the individual starts swiping cards and is notice will be very short. They will likely only be able to try three to four cards. With the number of RFID tag possibilities this is a



miniscule percentage and will not cause concern. Therefore, the brute force attack protection strategy is one that will work not only effectively but will enhance the working devices security.

3.4 Design Issues and Solutions The designed program was written to check if an incoming RFID scan is listed within the “Access Granted” list. This program works well and is efficient in operation, but it would be more beneficial to have a networked database. This flaw could be corrected in a future design. It would not be able to be created within the program that the group developed. In order to do so, the current program would have to be scratched, and a new one created. In addition to writing a new program, we would also have to approach the problem from a different angle. Since there are many different database alternatives (e.g. Access or SQL), there are many different approaches. Unfortunately, the team was scarce on time and was unable to pursue one of these alternatives from scratch. The solution to the database problem was using the built in “Access Granted” list in the program. This list would be comprised of all the RFID tag codes that are allowed access into the premises. The current solution is very bulky and not streamlined. Therefore, with every additional RFID tag the code gets longer. However, with a new program that utilizes a networked database, similar to the matrix system ArcelorMittal uses, the code becomes much simpler. The database can also have more demographics about who is entering, their position, time entered, etc. These demographics would help in creating a stronger report for the Emergency & Security Services team at ArcelorMittal.

Chapter 4 -‐ Assembling & Testing

4.1 Assembling the Prototype The design consisted of both hardware and software components. It was assumed that all the hardware parts were in working order from the manufacturer. These products were the Arduino Yun microcontroller, Servo Motor, and Parallax RFID Reader. The assembly of the prototype was one of the most important tasks of the design process. It not only determined if the design was working but also aided in ensuring the success of the software. The first step was to connect the Arduino Yun to the computer. This can be done through a USB to microUSB cable which is not included when purchasing the microcontroller. Once recognized by the Arduino Yun software we will need to upload the software to it. Once the software has verified that the software was compiled and uploaded, the components can be connected. In order to power the rfid reader we will want to connect the ground and voltage pins to the pins stated earlier in section 3.1.2. Next, the microcontroller pins can be connected to the enable and data transfer pins of the RFID reader. These pins are 2 and 8 respectively. Now that the RFID reader is connected, the motor can now be connected. The motor can be powered using the



onboard ground and power pins that were discussed in section 3.1.3 above. Once these are connected, the last wire can be connected to pin 9 on board the microcontroller. This will control when the motor turns on and operates the gate. The design will look similar to the schematic below.

Figure 9: Prototype Wiring Schematic

During the course of the semester, the team worked with the mechanical engineering team who were responsible for redesigning the entrance of the plant. Once the electrical engineering prototype had been complete, it was integrated into the 3D model created by the mechanical team. This design consisted of two gates, one for entry and one for exit, which would function to the specifications set forth by ArcelorMittal. The gate itself would have incremented latches that function as a belt. The gate would then cycle open and close using a gear attached to the motor, and the notches built into the gate. The gate setup can be seen in figure 10 below:

Figure 10: The motor attached and integrated with the gate



Figure 11: Final combined EE and ME prototype

4.2 Testing & Proof of Functionality Testing of the designed software was repetitive, but crucial to the overall success of the project. It was also important to ensure that the prototype was assembled and working correctly. Once the code is uploaded and power is connected to the microcontroller, testing can be performed. The three tests performed will be a card that is an employee with access, an employee without access, and an unauthorized individual. In order to test both the functionality and the integrity of the program, the first card to test is an authorized employee. This will help ensure all the pins are connected correctly, since it will function correctly, and that an employee with access can get into the plant. If the prototype did not work, the program would have to be debugged and the pin diagram rechecked. The next step is to verify that an unauthorized employee cannot inadvertently gain access to the plant. The same steps will be taken as testing the authorized employee, except this time the motor should not begin to open the gate. It also needs to be verified that there is a time gap between when the card is denied, the reader LED going from green to red, and the time a new card can be presented. This was also completed with an unauthorized card that was also not an employee. These card swipes were then mixed up and tested with the same results and no errors. During these testing stages the prototype functioned as it should. The code was also set to constantly be running during this time to verify there were no time outs reached when waiting for a card to be scanned. Since we don't have a device that can simulate an rfid code generator, we were unable to test that aspect. However, we had a very high



success rate, without any errors. This provided the team with a very confident feeling that the prototype would serve the purpose for ArcelorMittal’s gate security.

Chapter 5 -‐ Summary and Conclusion

5.1 Summary and Conclusions Overall, with the given constraints and changes, the project was successful and performed well. The prototype was able to read a RFID card, process it through the microcontroller, and then control a servo motor without error. The RFID reader constantly read new cards presented after being idle with excellent accuracy. It can be concluded that the prototype works on a small scale and the design can be successfully implemented into a large scale model.

5.2 Success and Failures The team goal was to provide a precise and efficient “smart” gate that secured the plant. The goal was to provide a device that not only secured the plant based on authentication but visually as well. The team had experienced both successes and failures during the course of the semester. The team was successful in producing a device that provides access to only authorized individuals and not to unauthorized ones. This part of the design was very successful. The software allows for the addition of RFID tags, and the ability to add additional devices. The smart function of the gate eliminates the guessing the guard has to do when one waves a card as they pass by the current guard building. On the other hand there were a few things that did not turn out as planned. The camera security system was unable to be implemented under the given time constraints, as well as learning ArcelorMittal’s security system was IP based and a separate entity. Therefore, the team would need to have implemented a second solution that would record all the activities and then overwrite them as space became full on the drive. One way to have fixed this would be to purchase a cheaper IP camera similar to the Foscam FI8919W which would have allowed for the recording to a network drive. Another alternative solution would be to use a laptop webcam paired with software similar to LoJack. When a model car would approach, a picture would be triggered and saved. Both of these would have been viable solutions to fix the failure of implementing the security camera. Overall the project was a success due to the expectations of ArcelorMittal. The team expects no failures with the execution of the deliverables that the team had produced. Besides the prototype, ArcelorMittal was looking for a budget to be created in order to implement a large scale model. Designing the prototype provided the insight to learn about how RFID and gate security systems work. Besides this background information, we also gained a vast majority of information about corporate infrastructure, safety and security. This not only enabled us to create a prototype and budget, but a very rewarding out of classroom experience.



5.3 Suggestions for the Future There are many improvements that can be made in future models of the design. Instead of using only an rfid reader and microcontroller, a sensor could be added to the device. This sensor would be responsible for checking if a car is present under the gate. Since safety is a big concern, it would only improve the overall design. This was something that was overlooked by the team early and was unable to be implemented into the design. Another suggestion would be to fix the teams failure and incorporate a camera, which could be a smartphone that could interface with a computer to demonstrate the security footage capture. Since the team found out late that the RFID gate opening module is separate from the security footage recording module within the ArcelorMittal technology stack we were unable to implement this goal. Lastly, more research could also be done using different databases. The database could be locally connected via USB, or networked and would serve as an industrial purpose. The database would be able to store more users, track them, and provide additional information about each user. An additional field in the database could be a mobile phone number. The user would then be able to call a designated hotline that communicates with the server. The server would then trigger the gate and log the user’s entry. With the newer cars on the market, this could be hands free and streamlined way employees could enter the plant. Not all of these are applicable to be addressed in a semester, but would become in high demand in future designs.

5.4 Small Scale Final Costs The final costs were analyzed once the prototype was completely assembled and working. As it can be seen in the table below, the team was well within the five hundred dollar constraint that was set forth by the MSU ECE department. All elements were purchased through vendors that the university typically orders from; therefore shipping was very minimal and amounted to $31.52. This is minimal but was not factored into the final costs of the small scale design.

Product Quantity Cost Total Per Unit

Arduino Yun Microcontroller 2 $74.04 $148.08

5V Servo Motor 2 $16.99 $33.98

Parallax RFID Reader 2 $44.99 $89.98

Parallax RFID Tag 2 $.99 $1.98

Total: $274.02

Table 3 - Small Scale Costs



5.5 Final Budget

5.5.1 Small Scale (Team 7 Design) The budget below is what a company would need to purchase in order to implement the RFID reader and servo motor prototype. This is relatively inexpensive comparatively. Since the code was developed by students and is relatively available, it would be free of charge as long as the company purchases the other components.

Product Quantity Cost Total Per Unit

Arduino Yun Microcontroller 1 $74.04 $74.04

5V Servo Motor 1 $16.99 $16.99

Parallax RFID Reader 1 $44.99 $44.99

Code 1 $0 $0

Total: $136.02

Table 4 - Small Scale Budget

5.5.2 ArcelorMittal Budget The budget below is what ArcelorMittal would need to purchase to implement a life size design solution for their current problem. This includes all hardware that needs to be purchased for each traffic lane.

Product Quantity Price Total

Axis Q1604-e camera 3 $1,240 $3,270

MXProx2 Card Reader 3 $120 $360

Cat 6 Ethernet Cable (~1000 ft.) 1 $106.29 $106.29

Total: $3736.29

Table 5 - ArcelorMittal Budget The above table does not include the hardware that they already have at ArcelorMittal’s central office in Chicago, Illinois. This office houses the infrastructure and information technology operations. The table below lists everything that would be utilized but not cost any additional money.



Product Function

ExacqVision Server Record Security Footage

80 GB Hard Drive Storage for Security Footage

Matrix System Server Manage & Authenticate RFID Readers

Table 6 - ArcelorMittal Resources

5.6 Final Schedule Task # of Days Start Date End Date

Gate Security 71 days Fri 1/23/15 Fri 5/1/15

Initial Meeting With Sponsor 1 day Fri 1/30/15 Fri 1/30/15

PreProposal 5 days Mon 2/2/15 Fri 2/6/15

Website Creation 2 days Mon 2/2/15 Tue 2/3/15

ArcelorMittal Site Visit 1 day Fri 2/6/15 Fri 2/6/15

Brainstorm Gate Interface to work with Arduino Yun, RFID Reader, servo motor

4 days Mon 2/9/15 Thu 2/12/15

Order All Parts (Microcontroller, Motor, Camera) 1 day Fri 2/13/15 Fri 2/13/15

RFID Input Program 4 days Mon 2/16/15 Thu 2/19/15

Setup Motor Program 4 days Thu 2/19/15 Tue 2/24/15

Interface RFID and Motor with microcontroller 3 days Wed 2/25/15 Fri 2/27/15

Debug User Interface and simplification of apps 5 days Thu 3/12/15 Wed 3/18/15

Complete Working Prototype design 20 days Thu 3/19/15 Wed 4/15/15

Work On Design Day presentation 20 days Thu 3/19/15 Wed 4/15/15

Miscellaneous Tasks and Fixes 12 days Thu 4/16/15 Fri 5/1/15

Table 7 - Prototype Schedule



Appendix 1 -‐ Individual Contributions

Figure12: Design Team 7 (From left to right)

Lauren Poole Due to the nature of our project and the limited amount of technical work that went into

completing this project my technical involvement was primarily a supportive role. My portion of the overall project, as defined by the lab coordinator, was to research the various components needed to configure the solution; RFID reader, RFID tag, microcontroller, and motor and research, which would be best for our design and most cost efficient. The purpose of the microcontroller was to serve as the link between the database, the RFID reader, and motor. After doing our own individual research on various microcontrollers we came together to discuss our finding. Trevor had found the Arduino Yun. Not only was the Arduino Yun cost efficient, but also came with a code that did exactly what we wanted our program to do. Unfortunately, the code did not work initially, after researching all day trying to detect the problems Bingyang took the code home to do further work, we had downloaded the program to his computer only. When looking for a RFID reader and tag it was from my research on the RFID system that we knew we wanted a passive RFID tag with an active RFID reader. Passive tags required no battery and had a longer lifespan. We then simply chose the RFID reader that was recommended for that specific tag.

Although not involved heavily in the direct coding of our gate system it was through my supportive role I was able to get a thorough understanding of our system and how it compared to our initial goals. My understanding assisted me greatly in constructing all documents (proposal,



fast diagram, design issue, poster, etc.), ensuring that they not only met all requirements, but also were clear and easy to interpret.

Trevor Emerick I had a very involved technical role in the design and implementation of our gate security

solution. As a manager, I felt it was crucial to have a complete understanding of every technical aspect of the project. As well as the technical design roles, I also had a large role in writing, and presenting technical documentation throughout the semester. I also was responsible for leading meetings with our sponsor, facilitator, and professors. In the early stages, I did a vast amount of research to understand the capabilities of the microcontroller, servo motor, and RFID reader. After the first few weeks of class, I had found a desired solution for the problem at hand. Unfortunately, this had to be scrapped later in the semester because of some database communication problems. The next step I took was to go back to the drawing board and research different solutions that were currently out there, whether they were with the same or different microcontrollers. I then checked to see how we could model our solution off one of these models. We found a program that we could model, which involved a user to control the entry after an RFID scan. The work flow was then analyzed and built by the team for our design, which was to be automatic. I worked with Bingyang to implement this solution with the servo motor and RFID reader. Once it was working we could incorporate it with the ME team’s design.

The next role I played was a liaison between our team and other personnel at

ArcelorMittal. ArcelorMittal wanted a budget for the overall cost to implement an industrial model of our design. Therefore, I contacted the Manager of the Security and Emergencies services team, Greg Racich. Greg was able to provide me with information on the current security infrastructure in place at ArcelorMittal in Chicago, IL. This allowed me to narrow down what brands we could use for cameras, RFID readers, and the peripherals. I was able to lower the budget and use servers that were already implemented throughout the company. This budget will be highly useful for ArcelorMittal when they receive bids to build an industrial size gate security system.

Jazmine Gaymon

Our project was a bit different from typical ECE capstone projects. We were asked by ArcelorMittal to partner with the Mechanical Engineering Senior Design Team to come up with a security gate system and provide research for how much an entirely new system would cost. Therefore, our project did not require an abundance of technical work to implement our design project.



I had an active role throughout the entire designing process of our security gate system. My primary technical role was research. I helped with researching the proper microcontroller to use for our design. We were originally looking at the Raspberry Pi microcontroller but opted for the Arduino Yun microcontroller because it was more robust and was easier to create and upload scripts using the Arduino 1.6.2 software.

As the presentation coordinator, it was vital that I researched every aspect of the

hardware we decided to use in order to understand critical points in our project. This was important for the sake of constructing PowerPoint presentations and making sure concepts were clear and concise for the audience. In the engineering industry, it is extremely important to know what you are talking about and be able to communicate through technical writing when proposing a new design.

I aided in troubleshooting as well. When we first began to assemble our design, I helped

wire the hardware components to produce a prototype. The prototype did not work. After debugging and looking for problems in the code, we looked back at our prototype and found that the wires were not connected correctly. The original schematic that we decided to use was incorrect due to the fact that we had a different microcontroller made by the same company.

I also helped Lauren with technical writing, making sure all our documents flowed

accordingly for audience comprehension.

Bingyang Wu I was responsible for most works done to create the prototype. The prototype consists of a

servomotor, an Arduino Yun microcontroller. The design had not been working as expected at the first time it was tested. I initially thought that it must be the problem of the code and spent roughly a week to finally find out that the pins were not correctly wired. Then I got the wiring problems fixed so that the reader could then be able to properly read the tags. One of the lessons I can take out of it is to be extra careful while looking for errors and never ignore the simplest possible issues. For the next few days, Trevor and I tried to get the servomotor to work. However, one of the issues we encountered was that the motor would keep running for whatever speed and angle values assigned once it was attached on the specific pin. After conducting some research on the Internet, Trevor and I realized that the only way to stop the servomotor in Arduino is to detach it from the pin temporarily. Therefore, we managed to write the proper code that turns on the motor and allows the motor to spin at desired speed, in specified direction, and for allocated time duration.

Next, I worked with Trevor to put all elements together and adjusted the code that

enables the servomotor to respond correctly to different tags being swiped. This goal was



achieved simply by a string comparison of the tag strings with the preset allowed strings. The last step was to add up more functions, such as display the name of the tag holder; count the number of people entered or exit the plant, to the system.

As the web designer, I was responsible for creating the team project website. The website

was built using Adobe Muse CC 2014. It is a user-friendly tool that meets the needs of both amateur and advanced users. There are basically two ways to publish the website. What I did is to export all the files from Muse and uploaded them to the specified server hosting all the websites from ECE 480 course. The team website I am building is of a simple and straightforward navigation style without any fancy effects. The visitors can easily get an idea of what our project is about from a glance of it.



Appendix 2 – References

"Arduino - ArduinoYun." Arduino - ArduinoYun. Arduino, n.d. Web. 27 Apr. 2015. <http://www.arduino.cc/en/Guide/ArduinoYun>. "AXIS Q16 Network Camera Series For Demanding Lighting Conditions." Web. 27 Apr. 2015. <http://classic.www.axis.com/en/files/datasheet/ds_q16_59000_en_150223_lo.pdf>. "Matrix Card Readers: MX ICLASS, MX2, MXProx2." Web. 27 Apr. 2015. <http://www.matrixsys.com/PDF_DATASHEETS/Matrix_Frontier_CardReader_DS.pdf>.



Appendix 3 -‐ Technical Documents

Final Code (Entering Gate) // RFID Settings #include <SoftwareSerial.h> // NewSoftSerial needs pin in and out, but RFID Reader only has IN int pinUnused = 12; int pinRfidEnable = 2; int pinRfidSerialIn = 8; int baudRateRfid = 2400; SoftwareSerial rfidSerial(pinRfidSerialIn, pinUnused); // These are used for serial communication int val = 0; double count = 0; char rfid[10]; int bytesRead = 0; char Granted = '02006E218C'; char Denied = '02006E2C31'; // Servo settings #include <Servo.h> Servo servo; int pinServoStart = 9; int pinServoStop = 7; int servoLockedRotation = 150; int servoUnlockedRotation = 30; int unlockTime = 1500; int pinLed = 13; void emptySerialBuffers() { // This empties the serial buffers to prevent repeat reads while(rfidSerial.available() > 0) { rfidSerial.read(); } while(Serial.available() > 0) { Serial.read(); }



} void setup() { // Serial to computer Serial.begin(9600); // Set up RFID Reader rfidSerial.begin(baudRateRfid); pinMode(pinRfidEnable, OUTPUT); digitalWrite(pinRfidEnable, LOW); // Set up servo servo.attach(pinServoStop); // Set up indication LED pinMode(pinLed, OUTPUT); digitalWrite(pinLed, LOW); } void loop() { // Read serial from RFID reader if(rfidSerial.available() > 0) { val = rfidSerial.read(); // Got signal from RFID Reader if(val == 10) { bytesRead = 0; while(bytesRead < 10) { if(rfidSerial.available() > 0) { val = rfidSerial.read(); // Line endings mean end of message if(val == 10 || val == 13) { break; } rfid[bytesRead] = val; bytesRead++; }



} if(bytesRead == 10) { // Send RFID tag to computer //Serial.println(rfid); digitalWrite(pinRfidEnable, HIGH); // Read serial from computer /*if(Serial.available() > 0) { // Got signal from computer // Disable RFID reader so we don't get repeats digitalWrite(pinRfidEnable, HIGH); val = Serial.read(); //emptySerialBuffers(); }*/ if( (strcmp(rfid, "02006E218C") == 0) ) { // Access Granted count++; Serial.println("Access Granted"); Serial.println("Visitor: Trevor Emerick"); Serial.print("Total number of people entered: "); Serial.println(count); digitalWrite(pinLed, HIGH); servo.attach(pinServoStart); servo.write(servoUnlockedRotation); delay(unlockTime); servo.attach(pinServoStop); delay(3500); servo.attach(pinServoStart); servo.write(servoLockedRotation); delay(unlockTime); servo.attach(pinServoStop); digitalWrite(pinLed, LOW); } else { // Acess Denied // Keep the reader from reading repeatedly



Serial.println("Access Denied"); digitalWrite(pinRfidEnable, HIGH); // Wait a moment so we can't brute force crack delay(300); digitalWrite(pinRfidEnable, LOW); } } //bytesRead = 0; } } // Reactivate RFID antenna digitalWrite(pinRfidEnable, LOW); }



Final Code (Exit Gate) // RFID Settings #include <SoftwareSerial.h> // NewSoftSerial needs pin in and out, but RFID Reader only has IN int pinUnused = 12; int pinRfidEnable = 2; int pinRfidSerialIn = 8; int baudRateRfid = 2400; SoftwareSerial rfidSerial(pinRfidSerialIn, pinUnused); // These are used for serial communication int val = 0; double count = 0; char rfid[10]; int bytesRead = 0; char Granted = '02006E218C'; char Denied = '02006E2C31'; // Servo settings #include <Servo.h> Servo servo; int pinServoStart = 9; int pinServoStop = 7; int servoLockedRotation = 30; int servoUnlockedRotation = 150; int unlockTime = 1400; int pinLed = 13; void emptySerialBuffers() { // This empties the serial buffers to prevent repeat reads while(rfidSerial.available() > 0) { rfidSerial.read(); } while(Serial.available() > 0) { Serial.read(); } }



void setup() { // Serial to computer Serial.begin(9600); // Set up RFID Reader rfidSerial.begin(baudRateRfid); pinMode(pinRfidEnable, OUTPUT); digitalWrite(pinRfidEnable, LOW); // Set up servo servo.attach(pinServoStop); // Set up indication LED pinMode(pinLed, OUTPUT); digitalWrite(pinLed, LOW); } void loop() { // Read serial from RFID reader if(rfidSerial.available() > 0) { val = rfidSerial.read(); // Got signal from RFID Reader if(val == 10) { bytesRead = 0; while(bytesRead < 10) { if(rfidSerial.available() > 0) { val = rfidSerial.read(); // Line endings mean end of message if(val == 10 || val == 13) { break; } rfid[bytesRead] = val;



bytesRead++; } } if(bytesRead == 10) { // Send RFID tag to computer //Serial.println(rfid); digitalWrite(pinRfidEnable, HIGH); // Read serial from computer /*if(Serial.available() > 0) { // Got signal from computer // Disable RFID reader so we don't get repeats digitalWrite(pinRfidEnable, HIGH); val = Serial.read(); //emptySerialBuffers(); }*/ if( (strcmp(rfid, "02006E218C") == 0) ) { // Access Granted count++; Serial.println("Granted"); Serial.println("Visitor: Trevor Emerick"); Serial.print("Total number of people exited: "); Serial.println(count); digitalWrite(pinLed, HIGH); servo.attach(pinServoStart); servo.write(servoUnlockedRotation); delay(unlockTime); servo.attach(pinServoStop); delay(3500); servo.attach(pinServoStart); servo.write(servoLockedRotation); delay(unlockTime); servo.attach(pinServoStop); digitalWrite(pinLed, LOW);



} else { // Acess Denied // Keep the reader from reading repeatedly Serial.println("Access Denied"); digitalWrite(pinRfidEnable, HIGH); // Wait a moment so we can't brute force crack delay(300); digitalWrite(pinRfidEnable, LOW); } } //bytesRead = 0; } } // Reactivate RFID antenna digitalWrite(pinRfidEnable, LOW); }