Simple sensors, case smart metering (by Rudy Van Raemdonck)

transcript

3.2 Simple sensors: case ‘smart metering’

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Template presentation Innovation Day 2016 CONFIDENTIAL

TRACK 3: EVOLVING ARCHITECTURES

Rudy Van RaemdonckCoordinator EmbeddedLabrudy.vanraemdonck@verhaert.com

SIMPLE SENSORSCASE ‘SMART METERING’

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A SIMPLE CAR PARKING SENSOR ...

https://www.youtube.com/watch?v=Wkvy0GtJE2E

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CONTENT

Case: GecoSense

Challenges in sensor development

Evolving architectures and sensor development

Conclusions and food for thought

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CASE: GecoSenseA retrofittable energy measuring sensor

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BOXX - ENGIE’S SMART THERMOSTAT SOLUTION

https://www.engie-electrabel.be/nl/particulier/boxx-besparen-energie-verbruik-thermostaat

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GECOSENSE – SYSTEM OVERVIEWRetrofittable energy meter sensor

Interface box (existing)Wireless link

BOXX intelligent thermostat

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• Count disk revolutions of installed energy meters(Ferraris type)

• In both directions (energy consumption and production)

• Without intrusion of the meter cabinet (sealed)• And fully removable• That interfaces to the BOXX thermostat• Consumes less than 1W• Is low cost (including installation)• And can be launched within a period of 9 months

GECOSENSE - BASIC REQUIREMENTS

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CHALLENGES IN SENSOR DEVELOPMENTWhy is sensor development complexity underestimated?

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SENSORS ARE EVERYWHERE …

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... ON (IN) OUR BODY

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... IN OUR HOMES/WORKING PLACES

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... IN OUR CITIES

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A MYRIAD OF SENSORS

Source : IBM Canada

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… AND NOWHERE!

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CAR SENSORS - WHERE ARE THEY?

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CAR SENSORS – TYPICAL LIST

Engine Coolant TemperatureFuel Pressure (Gauge)Intake Manifold Absolute PressureEngine RPMVehicle Speed SensorIgnition Timing Advance for #1 CylinderIntake Air TemperatureAir Flow Rate from Mass Airflow SensorAbsolute Throttle PositionOxygen Sensor 1 Bank 1Oxygen Sensor 2 Bank 1Oxygen Sensor 3 Bank 1Oxygen Sensor 4 Bank 1Oxygen Sensor 1 Bank 2Oxygen Sensor 2 Bank 2Oxygen Sensor 3 Bank 2Oxygen Sensor 4 Bank 2Distance TraveledFuel Rail Pressure Relative to VacuumFuel Rail PressureFuel Level InputEVAP System Vapor PressureControl Module Voltage

Catalyst Temperature Bank 1 Sensor 1Catalyst Temperature Bank 2 Sensor 1Catalyst Temperature Bank 1 Sensor 2Catalyst Temperature Bank 2 Sensor 2Absolute Load ValueRelative Throttle PositionAmbient Air TemperatureAccelerator Pedal Position DAccelerator Pedal Position EAccelerator Pedal Position FRoad condition sensorMagnetic sensorVehicle distance sensorForward obstacle sensorBlind spot monitoring cameraDrive recorderSide obstacle sensorOil level

Door open/close sensorBooth open/close sensorPassenger seat sensorRear obstacle sensorGPS sensorAirbag sensorRear view cameraDriver monitoring sensorSteering angle sensorFire sensorVehicle speed sensorCollision detection sensorPedestrian collision sensorCabin air pollution sensorTyre pressure sensorIntrusion alarm detectionAmbient light sensor...

Sensors are invisible assets!

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GECOSENSE – ENERGY MONITORING

Did you see the energy monitoring sensor in the promotional video?

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PERCEIVED VALUE OF SENSORS

WisdomWhat we decide

to do with it

KnowledgeData analytics, models

InformationContext

DataSensors

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THE PACE OF DATA FLOWA reflection of the fast society we are living in

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WisdomWhat we decide

to do with it

KnowledgeData analytics, models

InformationContext

DataSensors

THE DATA HIGHWAYO

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THE SHIFT TO ‘OPEN’ SENSORSDealing with future (not yet known) features

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TESLA – AUTOMATIC DRIVING

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SMARTPHONE – FALL DETECTION

SensorAccelerometer

PlatformSmartphone

Intentionalapplication

Portrait or landscape detection

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SMARTPHONE – FALL DETECTION

SensorAccelerometer

PlatformSmartphone

New (unintentional) applicationFall detection

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IT ALL ADDS UP!

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HIGH IMPLIED DEMANDS VERSUS LOW PERCEIVED VALUE

Sensor requirements

• Connected• Small• Autonomous• Low-cost• (Re)configurable• Reliable• Performant

UBIQUITOUS

INVISIBLE

LOW VALUE PERCEPTION

Complex!

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HIGH IMPLIED DEMANDS VERSUS LOW PERCEIVED VALUE

Sensor requirements

• Connected• Small• Autonomous• Low-cost• (Re)configurable• Reliable• Performant

UBIQUITOUS

INVISIBLE

Complex!

• On one hand, sensors are so ‘common’ they are taken for granted and not seen as valuable assets (low perceived value)

• On the other hand, our whole information society heavily depends on sensor data which implies they must be able to communicate reliable information in real-time, hence turning them into complex systems

• This puts the design process of sensors under a lot of pressure

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EVOLVING ARCHITECTURESAND SENSOR DEVELOPMENT6 hints to tackle the challenge

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• What to measure (register or disk rotation)?• How to detect disk rotation/direction? How to read register?• What is the maximum speed of the disk?• What is the required accuracy?• What are the power requirements?• How and what must be communicated to BOXX?

• Are all the meters the same (disk surface, disk-sensor distance)?

• What are the environmental conditions (ambient light, temperature)?

• Who will install the sensor?• What is allowed as interface to the existing cabinet?• How long should installation take?• What about visibility of the register after the sensor is

mounted?

• What is the maximum cost (sensor + installation)?• What are the expected volumes?

GECOSENSE - COUNTING PULSES… SIMPLE?TE

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#1 - HOLISTIC APPROACH

• Should be applied throughout the complete development cycle• Requires a multi-disciplinary team with an inter-disciplinary collaboration

• Engineering cost• Product cost, TCO• Minimal Viable Product• Funding

• Technology selection• Technology integration• Development• Testing, verification, validation,

certification

• Use cases• Usability• Features• Perceived value• Stakeholders

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GECOSENSE – THE PROJECT TEAM

ProjectCoordination

ProjectManagement

SalesManagement

SoftwareEngineering

HardwareEngineering

Optical Engineering

System Engineering

Lambda-X

Mechanical Engineering

Industrialization

Contract manuf.Management

Externalconsultants

Multi-disciplinaryproject team with inter-disciplinarycollaboration!

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#2 – UNDERSTAND THE PHYSICS

• Understanding the physics helps you in selecting the right measurement technology• Must be done early in the development process!

• Get or acquire domain knowledge• Literature, papers, patent survey• Start measuring!• Use simulation tools• Determine correlations• Consider influencing factors

(environment, time, …)

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GECOSENSE – OPTICAL SYSTEM MODELLING

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#3 – SENSOR AS A PLATFORM (EXAMPLES)

Possibilities• MCU family (footprint

compatible devices, reprogrammable)

• FPGA (reconfigurable)

• Software library (modular)

• Communication protocol(e.g. HART)

• Standard mechanical format / interface

• Overdesign for current application (performance, features)

• Variable assembly

• Bus architecture

• Extension connector

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#3 – SENSOR AS A PLATFORM (RATIONALE)

Properties of platforms• Flexible

• Reconfigurable

• Modular

• Scalable

• Generic

• Re-usable

• Standardization (open standards, interchangeable)

• Portable (hardware independent)

• Platforms enable the implementation of an evolving architecture• This can be realized on different levels (mechanical, hardware, software) and in

different project stages

Advantages forsensor development

• Design flexibility (agility!)

• Earlier start of development

• Lower cost of change (re-use)

• Risk mitigation

• New features can be added after go2market (future proof, sustainability, longevity)

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GECOSENSE – PLATFORM DESIGN (MECHANICAL)

Optical subsystem

Attachment/alignment Signal processing

Cover/protection

Interface (BOXX)

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GENERIC – PLATFORM DESIGN (HARDWARE)

Naked sensor

Sensor interface

Platform management

Processing

Communication i/f

Storage

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MCU(PIC32MX)

GECOSENSE – PLATFORM DESIGN (HARDWARE)

Meter disk

Optical transmitter (2x)

Transmitter driver(2x)

Optical receiver(2x)

Analog to Digital Convertor

Power supplyEMC filteringLevel shifting

Meter interface module

RAMFLASH

Watch-dog

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GECOSENSE – PLATFORM DESIGN (HARDWARE)

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GENERIC – PLATFORM DESIGN (SOFTWARE)

Hardware Abstraction Layer

Sensor i/f and Pre-processing Communication protocol

Signal Processing (algorithm)

Sensor Platform Management

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GECOSENSE – PLATFORM DESIGN (SOFTWARE)

Bootloader Initialization AutoCalibration

I/O driver (LEDs)

I2S handling (ADC) Send/receive

Pulse generation

Signal sampling Protocol driver

Band pass filter

Envelope detection Normalization

Dip detectionDirection detection

Dip counting (cons + prod)

Task scheduling Power management

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#4 – START WITH A WIDE ‘FIELD OF VIEW’

• Start with a broad view

• Evolve project focus as you learn (staged approach)

• Iterate

Explore

• Problem understanding

• Risk identification• Use cases• Learn fast / fail fast• Generate options• Conceptual design• Trade-off

Design

• Evaluation• Verification• User feedback• Pre-certification

Optimize

• Performance• Size/weight• Cost• Integration• Visual design• Validation• Certification

SensorProof of Concept

Preliminar functional sensor

Optimizedsensor

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GECOSENSE - PROJECT APPROACH

Explore Design Optimize

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#5 – STREAMLINE YOUR TOOLCHAIN

• Use the right tools at the right moment

• Organize for portability (reuse) of intermediate development results throughout the project stages

Explore

• Target = PC (or similar)

• Rapid prototyping (bread boarding, 3D printing)

• Simulation• Technology scouting• Starter kits• Algorithm modeling

Design

• Target = functional proto

• Functional decomposition and (re)grouping

• Design tools (EDA, mechanical design)

• Review checklists• Debugging tools• Model translation

tools (code generation)

Optimize

• Target =• final sensor• Configuration

management tools (features, bugs, version)

• Calibrated test bench• (Automated) test

procedure• Model optimization

tools (code optimization)

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GECOSENSE – USE OF TOOLS

Office tools (Excel, Word, Powerpoint)

Matlab (physical simulation and modelling)

Python (protocol simulation)

MPLab (C compiler for embedded software development)

SVN (software version control)

Bugzilla (bug reporting and follow-up)

Creo (mechanical design)

Altium designer (electronic design)

Zemax OpticStudio (optical modelling and design)

LTspice (electronic simulation)

Starter kits / breadboards Functional model / 3D prints Full sensor / Molded parts Final product / Test bench

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#6 – EXPLOIT THE FULL SYSTEM

• Sensor fusion IMU : accelerometer, gyroscope, magnetometer

• Distributed computing determine where to compute what optimize technical resources, communication bandwidth, autonomy Example: sensor, hub, backend

• Inclusion of context Example : GPS lock to road, day/night mode

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GECOSENSE – EXPLOITING THE SYSTEM

Exploited features• Temperature sensor and temperature

compensation

• Auto calibration

• Redundant meter disk monitoring (using two measuring channels)

• Totalize energy consumption and production on sensor

• No conversion to kWh, no trending

Advantages for GecoSense• Improved reliability over temperature

• Compensation for sensor degradation (long term stability),; autonomous operation

• Disk direction detectionImproved reliability

• Possibility for BOXX to recover from communication drop out

• Minimize sensor resources (cost reduction)

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GECOSENSE – READY FOR MARKET LAUNCH!

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GECOSENSE – FUTURE IDEAS

• Retrofit on meter itself for PV applications (solar cells) shorter distance to meter disk!measurement of both energy consumption and production

• Retrofit for meters with LED instead of disk

• Exchange more parameters with BOXX (signal quality, settings)

• All these ideas can be implemented with minimal effort, thanks to the evolving architecture of the GecoSense sensor

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CONCLUSIONClick to insert subtitle

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REDUCING THE PRESSURE FROM SENSOR DEVELOPMENT

Sensor development

UBIQUITOUS

INVISIBLE

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Sensor development

UBIQUITOUS

INVISIBLE

REDUCING THE PRESSURE FROM SENSOR DEVELOPMENT

Evolving architecture

#1Holistic

approach

#2Understand the physics

#3 Sensor as a Platform #4

Wide ‘angle of view’

#5 Streamline toolchain

#6 Exploit full system

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IS THIS A SIMPLE CAR PARKING SENSOR?

https://www.youtube.com/watch?v=Wkvy0GtJE2E

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...YOU MIGHT BE SURPRISED!

Signal processing (master)

Wireless communication (voice/ears)

Sensors (stereoscopic sight + hearing)

Signal processing (slave)

Wireless communication (beak)

Sensors (stereoscopic camera)

Signal processing (slave)

Wireless communication (ears)

Sensors (movement)

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