Author Topic: SmartPID - smart temperature&process controller  (Read 3603 times)

Offline arzaman

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SmartPID - smart temperature&process controller
« on: October 07, 2016, 02:40:33 PM »


Dear Homebrewing friends i start this thread  in order to introduce SmartPID most andanced temperature and porcess controller for consumer market. In few words SmartPID Controller is a professionally engineered Hi-tech product for temperature and process control having lots of functions and features, which are not present in other or normal 'Thermostats'

Before entering technical details few words about the “philosophy” and idea behind the project

When I start designing the SmatPID I try to capture some requirements and  functionalities that are actually not present in low cost thermostat like STC1000 and are more typical in the professional control device (PLC) but at the same time I put lot of effort to keep it simple, accessible, affordable for a consumer market and DIY enthusiast

apart form the core temperature control features (PID/PWM etc..) indeed very advanced and powerful  the main innovation I have introduced that make SmartPID unique are

Full process automation


Thanks to the power of the platform it's possible to develop custom application that needs process control with complex service logic and manage a complete workflow.
Basic thermostat just simply ready temperature and control a relay according to set point..In smartPID you can program steps, ramps, triggers, alarms and manage complex temperature profile over the time. 
Typical example is food processing like beer brewing, cheese making or food drying where according  to specific recipe parameters the heating process should be managed step by step controlling and orchestrating different elements (heater, pump, fan..)

Data logging and export (USB & wifi)

The possibility to log all process data and analyse real time or off line is another typical feature that is available only on professional devices or with external data logger.
SmartPID has an internal 8Mbit EEPROM where all the process data (temperature, set point, PWM power, control direction etc,,) are logged and can be accessed either locally via USB and a desktop application (CSV export) or remotely pushed via wifi connection to a cloud server.

WiFi connectivity for remote management and IoT cloud integration

Wifi connectivity and cloud integration is what make SmartPID really smart !
Small wifi optional module is integrated in the SmarPID box and once connected to the wifi access the device can provide lot of new feature
remote management → configuration and control of setup parameter and process parameter from any location via web or smartphone
data logg→ real time monitoring of main process parameter and storage in the cloud server
for the development and design phase the thingspeak cloud service has been used , a private cloud server will be deployed after project founding

DIN Box

Another key driver for the design was the “box size” and we decide to use a standard DIN box in order to make SmartpID ultra compact and backward compatible with STC1000 like thermostat, you can just unplug your current controller and plug SmartPID to get the new full set of features
Engineering all the HW to support the new features has been very challenging but the result is a very powerful platform with powerful CPU, lot of memory and I/O capabilities that is the base line for developing powerful applications

Arduino Compatibility

Last but not least important driver was to keep as much as possible the platform open and easy programmable so the natural choice was to do development under Arduino umbrella. The component selection like the MCU (SAMD21 arduino Zero and MKR1000 IoT new board) and the architure are fully arduino compatible. I have developed a custom bootloader and specific board definition that can be imported in the Arduino IDE so you can just connect SmartPID via USB port to your PC and develop you sketch using the arduino tool-chain and all the supported libraries.

Let’s now have an overview to HW and core features

HW configuration



-SAMD21 processor ARM cortex M0+
-8Mbit EEPROM for data log, recipe storage etc..
-1.3” OLED graphical display
-USB front port for programming, SW upgrade, data logging
-4 tactile switch to navigate trough menu
-1x Buzzer
-Jtag/SWD port
-WIFI module (detachable)
-110/220 V AC power supply
-2x temp probe input (DS18B20 or NTC)
-2x 220v AC 10A Relay output
-1x SSR output
-2x 12V 1A direct drive output

The core control functions are




-DUAL Independent control channel
-Multi control mode (heating , cooling or thermostatic)
-Dual control algorithm (PID or ON/OFF)

Is this little box powerful, flexible, smart enough for your applications ?

Next posts try to go in detail of major functions and remote management part
Any feedback is appreciated !

Arzaman
http://smartpid.com
https://www.facebook.com/smartPID

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #1 on: October 07, 2016, 02:43:56 PM »
I have prepared a feature comparison table between SmartPID and most common used thermostat to provide you an idea of the range of applications you can run on smartPID

As you can easily see...there's no match :)

When I complete the table I realize that comparing a fully programmable device with process automation capabilities and smart features like wifi and IoT capabilities with a thermostat maybe is not the right approach but at least once more you have the full feature list of the BASIC application !



arzaman
http://smartpid.com
https://www.facebook.com/smartPID

Offline Stevie

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SmartPID - smart temperature&process controller
« Reply #2 on: October 07, 2016, 03:33:53 PM »
Looks like your pre-production but it could be exciting.

Why did you opt for a single 12v SSR out? Considering your have multiple probes and the ability to control relays independently, it would be nice to control two SSRs for dual kettle control (mash and hlt or kettle).

I do like that it has the other outs allowing for pumps and fans to be controlled by the same unit.

Good luck

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #3 on: October 07, 2016, 03:42:29 PM »
Looks like your pre-production but it could be exciting.

yes project is in an advanced stage ! just reviewing HW for manufacturing
from aplicaiton point of view the basic one (smart themostat) is completed
the brewing app with all mashing/boiling/whirpool/cooling automation and recipe mangement is under test now

register web site news letter and FB page to get information and early bird discount

Quote
Why did you opt for a single 12v SSR out? Considering your have multiple probes and the ability to control relays independently, it would be nice to control two SSRs for dual kettle control (mash and hlt or kettle).

I do like that it has the other outs allowing for pumps and fans to be controlled by the same unit.

Good luck

output configuraiton is totally flexible you can control up to 2 SSR using the 12V outputs
2 out of 3 output can be also used to drive a direct load up to 1A (pump or valve)

the brewing application mange exactly your configuration: Mash Tun + HLT either electric or gas fired

have a look to this connection schema as example



more clear now ??


arzaman
http://smartpid.com
https://www.facebook.com/smartPID

Offline Stevie

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Re: SmartPID - smart temperature&process controller
« Reply #4 on: October 07, 2016, 03:54:59 PM »
Gotcha, but only one is capable of PWM?

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #5 on: October 07, 2016, 04:11:10 PM »

All the otput except the mechanical relay can be configured as PWM !
 
Consider that outputs can be assigned to process channels idipenently..total flexibilty to mange any process !

here screenshot of heating 1 channel resource assignement


Offline Stevie

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Re: SmartPID - smart temperature&process controller
« Reply #6 on: October 07, 2016, 05:27:03 PM »
So dc1 and dc2 can handle PWM on an SSR as welll? Very cool.

Do you plan on allowing more adjustments in the phone/web based app? Can one adjust the power out of an element along with the temp? Can one switch an element from PID temp control with PWM to pure on PWM?

So far it sounds like something I'd be interested in, but I'm not interested in vaporware filled with never realized promises *cough* brewpi spark *cough*

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #7 on: October 07, 2016, 09:24:14 PM »
So dc1 and dc2 can handle PWM on an SSR as welll? Very cool.

exactly..I say again ..total felxibility


Quote
Do you plan on allowing more adjustments in the phone/web based app? Can one adjust the power out of an element along with the temp? Can one switch an element from PID temp control with PWM to pure on PWM?

read carefully features description on web site and blog article as well post of FB pages..and you discover that SmartPID is really smart...wifi connection both for process data logging and remote configuration either via web or dedicated app..some snapshot below






Quote
So far it sounds like something I'd be interested in, but I'm not interested in vaporware filled with never realized promises *cough* brewpi spark *cough*

it has been designed to be productized ...lot of effort in professional engieering to provide a fully functional product off the shelf

staty tuned
arzaman
http://smartpid.com
https://www.facebook.com/smartPID

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #8 on: October 07, 2016, 09:50:06 PM »


Happy to announce after 2 weeks from SmartPID launching  that the second application on top of the SmartPID platform is nearly ready and is completely dedicated to home brewing process automation

What is new and different compared to the standard basic application (smart thermostat)? 
Substantially Smart Home Brewing App adds to a standard temperature control features all the process automation and workflow to manage all typical steps for beer making. We have customized vertically the SW for the specific application leveraging all the basic features available on the platform
Each vertical application has off course it’s own set of data, process parameter and configuration and so is the smart home brewing app that execute all process steps according to in memory “recipe”and controls HW resources (heating elements, pump/stirrer, buzzer ) in automatic way

These are main characteristic of the smart HB application

    -Single vessel (BIAB/RIMS) or two vessel (MASH + HLT) process management
    -Electric heating (PID/PWM) or Gas Fired heating (ON/OFF)
    -Recirculating pump or motorized mixer management
    -NTC/DSB18B20 temperature probe
    -Internal or external (in recirculating circuit) temp probe position
    -Step Mash management (mash in/out and 6 step mash)
    -Boil management with overboil and power control (electric only)
    -Hop addition alarms
    -Whirlpool management (hot or cold)
    -Cooling management
    -Full recipe management (new / edit /clone /delete)
    -Mash profile
    -Boil duration and hop addition time
    -10 possible recipe in memory
    -Delay start for brew day programming

Off course the brewing application benefit of all common features

    -Log of all process data locally in the EEPROM
    -Push of process data via wifi to thingspeak server
    -Download of process data via USB (CSV format)
    -Web visualization of process data
    -SamrtPID dedicated smartphone app for data visualization (android only)

If this is not enough the development roadmap foresse other uniques functions in particular the possibility to define the process parameter and recipe via web or smartphone interface and upload via wifi to the controller.
Even if it’s very easy to configure smartPID via local menu the possibility to have a web user area with all parameters and recipe as well all the log data of previous brew day we believe is a real plus. In order to simplify the recipe process from definition to run mode also import of mash and boil profile from major SW like Beersmith is in feasibility stage

In next posts we try to show a real case of set up and cabling  for BIAB equipments and a video with complete overview of the functions trough the EMULATOR

arzaman
http://smartpid.com
https://www.facebook.com/smartPID

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #9 on: October 10, 2016, 11:43:42 PM »
Video tutorial of smartpid brewing app..around 12min of explanation of process parameter and recipe management and 12min of complete brew day simulation ..enjoy and subscribe youtube channel !


https://youtu.be/KeQfYbRECTw


arzaman
http://smartpid.com
https://www.facebook.com/smartPID/

Offline R Horn

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Re: SmartPID - smart temperature&process controller
« Reply #10 on: October 12, 2016, 10:19:33 PM »
Cool Stuff

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #11 on: October 16, 2016, 08:19:27 AM »
Live test of SmartPID controller applied to a profi cook pot transformed into a single vessel BIAB system with full process automation and smart feature

https://youtu.be/jl4B4WM893Y

arzaman
http://smartpid.com
https://www.facebook.com/smartPID

Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #12 on: October 23, 2016, 08:13:16 AM »
During this month after launching we have collected lot of feedback and also questions either technical and commercial.
We have collected in the FAQ section on the web site, have a look for any doubt on the project !

http://smartpid.com/faq/

arzaman


Offline arzaman

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Re: SmartPID - smart temperature&process controller
« Reply #13 on: November 03, 2016, 07:45:55 PM »
SmartPID is not a simple controller or thermostat, is more an “open platform” powerful and flexible where the resources and I/O can be used for different applications, different environments and integration. My idea is to develop an ecosystem of “vertical” applications on top of a common set of features

the first two applications developed for homebrewer  are

smart thermostat (or basic application) that is the base line for any thermal regulated process . Can be used and adapted where it's need a PID control or  perform a retrofit o simple thermostat with something more advanced. Typical example is fermentation chamber

Smart homebrewing app that is focused on all brewing process automation from mashing to boiling from hop addition to whirlpool and cooling including recipe management



anything you would like to see on top of SmartPID??

Offline Stevie

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Re: SmartPID - smart temperature&process controller
« Reply #14 on: November 03, 2016, 08:07:32 PM »
I don't care for recipe management as much as I would like to have simple rest/ramp control. I would also like the ability to set a kettle to heat to a few degrees below boil allowing me to not need to watch it as closely.