Ride-On floor cleaning machine - control circuits replacement

[Konan]

The Machine:



A ride on floor cleaning machine that we've modifed to do a whole lot more ;)

Entirely driven on hydraulics, powered by an LPG (propane/gasoil) engine.

The Task: To replace this lot!



This is the main logic and power-switching board. It converts momentary action button presses and floatswitch/microswitch feedback into various modes of operation controlling lights, valve solenoids and vacuum motors. It also involves a couple of time delays.

The board is....

• Prone to shorts - note all the diodes connected over the metal backing
• Overly complicated for problem diagnostics - takes hours to find faults even if you know the circuit back to front and intermittent problems are near unsolvable
• Susceptible to water ingress - not good for a machine that's filled up with a hose outside in the raid
• Expensive - We have to import parts from the US

The prop1 version:



All wired up and ready for testing. The real challenge was squeezing the program into the space available (once learning PBASIC, that is). Managed to reduce its size by just enough by addressing a word in memory throughout the program and only referring to the upper and lower bytes separately for transmission to the DC16 (I would've used a byte and a single ULN as the system only has 8 outputs but was right on the sink limit).

The software runs on a permanent loop as the machine needs instant response to certain inputs so the serial communication. The DC16 is limited to state changes only to reduce response times.

Ready for fitment:



I've got some hot glue to add in places to reduce the chance of components coming adrift due to vibration (the board is on shock mounts). Just have to see how it behaves in the machine.

[JonnyMac]

Very cool.   Since we have a LOT of PBASIC 1 experience (since 1994) we're happy to look over your code and make suggestions.  If it can't be posted for competitive reasons you can send it to my work e-mail address.

[livinlowe]

I know most of the projects on this forum are Halloween, Christmas, etc., but I LOVE it when people use Prop-1's, etc. for real world applications! Great Job! I am sure your life will be simplified greatly using a microcontroller! <burns> Excellent </burns>  :)

[JonnyMac]

We have many non-holiday users; museums, amusement parks, industrial engineers, special FX artists -- it's an interesting lot. 

[menehune]

I think I remember someone using a prop1 in a pallet loader/factory application.

[Konan]

Thanks,

If I need to squeeze any more onto the ROM I'll seek some advice on the code. As it is, it's on and working as it should (fingers crossed). I got on OK with PBASIC1 thanks to having experience programing old microCPUs. It's far more like branching assembly than basic with it's if/goto structure.

I'm quite liking the ease of the prop1 controller. Yes, the stamp can be bought on a DIL package and added to your own board, but this is so quick and really laid out for getting connected up and running. Next project might be a personal one, I need something to control some pyrotechnics ;)

[EricTheMannn]

Amazing job, i love the organized wiring and detail information.

If you have some video that would be awesome to see in action!

-Eric