Pellet Control Unit is a high-performance industrial pellet controller, dedicated for OEM integration in custom design Pellet stove.
The module is tightly coupled with the custom stove hardware and provides graphical User Interface and touch control user experience. The unit is equipped with 5" color TFT display with resolution of 480x272 pixels and resistive touch user input. The implemented graphical interface provides multi-language support, with default BG and EN languages implemented. All stove actuators are controlled based on solid state components, avoiding electro-mechanical relays for reliability improvement, according to the application requirements. The device supports extension connection to internet gateway, alowing remote control and status information, using smartphone application and cloud service.
The integrated stove control algorithm includes:
✓ Reading water temperature, based on 1WIRE temperature sensor interface
✓ Reading flame activity, based on analog light strength sensor
✓ Automatic control of pellet conveyor, providing pellet fuel supply
✓ Dynamic power control of pellet ignition electrical heater, supporting automatic ignition process
✓ Power control of electrical fan, providing full flame strength control during the ignition and burning cycle
✓ Automatic control of stove cleaner system, according to the implemented burning cycle
✓ Animated icons are providing real time status information using Graphical User Interface
✓ Support internet remote control and status monitoring, using smartphone applications
Technical approach
The design approach is based around the most important technical requirements: Reliability and ease of use. Using bare metal firmware approach and high performance 16bit MCU fulfills both criteria. Avoiding electro-mechanical components, such as relays and switches is key approach for increasing the reliability over the long period of usage. The device is designed with custom graphics interface and supports non-volatile memory of the working state, allowing fast state recovery upon mains power interruption.
✓ Bare metal firmware approach, using 16bit MCU;
✓ Solid state control components, avoiding electro-mechanical relays;
✓ Touch input and optimized graphical interface;
✓ Implemented sensors failure detection procedures;
✓ Multi-language support, default implemented BG and EN languages;
✓ Optional interface for internet gateway module, providing remote control;
Provided services
✓ Providing technical requirements documentation and key components selection, based on the functional description;
✓ Schematic design, based on the selected key components, PDF export for customer's review;
✓ PCB design, pcb mechanical integration in the sellected device enclosure;
✓ Production of first revision prototypes, order PCBs and components, organizing PCB and device assembly;
✓ Firmware design. Design of basic driver firmware modules, design of application level firmware, in circuit debug and testing. hardware and firmware optimization;
✓ Production of second revision prototypes, order PCBs and components, organizing PCB and device assembly;
✓ Representing the customer and pass safety and EMC laboratory tests, according to the applied CE safety and EMC standards;
✓ Design and providing of complete production and system integration documentation;