Box providing insight into your machine's health and safety using vibration, current monitoring, Rfid, and cloud data logging.
Things used in this project
Hardware components
HARDWARE LIST
1 DFRobot Gravity: Digital Piezo Disk Vibration Sensor
1 Particle Argon
1 RFID reader (generic)
1 ControlEverything.com Particle Electron 1 channel 20 amp current monitoring controller
1 ElectroPeak 0.96" OLED 64x128 Display Module
1 Rotary Encoder with Push-Button
Hand tools and fabrication machines
scrollsaw
Laser cutter (generic)
Story
The purpose of my project was to create an automated way to tell if a saw blade might need to be changed or cleaned. I used a current monitor and piezo sensor to monitor the changes in current and vibrations for a machine with a sharp blade vs. one with a dull blade. I added a Rfid reader and controllable power strip to control when a machine could be turned on. The engine won't power on unless a valid access card has been presented.
Being able to tell when a machine might need its blade replaced is essential for any woodshop or machinist shop because of the hazards that a dull blade might cause and because a dull blade could provide uneven cuts of wood.
My solution is to use a vibration sensor with logging to Google sheets/excel to create FFT models in Excel and STD calculations to monitor waveforms. The data logged in Google Sheets could be processed in Matlab or any vibration analysis software. My project also includes sending values to Adafruit dashboard for real-time graphing of the current and vibration values.
Below is a graph depicting the difference in a dull blade vs a sharp blade.
Custom parts and enclosures
Laser Cut Acrylic Box
Schematics
Code
White Matter Vibration Monitor
C/C++
You use a current monitor and piezo disk to monitor for variations in the system
CODE
/*
* Project Capstone_Project
* Description: RFID Capstone Project
* Author: Daniel Mills
* Date:04-13-2022
*/
//SYSTEM_MODE(SEMI_AUTOMATIC);
///////////////////////////////
//-----Include and Objects Block
#include "credential.h" //creddential for ada fruit dashboard
#include "math.h"
#include <Adafruit_GFX.h> //library for graphics
#include <Adafruit_SSD1306.h> //library for OLED
#include <Adafruit_MQTT.h> //Library for publishing to Adafruit
#include "Adafruit_MQTT/Adafruit_MQTT.h"
#include "Adafruit_MQTT/Adafruit_MQTT_SPARK.h"
#include "clickButton.h"
#include <Encoder.h>
#include <Wire.h>
#include <SPI.h>
#include <Adafruit_PN532.h>
//Var for Encoder
Encoder myEnc(D2, D3);
int oldPosition;
int newPosition;
int encoderMap;
//Initialization
#define OLED_RESET D4
Adafruit_SSD1306 display(OLED_RESET);
String DateTime, TimeOnly;
//Rfid Vars
const int PN532_IRQ = A0;
const int PN532_RESET = A1;
Adafruit_PN532 nfc(PN532_IRQ, PN532_RESET);
uint8_t valid;
//Validation System for Rfid
uint8_t masterKey[4] = {0x13, 0x99, 0xC9, 0x1E};
uint8_t uidArray[4];
bool correctKey;
bool powerAccess;
//Button Vars
const int BUTTONPIN2 = D5;
int function = 0;
//Vars For Current and Vibration
//PECMAC125A I2C address is 0x2A(42) //Piezo is 0x50
#define Addr 0x2A
#define AddrP 0x50
//Piezo ((Pvalues)
long vibdat[4096][2];
int i;
int j;
byte dataP[2];
int raw_adc = 0;
float pSensor; //stores the piezo sensor readings for google sheet
//Current Vars
byte data[36];
int typeOfSensor = 0;
int maxCurrent = 0;
int noOfChannel = 0;
float current = 0.0;
//Vibration Bin Sorting Values
int x, y, c, d;
static int xx, yy, cc, dd;
//time vars
int startTime;
int last;
int lastTime2;
//Power Strip Var
const int POWERSTRIP = A5;
int Power; //MQTT Power Button Var
byte buf;
//Connecting to Adafruit Webservice
TCPClient TheClient;
// Setup the MQTT client class by passing in the WiFi client and MQTT server and login details.
Adafruit_MQTT_SPARK mqtt(&TheClient,AIO_SERVER,AIO_SERVERPORT,AIO_USERNAME,AIO_KEY);
/**** Feeds *********/
// Setup Feeds to publish or subscribe
Adafruit_MQTT_Publish mqttvib = Adafruit_MQTT_Publish(&mqtt, AIO_USERNAME "/feeds/vib");
Adafruit_MQTT_Publish mqttcurrent = Adafruit_MQTT_Publish(&mqtt, AIO_USERNAME "/feeds/current");
Adafruit_MQTT_Publish mqttuid = Adafruit_MQTT_Publish(&mqtt, AIO_USERNAME "/feeds/uid");
//Power
Adafruit_MQTT_Subscribe mqttPower = Adafruit_MQTT_Subscribe(&mqtt, AIO_USERNAME "/feeds/Power");
void setup() {
Serial.begin(115200);
attachInterrupt(D5, getMode, FALLING);
//Setup For Rfid
Serial.printf("Init Reader \n");
nfc.begin();
//////
//Rfid
rfidBegin();
//Setting Time for button clicks -- measured in millis
pinMode(BUTTONPIN2, INPUT_PULLUP);
pinMode(POWERSTRIP, OUTPUT);
//Getting Time Info -- This is for if info wanted to be recorded with the date
Time.zone(-7);
Particle.syncTime();
//Connect to Wifi
WiFi.connect();
while(WiFi.connecting()){
Serial.printf(".");
}
mqtt.subscribe(&mqttPower); //subscribe to power button from Adafruit
//Sets System Access False and turns the power off
powerAccess = false;
digitalWrite(POWERSTRIP, LOW);
//##Setup Information for the OLED
display.begin(SSD1306_SWITCHCAPVCC, 0x3c); // initialize with the I2C addr 0x3D (for the 128x64)
display.display(); // show splashscreen
display.setTextSize(1);
display.clearDisplay(); //clears the display
display.setCursor(0,0); // Start at top-left corner
display.setTextColor(WHITE);
display.printf("Please Scan Card"); //Outputs Switch Case
display.display();
//Setup for Reading Current and Piezo through I2C
//Initialise I2C communication as MASTER
Wire.begin();
// Initialise Serial Communication, set baud rate = 9600
Serial.begin(9600);
//Start I2C transmission
Wire.beginTransmission(Addr);
//Command header byte-1
Wire.write(0x92);
//Command header byte-2
Wire.write(0x6A);
//Command 2 is used to read no of sensor type, Max current, No. of channel
Wire.write(0x02);
//Reserved
Wire.write(0x00);
//Reserved
Wire.write(0x00);
//Reserved
Wire.write(0x00);
//Reserved
Wire.write(0x00);
//CheckSum
Wire.write(0xFE);
//Stop I2C transmission
Wire.endTransmission();
//Request 6 bytes of data
Wire.requestFrom(Addr, 6);
//Read 6 bytes of data
if (Wire.available() == 6)
{
data[0] = Wire.read();
data[1] = Wire.read();
data[2] = Wire.read();
data[3] = Wire.read();
data[4] = Wire.read();
data[5] = Wire.read();
}
typeOfSensor = data[0];
maxCurrent = data[1];
noOfChannel = data[2];
}
void loop() {
//*MQTT Start
MQTT_connect();
//Ping MQTT Broker every 2 minutes to keep connection alive
if ((millis()-last)>120000) { //function to ping the MQTT broker
Serial.printf("Pinging MQTT \n");
if(! mqtt.ping()) {
Serial.printf("Disconnecting \n");
mqtt.disconnect();
}
last = millis();
}
//*MQTT Subscription
Adafruit_MQTT_Subscribe *subscription; //looks for MQTT subscriptions for button input to turn on motor pump
while ((subscription = mqtt.readSubscription(100))) { //looks for receiving signal
if (subscription == &mqttPower) {
Power = atoi((char *)mqttPower.lastread); //takes last data and converts it char and converts it to a float
Serial.printf("Received %i from Adafruit.io feed Power Button \n", Power); //prints to screen
}
}
//Power Button
if (Power == 1){ //turns off the power if input was recieved from Adafruit
digitalWrite(POWERSTRIP, LOW);
Serial.printf("Power was turned off \n");
}
////Current Reader
for (int j = 1; j < noOfChannel + 1; j++){
//Commands for Reading Data
Wire.beginTransmission(Addr);
Wire.write(0x92); //Command for byte-1
Wire.write(0x6A); //Command for byt-2
Wire.write(0x01);
Wire.write(j);
Wire.write(j);
Wire.write(0x00);
Wire.write(0x00);
// CheckSum
Wire.write((0x92 + 0x6A + 0x01 + j + j + 0x00 + 0x00) & 0xFF);
// Stop I2C Transmission
Wire.endTransmission();
// Request 3 bytes of data
Wire.requestFrom(Addr, 3);
// Read 3 bytes of data
// msb1, msb, lsb
int msb1 = Wire.read();
int msb = Wire.read();
int lsb = Wire.read();
current = (msb1 * 65536) + (msb * 256) + lsb;
// Convert the data to ampere
current = current / 1000;
}
rfidCardRead();
///////////////////////////////
//Info will only show if Access is granted
if (powerAccess == TRUE){
//Encoder Info for Menu
int newPosition = myEnc.read();
if (newPosition != oldPosition) {
function = 0;
oldPosition = newPosition;
if (newPosition > 20){
myEnc.write(20);
}
if (newPosition < 0){
myEnc.write(0);
}
}
//maps the encoder to the Switch Case
encoderMap = map(newPosition, 0, 20, 0, 2);
// enter switch case
switch(encoderMap)
{
//Start
case 0:
if (function == 0){
display.clearDisplay(); //clears the display
display.setCursor(0,0); // Start at top-left corner
display.setTextColor(WHITE);
display.printf("MENU: \n->Current Read \nVib Read \nPublish Values \n"); //Outputs Switch Case
display.display();
}
else{
if(function == 1){
display.clearDisplay(); //clears the display
display.setCursor(0,0); // Start at top-left corner
display.setTextColor(WHITE);
display.printf("Channel: %i \n", j);
display.printf("Current Value: %0.2f \n", current);
display.display();
}
}
// Output data to dashboard
Serial.printf("Channel: %i \n", j);
Serial.printf("Current Value: %0.2f \n", current);
//Second Click ends logging and returns to menu
if(function == -1){
Serial.printf("SINGLE LONG click \n"); //for testing
function = 0;
break;
}
Serial.printf("Function %i", function);
break;
//Start
case 1:
Serial.printf("Function %i \n", function);
if (function == 0){
display.clearDisplay(); //clears the display
display.setTextColor(WHITE);
display.setCursor(0,0); // Start at top-left corner
display.printf("MENU: \nCurrent Read \n->Vib Read \nPublish Values \n"); //Outputs Switch Case
display.display();
}
else{
piezoRead(); // function collects values from the piezo sensor
if (function == 1){
//12-bit Resolution output every 1 second
if ((millis() - startTime > 1000)){
Serial.printf("\n%i,%i\n",millis(), raw_adc);
if(raw_adc >= 0 && raw_adc <= 25 ){
xx = 0;
xx = x++;
}
if(raw_adc >= 26 && raw_adc <= 50 ){
yy = 0;
yy = y++;
}
if(raw_adc >= 51 && raw_adc <= 75){
cc = 0;
cc = c++;
}
if(raw_adc >= 76){
dd = 0;
dd = d++;
}
display.clearDisplay(); //clears the display
display.setTextColor(WHITE);
display.setCursor(0,0); // Start at top-left corner
display.printf("Vib Values: %i\n", raw_adc); //Prints values to OLED
display.printf("0-25: %i\n", xx); //Prints values to OLED
display.printf("26-50: %i\n", yy); //Prints values to OLED
display.printf("51-75: %i\n", cc); //Prints values to OLED
display.printf("Vib > 76:%i\n", dd); //Prints values to OLED
display.display();
startTime = millis();
}
}
}
if(function == -1){
Serial.printf("SINGLE LONG click \n"); //for testing
function = 0;
break;
}
break;
case 2:
Serial.printf("Function %i \n", function);
if (function == 0){
display.clearDisplay(); //clears the display
display.setTextColor(WHITE);
display.setCursor(0,0); // Start at top-left corner
display.printf("MENU: \nCurrent Read \nVib Read \n->Publish Values \n "); //Outputs Switch Case
display.display();
}
else{
if (function == 1){
piezoRead(); // function collects values from the piezo sensor
pSensor = raw_adc;
Particle.publish("pSensor", String(pSensor)); //reads the vibration sensor values and puts them into a var to send to google sheets
//*Reads and Publishes Values to Adafruit
if((millis()-lastTime2 > 5000)) {
if(mqtt.Update()) { //starts MQTT updats
mqttcurrent.publish(current); //publishes the current values Adafruit
Serial.printf("Publishing Current %0.2f \n", current); //prints current values to serial monitor
mqttvib.publish(raw_adc); //pub the piezo values
Serial.printf("Publishing Vib %i \n", raw_adc); //prints piezo to serial monitor
//Prints Values to the OLED
display.clearDisplay(); //clears the display
display.setTextColor(WHITE);
display.setCursor(0,0); // Start at top-left corner
display.printf("Publishing Current: \n");
display.printf("%0.2f \n", current);
display.printf("Publishing Vibration:");
display.printf("%i \n", raw_adc);
//display.printf("Publishing Vib to \n");
display.display();
}
lastTime2 = millis();
}
}
}
if(function == -1){
Serial.printf("SINGLE LONG click \n"); //for testing
function = 0;
break;
}
break;
default:
function = 0;
break;
oldPosition = encoderMap;
}
}
}
///////////////////////////
//////////////////////////
//Void Functions
//Function Starts Rfid
void rfidBegin(){
uint32_t versiondata = nfc.getFirmwareVersion();
if (! versiondata){
Serial.printf("Didn't find PN53x board");
while (1);
}
Serial.printf("\nFound chip PN5"); Serial.print((versiondata>>24) & 0xFF, HEX);
Serial.printf("\nFirmware ver. "); Serial.print((versiondata>>16) & 0xFF, DEC);
Serial.printf("."); Serial.print((versiondata >>8) & 0xFF, DEC);
nfc.SAMConfig();
nfc.setPassiveActivationRetries(0xFF);
Serial.printf("\nWaiting for Card \n");
}
//Function for Looping Rfid
void rfidCardRead(){
uint8_t success;
uint8_t uid[] = {0, 0, 0, 0, 0, 0, 0}; //Buffer to store the returned UID
uint8_t uidLength; //Length of the UID (4 or 7 bytes)
success = nfc.readPassiveTargetID(PN532_MIFARE_ISO14443A, uid, &uidLength);
if (success) {
Serial.printf("\nSuccess getting target ID \n");
// Display some basic information about the card
Serial.printf("Card Type ISO14443A card \n");
Serial.printf("UID Value: ");
nfc.PrintHex(uid, uidLength);
Serial.printf("............. \n");
if (uidLength == 4){
Serial.printf("Mifare Classic Card \n");
Serial.printf("Authenticating Card \n");
uint8_t keya[6] = { 0XFF, 0XFF, 0XFF, 0XFF, 0XFF, 0XFF };
success = nfc.mifareclassic_AuthenticateBlock(uid, uidLength, 4, 0, keya);
if (success){
//Serial.printf("Sector 1 has been authenticated \n");
uint8_t data[16];
success = nfc.mifareclassic_ReadDataBlock(4, data);
if(success){
Serial.printf("Reading... \n");
nfc.PrintHexChar(data, 16);
correctKey = isMatched(uid, masterKey);
if (correctKey == 1) {
Serial.printf("Valid Access Card \n");
}
else{
Serial.printf("Invalid Access Card \n");
}
}
else{
Serial.printf("Card Reading Error \n");
}
}
}
}
Serial.printf("#####BREAK######");
}
//Function for Validating master card
bool isMatched (uint8_t uid[4], uint8_t masterKey[4]) {
int i;
for(i=0; i < 4; i++){
Serial.printf("%i", uid[i]);
if(uid[i] != masterKey[i] ){
Serial.printf("*Invalid Key \n");
Serial.printf(" \n");
Serial.printf("Your UID Value: %i \n", uid);
display.clearDisplay();
display.setTextColor(WHITE);
display.setCursor(0,0);
display.printf("Invalid Key - Access Denied"); //Outputs Switch Case Access
display.display();
//delay(1000);
powerAccess = FALSE;
digitalWrite(POWERSTRIP, LOW);
Serial.printf("Power strip is OFF");
Serial.printf("PowerAccess %i \n", powerAccess);
return false;
}
}
Serial.printf("*Valid Key \n");
display.clearDisplay();
display.setTextColor(WHITE);
display.setCursor(0,0);
display.printf("Valid Key - Access Granted"); //Output for Switch Case access
display.display();
powerAccess = TRUE;
digitalWrite(POWERSTRIP, HIGH);
Serial.printf("Power strip is ON");
Serial.printf("PowerAccess %i \n", powerAccess);
return true;
}
//Function for changing button state
void getMode(){
function++;
if(function == 2){
function = -1;
Serial.printf("Inside -1(2c) %i \n", function);
}
if(function != 2){
Serial.printf("Outide Function 0(0c) %i \n", function);
}
}
// Function to connect and reconnect as necessary to the MQTT server.
void MQTT_connect() { //this function is important to include for connecting to MQTT
int8_t ret;
// Stop if already connected.
if (mqtt.connected()) {
return;
}
Serial.print("Connecting to MQTT... ");
while ((ret = mqtt.connect()) != 0) { // connect will return 0 for connected
Serial.printf("%s\n",(char *)mqtt.connectErrorString(ret));
Serial.printf("Retrying MQTT connection in 5 seconds..\n");
mqtt.disconnect();
delay(5000); // wait 5 seconds
}
Serial.printf("MQTT Connected!\n"); //output for if connection was successful
}
////////////////////////////
//Function For Getting Piezo Values
void piezoRead(){
for(i=0;i<4096;i++) {
// Start I2C transmission
Wire.beginTransmission(AddrP);
// Calling conversion result register, 0x00(0)
Wire.write(0x00);
// Stop I2C transmission
Wire.endTransmission();
// Request 2 bytes
Wire.requestFrom(AddrP, 2);
// Read 2 bytes of data, raw_adc msb, raw_adc lsb
if(Wire.available() == 2){
dataP[0] = Wire.read();
dataP[1] = Wire.read();
}
// Convert the data to 12 bits
raw_adc = ((dataP[0] * 256) + dataP[1]) & 0x0FFF;
vibdat[i][0] = micros();
vibdat[i][1] = raw_adc;
}
}The article was first published in hackster, April 22, 2022
cr: https://www.hackster.io/daniel-mills/white-matter-vibration-monitor-7973e4
author: Daniel Mills
License 
All Rights
Reserved
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