ABB UCF SENIOR DESIGN PROJECT Switchgear System Control Interface GROUP 14 MEMBERS Christopher Miller – CpE Huy Tran – EE Michael Dean – CpE PROJECT SPONSER ABB Ltd. PROJECT CUSTOMER ABB Ltd. PROJECT MENTOR AND ABB LTD. CONTACT Michael B. Christian Product Manager of Medium Voltage Indoor Products ABB Ltd. TABLE OF CONTENTS ABB UCF Senior Design Project ........................................................................... i Group 14 Members ............................................................................................ i Project Sponser ................................................................................................. i Project Customer ............................................................................................... i Project Mentor and ABB Ltd. Contact ................................................................ i Executive Summary .............................................................................................. 1 Project Description ............................................................................................... 2 Project Motiviation ............................................................................................. 2 Product Features and Goals ............................................................................. 2 Basic Controller ............................................................................................. 2 Advanced Controller ...................................................................................... 3 Requirement Specifications .................................................................................. 4 Basic Controller ................................................................................................. 4 Basic Controller Requirement Specifications Description .............................. 4 Advanced Controller ......................................................................................... 5 Both Controllers ................................................................................................ 6 Known Standards .............................................................................................. 6 Market-Engineering Trade Off Matrices ............................................................ 7 Advanced Controller ...................................................................................... 7 Block Diagrams ................................................................................................. 8 Hardware Block Diagram............................................................................... 8 Software Block Diagram ................................................................................ 9 System Design Diagram .............................................................................. 10 Orders of Operation ........................................................................................ 11 Interaction Between Basic Controller the ABB IRS ..................................... 11 Interaction Between Advanced Controller - Control Board and Motorized Track ........................................................................................................... 11 Estimated Project Budget................................................................................ 12 Logic Design ....................................................................................................... 12 Idea Behind Logic Circuit............................................................................. 12 Switchgear Emulator ................................................................................... 14 Project Hardware Design Detail .......................................................................... 38 Printed Circuit Board Design Software ............................................................ 38 ii NI Ultiboard ................................................................................................. 39 DesignSpark PCB ....................................................................................... 39 Eagle ........................................................................................................... 39 KiCad........................................................................................................... 40 Express PCB ............................................................................................... 41 PCB Design Software Selection and Conclusion ........................................ 41 PCB Fabricators Comparisons ........................................................................ 42 PCB-Pool ..................................................................................................... 42 OSH Park .................................................................................................... 43 Express PCB ............................................................................................... 44 4PCB ........................................................................................................... 44 PCB Fabricators Selection and Conclusion ................................................. 44 PCB Composition ............................................................................................ 46 PCB Design Considerations............................................................................ 46 Soldering ......................................................................................................... 49 Through-hole Soldering ............................................................................... 50 Surface Mounting Soldering onto a Printed Circuit Board ........................... 50 Ladder Logic ................................................................................................... 51 Emergency Stop Button .............................................................................. 55 Introduction to The Operation and Positions ................................................... 56 Hardware Schematic ....................................................................................... 57 Pulse Generator for Blinking LED and Flip Flop in the PCB Board ................. 62 NE555 ......................................................................................................... 64 LM555 ......................................................................................................... 64 TLC555........................................................................................................ 65 LMC555 ....................................................................................................... 65 Voltage Step Down ......................................................................................... 66 Buck Converter ............................................................................................ 66 Microcontroller ................................................................................................ 69 MSP430....................................................................................................... 69 Arduino Microcontroller (Arduino Uno, Atmega328p) .................................. 69 Raspberry Pi (Broadcom 2835) ................................................................... 70 Conclusion ................................................................................................... 70 Programing Arduino Uno To Blink LED ....................................................... 70 iii Current Sensing Switch .................................................................................. 70 Cat 5 Ethernet Cable ...................................................................................... 73 Project Software Design ..................................................................................... 75 Idea Behind Software Architecture Design ..................................................... 75 Software Design 1 – Web Server Architecture ................................................ 76 Overview ..................................................................................................... 76 Local Server ................................................................................................ 78 Maintenance and Administration ................................................................. 78 Advanced Controller Hardware Platform ..................................................... 78 Web Server Architecture User Interaction Flowchart ................................... 79 Logging and Diagnostics ............................................................................. 80 Communication Protocol ............................................................................. 80 Safety Features ........................................................................................... 86 Software Design 2 – Standalone Command Application ................................. 87 Overview ..................................................................................................... 87 Deployment ................................................................................................. 89 Advanced Controller Hardware Platform ..................................................... 90 Standalone Command Application User Interaction Flowchart.................... 91 Command Application Implementation ........................................................ 91 Logging.......................................................................................................