SYSTEM DESIGN FINAL REPORT Aaron Landy IMDL Fall

SYSTEM DESIGN FINAL REPORT Aaron Landy IMDL Fall 2013 November 21, 2013 C-4 P 5 Automatic Beer Bottle Filler and Capper

DESIGN AND OPERATION

OVERVIEW System Block Diagram

OVERVIEW

SOFTWARE DESIGN Three primary systems: § Raspberry Pi § § Master system control Image processing Slave management Software distribution § Horizontal Axis Arduino § Primary real-time control § Bottle searching § Bottle handling § Vertical Axis Arduino § § Filling control Cap retrieval Capper control Height Adjustment

RASPBERRY PI Image processing Master system control Bottle volume estimation User interface Bottle height estimation Progress monitoring Slave management Master <-> Slave serial communication Software distribution Build in place Arduino Compile, Upload State save, resume Testing control C++, Open. CV Python make, g++, SCP

HORIZONTAL AXIS CONTROLLER Primary realtime control Bottle searching Task scheduling CDs to ADC input Sensor reporting Digital threshold monitoring Serial communication Trigger Claw on detect Motor Control Background state machine Program execution Arduino Sensors Periodic background sensor polling Real-time digital filtering

QUESTIONS ?

MOTIVATION Homebrewing is fun, bottling beer is hard Time consuming process requires individually filling and capping bottles of different shapes and sizes ~50 bottles per 5 gal batch

BOTTLE DETECTOR APPROACHES Simple Filtering and Area Blob Detection 1. Inverse Binary thresholding to isolate bottle against background, filter noise 2. Count pixels for bottle area 3. Measure longest range of pixels for bottle height Open. CV Simple. Blob. Detector: 1. Successive binary thresholding 2. Find contours in binary images to extract connected components 3. Group keypoint centers across binary images 4. Estimate blob centers, radii from grouped components

THRESHOLD CALIBRATION Source 12 oz 24 32 40 48 64 96

PIXEL AREA CONVERSION • Area in pixels must be converted to real 2 D area measure • Requires calibration based on bottle sizes • Must factor in relative positions of bottle and moving camera Area 20587 Width 90 22468 96 29708 135

OBJECTIVES Fill bottles with precise amounts Cap bottles securely without breaking Support inconsistent bottle shapes and sizes Seek/retrieve bottles automatically Do not contaminate, oxidize, damage, or waste beer

MECHANISMS Four primary mechanisms: 1. Bottle searching/retrieving claw § Infrared and bump sensors to locate bottle 2. Filling tube § Stainless steel tube lowered into bottle § Tube opening must be pressed against bottom of bottle to minimize agitation to prevent oxidation or contamination 3. Cap retrieving/placing magnet § Caps must be picked up from top of bottle and held during filling § Cap must be replaced precisely on top of bottle 4. Capping actuator § Forceful linear actuator with capping “bell” crimps/seals cap onto bottle

ELECTRONICS Raspberry Pi (Model B rev. 2) Infrared Range Finder and bump to detect bottles Raspberry Pi Camera module to calculate bottle height and volume Arduino + Stepper Motors + Motor Driver to drive linear motion axes Servos to open and close, turn claw