![university of texas at san antonioFinal ReportAutomated Volume Detection & Fluid Dispensing SystemSubmitted By:Team #2Brendan BakerFrederick WeissbachSean TovarSubmitted To:With public beverage service in mind, the engineers from Team 2 have designed a device aimed at automating the industry.Prof. August AlloUniversity of Texas at San Antonio1 UTSA Circle DriveSan Antonio, TX 782497 April, 2010<br />Table of Contents TOC quot;
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Table of Contents PAGEREF _Toc258403099 2Table of Figures PAGEREF _Toc258403100 41.0Executive Summary PAGEREF _Toc258403101 52.0Introduction PAGEREF _Toc258403102 62.1Gant Chart PAGEREF _Toc258403103 73.0Need for Design PAGEREF _Toc258403104 74.0Literature and Patent Search Results PAGEREF _Toc258403105 85.0Marketing Analysis and Marketing Strategy PAGEREF _Toc258403106 86.0Engineering Design Constraints PAGEREF _Toc258403107 86.1Global Design Constraints: PAGEREF _Toc258403108 96.2Local Design Constraints: PAGEREF _Toc258403109 97.0User Requirements PAGEREF _Toc258403110 107.1User Requirements PAGEREF _Toc258403111 107.2System Requirements PAGEREF _Toc258403112 117.3Interface Requirements PAGEREF _Toc258403113 128.0Engineering Codes and Standards PAGEREF _Toc258403114 129.0Design Concepts PAGEREF _Toc258403115 1310.0Product Specifications PAGEREF _Toc258403116 1511.0Operational Scenarios PAGEREF _Toc258403117 1512.0High Level Block Diagram PAGEREF _Toc258403118 1612.1Volume Detection PAGEREF _Toc258403119 1612.2Fluid Dispensing PAGEREF _Toc258403120 1713.0Major Components PAGEREF _Toc258403121 1713.1Image Acquisition PAGEREF _Toc258403122 1713.2PC/Volume Calculation PAGEREF _Toc258403123 1813.3DAQ Device PAGEREF _Toc258403124 1913.4Valve and Circuitry PAGEREF _Toc258403125 1914.0Detailed Design PAGEREF _Toc258403126 2014.1Edge Detection PAGEREF _Toc258403127 2014.2Volume Calculation PAGEREF _Toc258403128 2114.4Valve Dispensing PAGEREF _Toc258403129 2215.0Major Problems PAGEREF _Toc258403130 2215.1Lighting PAGEREF _Toc258403131 2315.2Dispensing PAGEREF _Toc258403132 2416.0Integration and Implementation PAGEREF _Toc258403133 2516.1Image Acquisition and Volume Calculation PAGEREF _Toc258403134 2516.2Labview Transfer PAGEREF _Toc258403135 2516.3Valve Integration PAGEREF _Toc258403136 2616.4Water Reservoir PAGEREF _Toc258403137 2617.0Comments and Conclusions PAGEREF _Toc258403138 2618.0Team Members PAGEREF _Toc258403139 2618.1Brendan Baker PAGEREF _Toc258403140 2618.2Frederick Weissbach PAGEREF _Toc258403141 2718.3Sean Tovar PAGEREF _Toc258403142 27<br />Table of Figures<br /> TOC quot;
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Figure 2.1: Gant Chart showing progress of each task PAGEREF _Toc258403155 7<br />Figure 9.1: Pugh matrix displayin alternative designs PAGEREF _Toc258403156 14<br />Figure 9.2: Description of alternative concepts PAGEREF _Toc258403157 14<br />Figure 12.1: Functional Block Diagram PAGEREF _Toc258403158 16<br />Figure 12.2: Volume Detection PAGEREF _Toc258403159 16<br />Figure 12.3: Fluid Dispensing portion of block diagram PAGEREF _Toc258403160 17<br />Figure 13.1: Webcam used for image acquisition PAGEREF _Toc258403161 18<br />Figure 13.2: PC used for volume calculation and hardware interface PAGEREF _Toc258403162 18<br />Figure 13.3: DAQ device used for outputting signal to the valve PAGEREF _Toc258403163 19<br />Figure 13.4: Schematic of circuitry controlling valve PAGEREF _Toc258403164 19<br />Figure 14.1: Image amplification PAGEREF _Toc258403165 20<br />Figure 14.2: Image subtraction of image with cup from image with no cup PAGEREF _Toc258403166 20<br />Figure 14.5: Cup plotted in real world units PAGEREF _Toc258403167 21<br />Figure 14.6: 3D model of the cup PAGEREF _Toc258403168 22<br />Figure 16.1: Main routine in Labview used to run the product PAGEREF _Toc258403169 25<br />1.0Executive Summary<br />With public beverage service in mind, Team 2, the engineers behind ‘Drinks Unlimited!’ have designed a device aimed at automating the industry. Stemming from the inconvenience of long lines and bad service, and the technology deprived traditional industry standard of human clerks, an idea of using a hands free and adaptable system surfaced. A marketable device would be created to accomplish two main tasks; allow the user to apply any common type of beverage apparatus and automatically fill the device hands free. The design evolved into the AVD&FDS, or Automatic Volume Detection and Fluid Dispensing System. Originally planned, the AVD&FDS would capture an image of the cup, integrate vertical edges and convert to volume, log the data, and then use a constant pressure system provided by a mechanical engineering senior design team to equally dispense the correct volume. Though the prototype idea and goal of operation stayed consistent, machine operation and implementation have changed due to problems and realizations during the prototyping process. Mainly, the method of volume calculation from the image of the drinking apparatus has differed vastly. The process proved to be more difficult, with a majority of efforts being noise removal and proper edge detection for all cup mediums. Code changes were made daily to adjust to each set up of different cameras and housing ideas. The design also went through many phases of lighting environments, as this is an important aspect of finding cup edges. The use of LabView as an interface for the user, data logging, and digital output was also implemented. Finally, using the constant pressure system provided by the mechanical engineering team was altered due to the type of valve used in their design. The valve requires pulses to turn valve on and off, and the FDS warrants a constant signal for an open valve. This will be safer and more fail-proof. Currently, for prototyping, a gravity based water dispenser will be used that will produce a constant flow rate due to constant reservoir level. The data logging system was also removed for the prototype, though pending deadlines, an example system may be incorporated for proof of concept. The final prototype hardware and software contains a PC, loaded with MATLAB and LabView and relevant image processing toolkits, a cheap USB webcam, a data acquisition device for digital output, a backlight assembly with LED lighting, a fluid valve, a gravity based reservoir, and an emergency shut off switch. The final design works efficiently, quickly, and consistently.<br />2.0Introduction<br />Technology has allowed consumer independence in numerous markets and even more distributors. All a consumer has to do to buy a product is simply enter a credit card number and they walk out the door with their new purchase or it arrives in the mail the next day. This process is fast, involves no clerk or miscounted change, is easy, and reliable. This experience is similar to what the AVD&FDS can offer. It detects the volume of a given container and will dispense a beverage of the user’s choice into the container without any input from the user beyond placing the container in the system. This system is completely consumer based and independent of employee/consumer interaction. The prototype developed will allow a consumer to pick a type of drinking cup i.e. glass, plastic/cardboard, coffee mug, and then simply place the cup under the dispenser and press go. The system will take care of the rest. It will correctly charge you for the amount of fluid dispensed and subtract the amount from a user account. This device will give the consumer a full glass of water without ever having to get close to the dispenser, thus making this device much more sanitary than the current standard used today. The design team as a whole has extensive experience in control system development and implementation that will help in their individual contribution to the design. Imagine if people started to carry their own drinking bottles and mugs to work, the gym, airports, etc with no fear of germs and knowing they are being charged exactly for the amount filled into their glass. Plastic bottles and littering could be drastically reduced while keeping the consumption of the same product the same.<br />2.1Gant Chart<br />Figure 2. SEQ Figure ARABIC 1 1: Gant Chart showing progress of each task<br />As the gant chart shows, the design process was split up into sections that directly tied into one another. The first part of the process was to conceptualize the idea and write down a design that was feasible to prototype during the allotted time. Once the design was in place, the rest of the process was devoted to separately working on the individual parts necessary to make this a successful prototype. Ordering parts, hardware, and the GUI came along at different rates than the software development because of the heavy dependence on the software. The innovation is through the code development.<br />3.0Need for Design<br />The need for this design arises from the long lines seen and experienced by every consumer in different situations. Large crowds during the morning rush at coffee shops, waiting in line during halftime of a sporting event, trying to get the attention of a bartender during a crowded night, the list goes on. This device could take the dependence off of the employee and usually understaffed concession stand, and put the responsibility in the consumer’s hands. This would alleviate the lines built up at the counter and disperse them across the available space at separate AVD&FDS locations.<br />4.0Literature and Patent Search Results<br />A Google patent search did not reveal any device that computes volume with the process we have chosen. Some similar products include an automatic bartender that has predetermined amounts of each ingredient programmed <br />5.0Marketing Analysis and Marketing Strategy<br />The AVD&FDS has the potential for commercial and home use. Fluid dispensing systems, i.e. fountain drinks, are a popular feature among many restaurants and concession stands. Our product could expand these featured services into a new dimension for these businesses without the extra expense of an employee to monitor the system. What this means is that the drink dispensing system could be deployed at a separate location, apart from the actual restaurant or concession stand, and still make money because of the automation that will be embedded in the product. The long lines formed at crowded events, such as collegiate or professional athletic events, could be a thing of the past when the machines disperse the lines amongst themselves. Several other areas that may not contain the restaurant but contain this product could include food courts, airports, shopping centers, etc. Creating a product that has the ability to shrink lines and attract more consumers for the business is the goal of this system. In the home, this product could be a feature of the refrigerator. Common household drinks could be attached inside and the dispenser could be on the outside of the refrigerator.<br />6.0Engineering Design Constraints<br />The design constraints applicable to the design are listed below in their respected category. The global constraints are limitations that affect the product in a global market as opposed to the local constraints that are focused on a local market.<br />6.1Global Design Constraints:<br />Engineering Codes and Standards - Our design abides within the codes and standards. The system will enhance the quality of purchasing beverages by consumers. This does not apply.<br />Economic Factors – This standard does affect our project because of its commercial benefits. The product will have to be affordable with a low economic risk.<br />Environmental Effects – Large scale manufacturing of this product could lead to proper disposal of waste electronics and the recycling of plastics and spare metals. This would affect our product given the right production scale.<br />Sustainability – Our product has the ability to have a initial large volume sales with sustained sales via software and hardware improvements.<br />Manufacturability – This manufacturing of this product will depend on the potential sales volume. Electronics can be outsourced while assembly of the product can be done nationally.<br />Ethical Consideration – Proper disposal or recycling of spare or excess materials is our main ethical consideration.<br />Health and Safety Issues – Sanitation of our product will have to be monitored because of the flexibility of customers bringing their own drinking glass.<br />Social Ramifications – The purpose of this product is to enhance the well-being of society through a greater flexibility of service.<br />Political Factors – This constraint is the least applicable to our design because it is a consumer based product that will have little to no impact on legislative decisions.<br />Legal Issues – Health and safety regulations along with electronic security will be the main risks of using this product because of the public used dispenser and stored accounts.<br />6.2Local Design Constraints:<br />Cost – The custom hardware, software, and precise instruments used could pose cost constraints.<br />Schedule – The product schedule is open due to the lack of similar product development.<br />Manufacturability – Converting a prototype into a precise, large-scale manufactured product is the main concern.<br />Engineering Codes and Standards – Precise instrumentation and aesthetics of our system is a high standard within production.<br />Ethical Considerations – Our company is small enough that this particular constraint does not seem to hinder our design.<br />Health and Safety Issue – General safety issues involved in the making of the product will apply in the factory, i.e., steel toed shoes, safety goggles, emergency protocols, etc.<br />Legal – Health and safety issues of the employees will have an impact on the contract structure and insurance that the company will offer along with specific procedures to manufacture the product.<br />7.0User Requirements<br />The design has a list of requirements to ensure the device is operable by a first time user while being fail-safe and sanitary. The list of requirements for the product is shown below. The device also must ensure marketability and capable of upgrades to properly adhere to a changing market. After the user requirements, there is a list of system requirements and interfacing requirements for the technical hardware limitations.<br />7.1User Requirements<br />1.) System must be hands free during fluid dispensing.<br />2.) Device must calculate cost of dispensed fluid.<br />3.) User must be able to use any sized cup.<br />4.) User must be able to select what type of cup to use (i.e. glass, plastic, mug, etc.)<br />5.) Device must be simple to use and easy enough for a child.<br />6.) Device must have an emergency shut down switch obvious to user.<br />7.) Device must have obvious ready/standby warnings for user.<br />8.) Device must have means of logging expenses per user.<br />9.) Device must be sanitary and protected from elements.<br />7.2System Requirements<br />1.) System must be fully automatic.<br />2.) System must have dispensable pressure system.<br />3.) System must accurately detect the edges of a any sized cup.<br />4.) System must be able to accurately calculate the volume of any sized cup.<br />5.) A 12VDC solenoid valve will be used to dispense the fluid.<br />6.) Proper calculation and interface hardware must be used with PC.<br />7.) Device must have buffering volume due to predetermined cup thickness based on type.<br />8.) Device must be conveniently fast, with calculation and fill time under 30 seconds.<br />9.) Device must find volume within 90%, not to exceed 99% fillable volume.<br />10.) Any USB camera will be applicable for imaging.<br />11.) Proper ambient and back-lighting is necessary for imaging.<br />12.) A digital output of 5V is required to toggle powersupply to valve control.<br />13.) Physical housing must be robust to ensure consistant results.<br />14.) Device must have internet connection to be used with data logging system.<br />7.3Interface Requirements<br />1.) The system will interface via USB.<br />2.) System must be able to plug into standard 120V/60Hz outlet.<br />3.) Must be able to capture image from USB camera.<br />4.) Must be able to output digital 5V.<br />5.) Timing must be synchronous with dispensing system.<br />6.) Constant background image must be loaded before cup image taken.<br />7.) User interface must project all applicable data with live updating to ensure quality to user.<br />8.0Engineering Codes and Standards<br />The device has been constructed to operate safely within any engineering codes and standards. The pertinent standards applicable to the AVD&FDS design are due to the collaboration of hardware devices used in the final prototype.<br />DAQ Device – NI USB-6009<br />Standards –<br />• IEC 61010-1, EN 61010-1<br />• UL 61010-1, CSA 61010-1<br />Further standards of safety information for this device may be found at ni.com/certification<br />Image Capture – Agama V2025 Webcam<br />Standards – <br />• Proper waste standards applicable per country<br />Contact local waste management authorities for more information on proper disposal.<br />Valve – Some cheap valve<br />Standards –<br /> • Proper safe electrical connections and housing for public use maintained. <br />PC – Software and Hardware<br />Standards –<br />• All traditional standards applicable with the use of a personal computer, licensed software, and the credentials of external coding help have been acknowledged and sternly implemented.<br /> <br />9.0Design Concepts<br />AVD & FDS does exactly what it says, detects volume and dispenses fluid automatically. This concept could have been implemented two other ways that deviate from the design chosen and described in this report. Below is a Pugh matrix that shows the other concepts considered before prototyping of the product began.<br />Figure 9. SEQ Figure ARABIC 1 1: Pugh matrix displayin alternative designs<br />Figure 9. SEQ Figure ARABIC 1 2: Description of alternative concepts<br />The final design chosen was the original design idea, concept 1 with a timer based off of calculated volume, even though it did not score the highest in the Pugh matrix. The reason this concept was chosen was because of the integrity and originality of the idea. The other two concepts were still somewhat original, but other similar devices are on the market and the engineering behind the ideas did not meet the novelty and originality initially conceived. The final prototype will include volume detection, hands free fluid dispensing, but there will be no barcode system. Further design ideas do include a barcode system and a way to receive cash to pay for the dispensed drink also.<br />10.0Product Specifications<br />The product needed particular specifications to be met before it could perform correctly and consistently. These most important of the specifications are listed below:<br />,[object Object]](https://image.slidesharecdn.com/finalreportcombined-100414171416-phpapp02/85/Final-report-combined-1-320.jpg)
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- 2. The camera being used must have a USB connection.
- 3. The valve must be able to be opened based off a 1mA output from DAQ device.
- 4. System must tell customer what the price of the dispensed fluid will be.