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PCB Design Updates. A total of 10 hours, but let's take 5 for this second iteration, since we are only making one more node, and reserve the other 5 for a future iteration.
Component layout design for enclosure.
PCB layout, preparing outlines from the enclosure.
Worked on PCB connector planning, did MCU pin configuration design.
Schematics design, adding compatibility for testbench.
Worked on schematics, setup analog sensor interface.
Schematic design (Setup microcontoller, 1-wire interface and power circuits).
Debugging vibrations sensor.
Design optimization for the nodes, preparing cost estimates.
Worked on load cell amplifier circuit.
Added improvements to the scrips, on increased precision for timed transmissions.
Prepared DAQ scripts for load cell tests.
Prepared a script for automated data exports, created a cron job for it. Got a circuity design for fluid level sensor amplification. Applied new changes for django server.
Setup XBee modules for accommodating second node.
Worked with Pov digging deeper into the difference between Transparent and API mode.
Successfully tested communication using Arduino and laptop to form a mesh.
Prepared the firmware for Node2, helped Jim with setting up XBees. Worked on testing! Added few changes to the raspberry scrip to filter the nodes, for freeboard setup.
Working on solution for the human date timestamps on redshift's data.
Updated arduino code to fix leakage value bug.
Worked on a design for Fluid level sensors to receive higher precision readings.
improved arduino code (leakage flow rate sensor - added conditions for low leakage rate cases)
Made improvements on leakage (cc per second) readings.
Prepared Arduino code for tests (added capturing of internal VCC).
Continued working on optimizing software filtering for all analog sensors.
Add smoothing to the position sensors. Optimized software filtering for all analog sensors.
Worked in improvements for the system. Optimizing sensors. Calibrating current sensor ( changes had to be done in the library).
Improving integration of CT (Current transformer). Investigated load cells, re-calibrated water level sensor.
Debugging the Node as IR sensors clock is not synchronizing.
Tested out current sensor.
Prepared the sketch for it.
Did some calibrations.
Introduced checksum validation for IR sensor.
updated _firmware3, removed unnecessary string conversions, fixed variable types.
Set up SNS service on AWS to send SMS alerts.
Did improvements on water level sensor, re-calibrated.
Cleaned the solenoid water valve, as it wouldn't close properly and leak the water when it should be closed.
Pushed changes to the github.
Found and fixed bugs on fluid level sensor code. Updated it's smoothing code.
Re-calibrated the water level sensor to 5V ref, as before it was 3.3V.
Added smoothing function for the load film sensor.
Added comments to the code.
Pushed updated firmware to the github "_firmware3"
_updating new firmware, adding code for film sensor.
Debugging the temperature sensors with Pov, for the new board V3.
We eliminated hardware issues, problem is in the code.
This is part of testing the new board.
Writing the C code (on the node’s side) to receive a packet from the PC. Process the packet to identify the sender. Retransmit the packet to another node
As there was several problems with sending the commands through Python, I implemented a simple C code to speed up the experimentation and avoid being blocked for a long time with problems not related to node connectivity
Implementing the Python code for the sending and receiving functions
I used 2 UART ports in the MEGA 2560, the first is used to communicate with the PC, and a second is used to communicate with the Xbee module. This configuration helps to use the serial monitor simultaneously with the Xbee module
Adding new components to schematic.
Re-routing copper traces to accommodate new parts.
Exporting file and preparing in photoshop for toner transfer.
Log time spent on documentation.
Documenting and adding minor adjustments to the PCB.
Reviewing BOM, PCB 3D model export for Patrice.
Continued to work on BOM and creating missing footprints.
Verifying and updating BOM.
Started populating PCB's documentation Task #845 fsonet hardware prototype v0.1.
Worked on selecting electronic components, worked on estimating the PCB size for enclosure.
Worked on organizing design plan and BOM.
Updated documentation for raspberry pi setup. Drafted an email about PCB features.
Setup tools and software for hardware design work.
Worked on IoT plan.
Worked on IoT plan presentation.
Documented Raspberry Pi setup. Issue 517
Researched about Xbee security. Documented XBee setup instructions.
Finished up and transfered to the Redmine cost estimates. Issue 511.
Documented tools used for load film tests (issue 503), updates on current transformer (issue 445)
Migrated documents from Sensorica docs to Redmine. (including work Humberto did with drawing graphs). Created repos for bit bucket, to upload load cell testing sketches.
Did the inventory check.
Helped Humberto with the flowcharts.
Prepped a guide on how to connect RazorSQL to Redshift DB. Added step about connecting via terminal.
Continued to document about the Freeboard setup. Setup users for Lotfi and Patrice on redshift.
Continued documenting the freeboard setup, configuration changes.
For node's monitoring, we set up the freeboard. Documented the processes of setting it up (Server hadening, securing SSH, apache2, and freeboard installation).
Update Sensor Node docs, with load cell and current sensor additions.
Researched towards current sensor characteristics, updated docs accordingly.
Research & documenting. Prepared the sketches & libraries for arduino. Got a schematic for circuitry.
Worked on Hardening the server, setting up the apache2, freeboard.
Documented IoT to Redshift walk-through on Redmine.
Updating Redmine documentation. Creating New Sensor Node Task including all appropriate documents and contributions.
Documenting the usage of multiple UART ports of the Mega2560
Cleaned up schematic:
Added new sensors.
I entered specs, or design guidelines for sensor nodes PCB, that I believe it is proper for the R&D, data collection and analysis phase. We discussed about it, but we didn't mark it down, and that causes miss-coordination for the design of future iterations.
I finished the BOM for the entire setup. I also created a BOM for the sensor node 2 PCB board that we need to make as a spare.
I had to make a physical inventory of parts that we have, separate those that are going to be used in a box. Those that we need to buy are marked "Onhand = no" in the spreadsheet. I communicated this list of parts to buy to Lai and to Jim.
We are now ready to order the parts that we don't have. Jim is completing the PCB design on Upverter to print a board.
I also coordinated with him on this.
Producing a Bill of Materials. Total is 10 hours, but let take 5 to complete and update for this iteration and reserve other 5 for the next iteration.
Worked on sourcing BOM for hardware design.
Literature review for hardware design.
Literature review for hardware.
Researched about Atmel crypto-chip, looked into on how could we start using their starter kits.
Researched between possible approaches towards IoT cloud and embedded systems integration.
Researched on AWS new features, like AWS IoT GreenGrass and possible edge services.
Did research on IoT security, fog systems.
Research about S3 and Machine learning costs.
Added cost estimates about DynamoDB to the spreadsheet.
AWS cost estimates. Prepared a spreadsheet for IoT component, issued ticket to AWS about IoT ThingShadow billing.
AWS cost estimates.
Researched solutions for data management.
Xbee API framework research/learning.
Researched for libraries and methods to reconfigure Xbees from transparent to API mode.
This is a task for Dave, to finish the design and 3D print a second box.
This needs coordination with the people working on the electronics.
NOTE: we need to integrate wire connectors in the box - ask Tibi, Jim or Scott.
Worked with Patrice to create a thick metal plate support for the sensor, we decided where it will be mounted on the pump, and worked at the SENSORICA lab to mount it and wire it, pack it.
PCB Printing x 10, meaning one hour each.
Task for Jim.
Message for Jim : try to make on PCB in one hour?
Worked with Pov on connectors for the new PCB board, V3. Also updated documentation.
Developed PCB using toner transfer method.
Testing the new node on site.
Firmware (1-wire temp sensors)
Firmware (Analog to digital converter, internal and ADC IC)
Firmware (Xbee and analog to digital converter).
Worked on XBEE communications.
Worked on XBEE communications.
Prepared XBees for development tests. Worked on communication protocols.
(new firmware) Worked on setting up timers, interrupts, call back functions.
Setting up UART for debugging.
Setting up debugging tools. Had a bunch compiler issues. :(
Reviewing and adjusting accordingly the PCB layout.
Light indication and lightpipes.
Creating footprints for KiCad.
Reviewed KiCad design techniques. Setup KiCad project templates.
Listing components and pin connections for PCB design.
Worked on preparing component libraries. Preparing design softwares on a local machine.
Helped Patrice with installing new pipes.
Tried to configure nginx on a new raspi.
Created new Things in IoT component, One for test purposes and another for future client. Updated to the newest software our 3 current gateways. Created services to run software on boot up. Added steps to the documentation.
Set up new raspberry pi for replacement. Updated documentation.
Set up DNS server for freeboard.
Researched for new libraries for communication protocol between arduino and raspberry pi. Continued to work on IoT plan.
Automated dynamoDB data puill, shared cloud folders, finished configuring local machine, review material for the slides.
Worked on setting up local machine, setup environments required for accessing dynamoDB. Help John with reconfiguring PLC's.
Worked on configuring Raspberry pi.
Prepared load cells amplifier board.
Configured Xbees, set up Raspberry pi.
Soldering nodes, 3/3 finished.
Soldering nodes. 1/3 Done.
Debugged Node2 temp sensor, replaced it's amplifier module. Updated firmware for node2. Noted communication issues (need to rewrite transmission protocols to send data as a single string)
Debugging of Node2 temp sensor. Assisted Patrice on his work.
Uploaded last redshift data to the redmine. Run multiple load cell tests on both cells. Formatted and prepared the data files. Connected Current Transformer (CT) on Node2. Run tests on it.
Debugging of CT. Tested CT on the pump's motor, scheduled with Larry to reinstall the node on compressor.
Prepared a PCB board for load cell tests (Soldered components into the prototyping PCB instead of having loose components on the breadboard).
Formatted load cell tests data, discussed new design requirements towards making the load film as a viable option.Debugging of the current transformer on Node2. Troubleshooting xbee signal strength between nodes.
Rebooted raspberry pi as it's scripts crashed since Node2 was active for a while (Asking Jim to fix the app). Load cell tests.
Participated in gland follower design, looked for available components. Installed Node2 at the compressor.
Worked on Node2 to ensure it's fully functional.
Load cell tests.
Gland follower design. Reconfigured xbees to work in a mesh network.
Helped Pat with the sensors holder plate design. Prepared CT wires for installation.
Helped Pat with the sensors holder plate design.
Testing load cells and experimenting with the film material.
Helped on testing the load cells. Helped Jim on debugging raspberry pi scripts. Worked on the node status report.
Helped to prepare new load cells, looked to buy another CT sensor for Node2, prepared a BOM for the circuit. Finished measuring time charts for sensors.
Participated on fixing freeboard, worked on setting up django server, helped Humberto with the graphs, work on separating git repos.
Monitored the pump, based on findings did tests on a position sensor. Looked into solutions to protect the sensors from getting wet.
Run tests on level sensor, seems to be not functioning on the first 5 cm.
Designed amplifier circuit for the fluid level sensor. Run the pump (turn on/shut down procedure). Did research on Django, about configuring database tables.
worked on improving current sensors accuracy. Run tests on the pump. Updated the firmware to fix few bugs.
Started the pump, worked on solutions for improving the sensors and their readings. Exported the data from redshift to redmine. Researched Digital pressure gauges.
Made a copy of the redshift table with an old data, then deleted all data from testbench2. Started the pump. Added a change for the python script which makes a JSON output for the freeboard. Worked on xbee mesh network setup. Worked on preparing redshift data dumps. Draw some conclusions after monitoring the pump.
Soldered CT sensor circuit on the node, run multiple tests.
Started the pump for a test run, worked on assembling new board. Restarted the freeboard.
Installing IR shaft temp sensor.
Testing new IR temp sensor. Preparing IR temp sensor (Re-crimping new wires).
Monitored the system. Noted items that require inspection.
Uploaded new firmware, run various tests to ensure it's functioning well.
Debugging the freeboard.
Debugged few things on freeboard, worked on calibrating the current sensor, fixed various things on the way.
Setup the freeboard.
Soldered an extension to the current sensor cable, crimped the wires and connected them to the plug. Soldered components for the sensor into the board. re-crimped rpm sensor cables. Soldered new 3.3V voltage regulator into the board. Sorted out the cables. Worked on debugging the IR temp sensor.
Debugging the node.. issues with IR temp, fluid level, position sensors wirings.
Working towards current sensors development. Found misleading info in the current sensor user guide, had to edit to shopping cart accordingly.
Double checked the components we have to confirm order list for Lai,
Edited AWS SMS subscription, on John's request.
Soldering resistors for the Film sensor circuit.
Desoldered voltage Ref circuitry as it was meant for load washers.
Connected all the sensors and left the board to be running.
Updated daily doc.
SSH to raspberrypi to run the scrip.
few updates for the load film code.
Worked on Updating Redmine.
Installing the new node.
Tested a node with all sensors together (works).
Pre-crimpped a plug for film sensors.
Soldered wires for film sensors. Wire color codes and pins are updated in the docs.
Finished up on new restructured firmware, did tests on last untested sensors (temperature).
Fixed one MOLEX connector for the Displacement sensor that was broken. I also tried different crimping techniques. Was there with Pov.
Worked with Pov on the new board at the sponsor location. Discussions about some bugs, some indications about testing the board, not to forget the ref pin on the Arduino. made one connector and did some documentation, mostly from the main doc for the board
and I also updated the main hardware working doc
Sensor wiring, assisted Patrice in mounting the vibration sensor, and discussed about the mounting of displacement sensors. Also soldered the last pins on the node between the vibration sensor and the Arduino nano.
At the sponsor's location with Scott. Measures again and selected resistors, Soldered them on the board, completing the board.
Soldered electronic pieces to the new PCB board. Only resistors need to be added, which is a simple task, and a digital level shifter piece that is at the sponsor location.
Board almost ready.
Online or physical shopping activities.
Prepared shopping cart for PCB components, etc.
Prepared a shopping list for development tools.
Worked on finding appropriate cable assemblies for the gland follower.
Made addition to the shopping list, prepared shopping carts.
Updates to new BOM. Deleted Redshift Cluster.
Preparing a shopping list for additional nodes. Double check available components and sensors.
Prepared a shopping list to:
resupply components for making another node,
re-order correct components as few were wrong,
get additional plug connectors and pins, new components for the load washers and current sensors.
Went to Abra to buy parts for building the replacement sensor node.
Used my car.
After that I went to the sponsor's location for a scrum meeting.
Went to the lab to get soldering equipment. Brought a box of small tools, the new hot air soldering equipment and a microscope and lights. Brought it back to the sponsor location.
Start by making another node, integrating all the solutions to the bugs we found with the first one.
The production of one more sensor node PCB