Designs of Wireless Monitoring Network System of Mill

Hao Cheng
Hebei Polytechnic University College of Computer and Automatic Control Tangshan 063009, China E-mail: hc621203@163.com

Wang Zhanlin Hebei Polytechnic University

College of Mechanical Engineering

Tangshan 063009, China E-mail: hc621203@163.com

Yang Zhigang Hebei Polytechnic University College of Computer and Automatic Control Tangshan 063009, China E-mail: hc621203@163.com

Wang Jianmin Hebei Polytechnic University College of Computer and Automatic Control Tangshan 063009, China E-mail: hc621203@163.com

Yang Ling Hebei Polytechnic University College of Computer and Automatic Control Tangshan 063009, China E-mail: yuan_830818@163.com
AbstractIn this paper, sensors, which are directly installed on the surface of the mill, are used to collect mills signals by wireless. The frame of the system is introduced and the hardware and software is designed in details in this paper. With the transmission mode of I2S and MCU of AT89S2051, the transform from analog signals to digital signals , datas transmission by wireless is achieved by this system. On this basis, the program designed is not only good at collect mills signals, but also restraining the interference, analyzing spectrum. So the program can effectively achieve the mill state detection. Keywords-wireless nRF24L01;AT89S2051 CLC: TP274 Literature ID collection; SPI;

installed on the shell of mill, so wires sensors needed is impossible to be connected.. As so, wires are installed somewhere near the mill but not the shell. If so, there are some questions: due to the relatively distant from the cylinder wall, so that the signal collected from mill can not be well reflected in the load condition of the ball mill. The acquisition system designed compensates for the shortcomings of traditional, which is communicated between dispatcher and sink by the way of wireless. Besides of achieving data collection, the program can effectively restrain the interference, analyze the spectrum and achieve the state monitoring. II. THE OVERALL DESIGN OF THE WIERLESS DETECTION NETWORK OF THE MILL

I.

INTRODUCTION

Its key to success to a ball mill grinding system and the whole process of optimal control to detect accurately the load state. At present, the main method used in industry is indirect methods, such as the noise method, vibration method. But their downside is that the sensor installation position is limited [1-3]. The mill signal which is useful to detect the load state is from the shell, but the shell is turning continuously. In this situation, traditional methods can not be used because the sensors is needed to

The overall design is shown in figure 1. With the bus IPC as the monitoring computer, high-speed data acquisition card, sensors of noises and vibrations, transmitter and librations source power are installed on the surface of the mill. When the mill run, the process of transmitting and receiving is on carrying. The transmitter which is installed on the surface of mill, transform the analog signals into digital signals. The signals are passed to high-speed data acquisition card using the cable and analyzed by the monitoring computer, so the system achieves the mills monitoring.

978-1-4244-5392-4/10/$26.00 2010 IEEE

to have SPI interface on a microcontroller but SPI interface is possible to use with simulated by procedure. And because the link layer is fully integrated on the chip, it is very convenient to program. Hardware design is simple, and the system programmability is good. Specific hardware connections are shown in Figure 2.
VDD C7 33nF 20 19 18 17 16 R3 22K C6 10nF C5 1nF

VCC P1.7 P1.6 P1.5 P1.4 P1.3 AT89S2051

20 19 18 17 16 15 14

VCC

U3 1 2 3 4 5

DVDD

VDD

IREF

VSS

VSS

CE

VDD VSS

15 14 13 12 11

CSN SCK MOSI VDD MISO IRQ XC2 9 VSS NRF24L01

ANT2 ANT1

A. The Choice of Radio-Frequency Chip nRF24L01 is a single-chip RF transceiver device introduced by Norway's Nordic Semiconductor Corporation, built-ins frequency synthesizer, power amplifier, crystal oscillators, modulators, and other functional modules, and integration of the enhanced ShockBurst Technology and output power and communication channels can be configured through the procedure..nRF24L01 has low power consumption and the current only is 9mA when it works in the power of -6dB when sending. At the receivers, when it is working, the current only is 12.3mA. It is possible to save energy by many low-power mode, Power-down mode and idle mode. Its voltage is 1.9V~3.6V, GFSK modulation, OSI link layer of hardware integration, header and the CRC Checksum of on-chip auto-generated, Data transfer rate of l Mb / s or 2Mb / s, the SPI interface supported which provides a connection interface with the MCU 125 channels when encountered interference it is easy to change the channel to avoid interference, QFN20-pin 4 mm 4 mm package requires minimal external components[4]. A small PCB antenna 2.4GHz is used and the distance of transmission is up to 30m on open place. Based on the above, nRF24L01 is suitable for the design of the mill with the wireless acquisition. In this design of hardware, interface devices signal environment and the mode of interface are well considered. So the design is relatively more reasonable, which has two parts interface between nRF24L01 and AT89S2051, interface between TLC2543 and AT89S2051. The following will respectively explain the two parts of the hardware design. B. The Interface Between nRF24L01 and AT89S2051 Enhanced ShockBurst mode nRF24L01 integrates all the high-speed link-layer operation, so there is not needed

22uF

Figure 2.Hardware interface between nRF24L01 and AT89S2051

CE enables the bits of transmission or reception. When the bit of CE is 1, the chip is designed to transmitter and when the bit of CE is 0, the chip is designed to receiver. CSN enables the selection of chips and is effective when its bit is low. When the bit is low, the SPI interface is waiting for commands. Every execution must go through the l1 to 0 of the CSN . SCK is the serial clock with the initial state of 1, set it to 0 after allowing receive. Thus a falling edge on the clock is generated. Data will be shifted left by serial by the falling edge of clock and then put the maximum bits to the MISO line. After those, set bit of SCK to 1, a rising edge is generated and the microcontroller is starting receiving the maximum bit. Above so, 1bit data is transmitted. Following those process 8 times, one SPI transmission is achieved. MOSI is the pin that puts the instructions from the MCU to nRF24L01 and put the state information and data from MCU to nRF24L01. IRQ is the flag bit for the data sent which becomes low when data is sent successfully. C. The Interface between TLC2543 and AT89S2051 TLC2543 is a chip with serial input structure of SPI using the A/D conversion. The chip has a 12-bit resolution, 11 analog input channels, sampling rate of 66Kbit / s. TLC2543 is simple of structure, easy to control, good stability, so it suitable for this design. Without SPI interface on this MCU, procedure simulation is used to simulate a SPI. Hardware connection between TLC2543 and AT89S2051 has shown in figure 3. In figure 3, AIN0~AIN10 are the analog input, REF + and REF-, is respectively positive and negative

III. WIRELESS TRANSMITTER DESIGN OF THE COLLECTION SYSTEM

22uF C3

R4 X2 16M 1M

10

C4

XC1

Figure 2.The monitoring system overall design of the mill

P1.2

VDD-PA

reference voltage, linked with +5V and ground. CS connects with the of P3.2 of MCU which is the analog select terminal. When CS becomes low from 1, internal counter is rested. Change from low to high, at a set time to prohibit DATA INPUT, and I / O CLOCK. INPUT connects the pin of P3.4 of MCU, which is the analog serial input and used to write control information. OUPUT connects the pin of P3.5, is used to receive data, I/O CLOCK is the input-output clock, receives the serial signal. At the first eight rising edge, eight bits data are written to the data register, at the forth falling edge, the analog signal selected start charge to the capacitance until the last falling edge, and then converts the previous 11 bits to DATA OUT. EOC is the end terminal of the conversion [7].
1 2 3 4 5 6 7 8 9 10 * AIN0 AIN1 AIN2 VCC EOC I/O CLOCK 20 19 18 CLK 17 INPUT 16 OUTPU 15 CS 14 13 12 11 VCC VCC 1 2 3 4 1 CS 6 CLK 7 20 19 18 17 16 15 14 13 12 11 EOC VCC

response is not received, data are transmitted automatically. If the limitation of ARC_CNT is reached, MAX_RT is settled to high and TX_PLD is not cleared. When MAX_RT or TX_DS is high, IRQ is low and MCU is informed. When the transmission is successful, if CE is low then nRF24L01 enter into the idle mode 1; if the stack is not empty and CE is high, nRF24L01 shifts into the next transmission; if the stack is empty and CE is high, nRF24L01 shifts into idle mode 2[8].
start Initial the subprograms of AT89S2051 Initial the configuration subprogram of NRF24L01 Wait N Active the mode of transmitter IRQ is 0 ? Y TX_DS is 1? Y It is successful to send data Renew the default Turn into the next transmitting N Record one failure of sending Retransmit

RST/VPP (RXD)P3.0 (TXD)P3.1 AT89S2051 XTAL2 XTAL1 (INT0)P3.2 (INT1)P3.3 (T0)P3.4 (T1)P3.5 GND

VCC P1.7 P1.6 P1.5 P1.4 P1.3 P1.2 P1.1(AIN1) P1.0(AIN0) P3.7

AIN3 DATA INPUT AIN4 AIN5 TLC2543 AIN6 AIN7 AIN8 GND DATA OUT CS REF+ REFAIN10 AIN9

INPUT 8
OUTPU 9

10

10uF

0.1uF

Figure3. Hardware interface between TLC2543 and AT89S2051

Software Design of the Wireless Collection System Software design of the wireless collection system includes two parts: MCU SPI Interface and TLC2543A / D conversion control procedures; wireless transmitting program by nRF24L01. SPI interface procedure is the procedure of serial clock, data input and data output. Those operations are choices of channels of control programs, formats of data transmit, the length of the selected of data transmitting. nRF24L01 with enhanced ShockBurstTM enable implementation of the agreement more easier and more effective, program more simple. The flow chart of program is shown in figure 4. When sending data, firstly configure the nRF24L01 to the mode of launch, secondly write the address of TX_ADDR and data of TX_PLD to the buffer of nRF24L01 according with the timing, then set CE to high and keep it at least 10s, transmitting data after the 130s delay. TX_PLD must be continuous for the low to write, but TX_ADDR is once written in the launching. If the auto-answer is open, nRF24L01 immediately come into the reception mode after data transmitted and the receive the response signal. If response is OK, this communication is OK, TX_DS is sited to high, at the same time, TX_PLD is cleared from the sending stack. If

D.

Figure 4. Flow chart of program of the receipt

E. Power Design of the Wireless Collection System The power supply is the one designed by mills vibration. When the mill is working, it begins to produce current which supply to the system. But when the mill is not working, there is no need for power supply, as the mill is not vibration, no need transmission , so power supply is not needed. With this power supply, others power such as battery are not needed, it is not only to save energy, but also address the need for frequent battery replacement problems. IV. WIRELESS RECEIVER DESIGN OF THE COLLECTION SYSTEM

The receiver, which is fixed, includes nRF24L01 EEPROM25AA640 D/A CS42L41 and AT89S2051. Through simulated interfaces SPI, I2C and I2S, AT89S2051 can control memorizer 25AA640 read the data configured with SPI, initiate the D/A CS43L41 with I2C, and carry the audio data from CS43L41 with I2S. V. THE MONITORING DESIGN The monitoring computer is a bus IPC, type

DYPCI8613 with high-speed data acquisition card that is a card based on PCI-bus and be directly placed in the PCI notch. The computer is used to acquire data, analyze waves and manage the entire system. The system feature is shown as follow: 12-bit-resolution A/D converter, linearity error 1 LSB max and 10s conversion time over operating temperature. The entire system program is based on VC software. CONLUSION It is the key of ball mill state detection to acquire data, which offers credible information of the out of the mill. In the paper, details is about A/D TLC2543, AT89S2051 and nRF24L01 wireless transceiver system, which is low costing , small volume and high-speed transmitting. The problem of directly placing sensors on ball mill is successfully solved by the wireless transmitting system. For figure 5,a,b,c, it is shown the noise spectrum, which is told by the monitoring system at the charge of 100%,80%,60%, and normal charge, less normal change and hollow.
(c) Figure 5.The noise power spectrum

REFERENCES
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