IOWA STATE UNIVERSITY Frozen Precipitation Detector for SODAR Systems Final Report Ashor Chirackal, Imran Butt, Michelle Tan and Luke Lehman 12/6/2010 SDDEC10-06 Disclaimer This document was developed as a requirement for Senior Design II at Iowa State University, Ames, Iowa. This document is not a professional design. The information included in this document aims to be accurate, but the team members, advisors, client, and Iowa State University make no claims about the accuracy or the quality of this document. Users of this document must ensure that no violations of any law regarding licensing and certifications occur. This document is copyrighted by the team members and advisors who produced this document and no part of the document may be reproduced without the permission of the course coordinator. Table of Contents Disclaimer ....................................................................................................................................... 2 Table of Contents ............................................................................................................................ 3 Executive Summary ........................................................................................................................ 8 Acknowledgment ............................................................................................................................ 9 Problem Statement ........................................................................................................................ 10 General Problem Statement .......................................................................................................... 10 General Solution Approach........................................................................................................... 10 Concept Diagrams ......................................................................................................................... 11 System Diagram ............................................................................................................................ 15 System Description ....................................................................................................................... 15 Operating Environment ................................................................................................................. 16 Non-technical Environment ...................................................................................................... 16 Technical Environment ............................................................................................................. 17 Intended Users and Uses ............................................................................................................... 17 Assumptions and Limitations ....................................................................................................... 17 Expected End Product and Other Deliverables ............................................................................. 18 Design Objectives ......................................................................................................................... 18 Functional Requirements .............................................................................................................. 19 Power Requirements ................................................................................................................. 19 Heater Control Requirements .................................................................................................... 19 Frozen Precipitation Detector (FPD)......................................................................................... 19 Non-functional Requirements ....................................................................................................... 19 Financial .................................................................................................................................... 19 Weather ..................................................................................................................................... 19 Constraints Considerations ........................................................................................................... 20 Power......................................................................................................................................... 20 Heater ........................................................................................................................................ 20 Acoustic Environment ............................................................................................................... 20 Technology Considerations .......................................................................................................... 20 Acoustics ................................................................................................................................... 20 Materials .................................................................................................................................... 20 Technical Approach Considerations ............................................................................................. 21 Piezoelectric sensor ................................................................................................................... 21 Design Approach .......................................................................................................................... 21 Research .................................................................................................................................... 21 Perform small scale tests: .......................................................................................................... 21 Partial Prototyping..................................................................................................................... 21 Complete Detailed Design ........................................................................................................ 22 Testing Approach Considerations ................................................................................................. 22 Safety Considerations ................................................................................................................ 22 Project Milestones and Evaluation Criteria .................................................................................. 23 Market and Literature Survey ....................................................................................................... 23 Possible Risks and Risk Management .......................................................................................... 24 Risks that will result in the failure of the product ..................................................................... 24 Risks that will disrupt the flow of the project management ...................................................... 24 Detailed Design ............................................................................................................................. 25 Input/ Output ............................................................................................................................. 26 User Interface ............................................................................................................................ 26 Hardware/ Software................................................................................................................... 27 Other Components..................................................................................................................... 27 Implementation.......................................................................................................................... 27 Testing Plan .................................................................................................................................. 27 Phase I ....................................................................................................................................... 27 Phase II ...................................................................................................................................... 27 Evaluation ..................................................................................................................................... 28 Design, calculations & schematics ............................................................................................... 28 TTL Comparators ...................................................................................................................... 28 Filters ......................................................................................................................................... 29 Amplifier Circuit ....................................................................................................................... 42 Peak Detector Circuit ................................................................................................................ 44 SODAR Test Results .................................................................................................................... 47 ............................... 47 ............................... 48 ............................... 49 Period and Amplitude Measurement ......................................................................................... 49 Frequency & Amplitude Measurements ................................................................................... 50 Signal after Amplification and Filtering (Clear) ....................................................................... 52 Signal after Amplification and Filtering (With Ice) .................................................................. 53 Future Work .................................................................................................................................. 56 Recommendations ......................................................................................................................... 57 Work Statement ............................................................................................................................ 57 Task Descriptions.......................................................................................................................... 59 EE 491: Senior Design 1 ............................................................................................................... 59 Defining and Planning .................................................................................................................. 60 Identify Need ............................................................................................................................. 60 Complete Project Definition...................................................................................................... 60 Define Requirements ................................................................................................................. 60 Perform Research ...................................................................................................................... 60 Map Project Schedule................................................................................................................ 60 Determine Budget ..................................................................................................................... 60 Documenting and Reporting ......................................................................................................... 60 Submit Weekly Status Reports .................................................................................................. 60 Develop Draft Website .............................................................................................................. 61 Update Project Website ............................................................................................................. 61 Write Draft Project Plan ............................................................................................................ 61 Write Final Project Plan ............................................................................................................ 61 Determine solution ........................................................................................................................ 61 Perform in depth study of piezoelectric plates .......................................................................... 61 Determine components .............................................................................................................. 61 Perform small case testing......................................................................................................... 61 Analyze based on results and make decision ............................................................................ 62 Test SODAR ................................................................................................................................. 62 Test the heating pad on the SODAR ......................................................................................... 62 Test the acoustic properties of the SODAR .............................................................................. 62 Basic parameters acquirement ................................................................................................... 62 Detailed Design ............................................................................................................................. 62 Create Preliminary Design ........................................................................................................ 63 Perform analysis ........................................................................................................................ 63 Determine final components ..................................................................................................... 63 Design Documents ........................................................................................................................ 63 Create Draft Design and Presentation ....................................................................................... 63 Present Design Review.............................................................................................................. 63 Write Draft Design Report ........................................................................................................ 63 Write Final Design Report ........................................................................................................ 63 EE492: Senior Design II ............................................................................................................... 64 Project Management ..................................................................................................................... 64 Weekly Status Reports .............................................................................................................. 64 Update Website ......................................................................................................................... 64 Design Poster............................................................................................................................. 64 Final Report .................................................................................................................................. 64 Final Report Draft ..................................................................................................................... 64 Final Presentation ...................................................................................................................... 64 Design ........................................................................................................................................... 65 Write user manual ..................................................................................................................... 65 Purchase components ................................................................................................................ 65 Fabricate Support Structure....................................................................................................... 65 Testing........................................................................................................................................... 65 Test and Debug Hardware ......................................................................................................... 65 Install Completed system .......................................................................................................... 65 Resources Requirements ............................................................................................................... 65 Time Resources ......................................................................................................................... 65 Cost Resources .......................................................................................................................... 66 Closing Summary.......................................................................................................................... 70 Lesson Learned ............................................................................................................................. 70 Contact Information ...................................................................................................................... 71 Client Contact Information........................................................................................................ 71 Faculty Advisor Contact Information ....................................................................................... 71 Team Contact Information ........................................................................................................ 71 Executive Summary This document was written for the senior design team (SDDEC10-06) at Iowa State University to record their work on building a better frozen precipitation detector for a SODAR unit. This document primarily details the sensor that was chosen for the project and other circuits that were designed in order to build the frozen precipitation detector. It also includes the testing results and other recommendations for future reference. SODAR units are used to measure wind shear in order to determine if a geographic area is a viable location for a wind farm. The SODAR reflects sound waves off of a pad and into the atmosphere. This pad needs to be clear of any frozen precipitation in order for the SODAR to function effectively. A pre-installed heater is used to melt any frozen precipitation that may accumulate on the pad. However, the current frozen precipitation detector does not allow for the frozen precipitation to be melted proficiently. Therefore, there is a need for a frozen precipitation detector that works efficiently. Acknowledgment The team would like to express their sincerest appreciation and gratitude to the following contributors for their help and support throughout this project: Dr. Timothy Bigelow (Faculty Advisor) for his supervision and advice throughout the project. Mr. Doug Taylor (John Deere) for helping the team to understand the aims of the project and also for his valuable feedback. Mr. Josh Underwood (ASC) for providing substantial information on the equipment. Dr. Manimaran Govindarasu (Senior Design I) for inspiring the team to develop a presentable project. Dr. Daji Qiao (Senior Design II) for providing guidance and feedback. Mr. Leland Harker (ECpE Electronic Shop) for helping the team with parts and components needed for the project. Dr. Alan Czarnetzki (University of Northern Iowa) for providing time and equipment for the team to test the design. Problem Statement The main purpose of this project is to optimize the number of times the heater should turn on in order to reduce the system’s power consumption by designing a frozen precipitation detector that is more efficient and accurate than the current model. General Problem Statement SODAR systems are used to measure wind shear up to 200 meters in the atmosphere. These systems are usually located at remote areas for data collection. The SODAR system that we designed for is the 4000WE model produced by Atmospheric Systems Corp. (ASC). This model has a heater, a temperature sensor and a snow detector installed in it. The system is also designed to be autonomous and is primarily powered by solar panels. The system also has a generator as a secondary source and to provide power for heater operation. The system operates by emitting sound waves from 4000Hz to 5000Hz through its 32 speakers. These sound waves are emitted in short, 20 cycle, bursts that occur every two to three seconds. These waves are then bounced off of an angled reflector pad that is located directly in front of the speakers. The waves travel approximately 200 meters into the atmosphere and reflect back into the SODAR. The purpose of the system is to measure and record wind shear data to be used for meteorological purposes as well as wind farm planning. In order to ensure the accuracy of the data collected, there is a need for a smooth and flat reflector pad. If the pad is uneven or has any other obstructions, the data collection might be distorted. In the winter, there is a chance for snow accumulation and it needs to be melted right away in order for the data to be accurate. The system currently employs a precipitation detector that produces many false positives resulting in excessive use of the generator and short fuel life. General Solution Approach The team’s approach is to use piezoelectric sensors to detect the presence of snow on the reflector pad. These sensors will make use of the signals generated from the SODAR to tell the difference when there is snow on the reflector pad or not. When snow is present on the sensor, the voltage being produced will be less than the voltage when the reflector pad is clear. The heater will only be turned on when the piezoelectric sensor has snow on it. The solution circuit that incorporates amplifiers, peak detectors, filters and TTL logic comparators will be powered by the SODAR. Concept Diagrams When the equipment is clear of snow/ice: Reflected sound waves Speakers Reflector pad/Heater Figure 1 Inside of the SODAR equipment without snow on the reflector pad. When the equipment is has snow/ice on the reflector pad: Reflected sound waves with distortion Speakers Layer of snow Reflector pad/ Inefficient heater Figure 2 Inside of the SODAR equipment with snow on the reflector pad. The piezoelectric sensors enable us to determine if the reflector pad has snow or ice on it. Using the sounds waves from the speakers, the sensors can detects the different voltage levels and turns on the heater only when there is snow present. Since the sensors work continuously and detect snow on the pad instead of as an attachment outside of the equipment, the sensors will signal for the heater to turn on with fewer false positives. Also, because of the thinness of these sensors, it will not obstruct the system’s operations. Reflected sound waves with distortion Speakers Layer of snow Reflector pad & heater Piezoelectric Sensors Figure 3 Inside of the SODAR equipment with snow on the reflector pad and piezoelectric sensors. A more illustrative diagram of the piezoelectric sensors is shown below: The figure above shows the piezoelectric sensors on the reflector pad. Each sensor will produce individual voltage signals. If there is snow present on one of the piezoelectric sensor e.g. V1, the voltage generated will be different from the one produced by sensors that are clear of snow e.g. V2 and V3. System Diagram For implementation to the current system: Power Source Temperature Sensor Heater AND Gate Piezoelectric Sensors Amplifiers Filters Sample & Hold Master Control OR Gates System Description Frozen Precipitation Detector The entire system used to receive information, process, and produce a TTL signal to control the heater. Piezoelectric Sensors These sensors are transducers that convert sound waves to electric voltages. Each sensor will provide different output voltage based on the how much snow was covering the surface of these sensors. Design Circuit In the design circuit are three main parts i.e. amplifiers, filters, and sample and hold. Outputs from the piezoelectric sensors are very small and so appropriate amplifications are needed for the signals to be properly analyzed. There will also be noise that surrounds the equipment hence filters are built to only take in signals from 4 KHz to 5 KHz. Since the speakers operates with burst signals, sample and hold circuit is added to maintain the signal for a few seconds longer. Logic Gates If multiple piezoelectric sensors are used, a logic gate AND is necessary to determine snow on different parts of the reflector pad. It could also take an input from the temperature sensor to only have the heater on when the atmospheric temperature is low i.e. winter. Also, logic ‘OR’gates can be used to combine 2 sets of sensors for redundancy. Heater The heater is mounted under the reflector pad and is not detachable. This is the component that the project needed to control by developing more effective sensors. It will be used only during the winter and should only be turned on to melt the snow when there is a certain level of snow accumulation. Power Source The equipment is powered primarily by the solar panels that are attached to it. This will also be the power source for this design. It will provide power to the new circuit only as the piezoelectric sensors will not require power to operate. Temperature Sensor The temperature sensor will measure the temperature and humidity in the atmosphere. This is a preinstalled component in the equipment. The readings from this sensor may be incorporated at a later date to improve robustness. Operating Environment Non-technical Environment The plan is that the detector will be able to withstand hot, humid, windy, cloudy, rainy and harsh winter weather. It will have to be able to function without any problems during snow storms, freezing rain and blizzards. During summer months, it should still be able to withstand the humidity and heat although the detector is not in use. The product will most likely be situated at remote, deserted locations with high chances of rodents and wild animals. The product will have to be able to stay in place on the reflector pad while operating regardless of the harsh winter weather or being agitated by rodents or wild animals. However, it should be able to be taken off for maintenance or replacement. The product will have to endure hot temperatures (>100F) emitted from the heater if the solution is to have the product placed directly on top of the reflector pad/heater. Also, it will have to function well from very low atmospheric temperature (~-30F). The detector will not be melted or burned by the heat from the heating pad and will not be frozen from the harsh winter weather. It should be able to withstand the high wind speed if the solution is to have the product placed as an attachment on the top of the equipment. Since the detector is operating during winter, snow and ice will be the common operating environment. Snow and ice will not interfere the operations if they are surrounding the equipment and not on the equipment. Accumulation of snow and ice will interrupt the SODAR operations thus it will turn on the heater. Technical Environment The current system works within an acoustic environment resulting from sound emitted from the SODAR speakers. The passive sensor will not emit frequencies from 4000Hz to 5000Hz which would interfere with operation of the SODAR. Intended Users and Uses The primary intended user for this project is our client, Atmospheric Systems Corp. (ASC. The design can be installed on older equipment where the current detector is facing problems or as a replacement for the current detector. The product will be installed in purchased equipment should ASC upgrade the systems for their clients. The product will be used to detect the presence of snow and ice that is on the reflector pad. It will then send signals to the master controller to turn on the heater effectively which in turn will melt the snow and ice on the reflector pad. Assumptions and Limitations All information about the SODAR system was provided to us by our contacts, Mr. Doug Taylor and Mr. Josh Underwood. Information was also gathered from the ASC website. Although we will still continue researching about the SODAR system, in order to further our solution, some assumptions must be made. Environment The SODAR equipment will be used in areas with freezing conditions/ precipitation, debris/ dust and wildlife. Heater The heater is not removable (glued-on) and cannot be altered. It will produce a constant amount of heat. The temperature on the reflector is assumed to be high (>100F). Temperature Sensor The temperature sensor is functioning well and is able to detect the current temperature accurately. Input from the temperature sensor can be used along with the logic gates we intend to use. Power Source The Frozen Precipitation Detector (FPD) will have a constant source of power unless the SODAR goes into hibernation mode. Installation The FPD is compatible with the SODAR systems. The FPD will be able to fit properly on the reflector pad. A limited amount of space will be available on the heater to set up our FPD. Piezoelectric Sensor The piezoelectric sensor will be able to handle the temperature changes from the heater and the environment. The piezoelectric sensor must be able to send reliable signals. Expected End Product and Other Deliverables The final design of the product is the frozen precipitation detector with the proposed sensors and the accompanying circuit. Should time and resources permit, logic gates and more sensors will be added. A manual/report will be included should the manufacturer intend to use the design in their products. Design Objectives The solution must be used to detect the snow and ice accumulation on the reflector pad. Our objective is to use piezoelectric sensors placed on top of the reflector pad to detect the sound emitted from the SODAR speakers. A customized circuit designed by the SODAR team will be used to decide if the heater is necessary. Since the solution is placed on the reflector pad, it needs be able to withstand the high heat from the heater. It must be able to tell the difference between the surface that has precipitation accumulation and the clear surface. The solution must not disrupt the SODAR operations. Functional Requirements Power Requirements The new detector must be primarily powered using the solar panels currently on the equipment. In order for the solution to be energy-efficient, the new detector must use the same amount of power or less. The FPD cannot use more power than what the solar panels generate. In case of primary loss of power, the new detector must use the generator that was already on the equipment. The generator has a finite amount of fuel. It cannot be depended on to power the detector for a long period of time. Heater Control Requirements The heater is to be controlled by the voltage that the FPD produces. A large amount of frozen precipitation will affect the accuracy of the SODAR readings and must be removed immediately. The heater needs to turn on when the voltage received by the circuit is lower than a certain threshold. Frozen Precipitation Detector (FPD) The FPD must be able to detect the snow or ice on the reflector pad. The detector must not disturb with the operations of the SODAR Non-functional Requirements Financial The FPD should be economical and affordable. In the case where the cost of the product exceeds the cost of the current detector, it should provide more benefits than the current detector. Though it is more expensive, the product will save on the fuel consumption expenses. A budget will be determined as the project progresses. Ideally, the new solution should be less than the cost of the current detector. Weather Design must withstand weather conditions as explained in the operating environment (Snow, extreme weather, unpredictable weather conditions like in Iowa or Kansas) Design must also withstand the temperature of the heating pad. Rain will not be an issue as long as it does not disrupt the operations of the SODAR system. Constraints Considerations Power Power consumption must be lower than the current system. There must be an increase in power efficiency to delay the hibernation mode of the equipment. If the system goes into hibernation mode, its operation will be stopped until fuel is replenished. The SODAR (without the heater) operates with 25 Watts primarily from the solar panels. Heater Heating pad should be turned on when necessary. We have limited power available. Primary power source is solar panels and secondary source is fuel tank (24 gal.). Heater runs at a Power of 1800 Watts currently. Heater cannot be changed or removed as it is permanently attached with the reflector pad. Operates as one unit and cannot divide into parts Acoustic Environment Design must not interfere with the SODAR system. The SODAR uses a frequency between 4000Hz and 5000Hz. Technology Considerations Acoustics The nature of our primary sensors depends upon the acoustic environment. We will need to conduct studies on the properties of sound in order to make effective use of sound as a detection tool. Materials Our primary sensors are piezoelectric sheets and their material properties need to be understood and employed effectively for snow detection. The piezoelectric sensors must be securely placed on the reflector pad. Lamination of the piezoelectric sensors will protect them from the environment and a sturdy adhesive will attach them to the reflector pad. Technical Approach Considerations Piezoelectric sensor The piezoelectric sensor should have the material strength to with stand the temperature extremes of the environment. The response of the piezoelectric sensor must be clear enough to be analyzed by the circuit. Design Approach In order to come up with an effective design by the end of the semester, we used the following approach: Research Problem definition and understanding the operation of the product Determination of functional and non-functional requirements Determine constraints and operating environment Determine several viable solutions o Read literature and research different sensors that could be used o Design system block diagram and system descriptions o Determine the components required for the sensors o Perform literature survey to confirm our design approach and improve our methods if needed Perform small scale tests: Acquire components necessary to perform small level testing Design a series component based tests to check performances Perform simulation and required circuit and system analysis before building component testing Perform component based testing based on the design and analysis Analyze the results of those components and make changes if necessary and retest if required Document analysis and results of each component Have two solutions (primary and secondary) determined Partial Prototyping If possible after performing component testing replicate the environment in which the final product will be used and perform basic tests Complete Detailed Design To be implemented in fall 2010. Based on the small scale testing results we will complete the design with the following specifications Input/output specification Hardware and Software specification Test Specification Simulation modeling Prototype and test design Produce design documents Testing Approach Considerations Safety Considerations Two important aspects regarding safety considerations for this project are the safety of the product and the safety of the users. Product safety is important because the damage on the product could put the SODAR operation into an early hibernation mode that will result in the interruption of data collection. This will also cause the heater to turn on when it is not needed resulting in increased power consumption and fuel usage. Some product safety issues that will be considered are: Electrical faults could occur since the product is connected with wires and this could result in short circuitry, overheating. The product could freeze due to hard weather conditions. Shifting could occur if the product is not fixed properly on the reflector pad. Damage could be caused by rodents that somehow got into the equipment trailer and this could result in the possibility of damaged wires, malfunctioning sensors and broken microprocessors/speakers. Equipment could be flammable if overheating occurs. User safety is also an important aspect since there will be some sort of human interaction with the equipment. Some of the user safety considerations are: Electrical shock could occur to users if any parts of the product are experiencing electrical faults. SODAR system is operating at a high sound intensity that could causes damage to the human ears. Abrasions could happen due to wires, tools and other objects. Severe burn could occur if user is interacting with the equipment when the heater is turned on. Other safety considerations will involve the wildlife/rodent interactions and environmental issues. Wildlife and rodents might be affected by the SODAR. Rodents/birds might be burned if detected as obstacles on the sensors. Project Milestones and Evaluation Criteria Our team has set a numbers of milestones in this project. One of the important milestones that we have determined is design and testing the prototype of our primary piezoelectric sensors. Next, we would like to come up with the prototype of our secondary sensor which we would like to implement as a back-up to our primary sensor. The team also considered testing documentation as an important milestone as well. Other milestones can be found in our project’s Gantt chart. Evaluation of the milestones is also an important task for the team. When the testing and developing procedures are in progress, the team will determine the evaluation criteria for the milestones. Market and Literature Survey The Frozen Precipitation Detection project is very unique to the client’s needs and specifications. The piezoelectric sensors are used in other applications such as quality assurance, process control, measurements of various processes etc. Their use in detecting snow is very unique and we haven’t been able to find an application of piezoelectric sensors that are used in detecting snow or ice. Some applications of piezoelectric films are outlined below. Detection and generation of sonar waves Power monitoring in high power applications Automotive engine management systems Acoustic emission testing Inkjet printers Possible Risks and Risk Management There are certain risks associated with this project. We have identified these risks and also how to manage our project in order to mitigate these risks. Risks that will result in the failure of the product Components used are incompatible with the equipment and the environment as a result of testing being done a laboratory. o Components used will be analyzed thoroughly before we begin testing. o Testing on the actual equipment will be performed. Complications might occur for mass-manufacturing of the product. o Dimensions of the product must be accurate. It should match the dimensions of the reflector pad. Ideas do not meet client’s wants. o Ideas and steps leading to the design of the product will be discussed and approved by the client before actual testing or implementing. Risks that will disrupt the flow of the project management Components might be damaged during experimental period. o Components must be handled with care at all time. Testing/Experiment results might be lost. o Good and proper documentation skills must be executed. Team members do not have enough expertise in the software/programming area. o Team members will have enough programming background to program the product. We might experience the loss of a team member. o Every task will be delegated to two members. o Team members will still need to participate in Senior Design 2 through video/phone conferencing even though they are away for internships/coops. The project might not be able to be tested under the right weather conditions. o Team must begin testing/experimenting during winter. Team members (or anyone around us) might be injured during experiments/fabrication. o All team members must be cautious at all time during these sessions. o All protective gears like earplugs must be worn if necessary. o Start experimenting at a low voltage level so that the sound generated will not be harmful to the human ears. o Testing will be done in a closed, soundproof room. o Before the start of the sound experiment, a warning will be given to the people that are in the same room so that they too will put on their protective earplugs. Time constraint (missing deadlines, scheduling conflicts, delay while waiting on materials) o Detailed planning must be done in order to move forward in the project. Financial constraint (unknown budget at the beginning of the project) o A cost analysis must be performed and will be reviewed during the selection of the best option. o Work with the current allocated budget that is given by the department before using for the subsidized fund. Having difficulties in locating potential components for testing/experimenting. o Design must use easily found components since the product will be used implemented for many SODAR systems. Detailed Design The input for the FPD will be the sound that the SODAR unit producesThe piezoelectric sensor on the reflector pad will detect the sound wave and generate a response voltage. This voltage will depend on whether frozen precipitation exists on the reflector pad. If frozen precipitation is on the reflector pad, the voltage will be lower than if the reflector pad was clear. This signal is sent through our circuit. First the voltage is amplified from the millivolt to the volt range. Second, the band-pass filter is used to only let the signal between 4 and 5 kHz through. Third, the peak detector holds the maximum voltage of the signal. Lastly, the signal is converted to TTL on/off signal by a comparator circuit. Input/ Output The voltage generated by the piezoelectric transducer (covered with snow) + V1 + V2 + V3 The voltages generated by the piezoelectric transducer (clear of snow) In this diagram, the arrows are the sound emitted by the SODAR speakers, and the ovals are the piezoelectric sensors receiving the sound. The small circles covering the first oval represent snow. Each of the sensors has a corresponding voltage (V1, V2, V3). With a clear surface, the voltages will give a certain voltage. If the surface is covered as in V1, the voltage will be lower. With a low voltage, the heater would be turned on. User Interface The SODAR is meant to be autonomous. Therefore, user interface should be kept to a minimum. Installation will be required from the user. The FPD needs to be attached to the SODAR and powered by the SODAR. A 12 pin input will connect the FPD to the heater. Hardware/ Software No software is necessary for the FPD. A customized circuit, designed by the SODAR team, will be used to turn the heater on or off. Other Components The circuit will use these components 1) 2) 3) 4) 5) 1.5k, 6.8k 1k, and .1k resistors 1000uF, 30pF, and .01uF capacitors 1k-10k potentiometer LM741/356 Operation Amplifier Diode Implementation Implementation of the FPD involves permanent attachment of the circuitry and piezo-electrics to SODAR systems. These SODAR systems must be operated in environments that produce frozen precipitation and must have a heating unit installed. No such unit was available to implement our design on in the time frame allotted. As such, a prototype unit was implemented on a SODAR system lacking the heating hardware. The output of the prototype FPD was routed to an LED indicator to simulate heater operation. The prototype FPD was not permanently installed on the SODAR system but was implemented in a similar fashion to the intended installation of a permanent FPD. Testing Plan The testing of the FPD was planned in two major phases. The first phase consisted of testing the individual pieces of the FPD circuitry. The second phase consisted of prototype testing on a SODAR system. Phase I The major parts of the FPD are as follows: Amplifier, Band-Pass Filters, Sample and Hold circuitry. Construction and testing of these parts was conducted simultaneously in order to produce a rapid prototype. Simulation of a SODAR signal was produced at a lower level in laboratory in order to test functionality of each of these subsystems. Signal pulses were generated using a signal generator and results were measured with oscilloscopes and digital multi-meters. After these subsystems were finalized, a prototype system was constructed. Phase II Integration with the SODAR system is a crucial part of the implementation of the FPD. Each FPD must be tuned to the amplitude and frequency of the SODAR system that it will be implemented on. The prototype we built was initially designed for a system producing impulses in the 4 kHz range. The SODAR system that we implemented our prototype on produced impulses in the 4.5 kHz range. The SODAR system is located at the University of Northern Iowa and our team made two trips to Cedar Falls, Iowa to evaluate and test our prototype FPD. Testing on the SODAR included tuning of the FPD to match the SODAR specifications. Testing on the SODAR included clear signals and frozen precipitation signals. Successful prototype operation was achieved during both visits. Evaluation The original client for the FPD project, John Deere Renewables, was unable to participate in the senior design project for the Fall 2010 semester. As a result of this complication we contacted the parent company producing the SODAR systems. Mr. Josh Underwood of Atmospheric Systems Corporation in Santa Clarita, California was our primary contact throughout the fall 2010 semester. Correspondence with Mr. Underwood included design criteria, SODAR specifications and informal evaluation of the FPD. Primary evaluation was conducted by the team at Iowa State laboratories in the Electrical Engineering department and at the Cedar Falls test site. Evaluation included testing of the individual subsystems using simulated inputs as well as testing using real-world inputs from the SODAR system. Evaluation was based on original design criteria provided by John Deere Renewables and was modified according to new client interaction and availability of necessary equipment. Primary goals included fabrication of a working prototype, implementation of a working prototype on a SODAR system and fulfillment of design criteria such as cost, energy consumption, ease of fabrication, durability etc. Design, calculations & schematics TTL Comparators A comparator was implemented at the end of the circuit in order to produce a digital signal that would turn the heater on or off. A 12V signal represents an on signal and a OV signal represents an off. The comparator circuit accepts a 0-3V signal from the output of the Peak Detector and turns the heater on when an approximately 20% reduction in signal is received from the piezoelectric sensor. Filters The team designed and implemented Butterworth filters to remove the noise signal from the output of the piezoelectric films. High Pass Filter Below is the frequency response of the High pass filter in Matlab The cutoff frequency was chosen as fc = 2000 Hz Code and Calculations s = tf('s') fc = 2000; %cutoff frequency wc = 2*pi*fc %cutoff frequencys (radians) K=2 %Order of transfer function Hhp= (s^2)/ ( s^2 + sqrt(2)* wc* s + wc^2) Transfer Function Frequency Response: Basic Design Component Calculation High Pass Filter Schematic Low Pass Filter Code and Calculations s = tf('s') fc = 8000; %cutoff frequency wc = 2*pi*fc %cutoff frequencys (radians) K=2 %Order of transfer function Hlp2= wc^2/( s^2 + sqrt(2)*wc*s +wc^2) Transfer Function based on our requirements Frequency Response of the Low Pass filter Basic Design Component Calculation Low Pass Filter Band Pass Filter Code and Calculations Band pass filter is obtained by simply multiplying the transfer functions of High pass and Low pass filter. Hbp = Hlp * Hhp Transfer Function of Band Pass Frequency Response of Bandpass Filter Band Pass Filter Combining the Low Pass and High Pass together, the schematic of the Band pass filter is given below. Filter Simulation on P-Spice Below is the result of the simulation run on P-Spice for the band pass filter. Frequency Response of the band pass filter Below are the results from the filter actually implemented Frequecy Response of Filter Circuit 1.4 1.2 Vo/Vin 1 0.8 0.6 Vout/Vin 0.4 0.2 0 Frequency (Hz) Amplifier Circuit The team used 741 op amps to amplify the voltage generated by the piezoelectric due to sound. Design Using Inverting configuration Rf=tunable potentiometer (104) Rin=1.1KOhm Testing the amplifier Using a high gain amplifier we got the following results With a Vinput of 100mVpp and after filtering Peak Detector Circuit The peak detector in Figure 1 is similar in many respects to the sample-and-hold circuit. A diode is used in place of the sampling switch. Connected as shown, it will conduct whenever the input is greater than the output, so the output will be equal to the peak value of the input voltage. In this case, a LM741 is used instead of the LM 101/102 as a buffer for the storage capacitor, giving low drift along with a low output resistance. Design Positive Peak Detector with Buffered Output http://www.freecircuits.net/circuit-42.html As with the sample and hold, the differential input voltage range of the LM101 permits differences between the input and output voltages when the circuit is holding. Test Results The team tested the Peak Detector for different frequencies. The peak detector tracks the amplitude or the peak value of an AC signal with in an accuracy of 9 to 13% Frequency Input Max from Filter Peak Detector Voltage Difference % loss 500 0.11 0.1 0.01 9% 1500 0.56 0.48 0.08 14% 2000 0.94 0.84 0.1 11% 2500 1.18 1.04 0.14 12% 3000 1.24 1.12 0.12 10% 3500 1.28 1.05 0.23 18% 4000 1.22 1.08 0.14 11% 4500 1.18 1.06 0.12 10% 5000 1.2 1.05 0.15 13% 5500 1.16 1.03 0.13 11% 6000 1.14 1.09 0.05 4% 6500 1.12 0.97 0.15 13% 7000 1.12 0.98 0.14 13% For 4.5Khz, which is the frequency used by SODAR, the performance of the peak detector at different amplitudes of input is given below Vin Volt at Peak Detector Difference % loss 0.25 0.18 0.07 28% 0.5 0.41 0.09 18% 0.75 0.64 0.11 15% 1 0.877 0.123 12% 1.25 1.105 0.145 12% 1.5 1.331 0.169 11% 1.75 1.553 0.197 11% 2 1.771 0.229 11% 2.25 1.984 0.266 12% 2.5 2.3 0.2 8% 2.75 2.54 0.21 8% 3 2.78 0.22 7% 3.25 3.01 0.24 7% 3.5 3.24 0.26 7% 3.75 3.48 0.27 7% 4 3.71 0.29 7% 4.25 3.9 0.35 8% 4.5 4.17 0.33 7% 4.75 4.405 0.345 7% 5 4.6326 0.3674 7% SODAR Test Results SODAR Speakers 1 Piezo Installation 1 Piezo Installation 2 Frozen Precipitation Detector 1 Frozen Precipitation Detector 2 Period andPiezo Amplitude Measurement Signal from 1 Frequency & Amplitude Measurements The team calculated the frequency and amplitude of the signal received by the piezoelectric by using the oscilloscope. Frequency: 4.402 KHz Pk-Pk Voltage Range: 30-160mV Different Phase voltages The team found three types of voltages received by the piezoelectric. The difference in voltages is due to the phases of the sound generated by the SODAR speakers. These voltages with associated waveforms are given below. Phase I Pk-Pk (Delta) = 148mV Phase II Delta (pk-pk) Voltage = 104mV Phase III Very low voltage from the third phase sound Delta (pk-pk) Voltage 38mV Signal after Amplification and Filtering (Clear) After ensuring that the piezoelectric was detecting the sound generated by the speakers, the team tested the piezoelectric signal after passing it through required amplification and filtering. The voltages measured and waveforms are given below: Pk-Pk Voltage 1: 3.62 V Pk-Pk Voltage 2: 2.30 V Pk-Pk Voltage 3: 0.563 V Delta (pk-pk) Voltage:2.3V Signal after Amplification and Filtering (With Ice) After checking the validity of amplification and filters the team tested if the piezoelectric can produce a lower voltage signal after covering it with snow. The picture below shows the piezoelectric covered with crushed ice. Waveforms: After covering the piezoelectric with crushed ice the sensor was only able to detect the two largest sound signals. The oscilloscope wasn’t able to capture the smallest signal which is Voltage 3. Voltage 1 (largest) Voltage 2 (2nd Largest) Attenuation Calculation: Following is the loss in signal strength due to snow accumulation for the sensor Voltage Signal (Phase) Clear (V) Covered (V) Loss (V) % Loss 1 3.62 0.82 -2.8 -77% 2 2.3 0.46 -1.84 -80% 3 0.536 0.02 -0.516 -96% The value for Voltage 3 in case of covered is an assumed value. Since the oscilloscope cannot detect a signal less than 10mV, we assume it is around the magnitude of 1-5mV. In this case the attenuation is greater than 95%. Output at the Peak Detector Below is the output at the peak detector based on the clear voltages seen by the peak detector after filtering Vin (clear) Peak Detector Difference % loss Phase1 3.62 3.36 0.26 0.071823 Phase2 2.6 2.123 0.477 0.183462 Phase3 0.534 0.475 0.059 0.110487 Vin (covered) Peak Detector Difference % loss Phase1 0.82 0.72 0.1 0.121951 Phase2 0.46 0.3825 0.0775 0.168478 Phase3 X X X X In case of covered with snow Difference in DC value of the peak detector Peak Detector( clear) Peak Detector (covered) Difference % loss 3.36 0.72 -2.64 79% 2.123 0.3825 -1.7405 82% 0.475 X X X As we can see that covering the piezoelectric with a moderate amount of crushed ice has resulted in a drop of approximately 80% of the voltage values at the peak detector and also at the filter output. Future Work Just as the SODAR system has multiple applications, so does the frozen precipitation detector. Our prototype system is ready to be adapted to the needs of the next client. The current revision of the FPD is prototyped on a breadboard using readily available and inexpensive through-mount components. This prototype should be constructed on PCB board for durability and sealed against the elements. PCB layout and construction are advised as future work because the final requirements of our design are not fully specified. For use on SODAR systems the FPD circuitry and piezo-electrics will need to be protected against elements such as heat, cold, wind and moisture. The piezo-electrics will need to be covered in a thin laminate material that will not significantly impede their function but will protect them from moisture. The FPD circuitry will need to be encased in a structure that will shield the components from moisture as well as direct sunlight in order to reduce maximum temperature. Integration with the SODAR system heating circuit is still partially incomplete due to lack of data on or access to a SODAR system equipped with heating elements and associated circuitry. Output from the FPD is a high/off low/on signal that is easily tunable to the required on/off data requirements of the system it is integrating with. This output needs to be matched to the system it will be interfacing with and the appropriate connector will need to be added to the system. Recommendations In addition to the future work required for successful implementation of our design there are a few recommendations. Interfacing with existing precipitation detecting elements on the SODAR system is recommended to improve reliability and robustness of our design. Additional piezoelectric sensors at different locations on the reflector board will further improve coverage and reduce failure. Lastly, multiple adjacent piezo-electrics are recommended to be tied to the same FPD circuit with the addition of simple logic to account for single or multiple failure of a piezoelectric. Work Statement Duration (Days) EE 491 Start Date Finish Date 1/19/2010 5/7/2010 Defining and Planning 40 1/19/2010 2/28/2010 Identify Need 6 1/19/2010 1/25/2010 Complete Project Definition 4 1/25/2010 1/29/2010 Define Requirements 7 1/29/2010 2/5/2010 Perform Research 91 2/5/2010 5/7/2010 Map Project Schedule 20 2/15/2010 2/25/2010 Determine Budget 9 2/19/2010 2/28/2010 Documenting and Reporting 106 1/19/2010 5/7/2010 Submit Weekly Status Reports 102 1/19/2010 5/1/2010 Develop Draft Website 2 2/21/2010 2/23/2010 Update Project Website 104 2/21/2010 5/7/2010 Write Draft Project Plan 9 2/19/2010 2/28/2010 Write Final Project Plan 3 2/28/2010 3/3/2010 Determine viable solutions 30 3/1/2010 3/31/2010 Primary: Piezoelectric electric sensor Perform in depth study of Piezoelectric plates 7 3/1/2010 3/8/2010 Determine system description 7 3/5/2010 3/12/2010 Determine components 3 3/12/2010 3/15/2010 Perform small case testing 6 3/16/2010 3/22/2010 Analyze based on results and make decision 2 3/22/2010 3/24/2010 Test SODAR 10 3/22/2010 3/31/2010 Test the heating pad on the SODAR 2 3/26/2010 3/28/2010 Determine the Environment Parameters 2 3/26/2010 3/28/2010 Test the Acoustic Properties of the SODAR 2 3/26/2010 3/28/2010 Basic Testing using Piezoelectric Sensors 2 3/26/2010 3/28/2010 Detailed Design 19 4/1/2010 4/20/2010 Create Preliminary Design 6 4/1/2010 4/7/2010 Perform Analysis 4 4/7/2010 4/11/2010 Determine Final Components 1 4/10/2010 4/11/2010 Draw Schematics 9 4/11/2010 4/20/2010 Design Documents 25 4/1/2010 4/26/2010 Create Draft Design and Presentation 7 4/13/2010 4/20/2010 Present Design Review 6 4/21/2010 4/27/2010 Write Draft Design Report 21 4/2/2010 4/23/2010 Write Final Design Report 4 4/22/2010 4/26/2010 EE 492 116 8/23/2010 12/18/2010 Based on the solutions determined begin designing Documenting and Reporting 109 8/31/2010 12/17/2010 Submit Weekly Status Reports 102 8/31/2010 12/11/2010 Update Project Website 102 8/23/2010 12/11/2010 Design Project Poster 44 11/28/2010 12/6/2010 Write Draft Final Report 31 10/28/2010 11/28/2010 Write Final Report 7 12/10/2010 12/17/2009 Prepare Final Presentation 7 12/10/2010 12/17/2010 Documenting 92 8/23/2010 12/1/2010 Write User Manual 92 8/23/2010 12/1/2010 Build system 37 8/23/2010 12/6/2010 Purchase Components 7 8/23/2010 12/17/2010 Put together the Frozen Precipitation Detector 37 8/23/2010 9/30/2010 Testing 90 8/24/2010 11/22/2010 Test and Debug Hardware 47 9/30/2010 12/1/2010 Install Completed System 7 11/15/2010 11/22/2010 Test on SODAR 7 11/22/2010 12/1/2010 Task Descriptions EE 491: Senior Design 1 The team will make sure that all deadlines are met and all deliverables are received at the end of the project. This shall be done by managing the project effectively with proper definition, preparation, design and fabrication. Defining and Planning The team will develop a project plan which serves as a binding agreement between the team and the client. The document shall ensure all requirements are completely understood by team members and client and the expectations and deadlines of the project are met. The team will discuss necessary tasks to complete the project along with their respective priorities. Identify Need The team shall work with the client and advisors to determine the needs to be met by the project. Complete Project Definition To define boundaries for the project proposal, the team shall meet with advisors and as a group to determine the requirements that will best meet the demands of the client. Define Requirements The team shall work with the client to decide the requirements that will be met by the end. The requirements shall be organized into functional and non-functional requirements, and differentiation will be made between what will be done and extra goals. Perform Research The team will research existing technologies and how they can be used for snow detection. Map Project Schedule The team shall map out a project schedule to make sure that all deadlines are met and all tasks are accomplished in a reasonable amount of time. The project schedule shall make sure that all members of the team are involved in all aspects of the project. Determine Budget The team shall devise a budget which will reflect the financial needs of the project. The budget shall be fluid allowing for changes in design based on the client’s desires. Documenting and Reporting Submit Weekly Status Reports The team shall document all steps in the design process through weekly reports, a website and a poster which shall display relevant information. A final project document will describe final project results. Develop Draft Website The team shall develop a website dedicated to the project. The website shall contain the project description and solution approach along with all the documentation associated with the project, as well as information on the team members. Update Project Website Throughout the course of EE491/EE492 the website with the current version of their documentation and any other information desired will be updated regularly. Write Draft Project Plan A plan will be drafted which lays out the course to be followed in the design phase of the project. Write Final Project Plan The plan is to be approved by the advisor, client and program coordinator, as well as each member of the team. This plan is to serve as a binding agreement between the team and the client. Determine solution Perform in depth study of piezoelectric plates The team shall work with the advisor in performing an in depth study on the use of piezoelectric sensors and their properties. This will involve reading manuals, articles, patents etc. The purpose is to give a better understanding of the properties of acoustics and their use to snow detection Determine components The team shall determine the components necessary to implement the solution. Perform small case testing The team shall acquire sample components to run basic level testing. The results will be well documented and shared with the advisor and client. Analyze based on results and make decision The team shall analyze the results of the basic experiments and decide on the effectiveness of the primary solution Test SODAR Test the heating pad on the SODAR The team shall perform tests on the heating pad of the SODAR to determine its characteristics such as o Time taken to melt a certain amount of snow o Behavior of the piezoelectric plates on the heater Test the acoustic properties of the SODAR The team shall also determine the effect of the acoustic environment on the piezoelectric plates. Basic parameters acquirement The team shall note the basic parameters such as space available, heating surface properties, location of power source etc. This will help the team in determining the installation constraints for the FPD Detailed Design The team shall follow all steps to create the design report. Work shall be approximately divided among all team members. Create Preliminary Design Based on the solutions determined the team shall work with the advisors and shall develop an initial design which takes all functional requirements and non-functional requirements into consideration. The results from the solutions development will also be used Perform analysis The team shall simulate their design to assure that it works, and shall make sure that all part specifications are appropriate before ordering them. Determine final components Appropriate components shall be selected for the project, keeping future system expansion in mind. Design Documents Create Draft Design and Presentation The team shall prepare to answer any questions the design review board has, to prove the feasibility of their design. Present Design Review The team shall present the design to the Design Review Board, and shall show the feasibility of the project, the effectiveness of the design, and why certain design elements were chosen. Write Draft Design Report The team will draft a document recording the technical design specifications of the project. The document shall include mathematical reasons why certain points were included and include technical drawings of the system. Write Final Design Report The final design shall be approved by the design board, advisors and clients before proceeding. EE492: Senior Design II Project Management The team shall make sure that all deadlines are met and all deliverables are received at the end of the project by managing the project effectively with proper definition, preparation, design and fabrication. Weekly Status Reports The team shall maintain contact with advisors and the course coordinator and update them on current project status. The team shall document project work each week, and report weekly via email on current status and plans for the upcoming week. The time spent by each member shall be recorded and a semester tally shall be kept of all hours spent on the project by the team members. Update Website Throughout the course of EE492 the team shall update the website with the current version of their documentation and any other information required. Design Poster The team shall create a poster for the project, highlighting the solution the team has developed. The team shall meet all poster guidelines laid out by the instructor. Using those guidelines, the team shall produce a poster that satisfies the course and client requirements. Final Report Final Report Draft The team shall develop a final report document for the final results of the project. The team shall meet with advisors and as a group, to discuss and evaluate the success of the project with respect to the requirements. The final report shall discuss the success or failure of the project. Work shall be divided among team members approximately equally. Final Presentation The team shall report on the final results of their project, providing information on testing and final installation of the prototype. The team shall be evaluated to see if they met all goals and requirements. Design Write user manual The team shall develop a user manual to accompany the completed prototype so that following groups or student may use it and not cause harm to themselves of the grid. Purchase components After testing, components will be changed as needed, and the final components for building the prototype unit will be purchased. Fabricate Support Structure The support mechanism for the solar array shall be built and tested, to be sure that it meets safety and other requirements, and then installed. Testing Before delivery, the team shall build and thoroughly test a prototype of the hardware, while carefully documenting outcomes or failures. Expected and actual results will be compared. Test and Debug Hardware The hardware shall be thoroughly tested to make sure that it meets all safety and technical requirements. Install Completed system The team shall develop a working prototype to be used for testing and final implementation. Resources Requirements Time Resources The following is cost estimates for student labor. In the nature of senior design, students are working on the project for free but this could be used as a reference. Typically, the labor cost of a part-time student is approximately $20/hour. Labor Cost/Hour ($) Labor Cost/Member($) Ashor Chirackal Imran Butt Time Commitment (Hours) 350 350 20 20 7000 7000 Michelle Tan 350 20 7000 Luke Lehman 180 20 3600 Members Total Labor Cost $ 24,600 Cost Resources The following is the updated cost estimates of the tools and components needed to test, build and develop the product. i. Frozen Precipitation Detector Materials 1. Amplifiers 2. Piezoelectric Sensors 3. Resistors, Capacitors, Potentiometers, Diodes, LEDs and Logic Gates 4. PCB 5. Software to design the PCB 6. Wiring, Conduits and Connectors 7. Other misc. components and tools Total Material Cost ii. Cost Estimates ($) 30 200 40 20 --10 10 310 Working Prototype Materials 1. Piezoelectric Sensors 2. Breadboards Cost Estimates ($) 50 20 3. Resistors, Capacitors, Potentiometers, Diodes, LEDs and Logic Gates 4. Amplifiers 5. Testing Cost (Transportation, etc) 6. Other misc. components and tools Total Material Cost 40 30 50 10 150 Closing Summary SODARs are one of the most used equipment for wind profiling. They are usually deployed at remote location to assess if the location is suitable for a wind farm. Currently, our client, ASC, manufactures this equipment to sell to different buyers. However, the equipment needs some improvements in order for the system to work more efficiently. Our team is developing a solution that will make the system work for a longer period of time before it goes into hibernation mode. In order for us to achieve that, we have to develop a new, more efficient, method of detecting frozen precipitation. This solution has been tested and it is feasible to be implemented on the SODAR equipment. We hope that our contribution in this project will help development in the wind industry. Lesson Learned This project definitely had some hassles. A major one was switching from John Deere to ASC and another one was finding a SODAR in Iowa to work on. However, we transitioned smoothly from John Deere to ASC and a SODAR was available to us at Cedar Falls. We learned how to overcome any conflicts that arose. This project taught us more about circuit design and piezoelectric technology. The circuit used in this project was of our own design specifically made to handle the input from the piezoelectric sensors. Before this project, we were unfamiliar with piezoelectric technology. Now, we understand the purpose behind piezoelectric sensors. Contact Information Client Contact Information Team Contact Information Josh Underwood Ashor Chirackal Marketing and Business Development Phone: 563-650-8711 Atmospheric Systems Corporation Email: ashorc@iastate.edu Office: (661)294-9621 Cell: (949)351-9516 Imran Butt Fax: (661)294-9667 Phone: 515-664-7972 Email: josh@minisodar.com Email: imranb@iastate.edu 26017 Huntington Ln., Unit F Valencia, CA 91355 Michelle Tan Phone: 515-708-2478 Faculty Advisor Contact Information Email: elle87@iastate.edu Prof. Timothy Bigelow Luke Lehman Assistant Professor Phone: 515-451-5014 Iowa State University Email: lehmanl@iastate.edu 2113 Coover Hall Ames IA 50011 Phone: 515-294-4177 Email: bigelow@iastate.edu