The Gasifier Control Unit v3.02
(now the Process Control Unit)
The GEK Gasifier Control Unit (GCU) is an open source sensing and control board designed to solve a broad range of instrumentation and automation needs in thermal industrial processes. We originally developed the board for testing and control of gasification machinery. However, it is proving equally useful for pyrolysis biochar reactors, as well as many other research and industrial control needs beyond biomass thermal conversion. The board is a "kitchen sink" solution, including most everything one couldKSlibs-20110719.zip want for thermal industrial control, all at a price point far removed from typical industrial and scientific instrumentation options.
The board offers a generous number of thermocouple, pressure, analog signal, and rpm timer inputs, with a similarly generous array of PWM speed control, servo driver and higher current DC switched outputs. Networking to other devices is supported via USB, serial, SD card and CANbus (the networking standard for contemporary engine systems). These features operate on top of a powerful native processor for stand alone operation, with a 4 line screen included for in situ instrument reading without a computer monitor.
Internally at ALL Power Labs, we use this board to generate datalogged test results like this.
The GCU is uniquely suited for research applications that need robust and integrated instrumentation and datalogging. It is equally relevant for industrial applications where sensor input is used to control various motors, solenoids, fans and other control devices. In both cases, our goal is to provide the type of expert sensing and control solutions usually only found for 10s of thousands of dollars through scientific or industrial equipment suppliers. The GEK GCU offers equal or superior features for $1395 with the "full fill" version, or $695 with the "half fill" (see details below). Most will probably realize that just the 16 channel thermocouple reader to serial or usb interface would cost this much from a typical scientific supplier.
The GEK GCU is based on an Atmel AVR processor, with Arduino compatible firmware and software installed on top. This allows us to leverage the tremendously large user base and code libraries of the Arduino environment, though deployed over a richer measurement and control base than typical Arduino projects. Power and ease of use, together at last-- all in the service of the "Cult of the Black Goo".
Here are the specific details of the full and half fill versions:
FEATURES (V3.02)
|
Full Fill
|
Lite |
Processor
|
Atmel ATmega 1280
|
Atmel ATmega 1280
|
Thermocouple Inputs
|
16 K-type
|
4 K-type |
Pressure Inputs (High Range, +/- 28 inH2O)
|
4
|
1 |
Pressure Inputs (Low Range, +/- 8 inH2O)
|
2
|
1 |
FET Outputs (5 A continuous)
|
8
|
4 |
Analog Inputs
(10-bit, Phidgets compatible connectors)
|
8
|
4 |
Frequency Counter Input
|
1
|
0 |
R/C Hobby Servo Outputs |
3 |
1 |
Display (4x20 character) |
yes |
yes |
4 Button Keypad |
yes |
no |
MicroSD Slot |
yes |
|
CANbus hardware |
yes |
no |
RS-232 Interface |
yes |
no |
Prototyping/Expansion Area |
yes |
yes |
User's Manuals
Technical Manual: v 0.6 - draft form (pdf)
Operating Manual: http://wiki.gekgasifier.com/w/page/48167424/PCU-Getting%20Started
GCU Part Positions
ATmega1280 microcontroller documentation:doc2549.PDF
Hardware
gcu3.03.sch
Code
Libraries
//install libraries in Arduino application folder/hardware/libraries/KSlibs.
KSlibs - Arduino support libraries
Note (the function GCU_Setup should be placed inside setup() with values to properly specify the GCU in use):
GCU_Setup(version,fill,psequence): //Specify GCU: (version,fill,psequence) //version = V2 or V3 / 2.0 or 3.0 //fill = FULLFILL | HALFFILL | LITEFILL / full, half, or lite fill boards //psequence: for V3.01 boards, check sequence of P sensor part numbers (e.g. MXP7007 or MXP7002, and use last digit). V3.02 boards use P777722: // P777222, P222777, P777722
|
Sketches
//Install sketches into the Arduino folder (Windows: My Documents/Arduino; Mac: User/X/Documents/Arduino)
//In the Arduino interface you will see these sketches show up under File/Sketchbook.
KS_Datalogging2 - Arduino sketch
KS_Engine3 - Arduino sketch for running Power Pallet (includes energy monitoring code, PID O2 control, alarm code) (note: when downloading from GitHub, you will need to rename the sketch "KS_Engine3". Baud rate for the Power Pallet is 57600).
Recommended Additional Libraries
You may want or need to install additional libraries, depending on the code you want to run:
PIDBeta
Code Examples
GCU Example Code
Communication and Datalogging
A serial terminal can be used to communicate and datalog with a computer:
Windows: puttytel
Datalogging/Graphing Application for the PCU/GCU (Windows)
Mac: terminal
How to do datalogging with the GCU
Process Control and Visualization Software
Sensors
Power Monitoring
AC Power Monitoring
OpenEnergyMonitor Library
Flow Measurement
Orifice Flowmeters: Building and Calibrating an Orifice Flowmeter & Code
APL Research Kit
Humidity
Humidity Measurement
Current
Current Measurement
Temperature
Temperature Measurement
Force/Weight
Force Measurement
Voltage
Voltage Measurement
Controls
Working with Inductive Loads
Using inductive devices (motors, relays, solenoids...) with the GCU
Networking
GCU Can-Bus Support
Menu Screens
The basic software that comes with the GCUv3.0 has five data screens displayed on the LCD.
1)Main Menu
2)Temperature
3)Pressure
4)Fet Drivers
5)Servo controllers
More pictures of GCU v3.0.
Ordering
If you would like to place an order for the GCUv3.0 visit the instrumentation page in the GEK gasifier store.
FAQ
- Q: The Arduino compiler states: "Error: DDRJ was not declared in this scope." A: Confirm that the Arduino Mega board is selected from the Arduino->Tools->Board menu.
2. GCU: Getting Started (pending)
3.http://www.gekgasifier.com/forums/showthread.php?t=338&highlight=thermya
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