Prototyping

By |2019-09-08T19:18:29+01:00September 8th, 2019|Uncategorized|

just testing….

Ing. Buero Dieter Munkes News   •   June 2, 2016

Neue Ansätze ausprobieren erfordert das man mal schnell etwas aufbaut.

Die ganze Story.

In 2010 wurde eine Prüfmaschine für eine EN14801 (Lebendauer Zahnimplantate ) entwickelt.

Damals mit automatisierungs Komponenten von Beckhoff, eigenem Leistungsteil und Vorverstärkern.

Im Verbund mit 8 Prüfstationen kann eine SPS das leicht handhaben. Mit weniger Stationen wird der Kostenanteil der Steuerung überproportional groß.

Die Lösung bestand aus Beckhoff IO, SPS , einem PC Win7 sowie einer Betriebsoftware geschrieben unter Delphi.

Folgende Nachteile: Einen PC mit allem Security updates.. die Enduser installieren zusätzliches, binden diesen ins Unternehmesnetzwerk ein.

Dies mag bequem sein, wird aber gerne zum Pflegefall.

Ziel 1-2 Stationen?

SPS -> zu teuer für Serie.

PC -> zu teuer bez. Wartung und pflege.

Messtechnik könnte Rauschärmer sein->Neubau

Da wäre als neuer Ansatz die SPS auf einen Microcontroller zu verlagern. Den PC gegen einen Raspberry zu tauschen. Die Benutzeroberfäche mit allen Grafiken in HTML5.

Fazit-> Wirklich alles neu machen.

Zur Abschätzung der Risiken wurden ohne nenenswerten Hardware Invest einige Tests gemacht:

SPS-Code in 1ms Timerinterrupt verlagern -> geht 20% load

Kommunikation Microcontoller zu PC per USB -> 1,6MByte/s, Bedarf 64KB/s

Einbindung Microcontoller an Raspberry -> geht ohne zusätzliche Treiber

HTML5 Website zur Bedienung-> nach 4 Wochen probieren , geht (Canvas und WebSocket)

Verbindung von Microcontoller , Datenaufbereitung und Verbindung zur Website per Websocket und JSON geschrieben in Python. Geht

So nun alles auf ein Board und die eigendliche Enwicklung beginnt.

Tools: C auf dem Controller, Python auf dem Pi und HTML5 für die Seite.

Auf dem Board sind Netzteil, USV, OLED, AD7730, DA, Micocontoller, 24V IO, RFID.

Das Board ist auf Anfrage erhältlich.

 

 

 

Calculation of measurement uncertancy

By |2018-05-23T15:36:29+01:00May 23rd, 2018|Uncategorized|

Calculation of measurement uncertancy

Ing. Buero Dieter Munkes News   •   June 2, 2016

During a project to gain accreditation (EN17025) for a laboratory i need to calculate the uncertancy of a measurement system.

I found that there are 2 ways to do it:

A) Get a lot off samples and do some statistics.

B) Get all uncertancy of influencing parameters and calculate a common result.

 

First create a map of influences. Ishikawa diagram or something like a mindmap.

Set in all parameters inclusive your reference. (Temperature, light, humidity…..)

 

Goto B)

Now i see that i don´t find exact parameters for the uncertancy parameters. You may assume them. But i don´t like this.

I found that my amplifier has 18ppm/K drift, ok I know the range. But there are drift from DMS, thermovoltages at contacts….

I got crazy with endless unknowns.

 

The way i found was: Take what you get on B) and do the remaining with A)

 

I my example it is a machine for testing lifetime of tooth implants. It´s a motor generating force down on an implant.

In series to this is a DMS Force Bridge. For regulation the force. See the first picture.

Now I put additional a reference sensor in series.

The uncertancy and calibration data are known by a Dakks calibration sheet.

I set the system to press with 100N down.

Now i put both sensor data into a histogramm seen on the second picture.

Now i calculate average and standardderivation from my internal sensor.

I calculate average from my reference.

I have the uncertancy from the calibrationsheet of the reference at 100N

So the common uncertancy is =sqrt(  (ref uncertancy)² +(AverageSensor-Averageref)²+(derivation internal sensor)²)

As both are gauss shaped i can expand the range to cover 99% of samples by a factor around 2.7

 

With this i can say that the system get 99% of samples within +-0,6N at 100N force.

To cover all influences you need to be sure that this influence ocure.

I let the system sample overnight to get a full daily temperature cycle.

 

Dieter Munkes

 

Recognizing dental implants in blister

By |2018-04-18T13:33:04+01:00April 17th, 2018|Uncategorized|

Recognize dental implants when they are packed in blister.

Ing. Buero Dieter Munkes News   •   June 2, 2016

One day it happens that one implant was wrong labeled. Ok you would think, “not a problem” . But think about a doctor who find out this after he drilled the hole. As patient you would not be amused.

Due to this risk I got the order to compare implants in glastube and blister against known parameters.

We descided to check length and diameter.

After tests, we saw that you need to change lightning (angle and intensity) for every edge to measure.

With this we build a lightning with contolled 16 LED around the blister.

From top a industrial 5M Pix camera, a Beckhoff industrial PC and some IO to contol the LED.

 

 

How does this work ?

We learn at a sample blister the dimensions and the lightning. Its a manual process.

We store this parameter with the given productname.

Now before labeling on a conveyor belt we get the productname from the labeling machine.

Load the parameterset, redo measuring and compare.

Now we give back “good or bad” to kick the blister off the conveyor belt.

Key to this application was the right lightning.

 

Tiny espresso machine

By |2018-04-21T22:46:21+01:00April 10th, 2018|Uncategorized|

Tiny espresso machine

Ing. Buero Dieter Munkes News   •   April 10, 2018

The lack of a good espresso during my holiday travels brings up the idea to build an own machine.

A fun, non profit project between Christmas and New year.

Requirements are easy for this:

  • Produce espresso
  • Weight almost nothing. Size almost nothing.
  • No open coffee powder handling.

 

Technical I need:

  • >10Bar
  • >80°C
  • 20-40ml Water.

Solution:

As I go out for diving during my holidays, there is the option to take the middle pressure from my regulator 9.5Bar. Nearly perfect.

Hot water on diveboats is mostly available. For handling coffee i took aluminium capsules.

 

Sounds easy but i need 2 designs to get it done.

The Solution is 50mm diameter x 65mm tall.

Build out of titanium.

Issues:

  • Main issue is to keep mechanical stength and keep your coffee hot.
  • If i do a classic calculation, i gets over 100kg force on top and bottom. I need to get the tube up to 1.5mm stength….
  • Take Aluminium and you get a coffee only worm, but hot fingers.

 

 

Now it works fine.

 

 

Lifetime test equipment with BroadR-Reach

By |2018-04-19T22:03:20+01:00December 18th, 2017|Uncategorized|

Testequipment with BroadR-Reach

Ing. Buero Dieter Munkes News   •   Sept 2, 2017

Actual communication in cars changes. We know LIN , CNA over the years, but now we are moving to BroadR-Reach.

Some words about:

  • Developed to cover the last mile in connecting houses.
  • 100Mbit over 2 twisted wires.
  • classic TCP/IP with changed physical layer.
  • Chipset is cheap and avaliable.

Sound fine , but what is the physical parameters for use in a car?

TPC/IP is pear to peer. There is no big switch in the middel of a car.

Every device has to have minimum 2 ports and a kind of switch. (chaining)

With this it can pick the interesting informations out of the stream and route the remaining.

 

Build test equipment

We got the order to build a tester with 6 simultaus devices running in climate-chamber.

They need to hold in sleep and life state, measure parameters and communicate to get errors and function tests.

BroadR-Reach can be done by media converter.

Fine so far, just one PC, one switch and 6 media converter…. we offered.

During setup we found:

  • All devices have the same fixed IP adress and same MAC-adress.
  • NO router in the world will handle this (or get real expensive)
  • The device sends everthing with TTL=1 -> no one route this
  • It uses for network keep alive multicast and for camera data broadcast.
  • Data content was like CAN over TPC

How we got this done:

We took 12 Raspberry PI on boards with UPS in one row. Add additional NIC to them.

Write some services in python for moving and nating  data between the networks.

With this the PC see everything in a normal network. The PC see every device now in it´s own range.

 

Finally, everything was fine. But we learned again that automotive may be special.

 

 

 

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