automated beverage dispenser georgia institute of technology april 24, 2009 katrina kumm mike fojas...
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Automated Beverage Dispenser
Georgia Institute of TechnologyApril 24, 2009
Katrina KummMike Fojas Mark PetersonNick WhiteNick Migliaccio
© Mark Peterson 2009
Overview• What, Why, Who, Cost
• Technical Objectives & Design Goals
• Top Level Design
• Hardware Design
• Software Design
• Problems & Solutions
• Acceptance Testing
• Scheduling & Task Management
• Budget & Cost Analysis
© Mark Peterson 2009
• Dispenser of mixed beverages with automated controls
• Drinks dispense cost effectively and efficiently
• Restaurants and bars are the target market
• Predicted Prototype/Development Cost ≈ $32,304
• Actual Prototype/Development Cost = $32,802
• Predicted Manufacturing Cost ≈ $1,780 per unit
• Actual Manufacturing Cost = $2,278 per unit
What, Why, Who, Cost
© Mark Peterson 2009
• Human machine interface is aesthetically pleasing
• Containers hold up to 2 liters
• Pump flow rate of 1 liters per minute
• Accuracy of +/- 10%
• Interface unit separate from dispensing unit
• Containers and I/O controllers are easily accessible
Proposed Technical Objectives / Design Goals
© Mark Peterson 2009
Proposed Hardware Diagram
© Mark Peterson 2009
Implemented Hardware Diagram
© Mark Peterson 2009
Control Unit (Overhead, Exterior)
© Mark Peterson 2009
Control Unit (Overhead, Interior)
© Mark Peterson 2009
Control Unit (Side View)
© Mark Peterson 2009
Control Unit (Side View)
© Mark Peterson 2009
Relay Circuit
© Mark Peterson 2009
OVERHEAD VIEW
(EXTERIOR)
OVERHEAD VIEW
(INTERIOR)
Bay 1 Bay 2 Bay 3 Bay 4 Bay 5
0.51
0.34
0.32
4
0.49
0.09
0.32
0.51
0.34
1
1
11
1
Flow Direction
(Front)
0.07
0.02
0.07
0.02
Spout
Spout
Dispensing Unit (Overhead View)
© Mark Peterson 2009
SIDE VIEW(EXTERIOR)
SIDE VIEW(INTERIOR)
0.51
0.35
0.16
Bay 1 Bay 2 Bay 3 Bay 4 Bay 5
0.31
0.51
0.35
0.07
0.06
0.18
0.03
0.07
0.06
0.18
0.03
0.11
0.11
Spout
Spout
Dispensing Unit (Side View)
© Mark Peterson 2009
OVERHEAD VIEW
1
0.23
0.09
0.11
0.09
0.04
Pump
Valve
Tank
Pump Unit (Overhead View)
© Mark Peterson 2009
FRONT VIEW
REAR VIEW
0.0
50
.15
0.2
4
0.04
Pump
Valve
Tank
Pump Unit (Front/Rear View)
© Mark Peterson 2009
SIDE VIEW1
0.06
Pump
Valve
Tank
0.24
0.09
0.24
0.15
0.07
Pump Unit (Side View)
© Mark Peterson 2009
Software Structure Diagram
HMI(Visualization Components*)
Load(control.c)
Save(control.c)
Add(control.c)
Make(control.c)
Setup(control.c)
*Note: Visualization Components is a proprietary data-type of B&R’s Automation Studio.
© Mark Peterson 2009
Welcome / Startup Main Menu
Display Liquids
Add RecipeTo DB
Add LiquidTo DB
Display Recipes Setup
NextButton
Make DrinkButton
BackButton
HomeButton
HelpScreen
Help Button
Add LiquidButton
DisplayLiquids Button
DisplayRecipesButton
SetupButton
Add RecipeButton
SaveButton
View Recipe
(Details)
RecipeSelected
Signal To Controller
Signal From
Controller
RemoveButton
* Located on every screen
**
ShutdownScreen
Off Button*View Liquid
(Details)
LiquidSelected
Proposed Software Flow Diagram
© Mark Peterson 2009
Make
Welcome / Startup Home
ViewRecipe
List
ViewLiquid
List
AddLiquid
AddRecipe Setup
HomeButton
Add LiquidButton
ViewLiquids Button
ViewRecipesButton
SetupButton
Add RecipeButton
Save Save
Signals To Controller
* Located on every screen
*
LiquidSelected
Implemented Software Flow Diagram
RecipeSelected
ConfirmDelete
ConfirmDelete
View Liquid
Back Next
Delete
Edit Edit
View Recipe
Back Next
Delete
ShutdownScreen
*Confirm
Shutdown
Off
HelpLayer
*Help
© Mark Peterson 2009
Solutions to Problems/Design Issues1. Difficulty finding alcohol grade pumps
▫ Found alcohol pump distributor▫ Purchased aquarium pumps
2. Adding/removing liquids from dispenser▫ Write software and add on hardware▫ Handled in ‘Setup’ screen and software logic
3. Liquid level tracking▫ Based on weight▫ Monitored by software▫ Feedback from flow meter
4. Water leakage▫ Silicon and then added hot glue
5. Inadequate power supply▫ Purchased new 24 V, 7.2 A power supply▫ Ran pumps in succession
© Mark Peterson 2009
• Human Machine Interface (HMI) is navigable
• Pumps dispense specified volume +/- 10%
• Make and dispense a 12oz drink in under 30 seconds
Proposed Acceptance Testing
© Mark Peterson 2009
“How did the demonstration go?”
Acceptance Testing Results
© Mark Peterson 2009
Schedule and MilestonesPlanned Actual
Make stand (3/12) Make stand (3/24)
Obtain pumps (3/16) Obtain pumps (3/25)
Test interface (3/12 – 3/24) Test interface (3/19 – 4/23)
Test pumps (3/23 – 3/30) Test pumps (4/7 – 4/17)
Software complete (4/6) Software complete (4/23)
Hardware complete (4/6) Hardware complete (4/23)
Test ABD (4/13) Test ABD (4/20)
Final Presentation (4/20) Final Presentation (4/24)
© Mark Peterson 2009
Explanation for Schedule Delays•Make Stand (~12 days late)
•Artificial deadline•Obtain Pumps (~9 days late)
•Alcohol grade pumps were stuck in customs for ~1.5 weeks
•Test Interface (~1 month over)•Issues with logic and interface usability
•Pump Testing (~14 days late)•Residual delay from first pump acquisition
•Software Completion (~17 days late)•Continuous software modifications until last night
•Hardware Completion (~17 days late)•Other delays prevented completion
•Test ABD (~7 days late)•Other delays prevented final testing phase
© Mark Peterson 2009
Item Quantity Cost Total Budget DifferenceB&R 10" Power Panel 4PP220.1024-xx 1 $400.00 $400.00 $400.00 $0.00B&R X20 Ethernet/Powerlink Bus Receiver 1 $500.00 $500.00 $500.00 $0.00Automation Studio v3.0 License 2 $800.00 $1,600.00 $1,600.00 $0.00B&R X20 8x Digital Output Module 1 $200.00 $200.00 $200.00 $0.00B&R X20 8x Digital Input Module 1 $200.00 $200.00 $200.00 $0.00Fluid Pumps 5 $200.00 $1,000.00 $250.00 -$750.00Weight Sensors/Level Sensors $0.00 $180.00 $180.00Containers $0.00 $50.00 $50.00Total $3,900.00 $3,380.00 -$520.00
Proposed Budget and Cost Analysis
© Mark Peterson 2009
Actual Budget and Cost Analysis
Item Quantity Cost Total Budget DifferenceB&R 10" Power Panel 4PP220.1024-xx 1 $400.00 $400.00 $400.00 $0.00B&R X20 Ethernet/Powerlink Bus Receiver 1 $500.00 $500.00 $500.00 $0.00Automation Studio v3.0 License 2 $800.00 $1,600.00 $1,600.00 $0.00B&R X20 8x Digital Output Module 1 $200.00 $200.00 $200.00 $0.00B&R X20 8x Digital Input Module 1 $200.00 $200.00 $200.00 $0.00Fluid Pumps 5 $42.00 $210.00 $250.00 $40.00Weight Sensors/Level Sensors 0 $0.00 $0.00 $180.00 $180.00Containers 5 $1.50 $7.50 $50.00 $42.50Solenoid Coil/Valve 5 $83.20 $416.00 $0.00 -$416.00Tubing/Brass fittings $75.00 $0.00 -$75.00Relays/Inverter Circuits for Pumps $75.00 $75.00 $0.00 -$75.007.2 amp Power Supply 1 $195.00 $195.00 $0.00 -$195.00Total $3,878.50 $3,380.00 -$498.50
© Mark Peterson 2009
Summary• What, Why, Who, Cost
• Technical Objectives & Design Goals
• Top Level Design
• Hardware Design
• Software Design
• Problems & Solutions
• Acceptance Testing
• Scheduling & Task Management
• Budget & Cost Analysis
Questions?