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1. 21 Figure 3 3 UCOOB V2011 Cytron s USB UART converter 13 3 4 Pulse Detonation Engine Controller Design The PDE controller is divided into hardware and firmware module The hardware module consists of microcontroller GPIO pins current reducing resistors and optocouplers firmware module will be discussed in section 5 1 2 Based on FKM s laboratory HIREF their Pulse Detonation structure consist of several injectors and a relay to be driven using microcontroller A total of 8 control signal was needed for the controller module Table 3 1 shows the tabulation of solenoid valves and relays for the engine Function Actuator Number of Control input signal Detail actuator Voltage VDC Fuel oxidizer Solenoid valve Active high injection Table 3 1 Tabulation of actuators and control voltage The controller is functioning by sending logic signals through GPIO pins of LPCXpresso LPC1769 Theoretically the signal from GPIO pins should drive the relay for ignition circuit and solenoid valves for fuel oxidizer and purge injectors Unfortunately the microcontroller LPC1769 can only give a maximum of 3 3V output from its GPIOs and limited current 6 Thus an isolator circuit need to be 22 built between microcontroller and associate actuators For this purpose isolator circuit based on optocoupler was designed 341 Isolator Circuit emitter detector Figure 3 4 Optocoupler internal schematic An optocoupler
2. 3 Purge tj Purge time Figure 1 2 Basic operation cycle for pulse detonation engine 1 Moreover the readings from the engine operation need to be taken stored or viewed in real time for various purposes such as calibration with analog meter statistical comparison with computer simulations and feedback response for the control mechanism Thus sensors data processing and data logging need to be integrated besides the control mechanism itself To summarize the problem statement this project focuses on the control mechanism and data logging function integrated with the sensors and actuators associated with FKM s HiREF laboratory Pulse Detonation Engine 1 3 Project Objective a To design and construct an electronic controller to control a Detonation Engine b To produce a system which is capable to sample and log the data on the engine operation 14 Scope of Work The primary scope of this project is to familiarize with the tools software and hardware that will be used in this project The core hardware that will be used is LPCXpresso LPC1769 microcontroller development board while the main software Is LPCXpresso IDE Integrated Development Environment LPC1769 have many on board peripherals such as GPIO General Purpose Input Output ADC Analog Digital Converter and standard serial communication protocols The secondary scope for this project is to design a controller for Pulse Detonation Engine operation T
3. Da ama 10k 10kohm 1 RZ 1 120 TE oe awas ve am E ti ie MJ ar 17 Terminal block block 2W4y 0 way Vi MN Beal AS 7 700 a Pin Header 1x40 ways i 40 male Straight Female Header 1x40 ways 55 Resistors Standard 20 05 2 00 si Various value Mi 21 Capacitors 0 1uF 10 2 00 MT a 22 Buzzer SV 1 00 3 00 OI ham 1 1 3 Minas 3 3V RS232 transceiver SOIC type 9 72 29 16 Analog Device Hitechtron Sdn Bhd Connector sockets 2510 1 set 4 80 4 80 cables Total RM 206 86 Table 5 4 Hardware development costing 56 CHAPTER 6 CONCLUSION amp SUGGESTION 6 1 Conclusion Based on the obyective of this project two conclusions were made First a controller for Pulse Detonation Engine has been designed successtully and the timing parameter of the detonation cycle can be changed until micro second interval accuracy using interrupt timer peripheral of LPC1769 for all stages in PDE operation cycle However the controller as still in testing prototype level and need to be integrated with the actual Pulse Detonation Engine in FKM s HiREF laboratory for further testing and verification Second the data logging module can successfully log ADC input signal using USB flash memory storage The highest performance for the data logger is around 88 samples per second 6 2 Suggestion for Future Improvement First the system can utilize Interrupt peripherals on boa
4. PDE Pulse Detonation Engine needs a very fast detonation pulse to produce enough thrust to drive an aerial vehicle especially in the Mach speed regime Philip K Panicker Donald R Wilson and Frank K Lu reported that there is a source claiming that PDE can operate in Mach number regime from 0 to about 5 2 Khalid M Sagr Ahmed Faiz Hassan Kassem Mohsin Sies and Mazlan A Wahid also reported that the engine was able to operate until Mach 9 regime 1 With this promising capability of PDE the only issue on control mechanism surrounding the practical implementation of PDE is the speed of actuators where it is needed to perform the fuel oxidizer injection ignition and purge phase of the engine s operation Practically the actuator was divided into mechanical and electrical valves The fastest mechanical valve was currently used in FI racing car engines which can operate at 20 000 rpm 2 To achieve that performance such system has a rather complex system contributed by many moving parts involved Unlike mechanical valve solenoid electrical controlled valves have simpler build which reduces the complexity They are also very fast reacting where it can have a fraction of millisecond ms reaction time Furthermore solenoid valves can be controlled precisely using TTL Transistor Transistor Logic signal from a computer 2 In addition such system is commercially available off the shelf today following the increasing demand in electroni
5. before and after attenuation 4 2 2 Data Logging Timing Analysis Table 4 4 Data logging position markings Micro second time stamp interval us a gt b b gt c c gt d 1136 1130 24 781 1135 1135 26 768 1135 1137 28 759 1136 1139 24 757 Table 4 5 Timing analysis at random data line 40 From the data logging using dummy ADC input several timing data was extracted at random location within the data lines which is shown in Table 4 5 Around 2 400 data was sampled and time stamped at major coding part eg start ADC end ADC start log end log as in Figure 3 14 From the data the average time for data logging 1s around 26 266 us per data sample or 38 data samples per second In other words it consumed 92 of the program loop cycle Thus the most time consuming part of the program is from position c until position d which is from ADC data logging started until end of ADC data logging Full Speed class USB can actually achieve a maximum of 12Mbit s data exchange rate The slow speed happens here is not the problem on USB peripheral in LPC1769 or USB flash memory but rather a problem in the program itself According to Chan a way to optimize the performance of data exchange 1s by writing multiple sectors per block data in FAT File System Figure 4 4 shows visualization of writing multiple sectors per block compared to single sector per block This understanding on performance leads the project to f
6. connection of the converter and observe the input form keyboard appear in the HyperTerminal window 17 CHAPTER 3 PROJECT METHODOLOGY The project methodology was done based on Universal Design Methodology UDM in Appendix 1 taken from http www embedded com The methodology can be applied to almost any projects with various engineering background which reguires hardware realization Based on Appendix 1 a project methodology shown in Figure 3 1 was developed to specifically parallel with the design aspects of this project 3 1 Project Methodology Flow Chart Based on the flow chart in Figure 3 1 the project was started with reviewing hteratures from related journals thesis proceedings and previous works By reviewing the literatures some detail aspect in the project such as definitions history theories and practical solution examples can be found and studied thoroughly Thus problem statement and scope of the project may come afterwards Next the work was continued by determining and familiarizing the tools and softwares needed by the project This stage may involve trainings or hands on tutorials on the related tools and softwares Then the project was proceed to the design phase of the project where the algorithm of the PDE operation was developed After that comes the testing verification and discussion conclusion phase The 18 project will keep on repeating the testing verification again and again until the des
7. frequency X 1000 ms 500 ms Fuel oxidizer injection timing factor X time required for 1 cycle 0 3 X 500 ms 150 ms Ignition timing factor X time required for 1 cycle 0 3 X 500 ms 150 ms 25 Purge timing factor X time required for 1 cycle 0 4 X 500 ms 200 ms Freguency Timing Interval ms Time Reguired for 1 cycle ms 1000 NEE 00 00 25 00 83 33 Table 3 3 Example timing intervals with respect to PDE operation frequency 3 4 3 PDE Controller Mechanism amp Firmware Design The mechanism of PDE controller is not simply providing logic High or Low operation to the solenoid valve injectors and ignition relay The switching of logic High and Low for PDE controller need to perform at a very precise and accurate timing proportion from fuel oxidizer injection stage to ignition and purging stage in one complete cycle repeatedly as in Figure 2 4 LPC1769 s timer peripheral was used to provide timing control as well as accurate delay between each stage Thus the firmware module for PDE controller is comprises of GPIO and internal timer only A flow chart as in Figure 3 6 was constructed as a framework of the code for microcontroller LPC1769 Set fuel oxidizer ignition and purging timers Set cycle counter multi cycle operation Fuel oxidizer injection Injection timer finished Yes Spark plug ignition Ignition timer finished Yes k Purg
8. in this project is 3 3V microcontroller system That means the logic High and Low for this microcontroller will be at 3 3V and OV This situation requires transceiver or logic converter to communicate with different system such as between microcontroller and USB port as well as between microcontroller and RS232 port Figure 2 9 RS232 Loopback Testing shorting red coloured pins 16 2 5 2 Serial Communication Interface Using Computer RS232 cable interfacing for RS232 communication protocol with earlier computer model is made possible with RS232 port on board Thus the connection is tested by performing loopback testing using pre installed HyperTerminal windows based terminal emulation software on computer It was done by shorting receiver RX and transmitter TX pins which are pin 2 and 3 of DE 9 socket as shown in Figure 2 9 The data input such as from keyboard will be shown in HyperTerminal window proving there is a connection between the PC itself loopback through RS232 cable For most computers and laptops today RS232 port was not provided by the manufacturers The only available and most common communication ports for today s computers and laptops are USB LAN and WLAN There are many USB UART converter models available in the market to solve such problem Typically the cable for the converter consists of a power supply VCC ground GND transmitter TX and receiver RX Simply short the RX and TX cable to test the
9. sample per second it can log is around 60 while the minimum is around 45 Thus code architecture for test 1 and 5 is filtered out for their low performance among five architectures That leaves only test 2 3 and 4 to analyse with The best performance for all three of them are at the 7 to 8 seconds which is around 88 sample per second Test 4 performance starts to fall at the 7 seconds while test 3 and 2 at the 8 seconds Thus we can say that test 3 and 2 has the best performance since it can consistently maintain high performance until the first 8 seconds Despite that test 3 shows low performance for the first second which means it has high performance data logging for only 6 seconds unlike 7 seconds for test 2 Overall test 2 has the best ADC data logging performance among all five tests using USB flash memory Table 4 6 shows the summary of data logging performance analysis Characteristic Average number of sample per second first 8 second o eree oj d e Number of seconds of highest c Number of seconds of highest rate refer b rate refer c f Average of highest amp lowest rate b d 2 S23 120 72 3 25 Table 4 6 Summary of data logging performance analysis 45 4 2 3 UART based Data Capture Performance Analysis amp Comparison Debug feature in most microcontroller using a terminal emulation software can be applied for getting ADC sampling data using microcontroller It provides
10. to relay solenoid valves from microcontroller pin port g R9 RLimiting External power supply 2 O a OA gt microcontroller ground No xternal power supply ground Figure 3 5 Isolator circuit schematic for all 8 control pins Components Supply Voltage Microcontroller pin High Low 3 3V 0V Pull down resistor 3 6k ohm Table 3 2 Resistor and supply voltage value for isolator circuit 24 3 4 2 PDE Controller Operation From section 2 3 2 previously the time interval between each stage is proportioned precisely at 30 30 and 40 for fuel oxidizer injection ignition and purge stage respectively If Pulse Detonation Engine operation is at 1 Hz the time interval required is 300 ms 300 ms and 400 ms respectively This configuration can be changed accordingly using simple mathematical calculation as shown in example below Table 3 3 shows timing interval examples according to frequency of PDE operation Even though the timing interval 1s proportionate according to the specific percentage proportion as mentioned before it can be changed by the user as long as the timing interval is correctly configured using the same mathematical calculation below Timing proportion factor calculation e Fuel oxidizer injection 30 or 30 100 0 3 factor e Ignition 30 or 30 100 0 3 factor e Purge 40 or 40 100 0 4 factor Timing interval calculation Frequency 2 Hz Time required for 1 cycle 1
11. B flash memory the microcontroller needs to function as a host to the USB flash memory device Figure 3 9 shows the implementation of USB Host mode using LPC1769 while Figure 3 10 shows the actual USB Host implementation using breadboard USB A LPC17xx connecior Figure 3 9 USB Host implementation for LPC1769 10 Figure 3 10 USB Host actual implementation using breadboard 30 3 5 3 ADC Data Logging Firmware ADC data logging firmware consist of several parts which are ADC timer USB Host and FAT File System As previously explained in earlier chapters ADC was used to convert analog signal from pressure transducer to digital form Based on flow chart in figure 3 11 the micro second timer will start first after system initialization Then the system will detect whether USB mass storage device was connected or not If it was detected the system will proceed to start the ADC peripheral and logged ADC value into the USB memory storage while the end flag is false The end flag was triggered externally providing data logging control for user to stop the data logging The data logging from LPC1769 to USB flash memory was done using Chan s FAT File System library This library is specialized for used in embedded system applications The source code for Chan s FAT File System is open source and being utilized by NXP Semiconductor to provide example source code library for USB mass storage application FAT File Access Table Fi
12. C Wait for ADC conversion complete flag Put ADC value in a buffer Open target file write ADC value and micro second timer stamp close target file No Stop ADC End flag true Figure 3 11 ADC data logging operation flowchart 33 3 6 Testing and Verification Testing and verification need to be done to ensure the expected functionality of all devices or application is met For this project the test was divided into two segments which are PDE controller functionality and ADC data logging performance 3 6 1 PDE Controller Testing and Verification The controller circuit was tested using light emitting diode LED as an indicator for high speed logic High and Low switching of PDE controller pinouts This testing method is used to ease the testing environment for PDE controller This is due to the fact that the FKM s HiREF laboratory was under maintenance and pulse detonation Moreover the pulse detonation engine in the laboratory was currently being upgraded to be used in power generation research using PDE as core platform Figure 3 12 and 3 13 shows the test circuit schematic and actual test circuit respectively From figure 3 12 and 3 13 there are a total of 8 LED which represent the control pins for all actuators From figure 3 13 we can assume that LED 1 most left until LED 6 is for fuel oxidizer injection solenoid valve LED 7 is for ignition relay and LED 8 is for purging solenoid v
13. C TOCON Enable and setup SysTick Timer at a periodic rate SysTick_Config SystemCoreClock TICKRATE_HZ1 N 12 IOCON_MODE_PULLUP IOCON_FUNC 11 IOCON MODE PULLUP IOCON_FUNCe 16 IOCON MODE PULLUP IOCON FUNC TOCON MODE PULLUP IOCON FUNC IOCON MODE PULLUP IOCOM_FUNC IOCON MODE PULLUP IOCOM_FUNC TOCON MODE PULLUP IOCON FUNC9 IOCON MODE PULLUP IOCON FUNCO TOCON_MODE_PULLUP IOCON FUNC8 s TOCON MODE PULLUP IOCON FUNCO Chip IOCON Chip TOCON PinMux LPC TOCON Chip IOCOM PinMux LPC TOCON Yi Start here 7 Import projectis IEj New project NNN NNN ON ON te t e eos sia Build all projects Debu ay projecta al El Console 33 7 Problema Eg Progress amp petra ses Aa em No consoles to display at this time amp Clean periph blinky Debug 5 Debug periph blinky Debug AS Edit norinh blinks nrniart cattinne Writable Smart Insert 161 2 periph blinky Figure 2 8 LPCXpresso IDE workspace LPCXpresso LPC1769 is supported by LPCXpresso IDE for embedded system development and debugging It is a development environment based on Eclipse IDE for NXP s ARM based microcontrollers With this IDE NXP Semiconductors through its developer s forum website LPCware com provide access for example libraries and standard peripheral libraries 15 18 Figure 2 8 shows the workspace and GUI for LPCXpresso IDE All peripheral libraries for LPC17xx
14. C data logging result UILILIL ILLL ILHI m HHH LI ILILI ICI ICI LILIT mm TTL KANANNYA TT WTAE j Ma LEELA PANTAT HELE Pa __ HLL LLL g T IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIHIHHH z ii TTT x I 5 TT E n MULL 5 MI a 2 BH HRS SRR SR RRR SHR PUTT TT Bs g 8 pig 8 8 8 8 8 io BE 8 8 88 RRA Figure 4 8 Test 3 ADC data logging result 43 number of sample test 4 100 aii in si SA Samp per secornas Ni SEE esi aa int TE EE HE ai ERA W ssssfsssss GESEGESRERE 20 NN E E E E s KEKE m I lt E oa 1 2 3 4 5 6 7 8 9 10 11 Figure 4 9 Test 4 ADC data logging result number of sample test 5 100 90 ii ole data per seconds 70 60 n 20 10 FHINN LN second N w ta un 6 J co wo bh bh bb N pa w Figure 4 10 Test 5 ADC data logging result Figure 4 6 until Figure 4 10 shows number of sample per second versus seconds at which the data was logged into USB flash memory From the results we can see a pattern at which the performance of all tests will experiencing rapid performance depreciation after T to 11 seconds of data logging Test 5 shows a 44 consistent performance but it has low performance average which is around 60 samples per second Test 1 has the worst average performance because the maximum
15. Development Board 242 LPCXpresso IDE Integrated Development Environment Serial Communication 251 UART Interface on Microcontroller 2 5 2 Serial Communication Interface Using Computer PROJECT METHODOLOGY 3 1 3 2 DS 3 4 3 5 3 6 Project Methodology Flow Chart Top Level Design Serial Communication Interface 3 3 1 UART USB Converter Pulse Detonation Engine Controller Design 34 1 Isolator Circuit 3 4 2 PDE Controller Operation 3 4 3 PDE Controller Mechanism amp Firmware Design ADC Data Logging 3 5 1 ADC Signal Attenuator 3 5 2 External Memory Storage 3 5 3 ADC Data Logging Firmware Testing and Verification 3 6 1 PDE Controller Testing and Verification 3 6 2 ADC Data Logging Testing and Verification 3 6 2 1 ADC Data Logging Firmware Timing Analysis Method viii 11 12 13 14 14 15 15 16 17 17 19 20 20 21 22 24 25 27 27 28 30 33 33 34 34 3 6 2 2 ADC Data Logging Performance Analysis Method RESULTS amp DISCUSSION 4 1 4 2 4 3 PDE Controller Analysis 4 1 1 LED Test Circuit Limitation ADC Data Logging Analysis 421 Signal Attenuator Linearity Analysis 42 2 Data Logging Timing Analysis 4 2 2 Data Logging Performance Analysis 4 2 3 UART based Data Capture Performance Analysis amp Comparison Final Project Prototype PROJECT MANAGEMENT 5 1 2 2 23 5 4 Market Survey 5 1 1 Need 5 1 2 Approach 5 1 3 Benefit Per Cost 5 14 Compe
16. ME thrust control system with close loop Feedback 3 2 3 FKM s HIREF Laboratory Pulse Detonation Engine Universiti Teknologi Malaysia UTM has developed a Pulse Detonation Engine prototype The research purpose prototype was build and tested in High Speed Reacting Flow HiREF laboratory in the Faculty of Mechanical Engineering FKM under direct funding from the Malaysian Government Development of HiREF s PDE includes the design and development of PDE fuel admission detonation tube control and data acquisition systems 1 Figure 2 2 shows the actual developed PDE by HiREF 2 3 1 Pulse Detonation Engine Structure The Pulse Detonation Engine structure consists of fuel oxidizer ignition and purging actuators It operates on propane and oxygen with single detonation tube 1 It was designed to operate up to 100Hz detonation cycles which consist of four stages as depicted in Figure 1 2 previously The mixing chamber has a diameter of 50 mm and 142 mm long while the stainless steel detonation tube has an inner diameter of 50 mm and 600 mm long 12 The oxygen and propane are injected through a 10 total of 6 injectors four for oxidizer two for fuel For this engine Compressed Natural Gas CNG injectors based on electrically controlled solenoid valve as in Figure 2 3 were used for the fuel oxidizer and purge air admission system From Figure 2 3 the left side picture is the CNG injector with while the right side 1s the moun
17. PCXpresso LPC1769 This development board can be fitted on breadboard for testing and fast embedded system prototyping 2 4 2 LPCXpresso IDE Integrated Development Environment 123 Develop periph _blinky example sre systicke LPCXpresse Il File Edit Source Refactor Navigate Search Project Run Window Help ca Wi he SSK Ait Gl POM Pea isis asti 076 Witi si Quick Access i EY IE Develop Project Explorer 23 Pericherals dU Registers EI tie if MassStorageHost c systickc E O gpio 17x 40xxh pinint c gpioint 17x 4ho h 6 b 15 iperf server a 77 while usTicks currentTicks lt delayTicks 12S Ipc board nxp Ipompresso 1769 r p 1S Ipe chip 175x 6x l s yaa b 155 Ipeusblib_KeyboardHost Gbrief main routine for systick example p LS Ipeusblib MassStorageHost 32 return Function should not exit eS Iwip_tcpecho_freertos oF gt 1S Iwip tepecho sa eu main void see i x NXP UPCI ro UsbifostLita MSIS2 Generic Initialization le periph_adc SystemCoreClockUpdate 4 13 periph blinky i si Board Init b Binaries gt jn Includes 4 S example gt ine ba g Chip_IOCON_PinMux LPC_IOCON 4 gt src Chip TOCON PinMux LPC TOCON gt of crstertup_ipcl 5x 6x 495 Chip TOCON PinMux LPC TOCON Chip_IOCOM_PinMux LPC_TOCON ra Chip TOCON PinMux LPC TOCON O Quick E3 fr van Eres at Cutline Sg Expre EE Chip_IOCON_PinMux LPC_IOCON Chip_IOCON PinMux LPC TOCON PinMux LP
18. PSZ 19 16 Pind 1 07 UNIVERSITI TEKNOLOGI MALAYSIA DECLARATION OF THESIS UNDERGRADUATE PROJECT REPORT AND COPYRIGHT Author s full name Mohd Hafizuddin Bin Abd Shukor Date of Birth 18 March 1991 Title Pulse Detonation Engine Controller and ADC Data Logging Academic Session 2013 2014 declare that this thesis is classified as CONFIDENTIAL Contains confidential information under the Official Secret Act 1972 RESTRICTED Contains restricted information as specified by the organization where research was done OPEN ACCESS _ agree that my thesis to be published as online open access full text acknowledged that Universiti Teknologi Malaysia reserves the right as follows 1 The thesis is the property of Universiti Teknologi Malaysia 2 The Library of Universiti Teknologi Malaysia has the right to make copies for the purpose of research only 3 The Library has the right to make copies of the thesis for academic exchange Certified by SIGNATURE SIGNATURE OF SUPERVISOR 910318 12 5851 Mr Zulfakar Bin Aspar NEW IC NO PASSPORT NAME OF SUPERVISOR Date 18 JUNE 2014 Date 18 JUNE 2014 NOTES ui If the thesis is CONFIDENTAL or RESTRICTED please attach with the letter from the organization with period and reasons for confidentiality or restriction I hereby declare that I have read this thesis and in my our opinion this thesis is sufficient in terms of scope and quality for the award of the degree of Ba
19. The engine is functioning by using the power administered from the detonation of fuel instead of typical technology which is combustion of fuel that will transfer the energy to rotate the shafts and move the pistons Until now UTM has its own Pulse Detonation Engine being developed under Faculty of Mechanical Engineering FKM High Speed Reacting Flow HiREF laboratory By referring to Figure 1 1 the key concept of the engine is to create pulsating detonation waves in the detonation tube through detonation in fuel oxidizer mixing chamber 2 After the fuel and oxidizer is injected and mixed in a certain ratio inside mixing chamber ignition will be initiated which results in a detonation After the detonation ends clean air will be purged inside the engine to remove burnt fuels Blast from the detonation will produce enough thrust to drive particular aerial vehicles The whole processes fuel oxidizer injection ignition purging are considered as one cycle of engine operation and it will repeat for many cycles for continuous operation of the engine The control mechanism for the engine is basically divided into mechanical and electrical based actuators that control the fuel oxidizer injection ignition and purge phase of the engine operation 2 Institutions throughout the globe are still competing on the most effective operation control and mechanism for this engine Fuel Oxidizer inlets Detonation Tube Figure 1 1 An example
20. alve LED blinking test circuit can gives observation on possible operational capability of PDE controller up to around 50 Hz 20 ms minimum frequency since the human eyes have limited eyesight capability This minimum frequency is adequate enough to observe the functionality of this PDE controller pinouts for actuators in Table 3 1 34 Input from isolator circuit output Figure 3 12 Test circuit schematic for PDE controller INPUTa from pin 4 female header i sia yO WO eta YA uc Dik I ome P fe y ee 9 7 p SING esta o Ge STO Ti afore MIO OVO 22000909Q ee cc il es 3 b s DI J gt e pull down resistors a ii kn Figure 3 13 Actual test circuit for PDE controller 3 6 2 ADC Data Logging Testing and Verification ADC data logging test and verification consist of 3 parts They are firmware timing analysis data logging performance and performance comparison between data capture using HyperTerminal versus data logging using USB flash drive All of these tests were critical to ensure the highest performance throughout the project is achieved and possibilities for future development improvements are discovered 3 6 2 1 ADC Data Logging Firmware Timing Analysis Method A test configuration using serial debug interface UART was established to collect data for timing analysis through HyperTerminal software Timing anal
21. and application notes This site also provides discussion forum where developers around 53 the world can ask any enguiry regarding embedded system design using NXP microcontrollers Furthermore it provides registration service for LPCXpresso IDE Users 5 3 4 End User Consultation This project was intended for Pulse Detonation Engine end user at FKM s HiREF laboratory The requirements specifications and problems may need to be consulted in person with the end user On Tuesday 26 November 2013 a site visit to FKM s HiREF laboratory was made The intention of site visit was to study and understand the operation mechanism of HiREF s Pulse Detonation Engine From the site visit problems and limitations was discovered in testing the controller and ADC data logging where the person in charge was not always available for assistance Furthermore there are also problems in the electrical circuitry for PDE s actuator circuit where the earlier controller circuitry was poorly made and the capacitor for ignition circuit was always breaks down Thus it is hard to debug and troubleshoot possible circuitry problems Some suggestion on testing alternatives was made to test the pressure transducer without having to operate the PDE such as building a customizable pressure device which can simulate variable pressure conditions in detonation tube 5 3 5 Teammate Colleague This Final Year Project was under Mr Zulfakar supervision There ar
22. as a limitation regarding to this project where the PDE controller and ADC data logging module for this project are separated into different system In other words this prototype can only be used as ADC data logger or PDE controller one at a time based on which firmware is programmed into microcontroller In order to implement the whole system which consist of controller and data logging module two microcontrollers is needed or two set of final prototype IS required 47 CHAPTER 5 PROJECT MANAGEMENT The management aspects for this project were divided into three major parts which are market survey time management and financial management 5 1 Market Survey The market survey was done by using NABC Need Approach Benetit Competition approach to justify the marketability factor of this project The main method used for gathering information on market survey is through articles journal paper and observation 5 1 1 Need The engine is still in research in many institutions The research based application need a cost efficient controller and data logger that can be re configure many times as the research process 1s progressing Moreover the controller needs to be compatible with specific PDE design configuration Furthermore there is still no standard controller for pulse detonation engine either for research or commercial purpose available in the market 48 5 12 Approach The project is using microcontroller electroni
23. c based approach that is integrated with electrical based actuators and analog sensors to control the operation and to read the operation parameters respectively Most microcontrollers available in the market were provided with open source compiler using C language for hardware programming C language provides the opportunity to use standard libraries for standard peripheral devices such as USB Universal Serial Bus RS232 port and SD memory card 5 1 3 Benefit per Cost Detonation Engine operation can be controlled via mechanical or electrical electronic approach Currently the available mechanical approach is using high speed FI technology valves up to 20 000 rpm which are expensive and too complex for PDE application 2 Thus electrical electronic based approach is much cheaper and easy to re configure using electronic based controller 5 1 4 Competition Currently there is no significant competition yet since the application is mostly still in research phase in most institutions 5 2 Time Management The time management for this project was done using a working timeline for FYPI and FYP2 separately The timeline was sectioned into weeks for FYPI and FYP2 as provided in Electrical Engineering Final Year Project Logbook Some phases of the project may have different allocated weeks than others since the expected time required to complete the phases are significantly different 49 Wi ATEJ 15 16 Understand the project ai
24. c injection for car engine Thus electronic control mechanism 1s more favored for PDE application 2 2 Rocket Engine Control System The Space Shuttle Orbiter Main Engines provide the primary thrust for NASA National Aeronautics and Space Administration Orbiter vehicles The engine has an engine mounted electronic control system called the controller 3 The controller has the capability to do self checkout prior to flight and perform monitoring and reporting of engine status and condition during all phases of operation 3 The phases of operation are engine start main stage and shutdown All of these phases are controlled through an electronic controller As reported by P F Seit and R F Searle the controller will receive command inputs for various operational phase positions appropriate valves monitors the engine for required performance precisions and conditions and provide redundancy management 3 As a result Space Shuttle Main Engine SSME controller will vary the thrust output and mixture ratio of fuel oxidizer in the mixing chamber with respect to command input To execute such command the controller will transmits signals for positioning of the valves actuators switching hydraulic and pneumatic solenoid valves and controlling the spark ignition 3 In order to have maximum precisions and accuracy for the performance and desired SSME conditions a close loop feedback control system was implemented 3 This approac
25. chelor of Engineering Electrical Electronics Signature er s is oes 7 So e Name of Supervisor Mr Zulfakar Bin Aspar Date 18 JUNE 2014 PULSE DETONATION ENGINE CONTROLLER WITH ADC DATA LOGGING MOHD HAFIZUDDIN BIN ABD SHUKOR A thesis submitted in fulfilment of the reguirements for the award of the degree of Bachelor of Engineering Electrical Electronics Faculty of Electrical Engineering Universiti Teknologi Malaysia JUNE 2014 ii I declare that this thesis entitled Pulse Detonation Engine Controller and ADC Data Logging is the result of my own research except as cited in the references The thesis has not been accepted for any degree and is not concurrently submitted in candidature of any other degree Signature Name HAFIZUDDIN BIN ABD SHUKOR Date i 18 June 2014 Specially dedicated to all good Muslim on the earth Honest people of Malaysia And my beloved parents Dr Abd Shukor Bin Abd Hamid and Mrs Maisharah Md Said ACKNOWLEDGEMENT Thesis writing for Final Year Project FYP is a mark of guality and commitment in engineering studies as well as a persuasion for personal virtues and ethics such as honesty self confidence and continuous self improvement This task has led me to work with invaluable people of different backgrounds which have teach me a lot on how to become an excellent person and engineer Particularly I would like to thank my FYP supervisor Mr Zulfakar Bin Aspar for his guida
26. cle for pulse detonation engine SSME thrust control system with close loop feedback Actual PDE prototype developed by HiREF CNG injector from LO Gas Time interval between each stage Ignition circuit a Pressure transducer b accelerometer c load cell LPCXpresso LPC1769 development board LPCXpresso IDE workspace RS232 Loopback Testing shorting red coloured pins Core Project Methodology Top level graphical representation of the project UCOOB V2011 Cytron s USB UART converter Optocoupler internal schematic Isolator circuit schematic for all 8 control pins PDE controller flow chart Attenuator Configuration 1 Attenuator Configuration 2 USB Host implementation for LPC1769 USB Host actual implementation using breadboard ADC data logging operation flowchart Test circuit schematic for PDE controller Actual test circuit for PDE controller Timing analysis framework PDE controller operation using test circuit Attenuator configuration plot xii PAGE 10 10 11 12 12 13 14 15 18 19 21 22 23 26 28 28 29 29 32 33 34 35 36 38 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 5 1 5 2 Attenuator Configuration 2 Plot Comparison of multiple sector and single sector per block writing Data logging file example Test 1 ADC data logging result Test 2 ADC data logging result Test 3 ADC data logging result Test 4 ADC data logging result Test 5 ADC data logging result ADC data capture
27. comprises of an emitter and a detector Based on figure 3 4 there is no physical connection between them which made an optocoupler an isolator between low and high voltage current side When the emitter side is connected to a voltage an infra red wave will be generated from emitter s diode and trigger the Base terminal of detector s transistor and thus connecting the Collector pin 4 and Emitter pin 3 In other words the emitter side can be connected to the microcontroller GPIOs while the detector side can be connected to a high voltage current of a separate power supply where the high voltage current side will have high voltage current whenever there is an infra red trigger from the emitter Figure 3 5 shows the schematic of connections between microcontroller LPCXpresso LPC1769 and output of optocoupler The optocoupler model being used is 4N25 black package type This optocoupler based control mechanism is suitable for high speed switching between logic Low and High signals from microcontroller s GPIOs 9 The output voltage from optocoupler depends entirely on input voltage current into emitter s diode and power supply voltage at detector Protection for the emitter input current is also need to be considered using a current limiting resistor at 23 each GPIO pins Table 3 2 shows the tabulation of resistors and supply voltage values A O gt A External power supply 1 se pull down resistors input
28. e turbojets and ramjets which are the most widely used class of engine Pulse jets and pulse detonation engine were categorized as unsteady state class engine Unsteady state class for those engines were explained by the unsteady condition of the deflagration combustion pulse Jets and detonation combustion pulse detonation engine in pulse nature The theory on the Pulse Detonation Engine PDE concept comes from two keywords which are detonation and pulse According to Thomas Bussing and George Pappas in Pulse Detonation Engine Theory and Concepts A detonation is a supersonic combustion wave that typically propagates at a few thousand meters per second relative to an unburned fuel air mixture 5 This explained the differences between typical and detonative combustion in term of power and speed High speed nature of detonation leads to an approximation of the process as supersonic shock waves Pulse nature of PDE was explained by Thomas Bussing and George Pappas aS rapid detonation process results in constant volume combustion with very high operating freguencies 5 From here pulse can be related closely with frequency or continuous ON and OFF combustion seguences 2 1 2 PDE Efficiency The main argument on why Pulse Detonation Engine was being researched by the aeronautic community was the promising efficiency opportunity Efficiency is the main concern in any engineering field that involves the use of limit
29. e other students under him which uses the same microcontroller platform LPCXpresso LPC1769 Hands on introductory class for LPCXpresso IDE and LPC1769 microcontroller application was made together with the students under supervision of Mr Zulfakar ex student They are Chairul Ramadan Bin J Effendy and Siti Haslina Bt Furthermore we discuss among ourselves about problems and firmware building regarding LCP1769 54 5 4 Financial Management Since this is a hardware based electronic project a lot of components and eguipment may need to be bought at local stores or be ordered online This process will contribute to the cost of the hardware to be produced Basically the bought project components can be referred from Top Level Graphical Representation of the Project in Figure 3 and Bill of Material BOM in Table 5 2 Thus the cost of the components was tabulated in the Table 5 4 No Component Name Model brand Ouantity Price guantity Total Price model number RM RM Cytron Technologies Sdn Bhd Op amp IMM o 1 100 800 00 Optocoupler Dai E 00 Gi 00 Black IC socket 8 mani p 020 20 ig 160 SOIC SSOP to PID Cytron 3 5 00 15 00 E CR Jumper wires male Cytron 2 packet 13 50 Em a S DB9 male RS232 pL 80 19 RS232 cable RS232 cable male male NN os 00 28 00 I rr to RS232 mas I 00 20 00 converter 11 UART to USB converter to USB converter Con i 1900 00 1900 00 iml ii Cieli INN Ma
30. ed fossil fuel Efficiency standard was being applied in many applications such as computers mobile phones car engine and electric power generation Efficiency is important to have a high output to cost ratio as well as output to input ratio Pulse Detonation Engine differs with conventional engine in many ways which made it more efficient According to Shmuel Eidelman and Xiaolong Yang PDE have high structural efficiency due to the absence of turbopumps and compressors in the system 4 This condition lead to higher thrust to weight ratio than turbo jet engines 2 Thus dramatically reducing the complexity as well as development cost Shmuel Eidelman and Xiaolong Yang also said that PDE can be developed at low cost using off the shelf materials using standard manufacturing methods 4 Furthermore the engine can have a thrust variable from 0 to max easily 4 This can be explained from the controllable pulse or frequency parameter of the engine operation For advance aeronautic application Philip K Panicker Donald R Wilson and Frank K Lu said that they PDE can be used in conjunction with other developing technologies for example the combustor in scram jet engines can be driven in PDE mode 2 In simple the efficiency factor for PDE was not only on the basis of output input ratio PDE are also efficient in structural development and flexibility to integrate into other technology 2 1 3 Issues On Practical Implementation of
31. er and purge air injection have 12V and 24V rating respectively 12 The difference in voltage rating was probably due to the difference in maximum pressure rating for fuel oxidizer and purge air where purge air injection needs higher pressure than fuel oxidizer injection The ignition control circuit based on automotive spark plug have special circuitry that involves a very large capacitor and power supply circuit It can be understood further as visualized in Figure 2 5 The spark plug provides ignition when 12 the power supply is disconnected to allow capacitor discharges current 12 Thus it can be understood that the control signal for ignition circuit is active low spark plug power supply circuit Signal from control circuit Figure 2 5 Ignition circuit 2 34 Measurement Sensors The sensors for HiREF s pulse detonation engine are used to measure detonation pressure detonation acceleration and the force produced from the fuel oxidizer detonation 12 All these measurements require three different transducers which are mounted on the PDE They are KISTLER 211B300 PIEZOTRON pressure transducer for measuring pressure KISTLER 8704B5000 accelerometer for measuring acceleration and KISTLER 9331B load cell for measuring force These transducers will generate output voltage with respect to the parameters it senses Figure 2 6 a Pressure transducer b accelerometer c load cell 13 2 4 LPC1769 Microco
32. es user to display data such as ADC sampling value in real time using terminal emulation software such as HyperTerminal or TeraTerm through a computer Furthermore the software can be used to provide simple GUI for the user to operate any applications that are using microcontroller as their platform Most manufacturers nowadays are moving to USB standard for most peripheral interfaces such as mouse keyboard and external memory while keeping the interface for VGA and Ethernet ports These technological developments lead to some constraints for embedded system developers in their design In order to counter such problem USB UART converter is implemented There are many manufacturers for the converter as well as the transceiver IC 3 3 1 UART USB Converter For this project UCOOB V2011 from Cytron Technologies Sdn Bhd is used This implementation makes the project easier to be debugged and at the same time providing serial communication directly from the microcontroller itself without having to build any special interfacing circuitry More than that the USB UART converter is powered by the USB host at which it is connected where for this project it is the computer It has dual voltage rating for 5V and 3 3V microcontroller system that can be easily switched using a jumper pin Thus serial communication interface using USB UART converter is the best communication method for this project Figure 3 3 below shows the converter in actual form
33. h can be applied in any control method to achieve certain accuracy at output The system will continuously monitor the controlled parameter and compare it with the command value and gives appropriate signals to perform calibration measures An example to a close loop feedback system is depicted in Figure 2 1 for SSME thrust control system below With such feedback system the calibration process is more economical where there is no need for resizing and additional machining on the engine s structure in order to achieve desired operating condition In addition the system is well established and proven many times for military flight control system 3 The technology is progressing very fast and sometimes there is certain new control configuration needed by the SSME New configurations may be required to adhere to certain calibration standard or operation sequences To perform rapid changes on how the controller operates the engine a feature called programmable digital logic is implemented 3 With this implementation any changes in operational sequences and function can be made by modifying the computer software installed This feature is almost similar to the main feature of any microcontroller where the software can be changed by direct programming through computer software Thus reducing the time and cost for hardware redesign 3 FEEDBACK ACTUAL ACTUATOR POSITION 4 AND VALVE THRUST THRUST PERFORMANCE Figure 2 1 SS
34. he design of the controller will be based on the operation sequences algorithm required for FKM s High Speed Reacting Flow HiREF Laboratory pulse detonation engine The algorithm will be implemented using LPC1769 s GPIO General Purpose Input Output It will involve the control of injection ignition and purge actuators Tertiary scope for this project is to establish data communication between microcontroller and computer as well as between microcontroller and external memory storage using standard communication protocol Analog reading from sensors will be acquired and processed using ADC and LPC1769 The digitized reading from the sensors will either be logged into external memory storage or be displayed and saved using a computer through terminal emulation software Overall the complete system for this project will be able to control detonation engine operations and log all readings into an external memory drive or displayed on computer CHAPTER 2 LITERATURE REVIEW 2 1 Pulse Detonation Engine PDE 2 1 1 PDE Theory and Concepts Typical rocket engine uses many concepts for their operation such as deflagration and detonation 5 Each of these concepts have been tested and applied mostly in aerial vehicle Deflagration concept was applied in gas turbine engine in an almost constant pressure isobaric environment Each engine was categorized into steady state and unsteady state engine 5 Steady state engine class examples ar
35. hmuel Eidelman Xiaolong Yang Analysis of the Pulse Detonation Engine Efficiency Science Applications International Corporation 1710 Goodridge Drive McLean VA 22102 Thomas Bussing George Pappas Pulse Detonation Engine Theory And Concepts ASI Adroit Systems Inc Bellevue Washington 98004 NXP Semiconductors UM10360 LPC17xx user manual Rev 2 19 August 2010 Microchip Technology Inc 3V Tips n Tricks 2006 http www embedded com electronics blogs beginner s corner 4024888 The universal design methodology Fairchild Semiconductor Corporation General Purpose 6 Pin Phototransistor Optocouplers 4N25 6 June 2002 NXP Semiconductors LPC1769 68 67 66 65 64 63 Product data sheet Rev 9 3 8 January 2014 NXP Semiconductors AN10974 LPC176x 175x 12 bit ADC design guidelines Rev 1 1 September 2010 Ahmad Faiz B Mad Zin Development of Pulse Detonation Engine 2011 Universiti Teknologi Malaysia Master of Engineering Mechanical Thesis http www cytron com my http arm com products processors cortex m index php http www nxp com http elm chan org fsw ff 00index_e html http www embeddedartists com products lpcxpresso lpc1769_xpr php http www Ipcware com APPENDIX 1 Final review System integration and test Ship product Appendix 1 Universal Design Methodology UDM from www embedded com 59
36. i nic ae ini Sine LPC1769 MCU and ea EERE Bi ee Donna RS232 interface 4 Conta ADC and UART on PDE s sensors 6 FyPireportwrtme O OO TT Figure 5 1 Working timeline for FYPI Wee work FYP2 a2 24 5 6 7 rere Establish configure ADC DART commameation ccc 2 Venfving ADC and UART Be aan iii ill 3 Identfying configure im Re id Testing the controller with HE _ ARRARAS sensor on board PDE an Ea Report draft submission EE Journal paper Hardboundreport submissen 1 Figure 5 2 Working timeline for FYP2 53 Sourcing Management Many elements such as end user for Pulse Detonation Engine component hardware integration testing equipment and firmware development need to be source out to execute this project Sourcing management is divided into several segments which are testing equipment electronic components tools firmware development end user consultation and teammate colleague 5 3 1 Testing Equipment The testing equipments used in this project are digital oscilloscope digital multimeter and PC laptop Table 5 1 shows tabulation of equipment with their respective source and usage 50 Digital e Embedded System Observe the behaviour of signal oscilloscope Laboratory Faculty of from pressure transducer for Electrical Engineering PDE Determine linearity of input signal versus output signal of a custom designed signal attenuator for pre
37. ift on the signal since single amplifier will produce inverted signal phase Figure 3 7 depicted the attenuator s configuration The second configuration was based on a buffer using op amp LM741 and voltage divider circuit as in Figure 3 8 The result for these attenuator analysis will be discussed in chapter 4 28 Figure 3 8 Attenuator Configuration 2 3 5 2 External Memory Storage The readings from ADC input needs to be stored by means of a memory storage device Due to the research purpose of Pulse Detonation Engine it is very critical that the data on the engine s operation need to be sampled and stored for further research analysis The memory device needs to have easy access using most computers today Thus USB mass storage was the most suitable medium for ADC data storage NXP s LPC product range is very popular with USB based driver libraries In their developer s forum website www LPCware com there is a special section for USB peripheral libraries for NXP s LPC product lines NXP provides up to date 29 USB peripheral drivers for LPC microcontrollers such as USB Host HID CDC and Mass Storage applications These drivers had been supported by NXP for years Unlike other model the easiest way to have an external mass storage device for LPC1769 microcontroller is through USB peripheral on board It has one USB peripheral with a maximum of 12Mb s USB 2 0 full speed class data exchange rate In order to use US
38. ineering Universiti Teknologi Malaysia UTM The data logging mechanism was implemented using open source Chan s FAT File Access table File System library integrated with 12 bit ADC Analog Digital Converter on board LPC1769 to measure and log PDE operation data into USB flash memory The final prototype for controller module was able to perform control operation when tested with a test circuit consist of LED Light Emitting Diode array where the timing interval between each stage of PDE operation cycle can be configured until microsecond accuracy while the data logging module can log up to 88 samples per second CHAPTER TABLE OF CONTENTS TITLE TITLE DECLARATION DEDICATION ACKNOWLEDMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS INTRODUCTION 1 1 Project Background 1 2 Problem Statement 1 3 Project Objective 1 4 Scope ot Work LITERATURE REVIEW 2 1 Pulse Detonation Engine PDE 21 1 PDE Theory and Concepts 212 PDE Efficiency 2 1 3 Issues On Practical Implementation Of PDE 2 2 Rocket Engine Control System 2 3 FKM s HiREF Laboratory Pulse Detonation Engine 2 31 Pulse Detonation Engine Structure 2 32 Pulse Detonation Engine Operation vil PAGE 11 111 vi vii XI xil XIV BR o NO e DI N ta ta A 11 2 4 2 9 2 3 3 Pulse Detonation Engine Control Circuit 2 34 Measurement Sensors LPC1769 Microcontroller Unit MCU 241 LPCXpresso LPC1769
39. ing timer finished Yes Cycle counter decrement No Cycle counter 0 Yes End Figure 3 6 PDE controller flow chart 26 27 3 5 ADC Data Logging From the objective data samples from ADC need to be stored for PDE analysis The data logging hardware module consist of ADC on board LPC1769 microcontroller sensor pressure transducer mounted on the PDE tube external memory storage and serial communication interface ADC for LPC1769 has 12 bit capability at 200kb s conversion speed 6 Since LPC1769 1s a 3 3V microcontroller system the resolution of the ADC is 0 8mV 11 3 5 1 ADC Signal Attenuator Some considerations need to be made when interfacing the pressure sensor with ADC input pins The voltage rating for the sensor must not be outside ADC input s absolute maximum rating The sensitivity of the transducer is 1 086mV psi The maximum allowable pressure is 5000 psi Thus the sensor supposedly will generate a maximum voltage of 5 43V The maximum input voltage for LPC1769 s ADC is 3 0V while the maximum output voltage for the sensor was 5 43V 11 Attenuation process needs to be made to the sensor s output before it is being fed into ADC pins A maximum voltage of 5 5V is assumed to simplify design parameter Thus two 5 5V to 3 0V attenuator configurations was designed The first configuration were made based on typical inverting amplifier which IS cascaded into two stages to provide zero degree phase sh
40. ired results are achieved A11Z WILD UNE MUCU nficuring I 1 I Il Failed I I I I Failed lt gt Figure 3 1 Core project methodology 19 3 2 Top Level Design In order to execute with the project a rough view of the actual final prototype IS visualized as in Figure 3 1 Based on the figure the LPCXpresso LPC1769 development board are interfaced with sensors or transducer actuators external memory and communication line The sensors will be interfaced using ADC Analog Digital Converter pins while the actuators with GPIOs For external memory and communication they will be interfaced with communication peripheral pins provided in LPCXpresso LPC1769 development board such as USB SPI and UART pins as these pins are very specific with its functions From the communication interface the system can be connected to computer for debugging controlling and displaying purpose Detonation Engine Sensors Controller transducers actuators PRC EE Peat e eren LPCXpresso LPC1769 eee F i HA unt a 3 IRE CO E_RE k l Ar microcontroller developement board p x n c u out uut BULU F3 uuu eee Tee O a Pee i ho m dus ma I External Communication Computer t memory interface Terminal interface emulation software Figure 3 2 Top level graphical representation of the project 20 3 3 Serial Communication Interface Serial communication enabl
41. le System is a computer file system architecture In simple FAT File System is a firmware interfacing medium for accessing standard memory storage devices such as USB flash memory SD card and hard disc drive Regardless of any data logging configuration the USB mass storage device was detected by a function from Chan s FAT File System library From flow chart in figure 3 11 after ADC value was put into a buffer data from the buffer along with micro second timer value and counter value are converted into a character string using C language function sprintf From here the data logging operation was controlled using functions from Chan s FAT File System library The functions are sequenced in a specific manner to ensure the data in a created text file in USB mass storage 1s updated each time the data was logged instead of creating new file or overwriting the file created Table 3 4 shows the sequence of functions to logged ADC values into USB mass storage 31 Register Unregister a work area 2 Open Create a file 3 3 fseek Move read write pointer Expand file size 4 Write file Table 3 4 Chan s FAT File System function in sequence From Table 3 4 the f mount function will detect the connection of USB mass storage device and register a file pointer If there is no problem the firmware will proceed to ADC data sampling After the data was put into a buffer and converted to a string along with micro second time
42. liran Reaksi Kelajuan Tinggi di Fakulti Kejuruteraan Mekanikal FKM Universiti Teknologi Malaysia UTM Mekanisme pengelogan data diimplementasikan menggunakan pustaka sumber bebas Sistem Fail FAT File Access Table daripada Chan dintegrasikan dengan Penukar Analog Digital 12 bit pada LPC1769 untuk mengukur dan mengelog operasi Enjin Denyut Letupan ke dalam memori imbas USB Prototaip akhir untuk modul pengawal berupaya melaksanakan operasi kawalan apabila diuji menggunakan litar penguji yang terdiri daripada susunan LED Light Emitting Diode dimana sela masa diantara setiap peringkat ulangan Enjin Denyut Letupan boleh dikonfigurasikan sehingga ketepatan mikrosaat sementara modul pengelogan data boleh mengelog sehingga 88 sampel per saat vi ABSTRACT This report describes the implementation and analysis of a controller and data logging mechanism based on microcontroller for the operation of Pulse Detonation Engine PDE The system was developed using LPC1769 microcontroller based on industrial standard ARM Cortex M3 architecture The purpose of implementing such system 1s to enable the engine to be operated at high speed accurately while the data on PDE operation is logged into external memory storage device The system implements PDE operation algorithm using General Purpose Input Output GPIO and Interrupt timer peripheral of LPC1769 based on existing PDE prototype developed by High Speed Reaction Flow HiREF in Faculty of Mechanical Eng
43. microcontroller series are being supported by NXP Semiconductors until today They can be downloaded online or found in the example directories of LPCXpresso IDE The libraries were a starting 15 point for any embedded system developers who are using NXP s LPC microcontroller as their implementation platform 2 5 Serial Communication Any microcontroller applications need a medium for interaction with its user The user may interact with microcontroller for control debug program or display purpose The most fundamental function of communication medium is for debugging purpose Debugging enables user to observe the behavior of a firmware program when testing microcontroller applications For all these purposes embedded system developers need to establish communication protocol such as serial communication Serial communication 1s the most widely used protocol for microcontrollers today Some serial communication protocols include Ethernet CAN SPI USB rc RS232 and UART USART The most common serial communication protocol for today s microcontrollers is by using RS232 or UART USART LPC1769 microcontroller has 4 sets of UART pin interfaces Each UART interfaces have a pair of transmit TX and receive RX channels 2 5 1 UART Interface on Microcontroller UART interface on microcontroller is necessary for UART serial communication before sending data to computer through RS232 cable LPC1769 microcontroller which will be used
44. nce and exposure on real life industrialized engineering world Moreover millions of thanks for his constructive critism which always tell my mind that becoming a very good engineer is not an easy job Without his supervision the experience in doing this project would be common and dull I also want to send my gratitude to the master students in Embedded System Laboratory which had helped me much in developing the project Their experience and expertise related to my project is very much respected Without them the project will be delayed and going nowhere Last I would also like to thank my fellow friends and colleagues that are also doing their project Their tips and suggestion on improving my work somehow furnish my project to become better ABSTRAK Laporan ini menerangkan implementasi dan analisis pengawal serta mekanisme pengelogan data berdasarkan mikropengawal untuk operasi Enjin Denyut Letupan Sistem dibangun menggunakan mikropengawal LPC1769 yang berdasarkan rekabentuk piawai industri ARM Cortex M3 Tujuan implementasi sistem ini adalah untuk membolehkan Enjin Denyut Letupan dioperasikan pada kelajuan tinggi secara tepat semasa data operasi dilog ke dalam peranti simpanan memori luaran Sistem mengimplementasikan algoritma operasi Enjin Denyut Letupan menggunakan periferal Input Output Kegunaan Am GPIO dan pemasa Interrupt mikropengawal LPC1769 berdasarkan Enjin Denyut Letupan sedia ada yang dibangunkan makmal A
45. ntroller Unit MCU LPC1769 is a microcontroller unit MCU manufactured by NXP Semiconductors It 1s based on widely used industrial standard 32 bit ARM Cortex M3 architecture 14 LPC1769 was intended for applications such as electronic based metering alarm systems lighting industrial networking and motor control Based on LPC17xx microcontroller series user manual the list below is some of the peripherals included on board LPC1769 6 e 3 3V microcontroller system e Upto 120 MHz CPU frequency e 512 kB flash memory program firmware up to 64 kB data memory RAM e 4UARIS e 2 CAN Controller Area Network channel e SPI interface 3 FC interfaces e 8 channel 12 bit ADC Analog Digital Converter e 10 bit DAC Digital Analog Converter 4 general purpose timers e 6 output general purpose PWM Pulse Width Modulation e 1 USB interface full speed class e 70 general purpose I O pins e Support both standard JTAG and ARM Serial Wire Debug SWD interface LPC link debugger LPC1769 pins li al x 22 gt mara PERE Ls C23 wa seshe LPC Link alacsaiaia n a14 R9 Bases Figure 2 7 LPC Xpresso LPC1769 development board 14 241 LPCXpresso LPC1769 Development Board LPCXpresso LPC1769 is the core development platform for LPC1769 im the market today It is a development board by Embedded Artist based on NXP Semiconductor s LPC1769 microcontroller unit MCU 17 Figure 2 7 shows the L
46. o the increasing input voltage This is suitable for sensor s interfacing to provide accurate data for PDE operation Vin V 000 100 200 300 400 500 Vout V _ 0 00 099 198 2 56 258 2 59 Table 4 1 Attenuator configuration 1 result 38 Figure 4 2 Attenuator configuration plot Vin V 000 100 2 00 30 400 5 00 Vout V 000 0 67 121 172 227 293 Table 4 2 Attenuator configuration 2 Result Figure 4 3 Attenuator configuration 2 Plot Despite attenuation mechanism had successfully made the pressure transducer s signal output compatible with the ADC input maximum voltage calibration for the voltage value with respect to the pressure psi rating need to be made Without the attenuator the maximum voltage input from the transducer 1s 5 43V at 5000 psi which 1s 1 086 mV for each psi A maximum input voltage of 5 5V IS assumed rather than 5 43V to design simplify design for signal attenuator Thus a simple calculation is needed to calibrate the reading Table 4 3 tabulates the comparison between before and after attenuation 39 5 43V 5 5V 0 9872727 X 3V X 2 961818V 5000 psi maximum reading X 5000 psi 0 6 mV psi ADC Reading Calibration Before Attenuation After Attenuation Smallest voltage resolution detected by LPC1769 s ADC 0 8mV Max input voltage at 5000 psi 5 43 V Voltage resolution at 1 psi 1 086 mV Table 4 3 Calibration comparison between
47. ocus on optimizing data writing speed Multiple Sector Write Cmd Data Single Sector Write Cmd Data Busy Figure 4 4 Comparison of multiple sector and single sector per block writing 16 4 2 2 Data Logging Performance Analysis When ADC data logging firmware was running a log file contained parameters is created The parameters can be programmed to be logged into USB flash drive An example of logged data sample from test 1 is shown in figure 4 5 From the figure the first value is the ADC sampling values followed by data writing counter and micro second timer stamp Figure 4 6 until Figure 3 10 show the results of five different data logging architectures 41 0038080909 0038091852 0038117795 0038150633 0038161573 0038194407 0038205348 0038238181 0038249122 0038260065 0038271007 0038281950 Figure 4 5 Data logging file example number of sample test 1 100 90 80 m sample per seconds 70 pie pe o 8 8 n we DER BB ESSO IEE EE ISE MEDIA a a GE Fr ji a mc a o ES SS as a a SE RE imme ge inni RE E RE ii i i Ea Ban EE Second 1 2 3 4 5 6 7 8 gt do M Be db do a Figure 4 6 Test 1 ADC data logging result 42 LA hu x di i III a M UTLI TECTED 14 Ir an LIL i RR iii 11 10 test 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Figure 4 7 Test 2 AD
48. of pulse detonation engine structure 1 1 2 Problem Statement Pulse Detonation Engine PDE concept mainly circles around its detonation process The detonation process has a very significant property which is the speed of detonation cycles Detonation based engine cycles are so fast that the fuel and oxidizer injection phase time interval is much longer than the detonation period 1 With the combination of injection for fuel and oxidizer ignition and purge phase time the timing control of the controlling actuators becomes more complex and harder to realized All of the phase needs to be accurately executed Figure 1 2 shows the visualization for timing proportions of all operation phase in one cycle This cycle should be repeated for continuous operation Moreover the pulse nature of the detonation process need a very fast accurate stable and effective control mechanism in order to maintain the repeating detonation cycles throughout the entire engine operation The repeating detonation cycles were measured in frequency instead of rotation per minute rpm in conventional combustion engine It is very important to control the frequency of detonations since it is directly proportional to the thrust output of the engine 2 Once the frequency of engine operation 1s realized it will allow proper control on the speed of the aerial vehicle associated with the engine I Injection ti Injection time 2 Ignition ts detonation time
49. r and writing counter f_open will open the file for any operation This function can be configured into many modes such as creating new file and opening existing file by specifying specific figures or definition in the arguments After that f Iseek will move the read or write pointer of the file Then f write writes the data specified by a buffer pointer in its arguments F Iseek function ensures the data are written by f_write function at the end of existing data in the file If this function is not used the data will be written at the first address Thus overwrites the existing data At the end of logging operation f_close will close the opened file Inability to do so may cause problems to the file opened for future logging operation The whole operation was repeated each time the ADC conversion was finished while the end flag 1s false The ADC peripheral example library provided by NXP Semiconductors can only perform simple ADC sampling operation and displayed through UART serial interface Major adjustment was made to include micro second timer and USB Host peripherals in the same system The stamping for micro second timer is configured using SysTick timer interrupt peripheral on board LPC1769 microcontroller The smallest time interval for this timer is micro second 32 Initialize ADC micro second timer USB Host and FAT file system Start micro second timer IS Mount USB pendrive true true End flag false Start AD
50. rd LPC1769 to simplify both PDE controller and data logging module so that the system will only use a single microcontroller for this system This will greatly reduce the cost for system implementation 5 Second the core platform for this project LPCXpresso 1769 can be changed into other industrial standard ARM based platform There are a lot of manufacturers for microcontroller or microcomputer that implemented ARM architecture into their design LPC1769 has limited development opportunity for non expert embedded system developer such as undergraduate students since there 1s very limited resources can be found for embedded system development Moreover This project focuses on ADC data logging based on USB flash memory and general purpose I O application There are many other options for development platform such as PIC series from Microchip Technology Inc Freescale Semiconductors and Atmel can be further explored to suit effectively with this project s requirement especially for high speed data logging purpose Moreover Linux based microcomputer such as Raspberry Pie and Beaglebone may be implemented for its excellent GUI Graphical User Interface and networking capability Second the performance can be increased by further deeply exploring FAT File System for external flash memories such as USB flash memory SD memory card and external hard disc drive The capability to use this memory media in the highest performance will lead to g
51. reater possibility in embedded system design that requires high speed and high volume data storage Third to increase user friendly and marketability property for this project a GUI to operate the prototype or final product need to be developed Visual Basic or Ot development software can be used for this particular purpose Fourth and last management matters with FKM s HiREF laboratory may also be improved to synchronize all testing requirements and specification matters This is very important since this project is related to other institution within UTM premise The success of project or research for both parties is detrimental to UTM s image and capability expectation by other people 58 References 10 11 12 13 14 15 16 17 18 Khalid M S Ahmed F H K Mohsin S Mazlan A W Transient Characteristics of C3H8 O2 Turbulent Mixing in a Hypersonic Pulse Detonation Engine Proceedings of the 9th WSEAS International Conference on APPLICATIONS of COMPUTER ENGINEERING Philip K Panicker Donald R W Frank K Lu Operational Issues Affecting the Practical Implementation of Pulsed Detonation Engines AIAA Paper 2006 7959 14th AIAA AHI Space Planes and Hypersonic Systems and Technologies Conference P F Seitz and R F Searle Space Shuttle Main Engine Control System 730927 National Aerospace Engineering and Manufacturing Meeting Los Angeles California October 16 18 1973 S
52. ssure transducer and microcontroller s ADC interfacing Digital Embedded System Continuity testing for soldered multimeter Laboratory Faculty of components on donut board or Electrical Engineering microcontroller development Self own board Troubleshoot errors in circuit connection PC Laptop Self own Writing reports outsource information Using IDE for developing debugging and programming microcontroller s firmware Simple GUI Graphical User Interface for serial communication Table 5 1 Equipment sourcing tabulation 5 3 2 Electronic Components Tools Most electronic components were sourced bought from Cytron Technologies in Taman Universiti Skudai Johor Due to unavailability of rare or outdated electronic components in the market they are sourced bought at 5 ro Hitechtron in Johor Bahru and via online ordering at Element14 formerly Farnell The components bought at Cytron Technologies and Hitechtron were immediately received on the same day of buying while online ordering via Element14 takes around 3 days for the ordered components to arrive Thus a Bill of Material BOM has been developed for this project as in Table 5 2 below Optocoupler 4N25 Black package eon an Tessa __ i bua ba Tea Bana I I 1 l N NI e e e e I al DI U2 N I ml gt N UART to RS232 converter Cytron Potentiometer small 10k ohm N6 8 7 7 7 Resis
53. t circuit From observation all controller pins from isolator circuit output are functioning well as shown in figure 4 1 From figure 4 1 LEDI until LED6 are turned ON while in fuel oxidizer injection stage The same goes for LED7 and LEDS for ignition and purging stage 411 LED Test Circuit Limitation The test was done with just only LED array which is far from the actual environment where the relays and solenoid valve 1s present These actuators are 37 using much current rather than LEDs in the test circuit This would affect the dynamic behaviour of the controller s functionality 42 ADC Data Logging Analysis ADC data logging analysis is divided into signal attenuator data logging timing and data logging performance 4 2 1 Signal Attenuator Linearity Analysis Signal attenuator for both configurations were tested using potentiometer input voltage 1V 2V 3V 4V 5V from a DC power supply For configuration 1 Table 4 1 shows the result of the test which was plotted in Figure 4 2 On the other hand the result for configuration 2 attenuator was tabulated in Table 4 2 and plotted in Figure 4 3 Figure 4 2 shows non linear result as input voltage is increased using configuration 1 attenuator This is not suitable for sensor s interfacing with ADC as this condition would lead to false and inaccurate measurement From Figure 4 3 the plotted result shows linear behaviour of configuration 2 attenuator with respect t
54. the opportunity to compare the data acguiring performance using terminal emulation software and portable data logging in this project The format of file created as well as the data arrangement in it is the same as in Figure 4 5 Figure 4 11 shows the result from ADC data captured through UART serial communication and text capture feature in HyperTerminal software From the result the data was captured at around 470 samples per second This performance level was tremendously higher when compared with ADC data logging using USB flash memory storage Unfortunately the data need to be saved manually using personal computer or laptop number of sample HyperTerminal capture 500 450 7 350 300 Bi E sample per seconds 250 200 150 100 0 second 1 2 3 4 5 6 7 8 9 10 11 12 Figure 4 11 ADC data capture using HyperTerminal 46 4 3 Final Project Prototype A prototype for this project was made as an example product for this project This prototype may also be tested in FKM s HiREF laboratory using the Pulse Detonation Engine developed there Soldering works and wiring were made on donut board based on schematics in previous chapters Figure 4 12 shows the prototype Power Supply 12V F ADC input coaxial USB memory Control Signal terminal connector UART USB converter Figure 4 12 Final project prototype 4 3 1 Limitation of Final Prototype This prototype h
55. ting structure built to interface the injectors with PDE CNG Injector Figure 2 3 CNG injector from LO Gas 12 11 2 3 2 Pulse Detonation Engine Operation The operation framework for FKM s HiREF Pulse detonation Engine is based on Figure 1 2 where it is a cycle that comprises of fuel oxidizer injection ignition and purge stages A precise time interval between each stage is needed From a Faculty of Mechanical Engineering FKM master thesis entitled Development of Pulse Detonation engine the time interval between fuel oxidizer injection and ignition is 30 of the whole cycle The same percentage also applies to the time interval between ignition and purge stage Last of the whole cycle time interval between purging and fuels oxidizer reinjection is 40 12 All of the time interval proportions can be visualized as in Figure 2 4 Fuel oxidizer Ignition Purge removes burnt fuel injection detonation Figure 2 4 Time interval between each stage 2 3 3 Pulse Detonation Engine Control Circuit The control circuit for FKM s HiREF PDE is divided based on each actuator which is fuel oxidizer injection ignition and purge air circuit As described before in section 2 3 1 the actuator for fuel oxidizer and purge air injection is CNG injectors based on electrically controlled solenoid valves The control circuit for ignition is based on an automotive spark plug 12 The solenoid valves CNG injectors for fuel oxidiz
56. tition Time Management Sourcing Management 5 3 1 Testing Equipment 5 3 2 Electronic Components Tools 5 3 3 Firmware Development 5 3 4 End User Consultation 5 3 5 Teammate Colleague Financial Management CONCLUSION amp SUGGESTION 6 1 6 2 Conclusion Suggestion for Future Improvement 35 36 36 37 37 37 39 40 44 45 47 47 47 48 48 48 48 49 49 50 52 53 53 54 56 56 56 REFERENCE Appendix 1 58 59 TABLE NO 3 1 3 2 3 3 4 4 1 4 2 4 3 4 4 4 5 4 6 5 1 5 2 5 3 5 4 LIST OF TABLES TITLE Tabulation of actuators and control voltage Resistor and supply voltage value for isolator circuit Example timing intervals with respect to PDE operation freguency Chan s FAT File System function in sequence Attenuator configuration 1 result Attenuator configuration 2 result Calibration comparison between before and after attenuation Data logging position markings Timing analysis at random data line Summary of data logging performance analysis Equipment sourcing tabulation Bill of material BOM for this project Components Tools readily available Hardware development costing Xi PAGE 21 23 25 31 37 38 39 39 39 44 50 52 52 55 FIGURE NO 1 1 1 2 Zall 2 2 23 2 4 2 5 2 6 2 2 8 2 9 3 1 32 3 3 3 4 a 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 4 1 4 2 LIST OF FIGURES TITLE An example of pulse detonation engine structure Basic operation cy
57. tors Standard i w w 48 l DS Various value in 21 Capacitors 0 1uF hama 22 Buzzer 5V rem 52 Element14 3 3V RS232 transceiver SOIC type 1 Analog Device Connector socket cable 2510 Will Hitechtron Sdn Bhd Table 5 2 Bill of material BOM for this project Some components tools don t need to be bought since it s already owned or provided by supervisor which are tabulated in Table 5 3 below LPCXpresso LPC1769 Development Embedded System Laboratory Board Faculty of Electrical Engineering Solder wire solder wick solder gun Embedded System Laboratory solder paste Faculty of Electrical Engineering Self own Table 5 3 Components Tools readily available 5 3 3 Firmware Development Development of embedded system using microcontroller platform leads to firmware or code outsourcing Each microcontroller may have their own unique architecture or peripheral libraries Usually the manufacturer will provide access to the generic microcontroller peripheral libraries through internet download For LPC1769 microcontroller there is at least one major source for embedded system development which is LPCware com This website is being supported by NXP Semiconductors and further developed to cater the needs for outsourcing and feedback It provides download access for peripheral s example libraries microcontroller s standard USB peripheral driver user manuals
58. using HyperTerminal Final project prototype Working Timeline for FYP1 Working Timeline for FYP2 xiii 38 40 41 41 42 42 43 43 45 46 49 49 PDE NASA UTM FKM HiREF IDE ADC MCU TTL NABC USB CAN SPI UART SWD GUI rpm CNG SSME PWM GPIO PDIP SOIC_N SMD IC XIV LIST OF ABBREVIATIONS Pulse Detonation Engine National Aeronautic and Space Administration Universiti Teknologi Malaysia Fakulti Kejuruteraan Mekanikal High Speed Reacting Flow Integrated Development Environment Analog Digital Converter Microcontroller Unit Transistor Transistor Logic Needs Approach Benefit per cost Competition Universal Serial Bus Controller Area Network Serial Peripheral Interface Universal Asynchronous Receiver amp Transmitter Serial Wire Debug Graphical User Interface Rotation per minute mille second Compressed Natural Gas Space Shuttle Main Engine Pulse Width Modulation General Purpose Input Output Plastic Dual In Line Package Standard Small Outline Package Surface Mounted Device Integrated Circuit CHAPTER 1 INTRODUCTION 1 1 Project Background Detonation Engine sometimes termed Pulse Detonation Engine PDE is a very efficient hypersonic pulse combustion engine targeted for aeronautic applications 1 It is still in research stage in many institutions including United States NASA National Aeronautics and Space Administration and Universiti Teknologi Malaysia UTM
59. ysis was done to determine the critical part of the coding that consumes the most time than others This is done to understand the behavior of program and to narrow down 35 the performance optimization options later By referring to the ADC operation flow chart in Figure 3 11 Figure 3 14 explains the data logging timing in timeframe form Initialize Start End ADC Start log End log parameter ADC conversion ADC value ADC value loo Figure 3 14 Timing analysis framework 3 6 2 2 ADC Data Logging Performance Analysis Method ADC data logging performance analysis were done by logging a dummy ADC input using any voltage source such as VCC of microcontroller into USB flash memory The data from ADC input was compared with data inside a log file created while logging the ADC values Based on the timer values and writing counter a chart of seconds versus number of ADC sample logged per second are plotted From here we can see the rate of sample logged into USB flash drive per second Based on observation in section 3 6 2 1 several different firmware architectures were tested for their performance The best architecture performance will be implemented in the final prototype 36 CHAPTER 4 RESULTS amp DISCUSSION 41 PDE Controller Analysis 1 _ AA sei STIA IIA Wi Pai Fuel oxidizer injection LED1 LED6 Ignition LED7 Purging LED8 Figure 4 1 PDE controller operation using tes

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