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Title
Abstract
Figures
Design Files
Design Files Summary
Bill of Materials
Results from Calibration Procedure
Discussion
Conclusions
References
All Topics
Engineering
Energy Engineering and Power Technology

Open source low-cost power monitoring system

Profile image of Joshua PearceJoshua Pearce

2018, HardwareX

https://doi.org/10.1016/J.OHX.2018.E00044
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21 pages

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1 file

Abstract

This study presents an entirely open-source, low-cost power monitoring system capable of many types of measurements including both loads and supplies such as solar photovoltaic systems. In addition, the system can be fabricated using only open source software and hardware. The design revolves around the Digital Universal Energy Logger (DUEL) Node, which is responsible for reading and properly scaling the voltage and current of a particular load, and then serializing it via an on-board ATTiny85 chip. The configuration of the DUEL node allows for custom sensitivity ranges, and can handle up to 50 A and 300 V. Up to 127 DUEL nodes communicate via Inter-Integrated Circuit (I2C) on a bus, which can be monitored and logged through an Arduino UNO, or other compatible microcontroller. Using accessible equipment, the DUEL node can be calibrated to a desirable accuracy and error. The DUEL nodes are also completely customizable, making them fit for any input range, where all commercially-available products are fixed range. The open source solution out performs commercial solutions as the price per measurement ($18.25) is significantly smaller, while the number of serviceable channels (127) is significantly higher.

Figures (40)
Fig. 1. A simple sustainable house designed by OBI. The proposed system would monitor loads and sources such as the 3000 W PV panels, LED lighting, ar water pump. Stars denote measurable electrical devices. . Adapted from [16]
Fig. 1. A simple sustainable house designed by OBI. The proposed system would monitor loads and sources such as the 3000 W PV panels, LED lighting, ar water pump. Stars denote measurable electrical devices. . Adapted from [16]
Fig. 2. An example system setup with 9 DUEL nodes, and 2 splitting hubs. a ee ee ee ee a ee Ee — —————————eEeE———————————————— eS The DUEL node is a custom circuit implementing an ATTiny85 used for measurement and I2C serialization. The DUEL node is a universal node for virtually any power range. The node measures voltage directly through a single diode rectifier and 10 KQ potentiometer. Current is measured using a CQ2334 Hall effect current sensor [51], amplified by an operational amplifier circuit. Though the standard DUEL nodes utilize the CQ2334, it is possible to construct the node without the Hall effect sensor, and instead break out signals with header pins, and hook up an external Hall effect, or current transformer fot non-invasive sensing [52]. This functionality allows the DUEL node to be configured for a wide range of current and voltage measurements.
Fig. 2. An example system setup with 9 DUEL nodes, and 2 splitting hubs. a ee ee ee ee a ee Ee — —————————eEeE———————————————— eS The DUEL node is a custom circuit implementing an ATTiny85 used for measurement and I2C serialization. The DUEL node is a universal node for virtually any power range. The node measures voltage directly through a single diode rectifier and 10 KQ potentiometer. Current is measured using a CQ2334 Hall effect current sensor [51], amplified by an operational amplifier circuit. Though the standard DUEL nodes utilize the CQ2334, it is possible to construct the node without the Hall effect sensor, and instead break out signals with header pins, and hook up an external Hall effect, or current transformer fot non-invasive sensing [52]. This functionality allows the DUEL node to be configured for a wide range of current and voltage measurements.
Fig. 3. An overview of the Main Hub. I2C is chosen as the method of communication with DUEL nodes due its single bus connection style, as seen in Fig. 5 which allows for a 7 bit address field that in turn allows for 127 addressable nodes [50]. Serial communication has th The measurement hub is designed around the Arduino UNO. There are a few justifications for this choice. First, there is a well-established support community for open source Arduino technology, as well as many open-source programs available for reference [55,56]. Second, the Arduino is a component used in many other OSE designs (e.g. The Compressed Earth Brick Press and Micro-Inverter [57,58]), so this will prevent more on-stock back up components. Lastly, the Arduino UNO will have more than enough spare input and outputs (IO) that may be used for future expansion and enhancements. The system is equipped with peripherals in order to handle debugging, power and communication, with the rest of the system, human machine interface (HMI) and data storage, as shown in Figs. 3 and 4.
Fig. 3. An overview of the Main Hub. I2C is chosen as the method of communication with DUEL nodes due its single bus connection style, as seen in Fig. 5 which allows for a 7 bit address field that in turn allows for 127 addressable nodes [50]. Serial communication has th The measurement hub is designed around the Arduino UNO. There are a few justifications for this choice. First, there is a well-established support community for open source Arduino technology, as well as many open-source programs available for reference [55,56]. Second, the Arduino is a component used in many other OSE designs (e.g. The Compressed Earth Brick Press and Micro-Inverter [57,58]), so this will prevent more on-stock back up components. Lastly, the Arduino UNO will have more than enough spare input and outputs (IO) that may be used for future expansion and enhancements. The system is equipped with peripherals in order to handle debugging, power and communication, with the rest of the system, human machine interface (HMI) and data storage, as shown in Figs. 3 and 4.
Fig. 5. The I2C connection standard. The pull-up resistors may be managed internally by the Arduino.
Fig. 5. The I2C connection standard. The pull-up resistors may be managed internally by the Arduino.
Fig. 6. The software flow programmed onto the Arduino in the main hub.
Fig. 6. The software flow programmed onto the Arduino in the main hub.
Fig. 9. The splitting-hub is used for connecting multiple DUEL nodes to the main-hub.
Fig. 9. The splitting-hub is used for connecting multiple DUEL nodes to the main-hub.
Fig. 7. The Main Hub Schematic.
Fig. 7. The Main Hub Schematic.
Fig. 10. The splitting-hub.
Fig. 10. The splitting-hub.
Resistor selection for current conditioning. Table 1 The enclosures are printed using a $17.99, 1 kg spool of PLA on a Creality Ender 3 3-D printer. A layer height of 0.2 mm and infill of 30% is used.
Resistor selection for current conditioning. Table 1 The enclosures are printed using a $17.99, 1 kg spool of PLA on a Creality Ender 3 3-D printer. A layer height of 0.2 mm and infill of 30% is used.
Fig. 12. The Splitting Hub Board Layout.
Fig. 12. The Splitting Hub Board Layout.
Connections to program DUEL with Arduino UNO. Table 3
Connections to program DUEL with Arduino UNO. Table 3
Potentiometer configuration for voltage conditioning. Fig. 15. The single layer board of the DUEL node. Table 2
Potentiometer configuration for voltage conditioning. Fig. 15. The single layer board of the DUEL node. Table 2
Fig. 14. The complete schematic for the DUEL node.
Fig. 14. The complete schematic for the DUEL node.
Fig. 16. The firmware flow chart for the DUEL node.
Fig. 16. The firmware flow chart for the DUEL node.
A description of project files available on the repository [66] and the registration at https://osf.io/9rts5/.
A description of project files available on the repository [66] and the registration at https://osf.io/9rts5/.
Bill of Materials for the Main-Hub.
Bill of Materials for the Main-Hub.
Bill of material for the Splitting Hub.
Bill of material for the Splitting Hub.
Bill of material for the DUEL node.
Bill of material for the DUEL node.
Fig. 17. The completed DUEL node.
Fig. 17. The completed DUEL node.
Fig. 18. The configuration for calibrating the voltage input of the DUEL node.
Fig. 18. The configuration for calibrating the voltage input of the DUEL node.
Fig. 19. The configuration for calibrating the current input of the DUEL node (10 Ohm 100 W resistance used).
Fig. 19. The configuration for calibrating the current input of the DUEL node (10 Ohm 100 W resistance used).
Fig. 21. The results of placing a simulated 10A AC input to the sensor. Additionally, a frequency response is generated. Fig. 20. The circuit used to simulate an AC current measurement.
Fig. 21. The results of placing a simulated 10A AC input to the sensor. Additionally, a frequency response is generated. Fig. 20. The circuit used to simulate an AC current measurement.
Fig. 22. The DUEL node calibration curve for DC current measurement.
Fig. 22. The DUEL node calibration curve for DC current measurement.
Fig. 25. The DUEL node calibration curve for DC voltage measurement (created by varying load). Fig. 24. The DUEL node calibration curve for DC current measurement (created by varying load).
Fig. 25. The DUEL node calibration curve for DC voltage measurement (created by varying load). Fig. 24. The DUEL node calibration curve for DC current measurement (created by varying load).
Fig. 23. The DUEL node calibration curve for DC voltage measurement.
Fig. 23. The DUEL node calibration curve for DC voltage measurement.
Fig. 26. The DUEL node calibration curve for AC current measurement.
Fig. 26. The DUEL node calibration curve for AC current measurement.
Fig. 28. DC Current Measurement Error. As an initial test of the system, a node is connected to measure a segment of the 3000 W solar photovoltaic array in the SEED Eco-home. Fig. 32 displays an example of the data logged over time. The dips in voltage at minute 40 and minute 100 are consistent with observed cloud cover.
Fig. 28. DC Current Measurement Error. As an initial test of the system, a node is connected to measure a segment of the 3000 W solar photovoltaic array in the SEED Eco-home. Fig. 32 displays an example of the data logged over time. The dips in voltage at minute 40 and minute 100 are consistent with observed cloud cover.
Fig. 27. The DUEL node calibration curve for AC voltage measurement.
Fig. 27. The DUEL node calibration curve for AC voltage measurement.
Fig. 31. AC Voltage Measurement Error. Fig. 32. Initial data from a segment of a 3 kW solar PV array.
Fig. 31. AC Voltage Measurement Error. Fig. 32. Initial data from a segment of a 3 kW solar PV array.
Fig. 29. DC Voltage Measurement Error.
Fig. 29. DC Voltage Measurement Error.
Fig. 30. AC Current Measurement Error.
Fig. 30. AC Current Measurement Error.

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