Engt 4050 Senior Technology Capstone Fall 2013 Group 357559

Engt 4050senior Technology Capstonefall 2013group B 5start Nategrou

Engt 4050senior Technology Capstonefall 2013group B 5start Nategrou Engt 4050senior Technology Capstonefall 2013group B 5start Nategrou ENG T 4050 Senior Technology Capstone Fall 2013 Group B-5 Start Nate Group B-5 Nathaniel Zake, Team Lead Mustafa Alzainaldeen Jason Carlton Imad Hamdan Bill Hartsock Jacob Perry Joshua Siebenaler Overview Brew Magic Mobile Application - Intro Design Implementation Results The Future and Further Possibilities Brew Magic Unitronics Vision 350 Android Communication Overview App Features Timers Mirrors PLC display Master and brewer’s timer Reset the brewer’s timer Temperature Monitoring Actual mash temperature Target mash temperature Toggle Power (on/off) Circulation pump Mash heating element Goals Extend the functionality of the PLC to a mobile application Ensure desired finished product Increase brewer productivity Maintain brewery safety Design Start JD Design Tools Android Mobile Application Java Programming Language TCP/IP Unitronics V350TM PLC Ladder Logic Modbus Communications Protocol TCP/IP Human Machine Interface (HMI) Describe the basic components used and why, particulary the decision to use Java and Modbus. Modbus is an industry standard communications protocol use by PLCs Modbus is a standard protocol available on the Unitronics PLC Java is a well known high-level programming language that is already widely used for Android applications Java provides several free-ware packages used for Modbus communications. Brew Magic Mobile: Phase 1 Features WIFI connection to PLC DHCP or manual network addressing LAN Connection test GUI Sync PLC display Timers Temperature Alarms I/O Circulation Pump Heating element Brew Magic Mobile: Phase 2 Features Additional GUI functionality and refinement Adjustments to temperature set point and timers Possible additional features Sync/store brew session data Connect remotely via Internet connection Implementation Bill Start I will provide the basic architecture and a brief description of Modbus and how it works in our project. Project Architecture/Tools Android Mobile Application Java Programming Language TCP/IP Unitronics V350TM PLC Ladder Logic Modbus Communications Protocol TCP/IP Human Machine Interface (HMI) Describe the basic components used and why, particulary the decision to use Java and Modbus. Modbus is an industry standard communications protocol used by PLCs. Modbus is a standard protocol available on the Unitronics PLC. Java is a well-known high-level programming language that is already widely used for Android applications. Java provides several free-ware packages used for Modbus communications. Modbus Protocol Industrial communications protocol developed by Modicon in 1979 has become the most commonly used protocol for device communication. It reads binary values in PLC coils and registers. Provide a brief description of Modbus Modbus Address Scheme Data Element PLC Value Hex Address Decimal Address Current Temperature MI3 – 16 bit Target Temperature MI4 – 16 bit Brew Timer TA7 – 32 bit D Master Timer TA 4 – 32 bit D Timer Reset MB55 – 1 bit Pump Toggle MB34 – 1 bit Heat Toggle MB31 – 1 bit 001F 31 Provide a brief explanation of how Modbus is used for this project. The data table contains values used by the Android app. Briefly, the java package creates a connection, designates addresses to read, runs transactions, and obtains results. Understanding the Java protocol and data formats from the PLC is key. Brew Magic Mobile App Two gauges for brew timer and master timer, toggle buttons for pump/heat with confirmation popups, two timers, and reset functionality. How to Communicate? Connection is straightforward. Android needs its data; PLC needs its data. Matching both is achieved via Modbus by setting proper connection info, requesting data, and receiving responses. The challenge is converting data between Android and PLC formats so they can communicate independently. The conversion layer handles this, making future updates easier — changes to graphics or protocol won’t require rewriting data exchange formats. Solution Graphical Display Conversion Modbus Communication IN OUT Android For Modbus to communicate with the PLC, proper value setting and conversion are necessary to transfer data accurately. This ensures that application data and PLC data remain synchronized, despite different formats. This conversion layer enables future-proofing, allowing updates in graphics or protocol without overhauling data handling. The system includes wireless connectivity handled through Modbus, which manages data transfer between Android and PLC over Wi-Fi, ensuring real-time control of brewery operations remotely. Issues Layout Sizing Proper sizing, button placement, intuitive flow, connectivity, and functional accuracy are critical. The Android layout requires precise sizing of buttons and controls, ensuring ease of use. Connection stability must be maintained so commands and data exchanges occur seamlessly. Results Starting Jake Project Deliverables include: Brew Magic Mobile app with input/output fields, control buttons, graphical temperature displays; communication classes enabling PLC-GUI translation; project documentation including architecture and testing results; a working prototype demonstrating remote brewery control. Project Timeline milestones and Gantt chart highlight phases such as design, build, testing, and implementation, all planned within anticipated durations for efficiency. The project budget, estimated at $125, is funded by the University of Toledo with contributions from team members, covering essential hardware components like pumps, sensors, displays, and computers. Future prospects include addressing issues like timer resets, DHCP configuration, app notifications, protocol updates, and feature expansion such as recipe modification, cloud connectivity, and multi-platform support, thereby enhancing functionality and user experience. Proven capabilities demonstrate that the mobile app can monitor and control PLC operations, including real-time status updates, data mirroring, and remote system management, with adaptability to other PLC systems. Questions? Thank you! Cheers! Image Sources: ENGT 4050 PowerPoint Presentations and Project documentation.

Paper For Above instruction

The integration of automation technologies into brewing processes offers significant advantages in efficiency, safety, and consistency. The Brew Magic project exemplifies how mobile application development, combined with industrial communication protocols, can revolutionize traditional brewing operations. This paper explores the design, implementation, and future potential of the Brew Magic mobile application, emphasizing the use of Java programming and Modbus protocol within a sophisticated control system.

Introduction

The modern brewing industry increasingly relies on automation and digital control systems to improve product quality, ensure safety, and enhance productivity. Central to this evolution is the ability to remotely monitor and control brewing equipment, which traditionally required manual interventions. The Brew Magic system exemplifies this trend by integrating a mobile application with a Programmable Logic Controller (PLC), enabling brewers to oversee brewing parameters wirelessly. This integration is made feasible through industry-standard communication protocols such as Modbus and robust software development using Java for Android platforms.

Design and Components

The core components of the Brew Magic system include a Unitronics Vision 350TM PLC, an Android mobile device, and various sensors and actuators. The PLC acts as the central controller, managing key brewing functions such as temperature regulation, timers, and pump control. The choice of Java as the development language stems from its widespread use in Android applications and its rich ecosystem of libraries, including those supporting Modbus communication. The use of Modbus, a proven industry standard, ensures compatibility between the Android application and the PLC, facilitating reliable data exchange.

Communication Protocols and Data Management

Modbus serves as the backbone for data exchange, allowing the Android app to read from and write to specific registers within the PLC. Its address scheme assigns unique hex and decimal addresses to data elements like current temperature (MI3), target temperature (MI4), brew timer (TA7), and control bits for pumps and heaters (MB55, MB34, MB31). The systematic approach to data management involves reading these registers over TCP/IP connections, converting the raw data to meaningful values, and presenting them via the application's graphical interface. Similarly, user inputs such as toggling a pump or adjusting temperature setpoints are converted into appropriate Modbus commands sent back to the PLC.

Implementation Strategy

The implementation process encompasses creating a connection layer within the Android app that communicates over Wi-Fi using TCP/IP protocol. Java packages like Jamod and Modbus4J facilitate this interaction, enabling the application to establish, maintain, and terminate connections reliably. Upon establishing the connection, the app designates specific PLC registers for reading or writing, depending on whether the data reflects sensor readings or control commands. The system employs a conversion layer that ensures data formats align, converting byte streams into floating or integer values suitable for display or control commands.

Graphical User Interface (GUI)

The user interface prioritizes clarity and ease of use, with gauges displaying real-time temperatures, toggle buttons for control functions, and timers to monitor brewing progress. The interface also includes reset options and confirmation pop-ups to prevent accidental operations. Phase 1 of the app emphasizes establishing communication and basic display features, while Phase 2 aims to incorporate advanced functionalities like session data storage, remote access, and customization options. Ensuring the GUI reflects real-time data updates is crucial for effective monitoring and control.

Challenges and Solutions

One primary challenge was aligning the data formats between Android (Java) and the PLC, necessitating a robust conversion layer. Additionally, ensuring stable connectivity over Wi-Fi required handling network interruptions gracefully. To address these, the development team adopted reliable Java libraries for Modbus, implemented error handling protocols, and designed an intuitive interface that prompts users during connection issues. The integration of the conversion layer also future-proofed the system against protocol updates or interface changes.

Results and Impact

The Brew Magic mobile application successfully demonstrated remote control over brewing parameters, providing live data visualization and control features. The system allows operators to start, pause, and adjust brewing processes effortlessly. This not only streamlines operations but also enhances safety by reducing manual interventions and potential errors. The project paves the way for broader adoption of mobile automation in the brewing industry and similar manufacturing sectors.

Future Directions

Expanding the Brew Magic system includes addressing technical issues such as timer resets, optimizing DHCP configurations, and integrating notifications for critical events. Future enhancements also envisage implementing cloud connectivity for data storage and analysis, supporting multiple operating systems like iOS, and incorporating advanced recipe management features. These developments promise to elevate the system's functionality and user experience, aligning with Industry 4.0 principles and smart manufacturing paradigms.

Conclusion

The Brew Magic project exemplifies a successful convergence of industrial automation, mobile computing, and communication technologies. By leveraging industry-standard protocols like Modbus and programming languages such as Java, the system achieves robust, scalable, and future-proof control capabilities. This case study underscores the importance of thoughtful component selection, system architecture, and user-centric design in developing effective remote automation solutions.

References

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