Smart Appliance Design Reference Manual Document Number: DRM129 Rev. 0, 04/2013 Smart Appliance Design , Rev. 0, 04/2013 2 Freescale Semiconductor, Inc. Contents Section number Title Page Chapter 1 Introduction 1.1 Introduction.....................................................................................................................................................................9 1.2 Smart appliance system advantages ...............................................................................................................................9 1.3 Freescale solutions..........................................................................................................................................................9 1.4 How a refrigerator works................................................................................................................................................10 1.5 Smart appliance sections ................................................................................................................................................10 Chapter 2 System Overview 2.1 Description......................................................................................................................................................................13 2.2 Smart appliance interfaces..............................................................................................................................................13 2.2.1 Low-end user interface.......................................................................................................................................13 2.2.2 Mid-end user interface.......................................................................................................................................14 2.3 Smart appliance system block diagram...........................................................................................................................15 Chapter 3 User Interface (UI) 3.1 Features...........................................................................................................................................................................17 3.2 Block diagram ................................................................................................................................................................18 3.3 Placement (UI)................................................................................................................................................................19 3.4 Hardware description......................................................................................................................................................20 3.4.1 Clock source ......................................................................................................................................................20 3.4.2 Displays..............................................................................................................................................................20 3.4.2.1 Segment LCD.......................................................................................................................................21 3.4.2.2 Dot LCD...............................................................................................................................................21 3.4.3 Micro SD card....................................................................................................................................................22 3.4.4 Audio..................................................................................................................................................................23 3.4.4.1 Microphone (MIC)...............................................................................................................................23 3.4.4.2 Speaker.................................................................................................................................................24 Smart Appliance Design , Rev. 0, 04/2013 Freescale Semiconductor, Inc. 3 Section number Title Page 3.4.5 Electrode keys....................................................................................................................................................25 3.4.6 Presence detection .............................................................................................................................................26 3.4.7 Power source .....................................................................................................................................................27 3.4.8 Modbus...............................................................................................................................................................28 3.4.9 Debugging interface...........................................................................................................................................29 3.5 Firmware User Interface.................................................................................................................................................30 3.5.1 Overview ...........................................................................................................................................................30 3.5.2 Flowchart...........................................................................................................................................................32 3.5.3 Scheduler............................................................................................................................................................33 3.5.4 System management..........................................................................................................................................34 3.5.5 Sound management............................................................................................................................................35 3.5.6 Clock and date....................................................................................................................................................37 3.5.7 Keys...................................................................................................................................................................38 3.5.8 Display...............................................................................................................................................................39 Chapter 4 Led Driver Board 4.1 Features...........................................................................................................................................................................41 4.2 Block diagram.................................................................................................................................................................42 4.3 Placement — LED Drive Board.....................................................................................................................................43 4.4 Hardware description......................................................................................................................................................44 4.4.1 Door switch........................................................................................................................................................44 4.4.2 LED circuit driver..............................................................................................................................................44 4.4.3 Communication hardware..................................................................................................................................45 4.4.4 Debug and Reset Connections...........................................................................................................................46 4.4.5 Power source .....................................................................................................................................................46 4.5 Firmware LED driver board............................................................................................................................................46 4.5.1 Overview............................................................................................................................................................46 4.5.2 Flowchart...........................................................................................................................................................47 4.5.3 RGB power drive...............................................................................................................................................48 Smart Appliance Design , Rev. 0, 04/2013 4 Freescale Semiconductor, Inc. Section number Title Page Chapter 5 Control Board 5.1 Features...........................................................................................................................................................................49 5.2 Control Board Block diagram.........................................................................................................................................50 5.3 Placement (Control Board).............................................................................................................................................50 5.4 Hardware description......................................................................................................................................................51 5.4.1 Power.................................................................................................................................................................51 5.4.2 Clocking.............................................................................................................................................................51 5.4.3 1323X Modular reference board connector.......................................................................................................51 5.4.4 Serial Interface...................................................................................................................................................52 5.4.5 Aux RS232 interface..........................................................................................................................................52 5.4.6 3-Phase motor control inverter...........................................................................................................................53 5.4.7 Control connectors.............................................................................................................................................54 5.4.8 Relays.................................................................................................................................................................55 5.4.9 Hall sensor..........................................................................................................................................................55 5.4.10 Thermostat.........................................................................................................................................................56 5.5 Firmware.........................................................................................................................................................................57 5.5.1 Overview ...........................................................................................................................................................57 5.5.2 Flowchart...........................................................................................................................................................58 5.5.3 Control state machine.........................................................................................................................................59 5.5.4 Temperature control ..........................................................................................................................................59 5.5.5 Defrost and fans.................................................................................................................................................60 Chapter 6 Modbus Protocol 6.1 Introduction.....................................................................................................................................................................61 6.2 Modbus General Operation.............................................................................................................................................61 6.3 Data base general operation............................................................................................................................................62 6.4 Communication system main operation .........................................................................................................................62 6.4.1 Read command operation...................................................................................................................................62 Smart Appliance Design , Rev. 0, 04/2013 Freescale Semiconductor, Inc. 5 Section number Title Page 6.4.2 Write command operation..................................................................................................................................63 6.4.3 Synchronization between messages ..................................................................................................................63 6.4.4 Communication errors .......................................................................................................................................63 6.5 Driver application use ....................................................................................................................................................64 6.6 Communication driver current implementation..............................................................................................................64 Chapter 7 Home Automation Gateway 7.1 Introduction.....................................................................................................................................................................65 7.2 Application features .......................................................................................................................................................65 7.3 Home automation gateway components.........................................................................................................................66 7.4 Zigbee wireless technology.............................................................................................................................................67 7.5 Zigbee home automation profile.....................................................................................................................................68 7.6 Zigbee smart energy profile............................................................................................................................................68 7.7 Freescale Software Tools................................................................................................................................................68 7.7.1 MQX Real-Time Operating System (RTOS).....................................................................................................69 7.7.2 MQX Key Benefits............................................................................................................................................69 7.7.3 RTCS..................................................................................................................................................................70 7.8 Beestack Zigbee protocol stacks.....................................................................................................................................71 7.9 External references..........................................................................................................................................................72 7.10 Hardware Description.....................................................................................................................................................73 7.10.1 Hardware implementation..................................................................................................................................73 7.10.2 Featured products...............................................................................................................................................73 7.10.3 Kinetis Family....................................................................................................................................................74 7.10.4 MC1322x...........................................................................................................................................................76 7.10.5 Additional hardware features.............................................................................................................................77 7.11 Firmware Description.....................................................................................................................................................78 7.11.1 System overview................................................................................................................................................78 7.11.2 Home automation gateway application..............................................................................................................78 7.11.3 Home automation gateway functionality...........................................................................................................78 Smart Appliance Design , Rev. 0, 04/2013 6 Freescale Semiconductor, Inc. Section number Title Page 7.11.4 Main application architecture.............................................................................................................................79 7.11.5 Home automation network software model.......................................................................................................80 7.11.6 Web interface.....................................................................................................................................................81 7.11.7 Dynamic web content and functionality............................................................................................................82 7.12 Zigbee Applications........................................................................................................................................................83 7.12.1 Zigbee home automation projects......................................................................................................................83 7.12.2 Zigbee coordinator.............................................................................................................................................84 7.12.3 Zigbee end device..............................................................................................................................................84 7.12.4 Zigbee smart energy device...............................................................................................................................85 7.12.5 Summary of clusters and endpoints...................................................................................................................85 7.13 HAGateway to Zigbee serial communication protocol..................................................................................................87 Chapter 8 Home Automation User's Guide 8.1 System setup...................................................................................................................................................................89 8.1.1 Configuring the software...................................................................................................................................89 8.1.2 Programming the Hardware...............................................................................................................................94 8.1.3 Hardware connections........................................................................................................................................96 8.2 Starting the system..........................................................................................................................................................97 8.3 Using the system.............................................................................................................................................................98 Smart Appliance Design , Rev. 0, 04/2013 Freescale Semiconductor, Inc. 7 Smart Appliance Design , Rev. 0, 04/2013 8 Freescale Semiconductor, Inc. Chapter 1 Introduction 1.1 Introduction The refrigerator is a necessary appliance in urban households, its marketing story is accompanied by continuous improvement and innovation in design and features that adapt to the trends of modern life, and today one of the most recent is developed in Freescale. Freescale continues with the development of advanced technologies that allow greater productivity, optimization, and higher-performance converged products that improve customers lives. This design reference manual describes the development of a Smart Appliance System using Freescale Microcontroller Solutions. 1.2 Smart appliance system advantages • A system that uses Freescale technology to control and increment the features of a common house appliance as a refrigerator. • Energy and power cost saving due to the use of advanced motor control algorithms, compressor motor type, energy saving functions related to open and close times (vacation mode), and communication to a home automation hub that decides the best times of the day to turn the refrigerator on at full power. This is based on a smart energy system that provides information from an energy provider. • Provides security for the user to know the status of the refrigerator through internet. 1.3 Freescale solutions The main concept behind the smart appliance system is to highlight the following features: • Energy efficient appliance—Refrigerator with overall lower power consumption Smart Appliance Design , Rev. 0, 04/2013 Freescale Semiconductor, Inc. 9 How a refrigerator works • User interface (UI)—Friendly operation for the user • Home automation—Demonstrates capabilities to set energy usage profiles, this depends on grid information from a smart hub or from manual user input. • Smart grid—Allows for an appliance to receive information about energy costs and peak power consumption to distribute loads in electrical service. • Smart home gateway—Serves as an information path from systems at home to the external network. • Advanced motor control in compressor—Compressor uses a low-voltage BLDC motor, instead of a common-use universal motor. The controller is able to regulate compressor speed for faster freezing times or use slower speeds to simply maintain a constant temperature. BLDC motors are also less acoustically noisy than universal (brushed) motors. Controlled motors are also known to consume less energy than uncontrolled motors because torque is optimized. • Internal light—Control color and light intensity of the internal refrigerator giving users a sense of aesthetic customization. • Harness reduction—Wire reductions in the system using the Modbus communication protocol. 1.4 How a refrigerator works A refrigerator is an appliance that uses a compression system. It uses fluid gas that changes from gaseous to liquid state and vice versa. When it evaporates, it cools the interior. This enables the preservation of food for a longer period of time. The main components for a refrigerator are • Evaporator—The refrigerant liquid flows through the pipes inside the freezer and turns into steam. • Condenser—The gas condenses and as it changes form, it releases heat into the environment. • Compressor—It circulates the refrigerant liquid. A belt connects it to the motor. • Electric Motor—This drives the compressor 1.5 Smart appliance sections The following block diagram illustrates each section of the system: Smart Appliance Design , Rev. 0, 04/2013 10 Freescale Semiconductor, Inc.