Project Overview
This project aims to stabilize a platform used in semiconductor equipment manufacturing by precisely measuring its tilt. The system detects tilt angles with a resolution of 0.001 degrees and transmits this data in real-time to an Android mobile app via Bluetooth. It is built using the CC2640R2F SimpleLink™ microcontroller, which integrates Bluetooth® 5.1 Low Energy wireless communication, and the ADIS16500 Precision Miniature MEMS IMU from Analog Devices for high-accuracy tilt sensing. The system is powered by a lithium-ion battery, making it portable and ideal for seamless integration into semiconductor manufacturing machinery.
Technical Description
Hardware Arrangement:
1. Control and Communication Module (CC2640R2F):
- Microcontroller (CC2640R2F):This MCU, based on a 32-bit Arm® Cortex®-M3 core, is the core controller of the system. It features Bluetooth 5.1 Low Energy capabilities, allowing wireless data transmission. The 128-kB flash memory provides sufficient space for running real-time control firmware and handling communication tasks.
- Bluetooth Interface: The Bluetooth 5.1 feature of the CC2640R2F enables real-time wireless data transfer to the Android mobile app. This ensures that tilt information is continuously sent to the operator's smartphone for immediate feedback.
- Firmware: The firmware developed for the CC2640R2F is programmed using Code Composer Studio (CCS). It processes tilt data from the IMU and manages Bluetooth communication, ensuring efficient data transmission and minimal latency. The firmware also implements power-saving mechanisms to extend battery life, such as sleep modes when tilt measurement is not actively required.
2. High-Precision Single-Axis IMU (ADIS16500)
- Tilt Sensing: The ADIS16500 Precision Miniature MEMS IMU from Analog Devices is responsible for detecting small tilt changes in the platform. It provides extremely precise tilt measurements with a resolution of 0.001 degrees, essential for maintaining the stability required in semiconductor equipment operations.
- Real-Time Feedback: The IMU continuously measures the tilt angle of the platform and sends the data to the CC2640R2F microcontroller, where it is processed and transmitted via Bluetooth.
3. Power Source (Lithium-Ion Battery):
- The system operates on a lithium-ion battery, offering portability and uninterrupted performance inside semiconductor machinery. The battery powers the entire platform stabilizer system, providing long-lasting energy for continuous operation.
- Power Management: Efficient power management routines are implemented in both hardware and firmware. The system minimizes energy consumption by utilizing sleep modes during periods of inactivity and optimizing sensor sampling rates for continuous operation.
Android Mobile App
The native Android mobile application, developed using Android Studio, provides a user-friendly interface for real-time monitoring of the platform’s tilt. The app displays tilt data continuously and alerts users in case of any tilt deviation that exceeds predefined limits.
- Real-Time Monitoring:The app shows the tilt angle in real-time, down to a precision of 0.001 degrees, giving operators full control over platform stability and alignment.
- Alerts and Notifications:If the platform tilt exceeds a certain threshold, the app triggers notifications, allowing operators to take corrective actions quickly.
- User Interface:Designed with an intuitive Graphical User Interface (GUI), the app makes it easy to interpret tilt data. It also provides features for resetting the system and viewing logs of previous tilt measurements for analysis.
The app communicates with the platform stabilizer system via Bluetooth 5.1, ensuring reliable and real-time data transfer, giving operators the ability to monitor and manage tilt adjustments on the go.
Design Approach
1. Hardware
- The CC2640R2F SimpleLink™ microcontroller, with Bluetooth 5.1 capabilities, serves as the core controller and communication hub of the system. Its 32-bit Arm® Cortex®-M3 core and 128-kB flash memory provide ample resources for running real-time tilt monitoring firmware.
- The ADIS16500 IMU offers high-precision tilt measurements, making it ideal for the sensitive requirements of semiconductor manufacturing equipment. With a resolution of 0.001 degrees, it ensures reliable platform stabilization.
- Powered by a lithium-ion battery, the system is portable and easy to integrate into machinery without the need for constant external power.
2. Firmware
- The firmware for the CC2640R2F is developed using Code Composer Studio (CCS), handling Bluetooth communication, tilt data processing, and power management. The software filters the IMU’s raw data and transmits only meaningful, accurate tilt measurements to the Android app.
- To extend battery life, the firmware employs power-saving strategies such as adjusting the sampling rate of the IMU and putting the system into low-power modes when the platform is stable.
3. Mobile Application
- The Android Studio-developed app allows users to monitor tilt data in real-time, providing an intuitive interface for viewing and interpreting the platform’s tilt information. Alerts and notifications ensure immediate operator action when needed.
- The Bluetooth 5.1 connection ensures real-time and reliable communication between the platform stabilizer and the mobile app, allowing for continuous monitoring even from a distance.
This platform stabilizer system offers a high degree of precision and reliability, critical for applications in semiconductor equipment manufacturing. By leveraging the CC2640R2F microcontroller and ADIS16500 IMU, the system ensures accurate tilt measurements, wireless connectivity, and efficient power usage, improving the overall stability and performance of critical manufacturing processes.