Execute Open-Source Arduino Code in a PIC Microcontroller Using the MPLAB IDE

The Arduino single-board computer is a de facto standard tool for developing microcomputer applications within the hobbyist and educational communities. It provides an open-source hardware (OSH) environment based on a simple microcontroller board, as well as an open-source (OS) development environment for writing software for the board.

Here’s an approach that enables Arduino code to be configured for execution with the Microchip Technology PIC32MX250F128B small-outline 32-bit microcontroller. It uses the Microchip Technology MPLAB X IDE and MPLAB XC32 C Compiler and the Microchip Technology Microstick II programmer/debugger.

Your own reasons for using this approach will depend on your personal needs and background. Perhaps as a long-term Arduino user, you want to explore a new processor performance option with your existing Arduino code base. Or, you want to take advantage of or gain experience with the Microchip advanced IDE development tools and debug with your existing Arduino code. All of these goals are easily achieved using the approach and the beta library covered in this article.

Several fundamental open-source Arduino code examples are described using the beta core library of Arduino functions I developed. The beta version is available, for evaluation purposes only, as a free download from the “Arduino Library Code for PIC32” link on my KibaCorp company website, kibacorp.com. From there, you can also download a short description of the Microstick II hardware configuration used for the library.

To illustrate the capabilities in their simplest form, here is a simple Blink LED example from my book Beginner’s Guide to Programming the PIC32. The example shows how this custom library makes it easy to convert Arduino code to a PIC32 binary file.

ARDUINO BLINK EXAMPLE 1
The Arduino code example is as follows: Wire an LED through a 1-K resistor to pin 13 (D7) of the Arduino. An output pin is configured to drive an LED using pinMode () function under setup (). Then under loop () this output is set high and then low using digitalWrite () and delay () functions to blink the LED. The community open-source Arduino code is:

Listing 1forwebPIC32 EXAMPLE 1 CODE MODIFICATIONS
The open-source example uses D13 or physical pin 13 on the Arduino. In relation to the PIC32MX, the D13 is physical pin 25. Pin 25 will be used in prototyping wiring.

Now, let’s review and understand the PIC32 project template and its associated “wrapping functions.”  The Arduino uses two principal functions: setup () to initialize the system and loop () to run a continuous execution loop. There is no Main function. Using the Microchip Technololgy XC32 C compiler, we are constrained to having a Main function. The Arduino setup () and loop () functions can be accommodated, but only as part of an overall template Main “wrapping” function. So within our PIC32 template, we accommodate this as follows:

Listing 2

This piece of code is a small but essential part of the template. Note that in this critical wrapping function, setup () is called once as in Arduino and loop () is configured to be called continuously (simulating the loop () function in Arduino) through the use of a while loop in Main.

The second critical wrapping function for our template is the use of C header files at the beginning of the code. The XC32 C compiler uses the C compiler directive #include reference files within the Main code. Arduino uses import, which is a similar construct that is used in higher-level languages such as Java and Python, which cannot be used by the MPLAB XC32 C.

The two include files necessary for our first example are as follows:

Listing 3

System.h references all the critical Microchip library functions supporting the PIC32MX250F128B. The Ardunio.h provides the Arduino specific library function set. Given these two key “wrapper” aspects, where does the Arduino code go? This is best illustrated with a side-by-side comparison between Arduino code and its Microchip equivalent. The Arduino code is essentially positioned between the wrapper codes as part of the Main function.

Blink side-by-side comparison

Blink side-by-side comparison

This approach enables Arduino code to execute on a Microchip PIC32 within an MPLAB X environment. Note that the Arduino code void setup () now appears as void setup (void), and void loop () appears as void loop (void). This is a minor inconvenience but again necessary for our C environment syntax for C prototype function definitions. Once the code is successfully compiled, the environment enables you to have access to the entire built-in tool suite of the MPLAB X and its debugger tool suite.

RUNNING EXAMPLE 1 CODE
Configure the Microstick II prototype as in the following schematic. Both the schematic and prototype are shown below:

Exercise 1 schematic

Exercise 1 schematic

Exercise 1 prototype

Exercise 1 prototype

BETA LIBRARY
Table 1 compares Arduino core functionality to what is contained in the Microchip PIC32 expanded beta library. In the beta version, I added additional C header files to accomplish the necessary library functionality. Table 2 compares variable types between Arduino and PIC32 variable types. Both Table 1 and Table 2 show the current beta version has a high degree of Arduino core library functionality. Current limitations are the use of only one serial port, interrupt with INT0 only, and no stream capability. In addition, with C the “!” operator is used for conditional test only and not as a complement function, as in Arduino. To use the complement function in C, the “~” operator is used. The library is easily adapted to other PIC32 devices or board types.

Table 1

Table 1: Arduino vs Microchip Technology PIC32 core library function comparison

Talble 2

Table 2: Arduino vs Microchip Technology PIC32 core library variable types

INTERRUPTS
If you use interrupts, you must identify to C the name of your interrupt service routine as used in your Arduino script. See below:

Interrupt support

Interrupt support

For more information on the beta release or to send comments and constructive criticism, or to report any detected problems, please contact me here.

LIBRARY TEST EXAMPLES
Four test case examples demonstrating additional core library functions are shown below as illustrations.

Serial communications

Serial communications

Serial find string test case

Serial find string test case

Serial parse INT

Serial parse INT

Interrupt

Interrupt

Editor’s Note: Portions of this post first appeared in Tom Kibalo’s book Beginner’s Guide to Programming the PIC32 (Electronics Products, 2013). They are reprinted with permission from Chuck Hellebuyck, Electronic Products. If you are interested in reading more articles by Kibalo, check out his two-part Circuit Cellar “robot boot camp” series posted in 2012 : “Autonomous Mobile Robot (Part 1): Overview & Hardware” and “Autonomous Mobile Robot (Part 2): Software & Operation.”

 

Tom Kibalo

Tom Kibalo

ABOUT THE AUTHOR
Tom Kibalo is principal engineer at a large defense firm and president of KibaCorp, a company dedicated to DIY hobbyist, student, and engineering education. Tom, who is also an Engineering Department adjunct faculty member at Anne Arundel Community College in Arnold, MD, is keenly interested in microcontroller applications and embedded designs. To find out more about Tom, read his 2013 Circuit Cellar member profile.

New 8-bit PIC Microcontrollers: Intelligent Analog & Core Independent Peripherals

Microchip Technology, Inc. announced Monday from EE Live! and the Embedded Systems Conference in San Jose the PIC16(L)F170X and PIC16(L)F171X family of 8-bit microcontrollers (MCUs), which combine a rich set of intelligent analog and core independent peripherals, along with cost-effective pricing and eXtreme Low Power (XLP) technology. Available in 14-, 20-, 28-, and 40/44-pin packages, the 11-member PIC16F170X/171X family of microcontrollers integrates two op-amps to drive analog control loops, sensor amplification and basic signal conditioning, while reducing system cost and board space.

PIC16F170X/171X MCUs reduce design complexity and system BOM cost with integrated op-amps, zero cross detect, and peripheral pin select.

PIC16F170X/171X MCUs reduce design complexity and system BOM cost with integrated op-amps, zero cross detect, and peripheral pin select.

These new devices also offer built-in Zero Cross Detect (ZCD) to simplify TRIAC control and minimize the EMI caused by switching transients. Additionally, these are the first PIC16 MCUs with Peripheral Pin Select, a pin-mapping feature that gives designers the flexibility to designate the pinout of many peripheral functions.

The PIC16F170X/171X are general-purpose microcontrollers that are ideal for a broad range of applications, such as consumer (home appliances, power tools, electric razors), portable medical (blood-pressure meters, blood-glucose meters, pedometers), LED lighting, battery charging, power supplies and motor control.

The new microcontrollers feature up to 28 KB of self-read/write flash program memory, up to 2 KB of RAM, a 10-bit ADC, a 5-/8-bit DAC, Capture-Compare PWM modules, stand-alone 10-bit PWM modules and high-speed comparators (60 ns typical response), along with EUSART, I2C and SPI interface peripherals. They also feature XLP technology for typical active and sleep currents of just 35 µA/MHz and 30 nA, respectively, helping to extend battery life and reduce standby current consumption.

The PIC16F170X/171X family is supported by Microchip’s standard suite of world-class development tools, including the PICkit 3 (part # PG164130, $44.95), MPLAB ICD 3 (part # DV164035, $189.99), PICkit 3 Low Pin Count Demo Board (part # DM164130-9, $25.99), PICDEM Lab Development Kit (part # DM163045, $134.99) and PICDEM 2 Plus (part # DM163022-1, $99.99). The MPLAB Code Configurator is a free tool that generates seamless, easy-to-understand C code that is inserted into your project. It currently supports the PIC16F1704/08, and is expected to support the PIC16F1713/16 in April, along with all remaining microcontrollers in this family soon thereafter.

The PIC16(L)F1703/1704/1705 microcontrollers are available now for sampling and production in 14-pin PDIP, TSSOP, SOIC and QFN (4 x 4 x 0.9 mm) packages. The PIC16F1707/1708/1709 microcontrollers are available now for sampling and production in 20-pin PDIP, SSOP, SOIC and QFN (4 x 4 x 0.9 mm) packages. The PIC16F1713/16 MCUs are available now for sampling and production in 28-pin PDIP, SSOP, SOIC, QFN (6 x 6 x 0.9 mm) and UQFN (4 x 4 x 0.5 mm) packages. The PIC16F1718 microcontrollers are expected to be available for sampling and production in May 2014, in 28-pin PDIP, SSOP, SOIC, QFN (6 x 6 x 0.9 mm) and UQFN (4 x 4 x 0.5 mm) packages. The PIC16F1717/19 microcontrollers are expected to be available for sampling and production in May 2014, in 40/44-pin PDIP, TQFP and UQFN (5 x 5 x 0.5 mm). Pricing starts at $0.59 each, in 10,000-unit quantities.

Source: Microchip Technology, Inc.

An Engineer Who Retires to the Garage

Jerry Brown, of Camarillo, CA, retired from the aerospace industry five years ago but continues to consult and work on numerous projects at home. For example, he plans to submit an article to Circuit Cellar about a Microchip Technology PIC-based computer display component (CDC) he designed and built for a traffic-monitoring system developed by a colleague.

Jerry Brown sits at his workbench. The black box atop the workbench is an embedded controller and is part of a traffic monitoring system he has been working on.

Jerry Brown sits at his workbench. The black box atop the workbench is an embedded controller and part of  his traffic monitoring system project.

“The traffic monitoring system is composed of a beam emitter component (BEC), a beam sensor component (BSC), and the CDC, and is intended for unmanned use on city streets, boulevards, and roadways to monitor and record the accumulative count, direction of travel, speed, and time of day for vehicles that pass by a specific location during a set time period,” he says.

Brown particularly enjoys working with PWM LED controllers. Circuit Cellar editors look forward to seeing his project article. In the meantime, he sent us the following description and pictures of the space where he conceives and executes his creative engineering ideas.

Jerry's garage-based lab.

Brown’s garage-based lab.

My workspace, which I call my “lab,” is on one side of my two-car garage and is fairly well equipped. (If you think it looks a bit messy, you should have seen it before I straightened it up for the “photo shoot.”)  

I have a good supply of passive and active electronic components, which are catalogued and, along with other parts and supplies, are stored in the cabinets and shelves alongside and above the workbench. I use the computer to write and compile software programs and to program PIC flash microcontrollers.  

The photos show the workbench and some of the instrumentation I have in the lab, including a waveform generator, a digital storage oscilloscope, a digital multimeter, a couple of power supplies, and a soldering station.  

The black box visible on top of the workbench is an embedded controller and is part of the traffic monitoring system that I have been working on.

Instruments in Jerry's lab include a waveform generator, a digital storage oscilloscope, a digital multimeter, a couple of power supplies, and a soldering station.

Instruments in Brown’s lab include a waveform generator, a digital storage oscilloscope, a digital multimeter, a couple of power supplies, and a soldering station. 

Brown has a BS in Electrical Engineering and a BS in Business Administration from California Polytechnic State University in San Luis Obispo, CA. He worked in the aerospace industry for 30 years and retired as the Principal Engineer/Manager of a Los Angeles-area aerospace company’s electrical and software design group.

Remote Control and Monitoring of Household Devices

Raul Alvarez, a freelance electronic engineer from Bolivia, has long been interested in wireless device-to-device communication.

“So when the idea of the Internet of Things (IoT) came around, it was like rediscovering the Internet,” he says.

I’m guessing that his dual fascinations with wireless and the IoT inspired his Home Energy Gateway project, which won second place in the 2012 DesignSpark chipKIT challenge administered by Circuit Cellar.

“The system enables users to remotely monitor their home’s power consumption and control household devices (e.g., fans, lights, coffee machines, etc.),” Alvarez says. “The main system consists of an embedded gateway/web server that, aside from its ability to communicate over the Internet, is also capable of local communications over a home area wireless network.”

Alvarez catered to his interests by creating his own wireless communication protocol for the system.

“As a learning exercise, I specifically developed the communication protocol I used in the home area wireless network from scratch,” he says. “I used low-cost RF transceivers to implement the protocol. It is simple and provides just the core functionality necessary for the application.”

Figure1: The Home Energy Gateway includes a Hope Microelectronics RFM12B transceiver, a Digilent chipKIT Max32 board, and a Microchip Technology ENC28J60 Ethernet controller chip.

Figure 1: The Home Energy Gateway includes a Hope Microelectronics RFM12B transceiver, a Digilent chipKIT Max32 board, and a Microchip Technology ENC28J60 Ethernet controller chip.

Alvarez writes about his project in the February issue of Circuit Cellar. His article concentrates on the project’s TCI/IP communications aspects and explains how they interface.

Here is his article’s overview of how the system functions and its primary hardware components:

Figure 1 shows the system’s block diagram and functional configuration. The smart meter collects the entire house’s power consumption information and sends that data every time it is requested by the gateway. In turn, the smart plugs receive commands from the gateway to turn on/off the household devices attached to them. This happens every time the user turns on/off the controls in the web control panel.

Photo 1: These are the three smart node hardware prototypes: upper left,  smart plug;  upper right, a second smart plug in a breadboard; and at bottom,  the smart meter.

Photo 1: These are the three smart node hardware prototypes: upper left, smart plug; upper right, a second smart plug in a breadboard; and at bottom, the smart meter.

I used the simple wireless protocol (SWP) I developed for this project for all of the home area wireless network’s wireless communications. I used low-cost Hope Microelectronics 433-/868-/915-MHz RFM12B transceivers to implement the smart nodes. (see Photo 1)
The wireless network is configured to work in a star topology. The gateway assumes the role of a central coordinator or master node and the smart devices act as end devices or slave nodes that react to requests sent by the master node.

The gateway/server is implemented in hardware around a Digilent chipKIT Max32 board (see Photo 2). It uses an RFM12B transceiver to connect to the home area wireless network and a Microchip Technology ENC28J60 chip module to connect to the LAN using Ethernet.

As the name implies, the gateway makes it possible to access the home area wireless network over the LAN or even remotely over the Internet. So, the smart devices are easily accessible from a PC, tablet, or smartphone using just a web browser. To achieve this, the gateway implements the SWP for wireless communications and simultaneously uses Microchip Technology’s TCP/IP Stack to work as a web server.

Photo 2: The Home Energy Gateway’s hardware includes a Digilent chipKIT Max32 board and a custom shield board.

Photo 2: The Home Energy Gateway’s hardware includes a Digilent chipKIT Max32 board and a custom shield board.

Thus, the Home Energy Gateway generates and serves the control panel web page over HTTP (this page contains the individual controls to turn on/off each smart plug and at the same time shows the power consumption in the house in real-time). It also uses the wireless network to pass control data from the user to the smart plugs and to read power consumption data from the smart meter.

The hardware module includes three main submodules: The chipKIT Max 32 board, the RFM12B wireless transceiver, and the ENC28J60 Ethernet module. The smart meter hardware module has an RFM12B transceiver for wireless communications and uses an 8-bit Microchip Technology PIC16F628A microcontroller as a main processor. The smart plug hardware module shows the smart plugs’ main hardware components and has the same microcontroller and radio transceiver as the smart meter. But the smart plugs also have a Sharp Microelectronics S212S01F solid-state relay to turn on/off the household devices.

On the software side, the gateway firmware is written in C for the Microchip Technology C32 Compiler. The smart meter’s PIC16F628A code is written in C for the Hi-TECH C compiler. The smart plug software is very similar.

Alvarez says DIY home-automation enthusiasts will find his prototype inexpensive and capable. He would like to add several features to the system, including the ability to e-mail notifications and reports to users.

For more details, check out the February issue now available for download by members or single-issue purchase.

MCU-Based Projects and Practical Tasks

Circuit Cellar’s January issue presents several microprocessor-based projects that provide useful tools and, in some cases, entertainment for their designers.

Our contributors’ articles in the Embedded Applications issue cover a hand-held PIC IDE, a real-time trailer-monitoring system, and a prize-winning upgrade to a multi-zone audio setup.

Jaromir Sukuba describes designing and building the PP4, a PIC-to-PIC IDE system for programming and debugging a Microchip Technology PIC18. His solar-powered,

The PP4 hand-held PIC-to-PIC programmer

The PP4 hand-held PIC-to-PIC programmer

portable computing device is built around a Digilent chipKIT Max32 development platform.

“While other popular solutions can overshadow this device with better UI and OS, none of them can work with 40 mW of power input and have fully in-house developed OS. They also lack PP4’s fun factor,” Sukuba says. “A friend of mine calls the device a ‘camel computer,’ meaning you can program your favorite PIC while riding a camel through endless deserts.”

Not interested in traveling (much less programming) atop a camel? Perhaps you prefer to cover long distances towing a comfortable RV? Dean Boman built his real-time trailer monitoring system after he experienced several RV trailer tire blowouts. “In every case, there were very subtle changes in the trailer handling in the minutes prior to the blowouts, but the changes were subtle enough to go unnoticed,” he says.

Boman’s system notices. Using accelerometers, sensors, and a custom-designed PCB with a Microchip Technology PIC18F2620 microcontroller, it continuously monitors each trailer tire’s vibration and axle temperature, displays that information, and sounds an alarm if a tire’s vibration is excessive.  The driver can then pull over before a dangerous or trailer-damaging blowout.

But perhaps you’d rather not travel at all, just stay at home and listen to a little music? This issue includes Part 1 of Dave Erickson’s two-part series about upgrading his multi-zone home audio system with an STMicroelectronics STM32F100 microprocessor, an LCD, and real PC boards. His MCU-controlled, eight-zone analog sound system won second-place in a 2011 STMicroelectronics design contest.

In addition to these special projects, the January issue includes our columnists exploring a variety of  EE topics and technologies.

Jeff Bachiochi considers RC and DC servomotors and outlines a control mechanism for a DC motor that emulates a DC servomotor’s function and strength. George Novacek explores system safety assessment, which offers a standard method to identify and mitigate hazards in a designed product.

Ed Nisley discusses a switch design that gives an Arduino Pro Mini board control over its own power supply. He describes “a simple MOSFET-based power switch that turns on with a push button and turns off under program control: the Arduino can shut itself off and reduce the battery drain to nearly zero.”

“This should be useful in other applications that require automatic shutoff, even if they’re not running from battery power,” Nisley adds.

Ayse K. Coskun discusses how 3-D chip stacking technology can improve energy efficiency. “3-D stacked systems can act as energy-efficiency boosters by putting together multiple chips (e.g., processors, DRAMs, other sensory layers, etc.) into a single chip,” she says. “Furthermore, they provide high-speed, high-bandwidth communication among the different layers.”

“I believe 3-D technology will be especially promising in the mobile domain,” she adds, “where the data access and processing requirements increase continuously, but the power constraints cannot be pushed much because of the physical and cost-related constraints.”

Real-Time Trailer Monitoring System

Dean Boman, a retired electrical engineer and spacecraft communications systems designer, noticed a problem during vacations towing the family’s RV trailer—tire blowouts.

“In every case, there were very subtle changes in the trailer handling in the minutes prior to the blowouts, but the changes were subtle enough to go unnoticed,” he says in his article appearing in January’s Circuit Cellar magazine.

So Boman, whose retirement hobbies include embedded system design, built the trailer monitoring system (TMS), which monitors the vibration of each trailer tire, displays the

Figure 1—The Trailer Monitoring System consists of the display unit and a remote data unit (RDU) mounted in the trailer. The top bar graph shows the right rear axle vibration level and the lower bar graph is for left rear axle. Numbers on the right are the axle temperatures. The vertical bar to the right of the bar graph is the driver-selected vibration audio alarm threshold. Placing the toggle switch in the other position  displays the front axle data.

Photo 1 —The Trailer Monitoring System consists of the display unit and a remote data unit (RDU) mounted in the trailer. The top bar graph shows the right rear axle vibration level and the lower bar graph is for left rear axle. Numbers on the right are the axle temperatures. The vertical bar to the right of the bar graph is the driver-selected vibration audio alarm threshold. Placing the toggle switch in the other position displays the front axle data.

information to the driver, and sounds an alarm if tire vibration or heat exceeds a certain threshold. The alarm feature gives the driver time to pull over before a dangerous or damaging blowout occurs.

Boman’s article describes the overall layout and operation of his system.

“The TMS consists of accelerometers mounted on each tire’s axles to convert the gravitational (g) level vibration into an analog voltage. Each axle also contains a temperature sensor to measure the axle temperature, which is used to detect bearing or brake problems. Our trailer uses the Dexter Torflex suspension system with four independent axles supporting four tires. Therefore, a total of four accelerometers and four temperature sensors were required.

“Each tire’s vibration and temperature data is processed by a remote data unit (RDU) that is mounted in the trailer. This unit formats the data into RS-232 packets, which it sends to the display unit, which is mounted in the tow vehicle.”

Photo 1 shows the display unit. Figure 1 is the complete system’s block diagram.

Figure 1—This block diagram shows the remote data unit accepting data from the accelerometers and temperature sensors and sending the data to the display unit, which is located in the tow vehicle for the driver display.

Figure 1—This block diagram shows the remote data unit accepting data from the accelerometers and temperature sensors and sending the data to the display unit, which is located in the tow vehicle for the driver display.

The remote data unit’s (RDU’s) hardware design includes a custom PCB with a Microchip Technology PIC18F2620 processor, a power supply, an RS-232 interface, temperature sensor interfaces, and accelerometers. Photo 2 shows the final board assembly. A 78L05 linear regulator implements the power supply, and the RS-232 interface utilizes a Maxim Integrated MAX232. The RDU’s custom software design is written in C with the Microchip MPLAB integrated development environment (IDE).

The remote data unit’s board assembly is shown.

Photo 2—The remote data unit’s board assembly is shown.

The display unit’s hardware includes a Microchip Technology PIC18F2620 processor, a power supply, a user-control interface, an LCD interface, and an RS-232 data interface (see Figure 1). Boman chose a Hantronix HDM16216H-4 16 × 2 LCD, which is inexpensive and offers a simple parallel interface. Photo 3 shows the full assembly.

The display unit’s completed assembly is shown with the enclosure opened. The board on top is the LCD’s rear view. The board on bottom is the display unit board.

Photo 3—The display unit’s completed assembly is shown with the enclosure opened. The board on top is the LCD’s rear view. The board on bottom is the display unit board.

Boman used the Microchip MPLAB IDE to write the display unit’s software in C.

“To generate the display image, the vibration data is first converted into an 11-element bar graph format and the temperature values are converted from Centigrade to Fahrenheit. Based on the toggle switch’s position, either the front or the rear axle data is written to the LCD screen,” Boman says.

“To implement the audio alarm function, the ADC is read to determine the driver-selected alarm level as provided by the potentiometer setting. If the vibration level for any of the four axles exceeds the driver-set level for more than 5 s, the audio alarm is sounded.

“The 5-s requirement prevents the alarm from sounding for bumps in the road, but enables vibration due to tread separation or tire bubbles to sound the alarm. The audio alarm is also sounded if any of the temperature reads exceed 160°F, which could indicate a possible bearing or brake failure.”

The comprehensive monitoring gives Boman peace of mind behind the wheel. “While the TMS cannot prevent tire problems, it does provide advance warning so the driver can take action to prevent serious damage or even an accident,” he says.

For more details about Boman’s project, including RDU and display unit schematics, check out the January issue.

Solar Array Tracker (Part 1): SunSeeker Hardware

Figure 1: These are the H-bridge motor drivers and sensor input conditioning circuits. Most of the discrete components are required for transient voltage protection from nearby lightning strikes and inductive kickback from the motors.

Figure 1: These are the H-bridge motor drivers and sensor input conditioning circuits. Most of the discrete components are required for transient voltage protection from nearby lightning strikes and inductive kickback from the motors.

Graig Pearen, semi-retired and living in Prince George, BC, Canada, spent his career in the telecommunications industry where he provided equipment maintenance and engineering services. Pearen, who now works part time as a solar energy technician, designed the SunSeeker Solar Array tracker, which won third place in the 2012 DesignSpark chipKit challenge.

He writes about his design, as well as changes he has made in prototypes since his first entry, in Circuit Cellar’s October issue. It is the first part of a two-part series on the SunSeeker, which presents the system’s software and commissioning tests in the final installment.

In the opening of Part 1, Pearen describes his objectives for the solar array tracker:

When I was designing my solar photovoltaic (PV) system, I wanted my array to track the sun in both axes. After looking at the available commercial equipment specifications and designs published online, I decided to design my own array tracker, the SunSeeker (see Photo 1 and Figure 1).

I had wanted to work with a Microchip Technology PIC processor for a while, so this was my opportunity to have some fun. I based my first prototype on a PIC16F870 microcontroller but when the microcontroller maxed out, I switched to its big brother, the PIC16F877. Although both prototypes worked well, I wanted to add more features and

The SunSeeker board, at top, contains all the circuits required to control the solar array’s motion. This board plugs into the Microsoft Technology chipKIT MAX32 processor board. The bottom side of the SunSeeker board (green) with the MAX32 board (red) plugged into it is shown at bottom.

The SunSeeker board, at top, contains all the circuits required to control the solar array’s motion. This board plugs into the Microchip Technology chipKIT MAX32 processor board. The bottom side of the SunSeeker board (green) with the MAX32 board (red) plugged into it is shown at bottom.

capabilities. I particularly wanted to add Ethernet access so I could use my home network to communicate with all my systems. I was considering Microchip’s chipKIT Max32 board for the next prototype when Circuit Cellar’s DesignSpark chipKIT contest was announced.

I knew the contest would be challenging. In addition to learning about a new processor and prototyping hardware, the contest rules required me to learn a new IDE (MPIDE), programming language (C++), schematic capture, and PCB design software (DesignSpark PCB). I also decided to make this my first surface-mount component design.

My objective for the contest was to replicate the functionality of the previous Assembly language software. I wanted the new design to be a test platform to develop new features and tracking algorithms. Over the next two to three years of development and field testing, I plan for it to evolve into a full-featured “bells-and-whistles” solar array tracker. I added a few enhancements as the software evolved, but I will develop most of the additional features later.

The system tracks, monitors, and adjusts solar photovoltaic (PV) arrays based on weather and atmospheric conditions. It compiles statistics on these conditions and communicates with a local server that enables software algorithm refinement. The SunSeeker logs a broad variety of data.

The SunSeeker measures, displays, and records the duration of the daily sunny, hazy, and cloudy periods; the array temperature; the ambient temperature; daily minimum and maximum temperatures; incident light intensity; and the drive motor current. The data log is indexed by the day number (1–366). Index–0 is the annual data and 1–366 store the data for each day of the year. Each record is 18 bytes long for a total of 6,588 bytes per year.

At midnight each day, the daily statistics are recorded and added to the cumulative totals. The data logs can be downloaded in comma-separated values (CSV) format for permanent record keeping and for use in spreadsheet or database programs.

The SunSeeker has two main parts, a control module and a separate light sensor module, plus the temperature and snow sensors.

The control module is mounted behind the array where it is protected from the heat of direct sunlight exposure. The sensor module is potted in clear UV-proof epoxy and mounted a few centimeters away on the edge of, and in the same plane as, the array. To select an appropriate potting compound, I contacted Epoxies, Etc. and asked for a recommendation. Following the company’s advice, I obtained a small quantity of urethane resin (20-2621RCL) and urethane catalyst (20-2621CCL).

When controlling mechanical devices, monitoring for proper operation, and detecting malfunctions it is necessary to prevent hardware damage. For example, if the solar array were to become frozen in place during an ice storm, it would need to be sensed and acted upon. Diagnostic software watches the motors to detect any hardware fault that may occur. Fault detection is accomplished in several ways. The H-bridges have internal fault detection for over temperature, under voltage, and shorted circuit. The current drawn by the motors is monitored for abnormally high or low current and the motor drive assemblies’ pulses are counted to show movement and position.

To read more about the DIY SunSeeker solar array tracker, and Pearen’s plans for further refinements, check out the October issue.

 

CC278: Serial Displays Save Resources (BMP Files)

In Circuit Cellar’s September issue, columnist Jeff Bachiochi provides his final installment in a three-part series titled “Serial Displays Save Resources.” The third article focuses on bitmap (BMP) files, which store images.

Photo1

A BMP file has image data storage beginning with the image’s last row. a—Displaying this data as stored will result in an upside-down image. b—Using the upsidedown=1 command will rotate the display 180°. c—The mirror=1 command flips the image horizontally. d—Finally, an origin change is necessary to shift the image to the desired location. These commands are all issued prior to transferring the pixels, to correct for the way the image data is stored.

LCDs are inexpensive and simple to use, so they are essential to many interesting projects, Jeff says. The handheld video game industry helped popularize the use of LCDs among DIYers.

Huge production runs in the industry “made graphic displays commonplace, helping to quickly reduce their costs,” Jeff says. “We can finally take advantage of lower-cost graphic displays, with one caveat: While built-in hardware controllers and drivers take charge of the pixels, you are now responsible for more than just sending a character to be printed to the screen. This makes the controllers and drivers not work well with the microcontroller project. That brings us to impetus for this article series.

“In Part 1 (‘Routines, Registers and Commands,’ Circuit Cellar 276, 2013), I began by discussing how to use a graphic display to print text, which, of course, includes character generation. In essence, I showed how to insert some intelligence between a project and the display. This intermediary would interpret some simple commands that enable you to easily make use of the display’s flexibility by altering position, screen orientation, color, magnification, and so forth.

“Part 2 (‘Button Commands,’ Circuit Cellar 277) revealed how touch-sensitive overlays are constructed and used to provide user input. The graphic display/touch overlay combination is a powerful combination that integrates I/O into a single module. Adding more commands to the interface makes it easier to create dynamic buttons on the graphic screen and reports back whenever a button is touched.

The prototype PCB I used for this project mounts to the reverse side of the thin-film transistor (TFT) LCD. The black connector holds the serial and power connections to your project. The populated header is for the Microchip Technology MPLAB ICD 3 debugger/programmer.

“Since I am using a graphic screen, it makes sense to investigate graphic files. This article (Part 3, ‘BMP Files,’ Circuit Cellar 277) examines the BMP file makeup and how this relates to the graphic screen.”

To learn more about the BMP graphical file format and Jeff’s approach to working with a graphic icon’s data, check out the September issue.

 

A Well-Organized Workspace for Home Automation Systems

Organization and plenty of space to work on projects are the main elements of Dean Boman’s workspace (see Photo 1). Boman, a retired systems engineer, says most of his projects involve home automation. He described some of his workspace features via e-mail:

My test equipment suite consists of a Rigol digital oscilloscope, a triple-output power supply, various single-output power supplies, and several Microchip Technology in-circuit development tools.

I have also built a simple logic analyzer, an FPGA programmer, and an EPROM programmer. For PCB fabrication, I have a complete setup from MG Chemicals to expose, develop, etch, and plate boards up to about 6” × 9” in size.

Photo 1: Boman’s workbench includes overhead cabinets to help reduce clutter. The computer in the foreground is his web server and main home-automation system controller. (Source: D. Boman)

Photo 1: Boman’s workbench includes overhead cabinets to help reduce clutter. The computer in the foreground is his web server and main home-automation system controller. (Source: D. Boman)

Boman is currently troubleshooting a small 1-W ham radio transmitter (see Photo 2).

Photo 2: Boman is currently troubleshooting a small 1-W ham radio transmitter (Source: D. Boman)

Photo 2: Here is his workbench with the radio transmitter. (Source: D. Boman)

Boman says the 10’ long countertop surface (in the background in Photo 3) is:

Great for working on larger items (e.g., computers). It is also a great surface for debugging designs as you have plenty of room for test equipment, drawings, and datasheets.

Photo 3: Boman’s setup includes plenty of spacefor large projects. (Source: D. Boman)

Photo 3: Boman’s setup includes plenty of room for large projects. (Source: D. Boman)

Most of Boman’s projects involve in-home automation (see Photo 4).

My current system provides functions such as: security system monitoring, irrigation control, water leak detection, temperature monitoring, electrical usage monitoring, fire detection, access control, weather monitoring, water usage monitoring, solar hot water system control, and security video recording. I also have an Extra Class ham radio license (WE7J) and build some ham radio equipment.

Here is how he described his system setup:

The shelf on the top contains the network routers and the security system. The cabinets on the wall contain an irrigation system controller and a network monitor for network management. I was fortunate in that we built a custom home a few years ago so I was able to run about two miles of cabling in the walls during construction.

Photo 4: Boman has various elements of his home-automation control system mounted on the wall. (Source: D. Boman)

Photo 4: Boman has various elements of his home-automation control system mounted on the wall. (Source: D. Boman)

Boman uses small containers to hold an inventory of surface-mount components (see Photo 5).

Over the past 10 years or so I have migrated to doing surface-mount designs almost exclusively. I have found that once you get over the learning curve, the surface-mount designs are much simpler to design and troubleshoot then the through-hole type technology. The printed wiring boards are also much simpler to fabricate, which is important since I etch my own boards.

Photo 5: Surface-mount components are neatly corralled in containers. (Source: D. Boman)

Photo 5: Surface-mount components are neatly corralled in containers. (Source: D. Boman)

Overall, Boman’s setup is well suited to his interests. He keeps everything handy in well-organized containers and has plenty of testing space In addition, his custom-built home enabled him to run behind-the-scenes cabling, freeing up valuable workspace.

Do you want to share images of your workspace, hackspace, or “circuit cellar”? Send your images and space info to editor<at>circuitcellar.com.

CC25 Is Now Available

Ready to take a look at the past, present, and future of embedded technology, microcomputer programming, and electrical engineering? CC25 is now available.

Check out the issue preview.

We achieved three main goals by putting together this issue. One, we properly documented the history of Circuit Cellar from its launch in 1988 as a bi-monthly magazine
about microcomputer applications to the present day. Two, we gathered immediately applicable tips and tricks from professional engineers about designing, programming, and completing electronics projects. Three, we recorded the thoughts of innovative engineers, academics, and industry leaders on the future of embedded technologies ranging from
rapid prototyping platforms to 8-bit chips to FPGAs.

The issue’s content is gathered in three main sections. Each section comprises essays, project information, and interviews. In the Past section, we feature essays on the early days of Circuit Cellar, the thoughts of long-time readers about their first MCU-based projects, and more. For instance, Circuit Cellar‘s founder Steve Ciarcia writes about his early projects and the magazine’s launch in 1988. Long-time editor/contributor Dave Tweed documents some of his favorite projects from the past 25 years.

The Present section features advice from working hardware and software engineers. Examples include a review of embedded security risks and design tips for ensuring system reliability. We also include short interviews with professionals about their preferred microcontrollers, current projects, and engineering-related interests.

The Future section features essays by innovators such as Adafruit Industries founder Limor Fried, ARM engineer Simon Ford, and University of Utah professor John Regehr on topics such as the future of DIY engineering, rapid prototyping, and small-RAM devices. The section also features two different sets of interviews. In one, corporate leaders such as Microchip Technology CEO Steve Sanghi and IAR Systems CEO Stefan Skarin speculate on the future of embedded technology. In the other, engineers such as Stephen Edwards (Columbia University) offer their thoughts about the technologies that will shape our future.

As you read the issue, ask yourself the same questions we asked our contributors: What’s your take on the history of embedded technology? What can you design and program today? What do you think about the future of embedded technology? Let us know.

CC269: Break Through Designer’s Block

Are you experiencing designer’s block? Having a hard time starting a new project? You aren’t alone. After more than 11 months of designing and programming (which invariably involved numerous successes and failures), many engineers are simply spent. But don’t worry. Just like every other year, new projects are just around the corner. Sooner or later you’ll regain your energy and find yourself back in action. Plus, we’re here to give you a boost. The December issue (Circuit Cellar 269) is packed with projects that are sure to inspire your next flurry of innovation.

Turn to page 16 to learn how Dan Karmann built the “EBikeMeter” Atmel ATmega328-P-based bicycle computer. He details the hardware and firmware, as well as the assembly process. The monitoring/logging system can acquire and display data such as Speed/Distance, Power, and Recent Log Files.

The Atmel ATmega328-P-based “EBikeMeter” is mounted on the bike’s handlebar.

Another  interesting project is Joe Pfeiffer’s bell ringer system (p. 26). Although the design is intended for generating sound effects in a theater, you can build a similar system for any number of other uses.

You probably don’t have to be coerced into getting excited about a home control project. Most engineers love them. Check out Scott Weber’s garage door control system (p. 34), which features a MikroElektronika RFid Reader. He built it around a Microchip Technology PIC18F2221.

The reader is connected to a breadboard that reads the data and clock signals. It’s built with two chips—the Microchip 28-pin PIC and the eight-pin DS1487 driver shown above it—to connect it to the network for testing. (Source: S. Weber, CC269)

Once considered a hobby part, Arduino is now implemented in countless innovative ways by professional engineers like Ed Nisley. Read Ed’s article before you start your next Arduino-related project (p. 44). He covers the essential, but often overlooked, topic of the Arduino’s built-in power supply.

A heatsink epoxied atop the linear regulator on this Arduino MEGA board helped reduce the operating temperature to a comfortable level. This is certainly not recommended engineering practice, but it’s an acceptable hack. (Source: E. Nisley, CC269)

Need to extract a signal in a noisy environment? Consider a lock-in amplifier. On page 50, Robert Lacoste describes synchronous detection, which is a useful way to extract a signal.

This month, Bob Japenga continues his series, “Concurrency in Embedded Systems” (p. 58). He covers “the mechanisms to create concurrently in your software through processes and threads.”

On page 64, George Novacek presents the second article in his series, “Product Reliability.” He explains the importance of failure rate data and how to use the information.

Jeff Bachiochi wraps up the issue with a article about using heat to power up electronic devices (p. 68). Fire and a Peltier device can save the day when you need to charge a cell phone!

Set aside time to carefully study the prize-winning projects from the Reneas RL78 Green Energy Challenge (p. 30). Among the noteworthy designs are an electrostatic cleaning robot and a solar energy-harvesting system.

Lastly, I want to take the opportunity to thank Steve Ciarcia for bringing the electrical engineering community 25 years of innovative projects, essential content, and industry insight. Since 1988, he’s devoted himself to the pursuit of EE innovation and publishing excellence, and we’re all better off for it. I encourage you to read Steve’s final “Priority Interrupt” editorial on page 80. I’m sure you’ll agree that there’s no better way to begin the next 25 years of innovation than by taking a moment to understand and celebrate our past. Thanks, Steve.

Autonomous Mobile Robot (Part 2): Software & Operation

I designed a microcontroller-based mobile robot that can cruise on its own, avoid obstacles, escape from inadvertent collisions, and track a light source. In the first part of this series, I introduced my TOMBOT robot’s hardware. Now I’ll describe its software and how to achieve autonomous robot behavior.

Autonomous Behavior Model Overview
The TOMBOT is a minimalist system with just enough components to demonstrate some simple autonomous behaviors: Cruise, Escape, Avoid, and Home behaviors (see Figure 1). All the behaviors require left and right servos for maneuverability. In general, “Cruise” just keeps the robot in motion in lieu of any stimulus. “Escape” uses the bumper to sense a collision and then 180 spin with reverse. “Avoid” makes use of continuous forward looking IR sensors to veer left or right upon approaching a close obstacle. Finally “Home” utilizes the front optical photocells to provide robot self-guidance to a strong light highly directional source.

Figure 1: High-level autonomous behavior flow

Figure 2 shows more details. The diagram captures the interaction of TOMBOT hardware and software. On the left side of the diagram are the sensors, power sources, and command override (the XBee radio command input). All analog sensor inputs and bumper switches are sampled (every 100 ms automatically) during the Microchip Technology PIC32 Timer 1 interrupt. The bumper left and right switches undergo debounce using 100 ms as a timer increment. The analog sensors inputs are digitized using the PIC32’s 10-bit ADC. Each sensor is assigned its own ADC channel input. The collected data is averaged in some cases and then made available for use by the different behaviors. Processing other than averaging is done within the behavior itself.

Figure 2: Detailed TOMBOT autonomous model

All behaviors are implemented as state machines. If a behavior requests motor control, it will be internally arbitrated against all other behaviors before motor action is taken. Escape has the highest priority (the power behavior is not yet implemented) and will dominate with its state machine over all the other behaviors. If escape is not active, then avoid will dominate as a result of its IR detectors are sensing an object in front of the TOMBOT less than 8″ away. If escape and avoid are not active, then home will overtake robot steering to sense track a light source that is immediately in front of TOMBOT. Finally cruise assumes command, and takes the TOMBOT in a forward direction temporarily.

A received command from the XBee RF module can stop and start autonomous operation remotely. This is very handy for system debugging. Complete values of all sensors and battery power can be viewed on graphics display using remote command, with LEDs and buzzer, announcing remote command acceptance and execution.

Currently, the green LED is used to signal that the TOMBOT is ready to accept a command. Red is used to indicate that the TOMBOT is executing a command. The buzzer indicates that the remote command has been completed coincident with the red led turning on.

With behavior programming, there are a lot of considerations. For successful autonomous operation, calibration of the photocells and IR sensors and servos is required. The good news is that each of these behaviors can be isolated (selectively comment out prior to compile time what is not needed), so that phenomena can be isolated and the proper calibrations made. We will discuss this as we get a little bit deeper into the library API, but in general, behavior modeling itself does not require accurate modeling and is fairly robust under less than ideal conditions.

TOMBOT Software Library
The TOMBOT robot library is modular. Some experience with C programming is required to use it (see Figure 3).

Figure 3: TOMBOT Library

The entire library is written using Microchip’s PIC32 C compiler. Both the compiler and Microchip’s 8.xx IDE are available as free downloads at www.microchip.com. The overall library structure is shown. At a highest level library has three main sections: Motor, I/O and Behavior. We cover these areas in some detail.

TOMBOT Motor Library
All functions controlling the servos’ (left and right wheel) operation is contained in this part of the library (see Listing1 Motor.h). In addition the Microchip PIC32 peripheral library is also used. Motor initialization is required before any other library functions. Motor initialization starts up both left and right servo in idle position using PIC32 PWM peripherals OC3 and OC4 and the dual Timer34 (32 bits) for period setting. C Define statements are used to set pulse period and duty cycle for both left and right wheels. These defines provide PWM varies from 1 to 2 ms for different speed CCW rotation over a 20-ms period and from 1.5 ms to 1 ms for CC rotation.

Listing 1: All functions controlling the servos are in this part of the library.

V_LEFT and V_RIGHT (velocity left and right) use the PIC32 peripheral library function to set duty cycle. The other motor functions, in turn, use V_LEFT and V_RIGHT with the define statements. See FORWARD and BACKWARD functions as an example (see Listing 2).

Listing 2: Motor function code examples

In idle setting both PWM set to 1-ms center positions should cause the servos not to turn. A servo calibration process is required to ensure center position does not result in any rotation. For the servos we have a set screw that can be used to adjust motor idle to no spin activity with a small Philips screwdriver.

TOMBOT I/O Library

This is a collection of different low level library functions. Let’s deal with these by examining their files and describing the function set starting with timer (see Listing 3). It uses Timer45 combination (full 32 bits) for precision timer for behaviors. The C defines statements set the different time values. The routine is noninterrupt at this time and simply waits on timer timeout to return.

Listing 3: Low-level library functions

The next I/O library function is ADC. There are a total of five analog inputs all defined below. Each sensor definition corresponds to an integer (32-bit number) designating the specific input channel to which a sensor is connected. The five are: Right IR, Left IR, Battery, Left Photo Cell, Right Photo Cell.

The initialization function initializes the ADC peripheral for the specific channel. The read function performs a 10-bit ADC conversion and returns the result. To faciliate operation across the five sensors we use SCAN_SENSORS function. This does an initialization and conversion of each sensor in turn. The results are placed in global memory where the behavior functions can access . SCAN_SENOR also performs a running average of the last eight samples of photo cell left and right (see Listing 4).

Listing 4: SCAN_SENOR also performs a running average of the last eight samples

The next I/O library function is Graphics (see Listing 5). TOMBOT uses a 102 × 64 monchrome graphics display module that has both red and green LED backlights. There are also red and green LEDs on the module that are independently controlled. The module is driven by the PIC32 SPI2 interface and has several control lines CS –chip select, A0 –command /data.

Listing 5: The Graphics I/O library function

The Graphics display relies on the use of an 8 × 8 font stored in as a project file for character generation. Within the library there are also cursor position macros, functions to write characters or text strings, and functions to draw 32 × 32 bit maps. The library graphic primitives are shown for intialization, module control, and writing to the module. The library writes to a RAM Vmap memory area. And then from this RAM area the screen is updated using dumpVmap function. The LED and backlight controls included within these graphics library.

The next part of I/O library function is delay (see Listing 6). It is just a series of different software delays that can be used by other library function. They were only included because of legacy use with the graphics library.

Listing 6: Series of different software delays

The next I/O library function is UART-XBEE (see Listing 7). This is the serial driver to configure and transfer data through the XBee radio on the robot side. The library is fairly straightforward. It has an initialize function to set up the UART1B for 9600 8N1, transmit and receive.

Listing 7: XBee library functions

Transmission is done one character at a time. Reception is done via interrupt service routine, where the received character is retrieved and a semaphore flag is set. For this communication, I use a Sparkfun XBee Dongle configured through USB as a COM port and then run HyperTerminal or an equivalent application on PC. The default setting for XBee is all that is required (see Photo 1).

Photo 1: XBee PC to TOMBOT communications

The next I/O library function is buzzer (see Listing 8). It uses a simple digital output (Port F bit 1) to control a buzzer. The functions are initializing buzzer control and then the on/off buzzer.

Listing 8: The functions initialize buzzer control

TOMBOT Behavior Library
The Behavior library is the heart of the autonomous TOMBOT and where integrated behavior happens. All of these behaviors require the use of left and right servos for autonomous maneuverability. Each behavior is a finite state machine that interacts with the environment (every 0.1 s). All behaviors have a designated priority relative to the wheel operation. These priorities are resolved by the arbiter for final wheel activation. Listing 9 shows the API for the entire Behavior Library.

Listing 9: The API for the entire behavior library

Let’s briefly cover the specifics.

  • “Cruise” just keeps the robot in motion in lieu of any stimulus.
  • “Escape” uses the bumper to sense a collision and then 180° spin with reverse.
  • “Avoid” makes use of continuous forward looking IR sensors to veer left or right upon approaching a close obstacle.
  • “Home” utilizes the front optical photocells to provide robot self-guidance to a strong light highly directional source.
  • “Remote operation” allows for the TOMBOT to respond to the PC via XBee communications to enter/exit autonomous mode, report status, or execute a predetermined motion scenario (i.e., Spin X times, run back and forth X times, etc.).
  • “Dump” is an internal function that is used within Remote.
  • “Arbiter” is an internal function that is an intrinsic part of the behavior library that resolves different behavior priorities for wheel activation.

Here’s an example of the Main function-invoking different Behavior using API (see Listing 10). Note that this is part of a main loop. Behaviors can be called within a main loop or “Stacked Up”. You can remove or stack up behaviors as you choose ( simply comment out what you don’t need and recompile). Keep in mind that remote is a way for a remote operator to control operation or view status.

Listing 10: TOMBOT API Example

Let’s now examine the detailed state machine associated with each behavior to gain a better understanding of behavior operation (see Listing 11).

Listing 11:The TOMBOT’s arbiter

The arbiter is simple for TOMBOT. It is a fixed arbiter. If either during escape or avoid, it abdicates to those behaviors and lets them resolve motor control internally. Home or cruise motor control requests are handled directly by the arbiter (see Listing 12).

Listing 12: Home behavior

Home is still being debugged and is not yet a final product. The goal is for the TOMBOT during Home is to steer the robot toward a strong light source when not engaged in higher priority behaviors.

The Cruise behavior sets motor to forward operation for one second if no other higher priority behaviors are active (see Listing 13).

Listing 13: Cruise behavior

The Escape behavior tests the bumper switch state to determine if a bump is detected (see Listing 14). Once detected it runs through a series of states. The first is an immediate backup, and then it turns around and moves away from obstacle.

Listing 14: Escape behavior

This function is a response to the remote C or capture command that formats and dumps (see Listing 15) to the graphics display The IR left and right, Photo left and Right, and battery in floating point format.

Listing 15: The dump function

This behavior uses the IR sensors and determines if an object is within 8″ of the front of TOMBOT (see Listing 16).

Listing 16: Avoid behavior

If both sensors detect a target within 8″ then it just turns around and moves away (pretty much like escape). If only the right sensor detects an object in range spins away from right side else if on left spins away on left side (see Listing 17).

Listing 17: Remote part 1

Remote behavior is fairly comprehensive (see Listing 18). There are 14 different cases. Each case is driven by a different XBee received radio character. Once a character is received the red LED is turned on. Once the behavior is complete, the red LED is turned off and a buzzer is sounded.

Listing 18: Remote part 2

The first case toggles Autonomous mode on and off. The other 13 are prescribed actions. Seven of these 13 were written to demonstrate TOMBOT mobile agility with multiple spins, back and forwards. The final six of the 13 are standard single step debug like stop, backward, and capture. Capture dumps all sensor output to the display screen (see Table 1).

Table 1: TOMBOT remote commands

Early Findings & Implementation
Implementation always presents a choice. In my particular case, I was interested in rapid development. At that time, I selected to using non interrupt code and just have linear flow of code for easy debug. This amounts to “blocking code.” Block code is used throughout the behavior implementation and causes the robot to be nonresponsive when blocking occurs. All blocking is identified when timeout functions occur. Here the robot is “blind” to outside environmental conditions. Using a real-time operating system (e.g., Free RTOS) to eliminate this problem is recommended.

The TOMBOT also uses photocells for homing. These sensitive devices have different responses and need to be calibrated to ensure correct response. A photocell calibration is needed within the baseline and used prior to operation.

TOMBOT Demo

The TOMBOT was successfully demoed to a large first-grade class in southern California as part of a Science, Technology, Engineering and Mathematics (STEM) program. The main behaviors were limited to Remote, Avoid, and Escape. With autonomous operation off, the robot demonstrated mobility and maneuverability. With autonomous operation on, the robot could interact with a student to demo avoid and escape behavior.

Tom Kibalo holds a BSEE from City College of New York and an MSEE from the University of Maryland. He as 39 years of engineering experience with a number of companies in the Washington, DC area. Tom is an adjunct EE facility member for local community college, and he is president of Kibacorp, a Microchip Design Partner.

CC 25th Anniversary Issue: The Past, Present, and Future of Embedded Design

In celebration of Circuit Cellar’s 25th year of publishing electrical engineering articles, we’ll release a special edition magazine around the start of 2013. The issue’s theme will be the past, present, and future of embedded electronics. World-renowned engineers, innovators, academics, and corporate leaders will provide essays, interviews, and projects on embedded design-related topics such as mixed-signal designs, the future of 8-bit chips, rapid prototyping, FPGAs, graphical user interfaces, embedded security, and much more.

Here are some of the essay topics that will appear in the issue:

  • The history of Circuit Cellar — Steve Ciarcia (Founder, Circuit Cellar, Engineer)
  • Do small-RAM devices have a future? — by John Regehr (Professor, University of Utah)
  • A review of embedded security risks — by Patrick Schaumont (Professor, Virginia Tech)
  • The DIY electronics revolution — by Limor Fried (Founder, Adafruit Industries)
  • The future of rapid prototyping — by Simon Ford (ARM mbed, Engineer)
  • Robust design — by George Novacek (Engineer, Retired Aerospace Executive)
  • Twenty-five essential embedded system design principles — by Bob Japenga (Embedded Systems Engineer, Co-Founder, Microtools Inc.)
  • Mixed-signal designs: the 25 errors you’ll make at least once — by Robert Lacoste (Founder, Alciom; Engineer)
  • User interface tips for embedded designers — by Curt Twillinger (Engineer)
  • Thinking in terms of hardware platforms, not chips — by Clemens Valens (Engineer, Elektor)
  • The future of FPGAs — by Colin O’Flynn (Engineer)
  • The future of e-learning for engineers and programmers — by Marty Hauff (e-Learning Specialist, Altium)
  • And more!

Interviews

We’ll feature interviews with embedded industry leaders and forward-thinking embedded design engineers and programmers such as:

More Content

In addition to the essays and interviews listed above, the issue will also include:

  • PROJECTS will be available via QR codes
  • INFOGRAPHICS depicting tech-related likes, dislikes, and ideas of hundreds of engineers.
  • And a few surprises!

Who Gets It?

All Circuit Cellar subscribers will receive the 25th Anniversary issue. Additionally, the magazine will be available online and promoted by Circuit Cellar’s parent company, Elektor International Media.

Get Involved

Want to get involved? Sponsorship and advertising opportunities are still available. Find out more by contacting Peter Wostrel at Strategic Media Marketing at 978-281-7708 (ext. 100) or peter@smmarketing.us. Inquire about editorial opportunities by contacting the editorial department.

About Circuit Cellar

Steve Ciarcia launched Circuit Cellar magazine in 1988. From its beginning as “Ciarcia’s Circuit Cellar,” a popular, long-running column in BYTE magazine, Ciarcia leveraged his engineering knowledge and passion for writing about it by launching his own publication. Since then, tens of thousands of readers around the world have come to regard Circuit Cellar as the #1 source for need-to-know information about embedded electronics, design, and programming.

Debugging USB Firmware

You’ve written firmware for your USB device and are ready to test it. You attach the device to a PC and the hardware wizard announces: “The device didn’t start.” Or, the device installs but doesn’t send or receive data. Or, data is being dropped, the throughput is low, or some other problem presents itself. What do you do?

This article explores tools and techniques to debug the USB devices you design. The focus is on USB 2.0 devices, but much of the information also applies to developing USB 3.0 (SuperSpeed) devices and USB hosts for embedded systems.

VIEWING BUS TRAFFIC

If you do anything beyond a small amount of USB developing, a USB protocol analyzer will save you time and trouble. Analyzers cost less than they used to and are well worth the investment.

A hardware-based analyzer connects in a cable segment upstream from the device under test (see Photo 1).

Photo 1: The device under test connects to the analyzer, which
captures the data and passes it unchanged to the device’s host. The
cable on the back of the analyzer carries the captured data to the
analyzer’s host PC for display.

You can view the data down to each packet’s individual bytes and see exactly what the host and device did and didn’t send (see Photo 2).

Photo 2: This bus capture shows the host’s request for a configuration
descriptor and the bytes the device sent in response. Because the endpoint’s
maximum packet size is eight, the device sends the first 8 bytes in one
transaction and the final byte in a second transaction.

An analyzer can also decode data to show standard USB requests and class-specific data (see Photo 3).

Photo 3: This display decodes a received configuration descriptor and its subordinate descriptors.

To avoid corrupted data caused by the electrical effects of the analyzer’s connectors and circuits, use short cables (e.g., 3’ or less) to connect the analyzer to the device under test.

Software-only protocol analyzers, which run entirely on the device’s host PC, can also be useful. But, this kind of analyzer only shows data at the host-driver level, not the complete packets on the bus.

DEVELOPMENT STRATEGIES

The first rule for developing USB device firmware is to remember that the host computer controls the bus. Devices just need to respond to received data and events. Device firmware shouldn’t make assumptions about what the host will do next.

For example, some flash drives work under Windows but break when attached to a host with an OS that sends different USB requests or mass-storage commands, sends commands in a different order, or detects errors Windows ignores. This problem is so common that Linux has a file, unusual_devs.h, with fixes for dozens of misbehaving drives.

The first line of defense in writing USB firmware is the free USB-IF Test Suite from the USB Implementers Forum (USB-IF), the trade group that publishes the USB specifications. During testing, the suite replaces the host’s USB driver with a special test driver. The suite’s USB Command Verifier tool checks for errors (e.g., malformed descriptors, invalid responses to standard USB requests, responses to Suspend and Resume signaling, etc.). The suite also provides tests for devices in some USB classes, such as human interface devices (HID), mass storage, and video.

Running the tests will usually reveal issues that need attention. Passing the tests is a requirement for the right to display the USB-IF’s Certified USB logo.

LAYERED COMMUNICATIONS

Like networks, USB communications have layers that isolate different logical functions (see Table 1).

Table 1: USB communications use layers, which are each responsible for a
specific logical function.

The USB protocol layer manages USB transactions, which carry data packets to and from device endpoints. A device endpoint is a buffer that is a source or sink of data at the device. The host sends data to Out endpoints and receives data from In endpoints. (Even though endpoints are on devices, In and Out are defined from the host’s perspective.)

The device layer manages USB transfers, with each transfer moving a chunk of data consisting of one or more transactions. To meet the needs of different peripherals, the USB 2.0 specification defines four transfer types: control, interrupt, bulk, and isochronous.

The function layer manages protocols specific to a device’s function (e.g., mouse, printer, or drive). The function protocols may be a combination of USB class, industry, and vendor-defined protocols.

CONTROLLER ARCHITECTURES

The layers supported by device firmware vary with the device hardware. At one end of the spectrum, a Future Technology Devices International (FTDI) FT232R USB UART controller handles all the USB protocols in hardware. The chip has a USB device port that connects to a host computer and a UART port that connects to an asynchronous serial port on the device.

Device firmware reads and writes data on the serial port, and the FT232R converts it between the USB and UART protocols. The device firmware doesn’t have to know anything about USB. This feature has made the FT232R and similar chips popular!

An example of a chip that is more flexible but requires more firmware support is Microchip Technology’s PIC18F4550 microcontroller, which has an on-chip, full-speed USB device controller. In return for greater firmware complexity, the PIC18F4550 isn’t limited to a particular host driver and can support any USB class or function.

Each of the PIC18F4550’s USB endpoints has a series of registers—called a buffer descriptor table (BDT)—that store the endpoint buffer’s address, the number of bytes to send or receive, and the endpoint’s status. One of the BDT’s status bits determines the BDT’s ownership. When the CPU owns the BDT, firmware can write to the registers to prepare to send data or to retrieve received data. When the USB module owns the BDT, the endpoint can send or receive data on the bus.

To send a data packet from an In endpoint, firmware stores the bytes’ starting address to send and the number of bytes and sets a register bit to transfer ownership of the BDT to the USB module. The USB module sends the data in response to a received In token packet on the endpoint and returns BDT ownership to the CPU so firmware can set up the endpoint to send another packet.

To receive a packet on an Out endpoint, firmware stores the buffer’s starting address for received bytes and the maximum number of bytes to receive and transfers ownership of the BDT to the USB module. When data arrives, the USB module returns BDT ownership to the CPU so firmware can retrieve the data and transfer ownership of the BDT back to the USB module to enable the receipt of another packet.

Other USB controllers have different architectures and different ways of managing USB communications. Consult your controller chip’s datasheet and programming guide for details. Example code from the chip vendor or other sources can be helpful.

DEBUGGING TRANSACTIONS

A USB 2.0 transaction consists of a token packet and, as needed, a data packet and a handshake packet. The token packet identifies the packet’s type (e.g., In or Out), the destination device and endpoint, and the data packet direction.

The data packet, when present, contains data sent by the host or device. The handshake packet, when present, indicates the transaction’s success or failure.

The data and handshake packets must transmit quickly after the previous packet, with only a brief inter-packet delay and bus turnaround time, if needed. Thus, device hardware typically manages the receiving and sending of packets within a transaction.

For example, if an endpoint’s buffer has room to accept a data packet, the endpoint stores the received data and returns ACK in the handshake packet. Device firmware can then retrieve the data from the buffer. If the buffer is full because firmware didn’t retrieve previously received data, the endpoint returns NAK, requiring the host to try again. In a similar way, an In endpoint will NAK transactions until firmware has loaded the endpoint’s buffer with data to send.

Fine tuning the firmware to quickly write and retrieve data can improve data throughput by reducing or eliminating NAKs. Some device controllers support ping-pong buffers that enable an endpoint to store multiple packets, alternating between the buffers, as needed.

LOST DATA

In all but isochronous transfers, a data-toggle value in the data packet’s packet identification (PID) field guards against missed or duplicate data packets. If you’re debugging a device where data is transmitting on the bus and the receiver is returning ACK but ignoring or discarding the data, chances are good that the device isn’t sending or expecting the correct data-toggle value. Some device controllers handle the data toggles completely in hardware, while others require some firmware control.

Each endpoint maintains its own data toggle. The values are DATA0 (0011B) and DATA1 (1011B). Upon detecting an incoming data packet, the receiver compares its data toggle’s state with the received data toggle. If the values match, the receiver toggles its value and returns ACK, causing the sender to toggle its value for the next transaction.

The next received packet should contain the opposite data toggle, and again the receiver toggles its bit and returns ACK. Except for control transfers, the data toggle on each end continues to alternate in each transaction. (Control transfers always use DATA0 in the Setup stage, toggle the value for each transaction in the Data stage, and use DATA1 in the Status stage.)

If the receiver returns NAK or no response, the sender doesn’t toggle its bit and tries again with the same data and data toggle. If a receiver returns ACK, but for some reason the sender doesn’t see the ACK, the sender thinks the receiver didn’t receive the data and tries again using the same data and data toggle. In this case, the repeated data receiver ignores the data, doesn’t toggle the data toggle, and returns ACK, resynchronizing the data toggles. If the sender mistakenly sends two packets in a row with the same data-toggle value, upon receiving the second packet, the receiver ignores the data, doesn’t toggle its value, and returns ACK.

DEFINING A TRANSFER

All USB devices must support control transfers and may support other transfer types. Control transfers provide a structure for sending requests but have no guaranteed delivery time. Interrupt transfers have a guaranteed maximum latency (i.e., delay) between transactions, but the host permits less bandwidth for interrupt transfers compared to other transfer types. Bulk transfers are the fastest on an otherwise idle bus, but they have no guaranteed delivery time, and thus can be slow on a busy bus. Isochronous transfers have guaranteed delivery time but no built-in error correction.

A transfer’s amount of data depends in part on the higher-level protocol that determines the data packets’ contents. For example, a keyboard sends keystroke data in an interrupt transfer that consists of one transaction with 8 data bytes. To send a large file to a drive, the host typically uses one or more large transfers consisting of multiple transactions. For a high-speed drive, each transaction, except possibly the last one, has 512 data bytes, which is the maximum-allowed packet size for high-speed bulk endpoints.

What determines a transfer’s end varies with the USB class or vendor protocol. In many cases, a transfer ends with a short packet, which is a packet that contains less than the packet’s maximum-allowed data bytes. If the transfer has an even multiple of the packet’s maximum-allowed bytes, the sender may indicate the end of the transfer with a zero-length packet (ZLP), which is a data packet with a PID and error-checking bits but no data.

For example, USB virtual serial-port devices in the USB communications device class use short packets to indicate the transfer’s end. If a device has sent data that is an exact multiple of the endpoint’s maximum packet size and the host sends another In token packet, the endpoint should return a ZLP to indicate the data’s end.

DEBUGGING ENUMERATION

Upon device attachment, in a process called enumeration, the host learns about the device by requesting a series of data structures called descriptors. The host uses the descriptors’ information to assign a driver to the device.

If enumeration doesn’t complete, the device doesn’t have an assigned driver, and it can’t perform its function with the host. When Windows fails to find an appropriate driver, the setupapi.dev.log file in Windowsinf (for Windows 7) can offer clues about what went wrong. A protocol analyzer shows if the device returned all requested descriptors and reveals mistakes in the descriptors.

During device development, you may need to change the descriptors (e.g., add, remove, or edit an endpoint descriptor). Windows has the bad habit of remembering a device’s previous descriptors on the assumption that a device will never change its descriptors. To force Windows to use new descriptors, uninstall then physically remove and reattach the device from Windows Device Manager. Another option is to change the device descriptor’s product ID to make the device appear as a different device.

DEBUGGING TRANSFERS

Unlike the other transfer types, control transfers have multiple stages: setup, (optional) data, and status. Devices must accept all error-free data packets that follow a Setup token packet and return ACK. If the device is in the middle of another control transfer and the host sends a new Setup packet, the device must abandon the first transfer and begin the new one. The data packet in the Setup stage contains important information firmware should completely decode (see Table 2).

Table 2: Device firmware should fully decode the data received in a control transfer’s Setup stage. (Source: USB Implementers Forum, Inc.)

The wLength field specifies how many bytes the host wants to receive. A device shouldn’t assume how much data the host wants but should check wLength and send no more than the requested number of bytes.

For example, a request for a configuration descriptor is actually a request for the configuration descriptor and all of its subordinate descriptors. But, in the first request for a device’s configuration descriptor, the host typically sets the wLength field to 9 to request only the configuration descriptor. The descriptor contains a wTotalLength value that holds the number of bytes in the configuration descriptor and its subordinate descriptors. The host then resends the request setting wLength to wTotalLength or a larger value (e.g., FFh). The device returns the requested descriptor set up to wTotalLength. (Don’t assume the host will do it this way. Always check wLength!)

Each Setup packet also has a bmRequestType field. This field specifies the data transfer direction (if any), whether the recipient is the device or an interface or endpoint, and whether the request is a standard USB request, a USB class request, or a vendor-defined request. Firmware should completely decode this field to correctly identify received requests.

A composite device has multiple interfaces that function independently. For example, a printer might have a printer interface, a mass-storage interface for storing files, and a vendor-specific interface to support vendor-defined capabilities. For requests targeted to an interface, the wIndex field typically specifies which interface applies to the request.

INTERRUPT TRANSFER TIMING

For interrupt endpoints, the endpoint descriptor contains a bInterval value that specifies the endpoint’s maximum latency. This value is the longest delay a host should use between transaction attempts.

A host can use the bInterval delay time or a shorter period. For example, if a full-speed In endpoint has a bInterval value of 10, the host can poll the endpoint every 1 to 10 ms. Host controllers typically use predictable values, but a design shouldn’t rely on transactions occurring more frequently than the bInterval value.

Also, the host controller reserves bandwidth for interrupt endpoints, but the host can’t send data until a class or vendor driver provides something to send. When an application requests data to be sent or received, the transfer’s first transaction may be delayed due to passing the request to the driver and scheduling the transfer.

Once the host controller has scheduled the transfer, any additional transaction attempts within the transfer should occur on time, as defined by the endpoint’s maximum latency. For this reason, sending a large data block in a single transfer with multiple transactions can be more efficient than using multiple transfers with a portion of the data in each transfer.

DEVICE FUNCTIONS

Most devices’ functions fit a defined USB class (e.g., mass storage, printer, audio, etc.). The USB-IF’s class specifications define protocols for devices in the classes.

For example, devices in the HID class must send and receive all data in data structures called reports. The supported report’s length and the meaning of its data (e.g., keypresses, mouse movements, etc.) are defined in a class-specific report descriptor.

If your HID-class device is sending data but the host application isn’t seeing the data, verify the number of bytes the device is sending matches the number of bytes in a defined report. The device should prepend a report-ID byte to the data only if the HID supports report IDs other than the zero default value.

In many devices, class specifications define class-specific requests or other requirements. For example, a mass storage device that uses the bulk-only protocol must provide a unique serial number in a string descriptor. Carefully read and heed any class specifications that apply to your device!

Many devices also support industry protocols to perform higher-level functions. Printers typically support one or more printer-control languages (e.g., PCL and Postscript). Mass-storage devices support SCSI commands to transfer data blocks and a file system (e.g., FAT32) to define a directory structure.

The higher-level industry protocols don’t depend on a particular hardware interface, so there is little about debugging them that is USB-specific. But, because these protocols can be complicated, example code for your device can be helpful.

In the end, much about debugging USB firmware is like debugging any hardware or software. A good understanding of how the communications should work provides a head start on writing good firmware and finding the source of any problems that may appear.

Jan Axelson is the author of USB Embedded Hosts, USB Complete, and Serial Port Complete. Jan’s PORTS web forum is available at www.lvr.com.

RESOURCES

Jan Axelson’s Lakeview Research, “USB Development Tools: Protocol analyzers,” www.lvr.com/development_tools.htm#analyzers.

This article appears in Circuit Cellar 268 (November 2012).

CC268: The History of Embedded Tech

At the end of September 2012, an enthusiastic crew of electrical engineers and journalists (and significant others) traveled to Portsmouth, NH, from locations as far apart as San Luis Obispo, CA,  and Paris, France, to celebrate Circuit Cellar’s 25th anniversary. Attendees included Don Akkermans (Director, Elektor International Media), Steve Ciarcia (Founder, Circuit Cellar), the current magazine staff, and several well-known engineers, editors, and columnists. The event marked the beginning of the next chapter in the history of this long-revered publication. As you’d expect, contributors and staffers both reminisced about the past and shared ideas about its future. And in many instances, the conversations turned to the content in this issue, which was at that time entering the final phase of production. Why? We purposely designed this issue (and next month’s) to feature a diversity of content that would represent the breadth of coverage we’ve come to deliver during the past quarter century. A quick look at this issue’s topics gives you an idea of how far embedded technology has come. The topics also point to the fact that some of the most popular ’80s-era engineering concerns are as relevant as ever. Let’s review.

In the earliest issues of Circuit Cellar, home control was one of the hottest topics. Today, inventive DIY home control projects are highly coveted by professional engineers and newbies alike. On page 16, Scott Weber presents an interesting GPS-based time server for lighting control applications. An MCU extracts time from GPS data and transmits it to networked devices.

The time-broadcasting device includes a circuit board that’s attached to a GPS module. (Source: S. Weber, CC268)

Thiadmer Riemersma’s DIY automated component dispenser is a contemporary solution to a problem that has frustrated engineers for decades (p. 26). The MCU-based design simplifies component management and will be a welcome addition to any workbench.

The DIY automated component dispenser. (Source: T. Riemersma, CC268)

USB technology started becoming relevant in the mid-to-late 1990s, and since then has become the go-to connection option for designers and end users alike. Turn to page 30 for Jan Axelson’s  tips about debugging USB firmware. Axelson covers controller architectures and details devices such as the FTDI FT232R USB UART controller and Microchip Technology’s PIC18F4550 microcontroller.

Debugging USB firmware (Source: J. Axelson, CC268)

Electrical engineers have been trying to “control time” in various ways since the earliest innovators began studying and experimenting with electric charge. Contemporary timing control systems are implemented in a amazing ways. For instance, Richard Lord built a digital camera controller that enables him to photograph the movement of high-speed objects (p. 36).

Security and product reliability are topics that have been on the minds of engineers for decades. Whether you’re working on aerospace electronics or a compact embedded system for your workbench (p. 52), you’ll want to ensure your data is protected and that you’ve gone through the necessary steps to predict your project’s likely reliability (p. 60).

The issue’s last two articles detail how to use contemporary electronics to improve older mechanical systems. On page 64 George Martin presents a tachometer design you can implement immediately in a machine shop. And lastly, on page 70, Jeff Bachiochi wraps up his series “Mechanical Gyroscope Replacement.” The goal is to transmit reliable data to motor controllers. The photo below shows the Pololu MinIMU-9.

The Pololu MinIMU-9’s sensor axes are aligned with the mechanical gyro so the x and y output pitch and roll, respectively. (Source: J. Bachiochi, CC268)