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Simple sensors, case smart metering (by Rudy Van Raemdonck)
The document discusses the development of simple sensors for smart metering, emphasizing the Gecosense project, which creates a retrofittable energy measuring sensor designed for easy installation and low cost. It addresses challenges in sensor development, including the importance of a holistic approach, understanding physics, and using interchangeable platforms to ensure versatility and adaptability in the sensor design process. The document concludes by outlining essential strategies to relieve the pressure around sensor development, promoting an evolving architecture and streamlined project management.
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Simple sensors, case smart metering (by Rudy Van Raemdonck)
- 1. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 1 Template presentation Innovation Day 2016CONFIDENTIAL TRACK 3: EVOLVING ARCHITECTURES Rudy Van Raemdonck Coordinator EmbeddedLab rudy.vanraemdonck@verhaert.com SIMPLE SENSORS CASE ‘SMART METERING’
- 2. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 2 A SIMPLE CAR PARKING SENSOR ... https://www.youtube.com/watch?v=Wkvy0GtJE2E
- 3. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 3 1 2 3 4 CONTENT Case: GecoSense Challenges in sensor development Evolving architectures and sensor development Conclusions and food for thought
- 4. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 4 CONFIDENTIAL 4 CASE: GecoSense A retrofittable energy measuring sensor
- 5. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 5 BOXX - ENGIE’S SMART THERMOSTAT SOLUTION https://www.engie-electrabel.be/nl/particulier/boxx-besparen-energie-verbruik-thermostaat
- 6. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 6 GECOSENSE – SYSTEM OVERVIEW Retrofittable energy meter sensor Interface box (existing)Wireless link BOXX intelligent thermostat
- 7. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 7 • 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
- 8. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 8 CONFIDENTIAL 8 CHALLENGES IN SENSOR DEVELOPMENT Why is sensor development complexity underestimated?
- 9. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 9 SENSORS ARE EVERYWHERE …
- 10. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 10 ... ON (IN) OUR BODY
- 11. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 11 ... IN OUR HOMES/WORKING PLACES
- 12. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 12 ... IN OUR CITIES
- 13. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 13 A MYRIAD OF SENSORS Source : IBM Canada
- 14. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 14 … AND NOWHERE!
- 15. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 15 CAR SENSORS - WHERE ARE THEY?
- 16. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 16 CAR SENSORS – TYPICAL LIST Engine Coolant Temperature Fuel Pressure (Gauge) Intake Manifold Absolute Pressure Engine RPM Vehicle Speed Sensor Ignition Timing Advance for #1 Cylinder Intake Air Temperature Air Flow Rate from Mass Airflow Sensor Absolute Throttle Position Oxygen Sensor 1 Bank 1 Oxygen Sensor 2 Bank 1 Oxygen Sensor 3 Bank 1 Oxygen Sensor 4 Bank 1 Oxygen Sensor 1 Bank 2 Oxygen Sensor 2 Bank 2 Oxygen Sensor 3 Bank 2 Oxygen Sensor 4 Bank 2 Distance Traveled Fuel Rail Pressure Relative to Vacuum Fuel Rail Pressure Fuel Level Input EVAP System Vapor Pressure Control Module Voltage Catalyst Temperature Bank 1 Sensor 1 Catalyst Temperature Bank 2 Sensor 1 Catalyst Temperature Bank 1 Sensor 2 Catalyst Temperature Bank 2 Sensor 2 Absolute Load Value Relative Throttle Position Ambient Air Temperature Accelerator Pedal Position D Accelerator Pedal Position E Accelerator Pedal Position F Road condition sensor Magnetic sensor Vehicle distance sensor Forward obstacle sensor Blind spot monitoring camera Drive recorder Side obstacle sensor Oil level Door open/close sensor Booth open/close sensor Passenger seat sensor Rear obstacle sensor GPS sensor Airbag sensor Rear view camera Driver monitoring sensor Steering angle sensor Fire sensor Vehicle speed sensor Collision detection sensor Pedestrian collision sensor Cabin air pollution sensor Tyre pressure sensor Intrusion alarm detection Ambient light sensor ... Sensors are invisible assets!
- 17. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 17 GECOSENSE – ENERGY MONITORING Did you see the energy monitoring sensor in the promotional video?
- 18. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 18 PERCEIVED VALUE OF SENSORS DEPENDABILITY/CRITICALITY Wisdom What we decide to do with it VISIBILITYPERCEIVEDVALUE Knowledge Data analytics, models Information Context Data Sensors
- 19. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 19 THE PACE OF DATA FLOW A reflection of the fast society we are living in
- 20. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 20 Wisdom What we decide to do with it Knowledge Data analytics, models Information Context Data Sensors THE DATA HIGHWAY On-demanddataContinuousdatafeed Off-lineOn-line DeferredprocessingInstantprocessing
- 21. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 21 THE SHIFT TO ‘OPEN’ SENSORS Dealing with future (not yet known) features
- 22. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 22 TESLA – AUTOMATIC DRIVING
- 23. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 23 SMARTPHONE – FALL DETECTION Sensor Accelerometer Platform Smartphone Intentional application Portrait or landscape detection
- 24. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 24 SMARTPHONE – FALL DETECTION Sensor Accelerometer Platform Smartphone New (unintentional) application Fall detection
- 25. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 25 IT ALL ADDS UP!
- 26. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 26 HIGH IMPLIED DEMANDS VERSUS LOW PERCEIVED VALUE Sensor requirements • Connected • Small • Autonomous • Low-cost • (Re)configurable • Reliable • Performant UBIQUITOUS INVISIBLE OPEN PACE LOW VALUE PERCEPTION Complex!
- 27. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 27 HIGH IMPLIED DEMANDS VERSUS LOW PERCEIVED VALUE Sensor requirements • Connected • Small • Autonomous • Low-cost • (Re)configurable • Reliable • Performant UBIQUITOUS INVISIBLE OPEN PACE LOW VALUE PERCEPTION 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
- 28. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 28 CONFIDENTIAL 28 EVOLVING ARCHITECTURES AND SENSOR DEVELOPMENT 6 hints to tackle the challenge
- 29. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 29 • 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? TECHNICALUSERBUSINESS
- 30. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 30 #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
- 31. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 31 GECOSENSE – THE PROJECT TEAM Project Coordination Project Management Sales Management Software Engineering Hardware Engineering Optical Engineering System Engineering Lambda-X Mechanical Engineering Industrialization Contract manuf. Management External consultants Multi-disciplinary project team with inter-disciplinary collaboration!
- 32. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 32 #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, …)
- 33. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 33 GECOSENSE – OPTICAL SYSTEM MODELLING
- 34. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 34 #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
- 35. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 35 #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 for sensor 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)
- 36. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 36 GECOSENSE – PLATFORM DESIGN (MECHANICAL) Optical subsystem Attachment/alignment Signal processing Cover/protection Interface (BOXX)
- 37. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 37 GENERIC – PLATFORM DESIGN (HARDWARE) Naked sensor Sensor interface Platform management Processing Communication i/f Storage
- 38. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 38 MCU (PIC32MX) GECOSENSE – PLATFORM DESIGN (HARDWARE) Meter disk Optical transmitter (2x) Transmitter driver (2x) Optical receiver (2x) Analog to Digital Convertor Power supply EMC filtering Level shifting UART Meter interface module RAM FLASH Watch- dog
- 39. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 39 GECOSENSE – PLATFORM DESIGN (HARDWARE)
- 40. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 40 GENERIC – PLATFORM DESIGN (SOFTWARE) Hardware Abstraction Layer Sensor i/f and Pre-processing Communication protocol Signal Processing (algorithm) Sensor Platform Management
- 41. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 41 GECOSENSE – PLATFORM DESIGN (SOFTWARE) Bootloader Initialization Auto Calibration I/O driver (LEDs) I2S handling (ADC) Send/receive Pulse generation Signal sampling Protocol driver Band pass filter Envelope detection Normalization Dip detection Direction detection Dip counting (cons + prod) Task scheduling Power management
- 42. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 42 #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 Sensor Proof of Concept Preliminar functional sensor Optimized sensor
- 43. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 43 GECOSENSE - PROJECT APPROACH Explore Design Optimize
- 44. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 44 #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 tools 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)
- 45. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 45 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
- 46. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 46 #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
- 47. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 47 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 detection Improved reliability • Possibility for BOXX to recover from communication drop out • Minimize sensor resources (cost reduction)
- 48. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 48 GECOSENSE – READY FOR MARKET LAUNCH!
- 49. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 49 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
- 50. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 50 CONFIDENTIAL 50 CONCLUSION Click to insert subtitle
- 51. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 51 REDUCING THE PRESSURE FROM SENSOR DEVELOPMENT Sensor development UBIQUITOUS INVISIBLE OPEN PACE LOW VALUE PERCEPTION
- 52. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 52 Sensor development UBIQUITOUS INVISIBLE OPEN PACE LOW VALUE PERCEPTION REDUCING THE PRESSURE FROM SENSOR DEVELOPMENT Evolving architecture #1 Holistic approach #2 Understand the physics #3 Sensor as a Platform #4 Wide ‘angle of view’ #5 Streamline toolchain #6 Exploit full system
- 53. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 53 IS THIS A SIMPLE CAR PARKING SENSOR? https://www.youtube.com/watch?v=Wkvy0GtJE2E
- 54. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 54 ...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) THEDRIVER (sensorplatform#1) THECHICK (sensorplatform#2) THEDOG (sensorplatform#3)
- 55. 3.2 Simple sensors:case ‘smart metering’ CONFIDENTIAL 55 Innovation Day is an initiative of Masters in Innovation, the umbrella brand of the Verhaert Group which aims to connect, train and accelerate professional innovators. Kruibeke Belgium Hogenakkerhoekstraat 21 B-9150 Kruibeke T +32 3 250 19 00 E info@verhaert.com www.verhaert.com Nivelles Belgium Noordwijk Netherlands Av. Robert Schuman 102 B-1400 Nivelles T +32 67 47 57 10 E info@lambda-x.com www.lambda-x.com Kapteynstraat 1 2201 BB Noordwijk T +31 71 760 05 50 E info@verhaert.com connect.verhaert.com INDUSTRY TECHXFER MEDICAL AEROSPACE TECHXFER FMCGCONNECT TECHXFER FMCGCONNECT MEDICAL Aveiro Portugal Av. Dr. Lourenço Peixinho 96D 4o 3800-159 Aveiro T +351 234 604 088 E info@load-interactive.com www.load-interactive.com CONNECT Gentbrugge Belgium Bruiloftstraat 55-57 B-9050 Gentbrugge T +32 9 330 27 90 E info@moebiusdesign.be www.moebiusdesign.com ON SITE CONSULTANCY