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General Category => Pimp My System => Topic started by: Henielma on October 06, 2014, 07:28:34 PM

Title: My automated brew system
Post by: Henielma on October 06, 2014, 07:28:34 PM
I brew like a simple pot on a stove. Because I think it is important to brew in a reproducible way I use automation to achieve this. Actually I use a predecessor of Tcontrol to control all the mash steps temperatures and timings. All the brewing is done without a pump. The inside of the kettle is RVS the outside is iron.

(https://lh4.googleusercontent.com/-kiDCOpk2588/T031svvkcRI/AAAAAAAAB5c/bz3OWaTbKuE/s400/2012-02-29%252010.20.25.jpg)

Mash tun with stirring motor on top and direct heater which is controlled by a proportional valve from a central gas heater. A handmade PCB with some I2C components is the interface to the parallel port of the brewing PC.
The stirrer used in the kettle is driven by 24 Vdc which is speed controlled by the PC depending on the heating in the last minutes.

(https://lh5.googleusercontent.com/-si6WMJ6JEGo/VDLl014swaI/AAAAAAAAAb8/5qzmrMZM7Fw/w649-h865-no/20141006_205542.jpg)

On the brewing PC I fill in the mash scheme for this beer.

(https://lh6.googleusercontent.com/-rEr_AQ9aN14/T032e2nJCTI/AAAAAAAAB58/SFxhFGwDs28/s400/2012-02-29%252010.20.05.jpg)

The home made brewing program is called BeerPID. The program BeerPID is not a PID controller anymore but uses a feedback an feed forward analog algorithm. Digital temperature sensors measure the temperature of the wort.

(https://lh4.googleusercontent.com/-ear9zH4znk0/T032Yi8M3II/AAAAAAAAB50/50kYUEiPYhk/s400/2012-02-29%252010.21.45.jpg)
This photo shows the bottom side of the mash tun during heating. Also the wiring of the electrical ignition and the flame monitoring sensor can be seen.

After mashing the mash tum is hoisted on the counter with a electrical cable hoist.
(https://lh6.googleusercontent.com/-bKBMDFNlRLM/T1kjnMGUA0I/AAAAAAAAB64/H8nQLDEBpa0/s400/2012-02-29%252011.51.20.jpg)

The heating of the sparge water is automatically started after the mashing and regulated to 82 degrees Celsius during the sparge.
(https://lh6.googleusercontent.com/-_TkhP7db4wc/U_uVnr0EJ9I/AAAAAAAAChQ/28ykOFUPZJ4/w1153-h865-no/2014-08-25%2B21.54.41.jpg)
The sparge water bucket is about 25 liter. It contains a chip fryer heating element mounted 4 cm above the bottem into the water.

After filtering and sparging the boiling starts.
(https://lh4.googleusercontent.com/-Oy-Za-hCnZw/T1kkE74rY9I/AAAAAAAAB7Y/-qZLPXWem9s/s400/2012-02-29%252013.39.20.jpg)
The software detects the start of the boiling so the first hop can be added. A timer on the screen is used to give alarm when next hop or sugar should be added.
Title: Re: My automated brew system
Post by: denny on October 06, 2014, 07:32:24 PM
Wow, that's the most unusual system I've ever seen!  Polar opposite from the way I brew.  Kudos on your creativity!
Title: Re: My automated brew system
Post by: narcout on October 06, 2014, 11:03:09 PM
Cool website.  The inflatable ballon CO2 production sensor is something I have never seen before. 
Title: Re: My automated brew system
Post by: pete b on October 07, 2014, 12:51:49 AM
Cool! I feel like I'm at a 1957 World's Fair demonstration of what brewing would be like in the year 2000. But seriously, I'm impressed.
Title: Re: My automated brew system
Post by: tommymorris on October 07, 2014, 01:10:01 AM

I brew like a simple pot on a stove. Because I think it is important to brew in a reproducible way I use automation to achieve this. Actually I use a predecessor of Tcontrol to control all the mash steps temperatures and timings. All the brewing is done without a pump. The inside of the kettle is RVS the outside is iron.

(https://lh4.googleusercontent.com/-kiDCOpk2588/T031svvkcRI/AAAAAAAAB5c/bz3OWaTbKuE/s400/2012-02-29%252010.20.25.jpg)

Mash tun with stirring motor on top and direct heater which is controlled by a proportional valve from a central gas heater. A handmade PCB with some I2C components is the interface to the parallel port of the brewing PC.
The stirrer used in the kettle is driven by 24 Vdc which is speed controlled by the PC depending on the heating in the last minutes.

(https://lh5.googleusercontent.com/-si6WMJ6JEGo/VDLl014swaI/AAAAAAAAAb8/5qzmrMZM7Fw/w649-h865-no/20141006_205542.jpg)

On the brewing PC I fill in the mash scheme for this beer.

(https://lh6.googleusercontent.com/-rEr_AQ9aN14/T032e2nJCTI/AAAAAAAAB58/SFxhFGwDs28/s400/2012-02-29%252010.20.05.jpg)

The home made brewing program is called BeerPID. The program BeerPID is not a PID controller anymore but uses a feedback an feed forward analog algorithm. Digital temperature sensors measure the temperature of the wort.

(https://lh4.googleusercontent.com/-ear9zH4znk0/T032Yi8M3II/AAAAAAAAB50/50kYUEiPYhk/s400/2012-02-29%252010.21.45.jpg)
This photo shows the bottom side of the mash tun during heating. Also the wiring of the electrical ignition and the flame monitoring sensor can be seen.

After mashing the mash tum is hoisted on the counter with a electrical cable hoist.
(https://lh6.googleusercontent.com/-bKBMDFNlRLM/T1kjnMGUA0I/AAAAAAAAB64/H8nQLDEBpa0/s400/2012-02-29%252011.51.20.jpg)

The heating of the sparge water is automatically started after the mashing and regulated to 82 degrees Celsius during the sparge.
(https://lh6.googleusercontent.com/-_TkhP7db4wc/U_uVnr0EJ9I/AAAAAAAAChQ/28ykOFUPZJ4/w1153-h865-no/2014-08-25%2B21.54.41.jpg)
The sparge water bucket is about 25 liter. It contains a chip fryer heating element mounted 4 cm above the bottem into the water.

After filtering and sparging the boiling starts.
(https://lh4.googleusercontent.com/-Oy-Za-hCnZw/T1kkE74rY9I/AAAAAAAAB7Y/-qZLPXWem9s/s400/2012-02-29%252013.39.20.jpg)
The software detects the start of the boiling so the first hop can be added. A timer on the screen is used to give alarm when next hop or sugar should be added.
PID, I2C, PCB, Vdc, digital, analog, feedback, feed forward; I am guessing you are an electrical engineer!
Title: Re: My automated brew system
Post by: BrewBama on October 07, 2014, 01:27:40 AM
Wow. Cool.

Polar opposite of my brew rig as well. I am in Denny's Cheap and Easy camp.
Title: Re: My automated brew system
Post by: Henielma on October 07, 2014, 05:34:53 AM
All thanks for the enthusiastic reactions.

PID, I2C, PCB, Vdc, digital, analog, feedback, feed forward; I am guessing you are an electrical engineer!
[/quote]

Good guess, Electronic Architect do they call it.

Cool website.  The inflatable ballon CO2 production sensor is something I have never seen before. 

Thanks and this CO2 production sensor works fine for already a few years.
Title: Re: My automated brew system
Post by: yso191 on October 07, 2014, 06:13:51 AM
Wow.  I thought I wanted to see it in person until I saw where you lived.  Seriously cool.
Title: Re: My automated brew system
Post by: ibru on October 07, 2014, 04:01:29 PM
Very nice. I'm looking at going electric myself.

Steve, don't let a little water stop you....

Bruce
Title: Re: My automated brew system
Post by: Henielma on October 07, 2014, 05:32:39 PM
Wow.  I thought I wanted to see it in person until I saw where you lived.  Seriously cool.

Good to hear the reactions. To see it live in person is probably difficult due to the distance. But looking this video from a few years ago gives a good impression how I brew.
https://www.youtube.com/watch?v=7T6Whz4tzjw (https://www.youtube.com/watch?v=7T6Whz4tzjw)

Also my home brew site (https://sites.google.com/site/henielma/home) gives more information.

Tomorrow I'am going to brew an American Pale Ale. If there is interest I will make a topic about the fermentation of this beer. Including the fermentation result in time measured by the CO2 production sensor.
Title: Re: My automated brew system
Post by: HoosierBrew on October 07, 2014, 05:58:52 PM

If there is interest I will make a topic about the fermentation of this beer. Including the fermentation result in time measured by the CO2 production sensor.


Yeah, I would definitely like to see that. What strain did you plan to use ?
Title: Re: My automated brew system
Post by: Henielma on October 07, 2014, 06:02:55 PM
The US-05 is the yeast for tomorrow.
Title: Re: My automated brew system
Post by: narvin on October 08, 2014, 03:45:48 AM
This is great.  I especially like the bucket heater for sparge water.  Do you have any wiring diagrams?
Title: Re: My automated brew system
Post by: Henielma on October 08, 2014, 06:30:11 AM
The mash water bucket does not have a special wiring diagram. This is the normal wiring of a chips fryer.

(https://lh6.googleusercontent.com/KGHGNYAQ2-oZPXkXoGUvNPH7ooBrEHD2MtmzZyZMJQs=w259-h194-p-no)

The interface board to the PC is hand soldered.
(https://lh5.googleusercontent.com/-G8jR_05-qGE/VDTWJ0ENo2I/AAAAAAAAClw/-5IsZCsqr1M/w1153-h865-no/Interfaceprint.jpg)

A pdf of the schematic (https://sites.google.com/site/henielma/brewing-day/IO-interface%20Beer%20PID.pdf?attredirects=0&d=1) is added to my site at the end of the page brewing day.
(https://lh6.googleusercontent.com/-KSUAt4zxoUM/VDTZnub319I/AAAAAAAACmI/WWlkjVYpXRM/w1124-h865-no/Schema.jpg)

a screenshot of the LabVIEW application BeerPID.
(https://lh5.googleusercontent.com/-v2GQbTjRUjc/VDTYnnmYkrI/AAAAAAAACl8/DTKK6O9lfIU/w1153-h865-no/Screenshot%2Bmet%2Bspoelwaterton.jpg)
Title: Re: My automated brew system
Post by: S. cerevisiae on October 09, 2014, 04:03:09 AM
Let me see if I have your PC interface schematic figured out correctly.  It looks you are bit-banging data bits out on pin 6, generating the I2C clock signal on pin 5, and bit-banging data bits in on pin 13 (bits are inverted from what appears at the base of T1).  You have pins 10, 11, and 12 gated out such that they source current and serve as VCC for pin 8 with R4 acting as the collector load resistor on OK2.  Pin 25 is signal ground.  The optocouplers isolate the board power supply from the PC power supply.  Am I close?

Title: Re: My automated brew system
Post by: Henielma on October 09, 2014, 05:26:40 PM
You are completely right! That is the trick. My LabVIEW application does the bitbanging.

Only disadvantage nowadays is that it becomes more difficult to find a PC with a parallel port. Nowadays is a USB port more logical to use.

Title: Re: My automated brew system
Post by: S. cerevisiae on October 09, 2014, 06:56:08 PM
Yes, the IEEE 1284 parallel port is a dead-end street when it comes to embedded system interfacing today. 
Title: Re: My automated brew system
Post by: redbeerman on October 23, 2014, 05:24:51 PM
And Windows is not so good when you have real time interrupts that need to be dealt with.  It usually prioritizes it's own first, like updates and other outside world stuff.  For good process control a RTOS is almost essential.  But you guys know this already.  A lot depends on how much you have going on, just controlling temperature or handling functions that occur over minutes as opposed to milliseconds it may work OK.  I've seen it go both ways depending on the application. Cool system.  I'm a little hesitant about putting heaters in plastic buckets.  A single fault and you may have a fire if there is not water there.
Title: Re: My automated brew system
Post by: Henielma on October 24, 2014, 10:50:23 PM
The cycle time for my Labview applications is 1 second so it is not very hard real-time. But you have a point for more time critical processes.

The heater in the plastic bucket is no problem when there is at least 4 liters of water in it. With less then 5 liters of water in the bucket I disconnect the power to the element. And also the chips fryer element has still two protections against overheating. The first is the original thermostat which I set to 90 degrees C and the second protection is the original overheating protection of the chips fryer. Both are in series with the PC temperature control and switch off if over temperature is reached.