Machine Shop RFID

Summary

Use Beaglebone Black and EM4001 RFID reader to log and lock-out the HAAS mill based on DMS badge #.

Authorized badges will be entered manually, due to low volume of authorized users, but system will eventually support interconnect with other DMS systems to centralize this in the future.

Information / Procedures

• The BBB static address is 192.168.200.152 (haas-vf-2.dms.local)
• User "rfid" runs the rfid_access.pl control program
• Admins must establish an SSH session to add/remove authorized users
  • Commands:
    • SSH [[1]] where ‘rfid’ is the username
    • enter password
    • List directory contents: "ls" Unix/Mac "dir" Windows
      • disabled_init_d
      • rfid_access.pl
      • rfid_edituser.pl
      • rfid_service.sh
      • old_tags.db
      • rfid_access.service
      • rfid_ntpdate.service
      • rfid_access.log
      • rfid_auth_tags.db
      • rfid_ntpdate.sh
    • Run "perl rfid_edituser.pl" for usage
      • usage: rfid_edituser.pl (add/del/list) [hex tag ID] [username first_last]
        • Insert rfid tag with 2 leading zeros
        • The script will convert the rfid tag to hex
          • Example command: perl "rfid_edituser.pl add 00555555 first_last"
      • After the command succeeds, run the 'list' command to make sure the new user was added successfully.
        • perl rfid_edituser.pl list

Log of work

• 09/01/2015
  • Zach M. & Bryan G.
    • Meeting @5:30pm to discuss initial implementation and attempt quick proof-of-concept by reading badges

• 09/10/2015
  • Zach M.
    • Reader confirmed working with text output at 9600-8-N-1

• 09/23/2015
  • Zach M. & Bryan G.
    • Makeshift "control cape" with control relay shown off, still need to get 2mm to .1" adapter PCB constructed
    • Pictures inside HAAS control box of connector and mounting location
      • 
    • Propose that we use a generic switching power module to provide 5VDC from 1-phase of input power
    • Need to buy: START/STOP connectors
    • Need to create: START/STOP harness which tees off to the BBB control cape, mounting plate from HAAS mounting holes to BBB mounting holes, new swing arm end-cap with provision to mount RFID reader PCB, beeper, and R/Y/G LEDs

• 11/4/2015
  • Zach M. & Bryan G.
    • Determined which wires go to the START/STOP buttons
      • START is N-O, STOP is N-C
    • Found Molex connector to mate with HAAS PCB
    • Bryan to make mounting/adapter plate for BBB mounted in HAAS control enclosure
    • Zach to update CAD file for swing arm end-cap to hold RFID module

• 11/9/2015
  • Zach M.
    • Purchased qty 10 of Molex locking header at Altex for $4.87
    • Altex didn't have the 22-01-2055 "other side", but Mouser does. Order going in today.

• 11/10/2015
  • Zach M.
    • File:ReaderBoardwithLEDs.pdf for end-cap board is complete

• 11/15/2015
  • Bryan G.
    • Completed first-pass end-cap model for 3D printer

• 12/11/2015
  • Bryan G.
    • Final end-cap printed and installed on HAAS swing arm

• 01/02/2016
  • Zach M.
    • Wiring in HAAS cabinet and swing-arm started
      • BBB and control daughter-board installed
        • 
      • New 10-conductor cable pulled down swing arm and terminated on both ends with Molex 12-position connector
      • RFID reader PCB w/ LEDs and beeper installed in swing-arm end
        • 
    • Initial testing
      • Green LED and relay closure verified after authorized tag read
      • Red LED remains lit and no relay closure after non-authorized tag read
    • Remaining work
      • Create and install harness to hijack ON/OFF cable (in progress)
      • Terminate network RJ-45 and attach to BBB for remote access
      • Wire in switching PSU for BBB 5V supply

• 01/04/2016
  • Zach M.
    • Brooks terminated and tested the RJ-45 network drop. Connectivity verified.
    • Completed wiring for ON/OFF cable
    • First successful test of RFID control w/ Zach & Bryan's cards!!!

Data Sheets

• File:ID-2LA, ID-12LA, ID-20LA2013-4-10.pdf -- used to read badges
• File:TLP3545 datasheet en 20120316.pdf -- used to sense HAAS +5 VDC for usage time logging
• File:Edr.pdf -- relay used to block ON button signal

Source Code

• rfid_access.pl
• rfid_edituser.pl

Resources

- https://github.com/VegetableAvenger/BBBIOlib 
- http://processors.wiki.ti.com/index.php/PRU-ICSS