Cleanroom Parameters Monitoring Systems (CPMS).

i

CLEANROOM PARAMETERS MONITORING SYSTEMS (CPMS)

MOHAMAD SYAHIR BIN JAPAR

This report is submitted in partial fulfillment of requirement for the Bachelor of
Electronic engineering (Industrial Electronics) with Honors

Faculty of Electronics & Computer Engineering
University technical Malaysia Melaka

June 2014

ii

UNIVERSTI TEKNIKAL MALAYSIA MELAKA
FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER

BORANG PENGESAHAN STATUS LAPORAN


PROJEK SARJANA MUDA II

Tajuk Projek

:

Sesi Pengajian

:

Cleanroom Parameters Monitoring System (CPMS)
1

3

/

1

4


Saya MOHAMAD SYAHIR BIN JAPAR
(HURUF BESAR)
mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syaratsyarat kegunaan seperti berikut:
1.

Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.

2.

Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3.

Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi
pengajian tinggi.

4.

Sila tandakan ( √ ) :


SULIT*

*(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia seperti yang termaktub di dalam AKTA
RAHSIA RASMI 1972)

TERHAD**

**(Mengandungi maklumat terhad yang telah ditentukan oleh
organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh:

__________________________

___________________________________


(TANDATANGAN PENULIS)

(COP DAN TANDATANGAN PENYELIA)

iii

“I hereby, declare this report is the result of my own research except as cited of the
reference”

Signature

:

Author Name :

MOHAMAD SYAHIR BIN JAPAR

Date

……………………………………………………


:

iv

“I / we acknowledge that I have read this piece in my / our this work is sufficient in
scope and quality for the award of Bachelor of Electronic Engineering (Industrial
Electronics) With Honors"

Signature

: ……………………………….

Name

: MUHAMMAD NOORAZLAN SHAH BIN ZAINUDIN

Date

: ………………………………..


v

Dedicated to my beloved family especially my father and mother, lecturer and to all my
friends

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ACKNOWLEDGEMENTS

Alhamdullilah, I would like to express my deepest appreciation to my supervisor,
En. Muhammad Noorazlan Shah Bin Zinudin who have helped me making this project
possible. His support,guidance and advice throughout this project are greatly
appreciated. Indeed without his guidance, i would not complete this project successfully.
In addition, thenks to all my friends that helping me to complete this project and
make my dream come. The guidance and support received my friends who are
contributing to this project, was vital for the succes of the projects
Finally, first in my heart, I would also like to thanks especially my parents for
their continued moral and financial support throughout my studies and project. Without
them, I would not to be here and finish my degree.

Thank You.

vii

ABSTRACT

Cleanroom Parameters Monitoring System (CPMS) is a device that can display
the critical parameters inside the sensitive area. These project refer to monitoring inside
the cleanroom area because this place need to protect the products and also the
equipments from contamination. Contamination can generated from the facilities,
people, tools and fluids inside the cleanroom environment. By monitoring the critical
parameters such as temperature, humidity, dew points, particle count and light intensity
it can reduce and prevent these contaminants. These projects will show the actual
parameters inside the cleanroom area and give an indicator to the parameters that exceed
the specifications based on the cleanroom standard. Parameters that will be measured for
this project is temperature, dew points, relative humidity, particle count and light
intensity.

viii


ABSTRAK

Cleanroom Parameters Monitoring Sytem (CPMS) merupakan alat yang akan
memaparkan parameter yang kritikal di dalam kawasan sensitif. Projek ini merujuk
kepada pemantauan didalam kawasan bilik bersih (cleanroom) kerana kawasan ini perlu
melindungi produk dan peralatan daripada pencemaran. Pencemaran boleh terhasil
daripada manusia, peralatan dan cecair di dalam persekitaran bilik bersih. Dengan
pemantauan suhu, kelembapan, bilangan habuk dan kecerahan cahaya, ianya dapat
melindungi dan mengurangkan pencemaran. Projek ini akan memaparkan keadaan
sebenar parameter di dalam persekitaran bilik bersih dan memberikan petunjuk
sekiranya parameter melebihi daripada spesifikasi bilik bersih yang telah ditetapkan.
Parameter yang akan di ukur bagi projek ini adalah suhu, kelembapan, titik embun,
kiraan habuk dan kecerahan cahaya.

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TABLE OF CONTENTS

CHAPTER


1.0

CONTENTS

PAGE

PROJECT TITLE

i

PROJECT STATUS FORM

ii

DECLARATION

iii

APPROVAL


iv

DEDICATION

v

ACKNOWLEDGEMENT

vi

ABSTRACT

vii

ABSTRAK

viii

CONTENTS


ix

LIST OF TABLES

xii

LIST OF FIGURES

xiii

LIST OF ABBREVIATIONS

xvi

INTRODUCTION

1

1.1 Project Overview

1

1.2 Objectives of Project

2

1.3 Problem Statement

3

1.4 Scopes of Work

3

1.5 Project Planning

3

x

2.0

1.6 Thesis Outline

4

LITERATURE REVIEW

5

2.1 Background Study

5

2.2 Software Overview

6

2.2.1 Arduino IDE

6

2.3 Hardware Overview
2.3.1 Arduino UNO Rev 3

7
7

2.3.2 DHT 11 Sensor

8-12

2.3.3 Dust Sensor

13-14

2.3.4 Light Dependent Resistor (LDR)

15-16

2.3.5 Real Time Clock DS 1307

17-18

2.3.6 2.4” TFT LCD Touch Shield

18-19

2.4 Related Project

20-22

2.4.1 Reading DS1820 temperature sensor with PIC16F628A

20

2.4.2 Temperature Alarm Using PIC16C84 Microcontroller

21

2.4.3 Temperature and Humidity Display with Adaptive

22

Brightness Control Using PIC12F683

3.0

2.5 Comparison Projects

23

METHODOLOGY

24

3.1 Project Methodology

24-25

3.2 Data Collection Method

26

3.3 Flow Chart Methodology

27

3.4 Block Diagram

28

3.5 Gantt Chart

29

3.6 Project Planning

30

xi

3.7 Setup an Arduino UNO Board

4.0

31-34

3.7.1 USB cable

32

3.7.2 Arduino IDE

33

3.7.3 Arduino Main Board to Computer

34

RESULT AND DISCUSSION

38

4.1 Overview

38

4.2 Testing The Sensors On Arduiono Board

39

4.2.1 Dust Sensor

39

4.2.2 DHT 11 Sensor

40

4.2.3 LDR Sensor

41

4.2.4 Test The Display

42

4.2.5 Displaying Sensor Data On TFT LCD Shield

43

4.3 Installation

44

4.4 Product Features

45

4.4.1 Sensor supply for Temperature, Humidity, Dew Points,

45

Light Intensity and Dust.

5.0

4.4.2 Accurate and user friendly.

46-47

4.4.3 Parameter Limit Indicator

48

4.4.4 Large Color Display

48

4.5 FS209E and ISO Cleanroom Standards

49

CONCLUSION AND RECOMMENDATION

50

5.1 Overview

50

5.2 Project Conclusion

51

5.3 Recommendations

52

xii

REFERENCES

53-54

APPENDICES A

55

APPENDICES B

56

APPENDICES C

57

APPENDICES D

58

xiii

LIST OF TABLES

NO

TITLE

PAGES

1

Table 2.1 : DHT 11 Specifications

9

2

Table 2.2 : Electrical Characteristics for Dust Sensor

14

3

Table 2.3: TFT LCD Specifications

19

4

Table 2.4 : Comparison with others project

23

5

Table 4.1: Accuracy of DHT 11

48

6

Table 4.2: Accuracy of Dust Sensor

48

7

Table 4.3: Sensitivity of LDR sensor

49

8

Table 4.4: Class Limit for FS209E and ISO

51

xiv

LIST OF FIGURES

NO

TITLE

PAGES

1

Figure 2.1: Arduino IDE Software

6

2

Figure 2.2: Arduino UNO Rev 3 Main Board

7

3

Figure 2.3: DHT 11 Sensor

8

4

Figure 2.4: Communication Process

11

5

Figure 2.5: Data “0” indication

12

6

Figure 2.6: Data “1” indication

12

7

Figure 2.7: Grove Dust Sensor

13

8

Figure 2.8: Grove Dust Sensor Block diagram

14

9

Figure 2.9: Light Dependant Resistor (LDR)

15

10

Figure 2.10: Resistance versus Luminance Graph

16

11

Figure 2.11: Real Time Clock DS1307 (RTC)

17

12

Figure 2.12: Operating Circuit And Pin Configuration for RTC
DS1307

17

13

Figure 2.13: TFT LCD Touch Shield

18

14

Figure 2.14: Project 1

20

15

Figure 2.15: Project 2

21

16

Figure 2.16: Project 3

22

xv

17

Figure 3.1: Steps of Methodology

25

18

Figure 3.2: System Flow Chart

27

19

Figure 3.3: Block Diagram

28

20

Figure 3.4: Gantt Chart fpr Semester 1

30

21

Figure 3.5: Arduino UNO Rev.3

31

22

Figure 3.6: USB Cable B Type

32

23

Figure 3.7: Arduino IDE

33

24

Figure 3.8: Found New Hardware

34

25

Figure 3.9: Found New Hardware Wizard

34

26

Figure 3.10: Found New Hardware Wizard

35

27

Figure 3.11: Browse for Folder

35

28

Figure 3.12: Hardware Installation

36

29

Figure 3.13: Found New Hardware Wizard

36

30

Figure 3.14: Device Manager

37

31

Figure 4.1: Dust Sensor Result on Serial Monitor

39

32

Figure 4.2: DHT 11 Result on Serial Monitor

40

33

Figure 4.3: LDR Result on Serial Monitor

41

34

Figure 4.4: Testing LCD Display

42

35

Figure 4.5: Displaying Sensor Data on LCD

43

36

Figure 4.6: Assembling Cleanroom Parameters Monitoring System
(CPMS)

44

37

Figure 4.7: DHT 11 Parameters

45

38

Figure 4.8: LDR Parameter

45

39

Figure 4.9: Particle Count Parameter

46

40

Figure 4.9: Resistance as Function of Illumination

47

41

Figure 4.10: Limit Indicator for Parameters

48

42

Figure 4.11: Large LCD Color Display

48

xvi

LIST OF ABBREVIATIONS

CPMS

-

Cleanroom Parameter Monitoring System

OTP

-

One Time Programmable

TFT

-

Thin Film Transistor

ICSP

-

In Circuit Serial Programming

FTDI

-

Future Technology Devices International

USB

-

Universal Serial Bus

DC

-

Direct Current

LDR

-

Light Dependent Resistor

LCD

-

Liquid Crystal Display

LPO

-

Low Pulse Occupancy

RH

-

Relative Humidity

PM

-

Particulate Matter

1

CHAPTER I

INTRODUCTION

1.1

Project Overview
Clean room is a strictly area where critical parameters need to be monitor
for protect sensitive equipment or manufacturing products from contamination.
There are several designs why the clean room needs to be monitor which are
verify the process environment inside the critical area is perform according to
the require specifications[1]. The others reason is for document the data of the
process environment conditions. Clean room environment is sensitive with
product and personnel moving and changing where contamination can be happen.
By monitoring this critical parameter, it can trend charts and records of event that
can help to define maintenance cycles of cleaning.

2

1.2

Objectives of Project
The specific objectives of this project are to:
1. Monitor the actual parameters of clean room environment.
2. Alerts the conditions that exceeding classification.
The first objective is to monitor and analyze the actual parameter of
cleanroom environment. By using DHT 11 (temperature & humidity sensor) and
air contaminant sensor environment inside the cleanroom can be monitor and will
be display out on the TFT LCD color display. The he data of the temperature,
humidity, dew points and dust can be monitor and analyze every hour by the
employee. The reasons why the cleanroom should be monitor is to verify either
the process environment is perform according to the requires specifications
because this areas are built to the specific requirements of the product that to be
built.
The second objective

is

alerts

the conditions

that exceeding

classifications. This is to alert the people of the actual parameters inside that area.
The parameters that exceed the specifics requirement becomes red font color to
show that the parameters is not on the requirement. By that it can help to records
the data and define maintenace cycles of cleaning process.

3

1.3

Problem Statement
The purpose of this project is to monitor the quality of environment in
clean room area where the products are manufactured which the concentration of
airborne particles is controlled to the specified limits. The contaminants inside
the clean room are produced by the people, process, facilities and equipment.
The way to control the contamination is by control the overall
environment inside that area where temperature, humidity, dew points,light
intensity and dust need to be tightly controlled. In this project, it will show the
current value of temperature, humidity, dew points, dust and light intensity.

1.4

Scopes of Work

The scopes of works in this project are:
1. The design of this CPMS is to minimal the device for portable user inside
the clean room area.
2. The implemented of CPMS will consists of totally 3 sensor in 1 device
which are humidity and temperature sensor, air contaminant sensor , dew
points and light intensity sensor.
3. The coding software that will be used for this project is Arduino.

1.5

Project Planning

This project is implemented based on the project planning schedule. It
was started from September 2013 and finish May 2014.

4

1.6

Thesis Outline
This thesis report contains 5 chapters that will explain more details on
each chapter to give an understanding about the whole project.
Chapter one will explain detail on the introduction of this project. In this
chapter, it presents an overview of quality environment for the cleanroom,
objective project, scope of works and project planning.
Chapter two will covers more about the literature review on the software
and hardware that will be used in this project. This chapter will discuss about the
source and article that related to this project. It will also relate the theory of
components and programming language by using Arduino Uno Rev.3. So this is
important to understand more about the overall concepts.
Chapter three will explain more about the project methodology, project
planning and project finishing. It will show the progress of this project according
to the due date which had been set before the project is in progress. In this
chapter also will include the flow chart and block diagram that will explain more
about the project system and it will also include Gantt chart for Semester I and II.
Chapter four is about the result and discussion for final year project. In
this chapter it will show how to set up the arduino software connect with
Windows and installation of arduino libraries. Other than that, this chapter will
discuss about how to troubleshoot the problems if anything happen to the
software and hardware.
Chapter five is the last chapter in this project that will represent the
conclusion based on the objective that had been specified in introduction part.
Next, this chapter also will discuss about the future planning of this project
which are suggestion for improvement on this project.

5

CHAPTER II

LITERATURE REVIEW

2.1

Background Study
This chapter desribres and discusses the sources and articles that has been
studied and related to the project. This chapter also will describe the theory of
software and hardware overview that is used in this project. The literature review
must be done to comprehend the whole system and decide the best inputs,
outputs and devices. The project will be compared with the others project that
was designed. In addition, this chapter also describes all equipment, components
and programming languages that are used in the project.. All information such as
operation and specification of project also stated.

6

2.2

Software Overview

2.2.1 Arduino IDE

Figure 2.1: Arduino IDE Software
Arduino software is one of the software that will be use for this project.
This software is an open source based on the simple microcontroller board and
writing software for the board. By using this software, it can develop interactive
objects, taking inputs from the variety of swithces or sensors and control the
outputs such as lights, motors and others physical outputs[3]. This software also
can communicate with software that running on the computer. In writing the
sketch code and load to the arduino, arduino IDE is the software tool.

7

2.3

Hardware Overview

2.3.1 Arduino UNO Rev.3

Figure 2.2: Arduino UNO Rev 3 Main Board
Arduino UNO is the main board for this project. This main board consists
of microcontroller board based on Atmega328 and 14 digital input/output pins.
Arduino uno also has 6 analog inputs, 16 MHz crystal oscillator, USB
connection, power jack, ICSP header and reset button. This board contains
everything needed to support microcontroller and connect to USB cable. It can
also power it with AC to DC adapter or battery for get started. This board are
differs from all boards because it does not use FTDI USB to serial driver chip
and the features Atmega8U2 are programmed as USB to serial converter[3].

8

2.3.2 DHT 11 Sensor

Figure 2.3: DHT 11 Sensor
DHT 11 is the sensor used for this project. This sensor will display the
current parameters for temperature, humidity and dew points where the sensor
complex are calibrated with digital signal output[2]. To ensures high reliability and
long term stability, this sensor is using exclusive digital signal acquisition technique
and sensing technology. It consists of resistive type humidity measurement
component and NTC temperature component. This sensors is connected with high
performance of 8 bit microcontroller that offering excellent quality, cost
effectiveness, fast response and anti interference ability.
The DHT 11 is calibrated in the laboratory that haas extremely accurate for
humidity calibration. It is stores as programs in OTP memory that used by the sensor
internal signal detecting process[9]. To make the system integration quick and easy,
this sensor using single wire serial interface. The DHT 11 convenient to connect and
special packages can be provided according to the users.