diff --git a/content/posts/smart-yogurt-maker-part-01/index.md b/content/posts/smart-yogurt-maker-part-01/index.md new file mode 100644 index 0000000..e3e0b3f --- /dev/null +++ b/content/posts/smart-yogurt-maker-part-01/index.md @@ -0,0 +1,250 @@ +--- +title: "Smart Yogurt Maker Part 1" +date: "2022-01-25" +author: "William Floyd" +featured_image: "media/IMG_20220125_113949_cleaned.jpg" +categories: [ + "Development", + "Hardware", + "Software" +] +tags: [ + "ESPHome", + "Rice Cooker", + "Home Assistant", + "Smart Home", + "Automation", + "Yogurt" +] +--- + +A certain [Rice](/2018/smart-rice-cooker) [Cooker](/2018/dumb-rice-cooker) has been languishing in a box for the last several years - now it is time to revisit it. +It is a tale of Solder, Software, and Streptococcus thermophilus. + +*** + +# "Last time, on Rice Cooker Adventures" + +This story picks up where I left off 3 years ago - the rice cooker has thermistors taped to the bottom of the pot with high temperature fiberglass tape. Specifically, I have 4 of the same thermistor in 2 parallel lines of 2 series resistors, like so. + +![Thermistor Diagram][thermistors] + +This serves to roughly average the resistances, to account for possible hotspots on the pot, while only taking a single ADC pin. + +However, time has not been kind to my memory, and the specific parameters of these thermistors are unknown, so first, it's time to do some testing. + +# Side Quest: Thermistor Calibration + +I have a thermocouple that I can use to verify the temperature of the pot with, so here is the setup: log the resistance through the thermistor bank at close to room temperature, rolling boil, and a middle temperature (during cooldown). These three sample points may then be used to find the parameters of the thermistor exactly. + +From hazy memory (and counting parts in inventory), my suspicion was that I had used a $100k\Omega$ thermistor. +Brand is unknown, but representative datasheets online cite a $\beta$ value of 3950 - let's see how we compare. + +## Wait, what does $\boldsymbol{\beta}$ mean? + +For a more in depth read, look [here](https://www.qtisensing.com/wp-content/uploads/Beta-vs-Steinhart-Hart.pdf), but in summary early studies proposed that for NTC thermistors, the temperature $T$ could be determined given a measured resistance $R$, coefficient $\beta$ and reference resistance $R_0$ and temperature $T_0$, like so: + +$$ +\frac {1}{T}=\frac{1}{T_{0}}+{\frac {1}{\beta}} \ln{\frac {R}{R_{0}}} +$$ + +While this may work for small temperature ranges (approximately $20^\circ \text{C}$ or so), we require a larger range, and so we are instead going to look at the... + +## Steinhart-Hart Equation + +Briefly summarizing [Wikipedia](https://en.wikipedia.org/wiki/Steinhart%E2%80%93Hart_equation), the equation states: + +$$\frac{1}{T}=A+B\cdot\ln\{\left(R\right)}+C(\ln \left(R\right))^{3}$$ + +Which, when using 3 sample points, results in: + +$$ +\begin{bmatrix} + 1 & \ln R_1 & \ln^3 R_1 \\\\ + 1 & \ln R_2 & \ln^3 R_2 \\\\ + 1 & \ln R_3 & \ln^3 R_3 +\end{bmatrix}\begin{bmatrix} + A \\ + B \\ + C +\end{bmatrix} = \begin{bmatrix} + \frac{1}{T_1} \\\\ + \frac{1}{T_2} \\\\ + \frac{1}{T_3} +\end{bmatrix} +$$ + +In my case, I found the points of reference using a setup like so: + +![Measuring water temperature and thermistor resistance](media/IMG_20220124_174144.jpg) + +Do note that in order to reach a full boil (and $100^\circ \text{C}$ on the thermocouple), the lid of the rice cooker was attached. + +While I could show the calculations, and they wouldn't be difficult, I'll be honest: I used an [online calculator](https://www.thinksrs.com/downloads/programs/therm%20calc/ntccalibrator/ntccalculator.html). + +![Calculator results](media/calc.png) + +Using the measurements: + +$$ +\begin{array}{|l|l|} +\hline \mathbf{R}(\boldsymbol{\Omega}) & \mathbf{T}\left({ }^{\circ} \mathbf{C}\right) \\\\ +\hline 81 \mathrm{k} & 33 \\\\ +\hline 21.3 \mathrm{k} & 66 \\\\ +\hline 6.4 \mathrm{k} & 100 \\\\ +\hline +\end{array} +$$ + +Yielded + +$$ +\begin{aligned} +A &= 1.032978070 \cdot 10^{-3}\\\\ +B &= 1.733021623 \cdot 10^{-4}\\\\ +C &= 1.902682261 \cdot 10^{-7}\\\\ +\hline +R_{(25^\circ \text{C})} &= 117072.68 \Omega \\\\ +\beta_\text{calculated} &= 4202.76 \text{K} +\end{aligned} +$$ + +As we can see then, the actual $\beta$ value is larger than predicted ($3950\text{K}$ predicted vs. $4203\text{K}$ actual), as is the reference resistance ($100\text{k}\Omega$ predicted vs. $117\text{k}\Omega$ actual). +In fact, neither of these are even in the commonly stated "$\pm 1 \\%$" range. +Good thing we're calibrating, hey? + +# "Back to our regularly scheduled programming" + +How to use this data then? +Being short on time, I opted to take the easy way out, and use the wonderful [ESPHome](https://esphome.io/), as I already use Home Assistant. +As it turns out, they already have us covered, with a [NTC Sensor component](https://esphome.io/components/sensor/ntc.html) already built in. +This, coupled with a [resistance](https://esphome.io/components/sensor/resistance.html) and [ADC](https://esphome.io/components/sensor/adc.html) sensor allow using a voltage divider to measure the resistance of the thermistor. + +You know those calculations and equations we did above? +Unnecessary, all of it. +ESPHome supports doing Steinhart-Hart calculations itself, and only needs the three sample points. + +In the meantime, a Wemos D1 Mini on a breadboard is ready to go (they're cheap and chearful). +I wire it up with a $6.8\text{k}\Omega$ resistor (what I had handy), and away I went. +The circuit looks something like this, where the two trailing wires connect to the thermistor bank: + +![Wired breadboard](media/IMG_20220125_114006_cleaned.jpg) + +To prevent confusion, here is my final working config, then I'll explain. + +```yaml +sensor: + - platform: ntc + sensor: resistance_sensor + calibration: + - 81.0kOhm -> 33°C + - 21.3kOhm -> 66°C + - 6.4kOhm -> 100°C + name: Rice Cooker Temperature + unit_of_measurement: °C + + - platform: resistance + id: resistance_sensor + sensor: source_sensor + configuration: DOWNSTREAM + resistor: 6.96kOhm + reference_voltage: 3.306V + name: Resistance Sensor + + - platform: adc + id: source_sensor + pin: A0 + name: Voltage Sensor + filters: + - multiply: 3.2 + update_interval: 1s +``` + +# Calibrate all the things + +## Series Resistor +Easy, measuring mine I found it to be $6.96\text{k}\Omega$, certainly different from the $6.8\text{k}\Omega$ it's meant to be. +Throw that in the config. + +## Reference Voltage +This is also easy enough, measure the $3.3\text{V}$ pin off the D1 mini. +Mine came out to be $3.306\text{V}$, respectably close to rated! +That goes in the config too. + +## Multiply Filter +As it turns out, the D1 mini has an internal voltage divider to convert the $3.3\text{V}$ of the input voltage down to the $1\text{V}$ the ADC is rated for. +This is nice, as it protects the ADC, but it must be accounted for. +But there's a catch - on my board this wasn't quite right - the voltage read was still slightly wrong. +I could try manually tuning this, but there is an easier way. +Instead, I measured the actual voltage ($3.306\text{V}$), and compared it to the voltage being read. + +Say there was no error, then we would say $V_\text{actual}=V_\text{measured}$, and if there is an error of a multiple difference between the two, we can say $V_\text{actual}=m\cdot V_\text{measured}$. Thus, to find this multiplier, we say: + +$$ +m = \frac{V_\text{actual}}{V_\text{measured}} +$$ + +Using this method, I find my multiplier to be $3.2$, not $3.3$. + +With that, the board is finally reading the correct voltage, the correct resistance, and the correct temperature. + +# "You're so controlling!" + +Given that I have Home Assistant, automating it becomes easy. + +I'm currently using a [Tasmota](https://tasmota.github.io/docs/) flashed smart outlet to control the power to the heating element of the rice cooker (for reference, it pulls up to $400\text{W}$ at full load). +In future, I would like to condense all functionality into a relay controlled directly by the ESP8266, to allow greater safety in case of network issues or even local PID tuning. + +I am also using a [PID controller for Home Assistant](https://github.com/soloam/ha-pid-controller). +It seems to work fine, I am just bad at PID tuning, so results may vary depending on hardware, amount of mass in the cooker, ambient temperatures, etc. +That being said, a simple automation to turn the heater on when the PID response goes high and turn off when not high yields acceptable results. + +From fiddling with the settings, I currently am using the following parameters: + +$$ +\begin{aligned} +P &= 60 \\\\ +I &= 5.6 \\\\ +D &= 6.7 \\\\ +\end{aligned} +$$ + +Further tuning is required, but this held well overnight - mostly... + +![First overnight test](media/log.png) + +I did change the set point from $105^\circ\text{F}$ to $107^\circ\text{F}$ halfway through, as well as tweaked some of the PID tuning. +The concerning spike at 9:00 is marked by a momentary loss of connection with the ESP board - my automation failed to account for a loss of connection and so allowed the heat to continue rising. +Thankfully, this was a short-lived event, but it is concerning nonetheless, and will require testing of my automation to prove that power loss tends towards a "safer" outcome. +Do note that "safer" means no dead yogurt culture - the safety features of the rice cooker remain unchanged and functional. + +# The proof is in the... yogurt? + +So how did it do? +I am notoriously _not_ picky when it comes to food, but I think it turned out great! +Filling the rice cooker about halfway with whole milk, I heated it to $180^\circ \text{F}$ for a few minutes (I read I ought to go for longer...), cooled to about $110^\circ \text{F}$, then added a liberal few spoonfuls (think 1/5 volume of milk) of plain Dannon yogurt. +I let it proof in the rice cooker for 7.5 hours, with the lid sealed. + +![First batch, still warm](media/IMG_20220125_105918.jpg) + +I put the whole rice cooker in the fridge to cool, with the lid sealed. +Trying it later that same evening, I quite enjoyed it. +I'll start my next batch from this one, and hopefully it'll be even better. + +![Spoonful of the good stuff](media/IMG_20220125_180035.jpg) + +# "Next time, on Rice Cooker Adventures" + +Now that I have a temperature controllable rice-cooker, and the ability to remotely start, stop, and modify set points, I may try other foods. +For now, I need to: + +* solder a perfboard version of the circuit +* add a relay to control the cooker directly +* ensure the outlet will turn off if the ESP8266 loses connection +* PID tune the setup for the most common scenario (steady $107^\circ \text{F}$ with the lid shut) + +First though, I'm gonna go eat some fresh yogurt... + +[thermistors]: media/circuit.svg "Thermistor Diagram]" + +{{< mathjax >}} \ No newline at end of file diff --git a/content/posts/smart-yogurt-maker-part-01/media/IMG-20220125-WA0001.jpeg b/content/posts/smart-yogurt-maker-part-01/media/IMG-20220125-WA0001.jpeg new file mode 100644 index 0000000..00cbcd6 --- /dev/null +++ b/content/posts/smart-yogurt-maker-part-01/media/IMG-20220125-WA0001.jpeg @@ -0,0 +1,3 @@ +version https://git-lfs.github.com/spec/v1 +oid sha256:b16af600f8f8ee3259c70060b5893c1979ade38064aa3c09f6ce54c43e91bd77 +size 63394 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