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SPIRIT-C Solar Powered Image Response Infrared Tracking Camcorder Justin Eiler Jeff Morroni Adeel Baig Andy Crahan Jim Patterson Overview Design an infrared tracking camcorder All components solar powered Stepper Motors control camera movement Pyro-electric sensors detect IR emission Spartan-3 + PicoBlaze provides system control Presentation Outline System Components – Manual Control – Adeel Baig – Solar Power System – Jeff Morroni – Stepper Motor Controllers – Jeff Morroni – Infrared Sensors – Andy Crahan and Adeel Baig – System Integration – Jim Patterson – Software – Justin Eiler, Jim Patterson, Andy Crahan – System Mounting – Justin Eiler Parts List, Schedule, and Milestones System Block Diagram Solar Panel Peak Power Tracker Spartan-3 Voltage/Current Sensors Data IR Sensor PCB with A/D Converters Deep Cycle Battery Power Mechanical LED Motor Controller PCB Stepper Motors Digital Camcorder Computer Manual Control Genesis controller has a DB-9 interface The controller is active low When a switch is pressed, the output is shorted to ground 74HC157 Quad 2 line to 1 line multiplexer 2 inputs for every output 1 select signal for the chip Controller Pins Solar Power System Solar Panel Spartan-3 Peak Power Tracker Voltage/Current Sensors Deep Cycle Battery IR Sensor PCB with A/D Converters Motor Controller Stepper Motors Digital Camcorder Flyback Converter and Current/Voltage Sensors •FPGA controls Peak Power and Converter Shutoff •Uses voltage and current sensors to compute peak power point and determine if battery is charged Current and Voltage Sensors •LMP8270 uses common mode voltage to sense current •Simple Voltage Divider Senses Voltage •FPGA computes peak power point and battery charge state Solar Panel Sharp NE-80EJE donated from Namaste Solar Electric 80W, 17.1 Vmax, 4.67 Imax Length of 4.0’ Width of 1.8’ Deep Cycle Battery 105 Amp Hours 12.5V nominal output Solar Power System Status Peak Power Model 2 1.8 1.6 Input Power 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Duty Cycle Flyback converter built and tested Deep Cycle battery integrated with flyback converter Solar cells modeled with resistor in series with a voltage source Motor Controller Schematic L297 Stepper Motor Controller Half/Full Step Capability Direction Input Enable Input Clock Input L298 Dual Full-Bridge Driver Capable of Driving Motors up to 2A Current Sensing Capability allows for quick current decay when windings are turned off Stepper Motor •0.8A Winding Current •0.9 degree step sizes PCB Layout Pyro-electric IR Sensors Only pyro-electric sensors have the rapid motion detection we require for high speed filming These operate like current sources with output proportional to the rate of change in temperature Extremely fast responses set them apart They are also insensitive to external DC effects Current PIR Status Successful testing of PIR directional signal generation Amplification and filtering circuit performs as desired, railing the right and left movement signals to 5V This is dropped to 3.3V for direct signal interpretation on the FPGA PIR Output Filter, Amplification, and Latching Gain stage 1 sets amplifier gain and DC operating point Also creates band-pass filter to amplify only signals above DC yet below 10Hz Gain stage 1 feeds stage 2 through a RC high pass filter Stage 2 output (pin 14) is biased to 2.5V under no detection Gain stage 2 feeds a window comparator of 2 opamps to rail the PIR signal Comparator provides a small voltage window for PIR signal to avoid noise of minor sensor fluctuations Resistors bias comparator references to 175mV above and below 2.5V for left and right detections respectively Thus the window comparator provides 350mV dead zone centered at 2.5V to ignore noise Multi-vibrator IC used to latch output signals Circuit Timing Issues: Multivibrator The second gain stage feeds the CD4538 dual single shot multi-vibrator. The CD4538 is re-triggerable and re-settable for continuous motion detection. Dual chip enables left versus right signal processing. Each single shot has an active high output feeding the left and right signal outputs. With cross coupling of the trigger inputs, the first single shot triggered will inhibit the others trigger Re-triggering occurs under two successive valid triggers (3) and (4) prior to the output Q falling low. A re-trigger as timing node T2 increases from Vref1 to Vref2 causes an increase in output pulse width. Thus, continued motion during timeout will re-trigger the timing circuit and extend the pulse period until motion is no longer detected. Motion Sensitivity This window comparator enables accurate motion sensing for a valid trigger: skateboarder, intruder, small child, etc. The PIR with a Fresnel lens mounted 0.6 inches off the sensor produces accurate motion detection in two directions (left and right or up and down) The Fresnel lens enables motion detection of up to 90 feet For the design expo we are optimizing the PIR sensitivity for approximately 8 feet Spartan-3 and PicoBlaze PicoBlaze Features 16 byte-wide general-purpose data registers 1K instructions of programmable on-chip program store, automatically loaded during FPGA configuration ALU: CARRY and ZERO indicator flags 64-byte internal scratchpad RAM Automatic 31-location CALL/RETURN stack 2 clock cycles per instruction Fast interrupt response; worstcase 5 clock cycles Why PicoBlaze? 8-bit micro-controller Re-uses logic resources Interrupt handling Excellent for control and state machine applications System Block Diagram Solar Panel Peak Power Tracker Spartan-3 Voltage/Current Sensors Data IR Sensor PCB with A/D Converters Deep Cycle Battery Power Mechanical LED Motor Controller PCB Stepper Motors Digital Camcorder Computer System Integration PicoBlaze - send control signals to ADC, DAC, and MUXes for receiving IR sensor information and converter information MUXes - continuously polled at 50MHz for information, scrolling through each of 15 sensors and saving current state information ADC - synchronized to 25 MHz clock signal receive output voltage and current from converter DAC – synchronized to 25 MHz clock signal send PWM signal to gate drive converter MOSFET FPGA state machines Input - IR signal, converter voltage and current Outputs - motor control signal, converter PWM signal IR Sensors and Converter Control Converter control Voltage Regulator Output IR signal processing IR signal processing Header – IR sensors separately connected IR Network – separate gain stages, filtering and latching MUXes – MAX306CPI left and right channels MUXes 15 IR networks Header Converter Control ADC Level Shifters ADC – 0808CCN converter V and I digital signal DAC – 0830LCN digital signal PWM voltage Level Shifters – HCF40109 digital signals from 5V3.3V DAC State Machine Pad_start = 1 Reset = 0 Start_up Reset = 1 Pad_left = 0 Move_Left Manual Automatic Pad_start = 0 Pad_down = 0 Move_Down Pad_up = 0 Move_Up Pad_right = 0 Move_Right *All 4 Move_x states return to previous state after one cycle Software Verilog HDL (State Machine) - Manual control IR signal flow Motor control PicoBlaze Assembly Language - Serial communication Sensor polling Converter control Example Code for Manual Control case (state) MANUAL: begin automode = 0; if(pad_up == 1) begin state = MOVE_UP; end else if (pad_down ==1) begin state = MOVE_DOWN; if(pad_left == 1) begin state = MOVE_UP_LEFT; end if(pad_left == 1) begin state = MOVE_DOWN_LEFT; end else if(pad_right == 1) begin state = MOVE_UP_RIGHT; end else if(pad_right == 1) begin state = MOVE_DOWN_RIGHT; end end *Verilog HDL used to code FPGA else if(pad_left == 1) begin state = MOVE_LEFT; if(pad_down != 1) begin state = MOVE_DOWN_LEFT; end else if(pad_up != 1) begin state = MOVE_UP_LEFT; end end Test Code for Micro-controller cold_start: • LOAD s0, 00 OUTPUT s0, FF LOAD s1,ascii_X INPUT TEST JUMP JUMP s0, buffer_full s0, b_full Z, UART_write rs232_echo OUTPUT LOAD s1, uart_data_tx s1, 00 INPUT TEST JUMP s0, data_present s0, b_full Z, led_echo INPUT s1, uart_data_rx INPUT OUTPUT s0, switch_in s0, leds_out send_prompt: send_to_UART: UART_write: rs232_echo: UART_read: led_echo: finish: JUMP send_to_UART • • PicoBlaze has own assembly language Code tests UART, LED’s, switches, and serial port Assembler converts this to Verilog HDL code System Mounting Tripod mount Solar Panel independently supported but attached to tripod Pan stepper motor (possibly geared) Tilt stepper motor attached to yoke IR sensors mounted on array below top of tripod Parts List Project Schedule Milestones •Milestone 1 - Hardware assembled and software written - Minimal system integration •Milestone 2 - Hardware and software fully integrated - System mounting completed Questions?