I am currently working on an engineering project for the final module of my mechanical engineering HNC (although it has taken an electrical bias!) I work in a machine shop as a production engineer and all of our CNC machines are plumbed into a central coolant tank, when a machinist needs to top up a machines coolant tank they manually open a ball valve to fill the tank (and then usually forget they have opened the valve and create a a large coolant spill). My project aims to automate this.
I have spec'ed a suitable solenoid valve and a flashing beacon to be controlled by an arduino using an ultrasonic sensor as a fluid level sensor. These two items will be powered by 230V ac so will be controlled by two of the below relay modules.
(I will be using these as normally open relays)
So the system will have 1 input
-Ultrasonic range sensor HC-SR04
And 3 outputs
-1 relay to open the solenoid valve to fill the tank
-1 relay to turn on the flashing beacon if the coolant level gets too low or too high
-1 LED that will flash whenever the solenoid valve is open
I want the system to:
Activate the solenoid valve relay to start filling the tank when the HC-SR04 sensor reads a range of 7cm and not stop filling untill it reads a range of 4cm.
Flash 1 LED (not the one on the arduino) on and off while the solenoid valve is open and filling is taking place.
Activate the flashing beacon relay if the reading from the HC-SR04 sensor reads greater than 9cm or less than 2cm.
Does this sound like an incredible difficult program to write?
I have limited time for this project and do not think have the resource to learn C++ & write the program before my deadline.
Is there a simple way I could program this like a PLC using logic?
I need to use electronics due to limited space in the tank, a mechanical float valve occupies far too much space to fit inside the tank and the way in which the pipe work is configured means that the valve is not situated conveniently by the machine, it is further away and then the final stretch of pipe to the machine is a flexible hose. Further more an electronic system allows me to fit a VERY HIGH and VERY LOW coolant level alarm
There are commercial automated aquarium "top off" systems that use small float switches and a control box/valve assembly.
Cheap ultrasonic sensors are sensitive to obstructions in their peripheral vision, so if you are already space constrained then it's unlikely that you'll be able to mount a sensor that has a clear enough view of the liquid surface to give a reliable level reading.
Given that you are in a workshop I would suggest that you plumb in a pipe to the side of the sump somewhere near the bottom and run a tube to bucket that acts as a secondary sump that has the room for whatever float switches or sensors you desire. The liquid level in both sumps will always be the same thanks to gravity and the magic of physics.
If you are determined to use a microcontroller then you may be able to complete the project using "copy and paste" coding from examples that you find on the web, but as this is a student project it's possible that your supervisor might ask a basic coding question. If you cannot give a convincing answer then you project may be graded as a fail even though the device works.
Hi, as you can imagine I cant just install a fish tank top up system for my project, further more the plastics are unlikley to be compatible with the machine coolant concentrate. This option also allows me to show how the system could be expanded with multiple sensors controlling multiple valves to automatically fill all the machines on a machine line.
Although tight space on the exposed section of the shallow tank that I have to work with is free from obstructions in peripheral view of the sensor, I have already downloaded some sample code and tested the ultrasonic sensor in situe. Therefore a secondary is not needed and even if it was, it is not an option due to limited space and management have said that I should not permanent modify the tanks in any way shape or form, drilling and plumbing in a pipe to a secondary tank would cause down time and is asking for a problems with leaks.
As I am a mechanical student and therest of my project has involved spec'ing pumps/pipes/valves etc and calculating flow rates & frictional losses, I am not specifically being marked on my ability to code, collaborative working is a criteria that is actually required for the project, you are not expected to be an expert in every feild. By no means would I be claiming the work as my own
kristian30041995:
I have already looked into this option
I need to use electronics due to limited space in the tank, a mechanical float valve occupies far too much space to fit
WHY ?
If you use a ballcock as used on a domestic water system i could understand it.
Small float valves are available.
Unless you have a very small header tank or special requirements i do not understand it.
IT may be more cost effective to have a bigger header tank.
Using arduino could work though if it is a requirement of the project.
kristian30041995:
the way in which the pipe work is configured means that the valve is not situated conveniently by the machine, it is further away and then the final stretch of pipe to the machine is a flexible hose. Further more an electronic system allows me to fit a VERY HIGH and VERY LOW coolant level alarm
In case you missed it I have already explained why
kristian30041995:
Hi, as you can imagine I cant just install a fish tank top up system for my project, further more the plastics are unlikley to be compatible with the machine coolant concentrate.
I believe one of the design goals for the coolant is to make it compatible with everything.
It sounds like if you don't want to learn some basic C then you should report your own post to a moderator and ask to move it to "Gigs and Collaborations". You can pay for code there.