$9,456
pledged of $15,000pledged of $15,000 goal
120
backers
3days to go

All or nothing. This project will only be funded if it reaches its goal by Mon, August 20 2018 5:00 AM UTC +00:00.

$9,456
pledged of $15,000pledged of $15,000 goal
120
backers
3days to go

All or nothing. This project will only be funded if it reaches its goal by Mon, August 20 2018 5:00 AM UTC +00:00.

What is a prototype?

A prototype is a preliminary model of something. Projects that offer physical products need to show backers documentation of a working prototype. This gallery features photos, videos, and other visual documentation that will give backers a sense of what’s been accomplished so far and what’s left to do. Though the development process can vary for each project, these are the stages we typically see:

Proof of Concept

Explorations that test ideas and functionality.

Functional Prototype

Demonstrates the functionality of the final product, but looks different.

Appearance Prototype

Looks like the final product, but is not functional.

Design Prototype

Appearance and function match the final product, but is made with different manufacturing methods.

Production Prototype

Appearance, function, and manufacturing methods match the final product.

8e9e8f27a95d7efb0247b9a765a52468 original

Prototype Gallery

These photos and videos provide a detailed look at this project’s development.

About

This campaign will be re-launched in a new format, with user-configurable options for all the features, and starting at only $28. Please click HERE to support our new campaign.

The main target of the Mega-IO card is the Home Automation, DIY user. The Mega-IO Industrial version  (MegaIO-IND) brings a low cost solution to the control of industrial processes.

MegaIO-Industrial top view
MegaIO-Industrial top view

 MegaIO-Industrial Specifications

  • 24VDC Power Supply
  • Four Optically-Isolated 4-20mA Inputs
  • Four 4-20mA Outputs
  • Four 0-10V analog Inputs  
  • Four 0-10V analog Outputs  
  • Four Optically-Isolated Digital Inputs  
  • Four Optically-Isolated Open Drain  Outputs
  • Four Optically-Isolated 10A/250V Relays with status LED's
  • Four General Purpose LED's
  • RS485, CAN, 1 Wire communication
  • Real time clock with battery back-up
  • Configurable Interrupts

The Raspberry Pi expansion connector is passed through and can be used to access all the GPIO pins, or to install any 3rd party add-on card. Up to four MegaIO-Industrial cards cand be stacked on top of each other. Any number of cards can be controlled from a single Raspberry Pi using the RS485 port.

MegaIO-Industrial Block Diagram

Mega-IO Industrial Block Diagram
Mega-IO Industrial Block Diagram

Board Layout

MegaIO-Industrial Board Layout
MegaIO-Industrial Board Layout

High Voltage Area

In order to switch 250V and 10A, we extended the short side of the board outside the Raspberry Pi area, and separated all the high voltage runs from the low level digital.

MegaIO-Industrial back view
MegaIO-Industrial back view

The HIGH VOLTAGE AREA of the board will be isolated with a fiberglass shield (not shown in the picture) mounted on the bottom corner holes

DC to DC converters are used for power and ground separation between the two areas. Optical isolators provide digital signal separation, and a physical cutout gap assures high voltage separation. 

The trace thickness and spacing is calculated according to the IPC-2221B for 250V and 10A.

Linearity

To check the linearity of the card we used a four digit Fluke 28 II. After calibrating the end points, the worst case linearity is 0.2% for all current I/O's and 0.15% for voltage I/O's

MegaIO-Industrial full scale linearity
MegaIO-Industrial full scale linearity

User's Guide

User's Guide is available for download from our website.

Software

All the features of the MEGAIO-IND card are accessible from a command line interface which can be downloaded from GitHub. Python drivers are available as well.

CODESYS Drivers

We provide drivers for CODESYS, "the leading hardware independent IEC 61131-3 development system under Windows for programming and creating controller applications." A demo project shows how to read any input and control any output, either from a stand-alone windows application or from the browser.

Self Testing

Command-line functions are available for self-testing all inputs and outputs using external jumpers. Jumper any 0-10V input to and 0-10V output, any 4-20mA to any 4-20mA output, any opto-isolated input to any open-drain output and run a command to test both I/O's

MegaIO-Industrial Application: PID Controller

Here is a simple (and useless) application: balance a ball in a tube.

 

ELECTRICAL SPECIFICATIONS

MICROCONTROLLER: STM32F072R8T6

  • Core Processor: ARM® 32-bit Cortex®-M0
  • CPU Frequency: 48MHz
  • Program Memory: 64KB
  • RAM: 16K x 8
  • Operating Voltage: 3.3V
  • Operating Temperature: -40°C ~ 85°C

OPEN DRAIN OUTPUTS:

  • Driver: TBD62083A
  • Output Current: Max. 0.5 A
  • Output Voltage: Max. 50V
  • Output Low Voltage: Max 0.325V @ 100mA
  • Operating Temperature: -40°C ~ 85°C
  • Power Dissipation: Max. 0.96W
  • Turn-on Delay: Typ. 0.4μS
  • Turn-off Delay: Typ. 0.8μS

OPTICALLY ISOLATED INPUTS:

  • Optoisolators: LTV-827S-TA1
  • Isolation Voltage: 5,000Vrms
  • Response Time: Typ. 4μS
  • Maximum Forward Current: 50mA
  • Maximum Reverse Voltage: 6V
  • Input Capacitance: Max. 250 pF
  • Operating Temperature: -30°C ~ 110°C

0-10V ANALOG INPUTS:

  • TVS Protection: SMAJ18A
  • Min. Peak Pulse Power Dissipation: 400 Watts
  • Peak Forward Surge Current: 40 Amps
  • Steady State Power Dissipation: 1W
  • Maximum Inst. Forward Voltage @ Ipp = 35A: 3.5V
  • Operating Temperature: -55°C ~ 150°C
  • Input OP-AMP: LM258QT
  • Operating Power Supply: 24VDC
  • Max. Input Voltage: 32V
  • Operating Temperature: -40°C ~ 105°C

0-10V ANALOG OUTPUTS:

  • Output OP-AMP: LM258QT
  • Operating Power Supply: 24VDC
  • Output Current Source: Typ. 40mA
  • Output Current Sink: Typ. 20mA

4-20mA ANALOG INPUTS:

  • TVS Protection: SMAJ18A (see 0-10V Analog Inputs)
  • Optoisolators: LTV-827S-TA1 (see Optoisolated Inputs)
  • Dual Optoisolators for Aging Compensation
  • Rail-to-Rail OP-AMP: LTC6088
  • Operating Temperature: -40°C ~ 85°C

4-20mA ANALOG OUTPUTS:

  • Output Driver:  DMN4060SVT-7 N-Channel MOSFET
  • Vdss Max.: 45V
  • Continuous Current Drain: 4.8A
  • Power Dissipation Max.: 1.2W
  • Operating Temperature: -55°C ~ 150°C

RELAYS: SRD-05VDC-SL-C

  • Voltage Rating Max. : 250V
  • Current Rating Max: 10A
  • Contact Resistance: Max. 100mΩ
  • Operation Time: Max 10mS.
  • Release Time: Max 5 mS.
  • Max. ON/OFF switching: 30 operations/min.
  • Max. Inductive Load (cosΦ=0.4 L/R=7msec) : 5A 28VDC
  • Operating Temperature: -40°C ~ 85°C

MECHANICAL SPECIFICATIONS

IO SCREW TERMINAL BLOCKS

  • Pitch: 2.5mm
  • Screws: M1.6, Steel, Ni Plated
  • Pin Header: Brass, Tin Plated
  • Wire Cage: Brass, Ni Plated
  • Rated Voltage: 300V
  • Rated Current: 10A
  • Max. Voltage: 1500VAC 1 min.
  • Wire Range: 24 - 12 AWG
  • Torque: Max. 0.1Nm (0.88 lb.in)
  • Recommended Strip Length: 5-6 mm.
  • Operating Temperature: -40°C ~ 105°C

IO PLUGGABLE TERMINAL BLOCKS

  • Rated Voltage: 125V
  • Rated Current: 4A
  • Max. Voltage: 1250VAC 1 min.
  • Wire Range: 28 - 20 AWG
  • Strip Length: 8mm
  • Operating Temperature: -40°C ~ 105°C

RELAY SCREW TERMINAL BLOCKS

  • Pitch: 5mm
  • Screws: M2.5 Steel, Zinc Plated
  • Pin Header: Brass, Tin Plated
  • Wire Cage: Phosphor Bronze, Ni Plated
  • Rated Voltage: 300V
  • Rated Current: 16A
  • Wire Range: 22 - 14 AWG
  • Torque: 0.4 Nm (3.5lb.in)
  • Recommended Strip Length: 4.5-5 mm.
  • Operating Temperature: -30°C ~ 120°C

RELAY PLUGGABLE TERMINAL BLOCKS

  • Pitch: 5mm
  • Screws: M2.5 Steel, Zinc Plated
  • Pin Header: Brass, Tin Plated
  • Wire Cage: Phosphor Bronze, Ni Plated
  • Rated Voltage: 300V
  • Rated Current: 10A
  • Wire Range: 22 - 14 AWG
  • Torque: 0.4 Nm (3.5lb.in)
  • Recommended Strip Length: 7 mm.
  • Operating Temperature: -40°C ~ 105°C

COMMUNICATION TERMINAL BLOCKS

  • Rated Voltage: 150V
  • Rated Current: 2A
  • Contact Resistance: 20mOhm
  • Wire Range: 26-20 AWG
  • Withstanding Voltage: 1300 VAC/1min
  • Operating Temperature: -40°C ~ 105°C
  • Pitch: 2.5mm

SOCIAL MEDIA

YOUTUBE.COM

Risks and challenges

We built two rounds of prototypes and the hardware is fully functional.
There is no technical risk that the board will not work as specified.
All the software blocks are in place, we need to wrap them up before delivery. The only conceivable risk is that we do not get enough interest from backer to justify building the boards.

As one of the visitors to our website said, ""I see it as a great disruptor to the archaic industrial controls industry...". Please support our project and help us "disrupt the archaic industrial controls industry".

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