Table of Contents
Background
This project was developed for Zaara Biotech, a company that uses spirulina to produce protein-rich biscuits. To support their production, spirulina needs to be cultivated efficiently, and that’s where the OrgoReactor comes in.
About the Project
The OrgoReactor is a compact photobioreactor designed for the cultivation of Spirulina, a nutrient-rich microalgae with immense health and environmental benefits. The device incorporates an onboard processor and a memory touch display, allowing users to easily input parameters and control reactor operations. It enables precise regulation of temperature and pH levels, which are vital for optimal Spirulina growth.
Successfully led a team of five skilled individuals in the challenging task of designing and developing a photobioreactor from scratch.
The project involves the development of a photobioreactor (PBR) as a part-time project for Zaara Biotech. A PBR is a specialized bioreactor that utilizes a light source to cultivate phototropic microorganisms. The main objective of this project is to design and build a PBR device that can efficiently cultivate these microorganisms by providing them with optimal conditions for growth.
The device incorporates an onboard processor and a memory touch display, allowing users to input various parameters and control the reactor's operation.
Capable of controlling the temperature and pH levels of the reactor directly and from any part of the world using IoT.
Timer function and valve control settings that enable users to customize the operation of the device according to their specific requirements.
Features
The Team
We are Rayan Abdul Gafoor, Abhishankar, Kashyap Krishna, Akshay Jojo, and Jibin Prekash , a team of passionate engineers who collaboratively designed and developed the OrgoReactor from concept to completion.
My Contribution
I led a team of five members in developing the OrgoReactor from scratch, overseeing the entire process from concept to completion. My key responsibilities included electronic design, PCB fabrication, system integration, and debugging , ensuring seamless functionality and reliable performance of the reactor.
Electronics Design
The electronics design of the OrgoReactor was created using EasyEDA, ensuring precise circuit development and component placement. A two-layer PCB was then fabricated through LionCircuits, providing a reliable and compact hardware foundation for the system.
Main Components
- Esp32
- Nextion Capacitive Touch Display
- pH Sensor
- Temperature Sensor
- Relay Modules
- RTC Module
- LED Panel
- Buzzer
BOM
| ID | Name | Designator | Quantity |
|---|---|---|---|
| 1 | FMQ-BUZZER2 | BUZZER1 | 1 |
| 2 | 0.22uF Electrolytic Capacitors(860010772002) | C1,C5 | 2 |
| 3 | 0.1uF ceramic capacitor | C4,C7 | 2 |
| 4 | 10uF Electrolytic Capacitors | C6 | 1 |
| 5 | 100nF SMD 0603 Ceramic CAPACITOR | C11,C15 | 2 |
| 6 | 1MΩ SMD 0603 RESISTOR | R14 | 1 |
| 7 | Zener diode PHC33 | D1 | 1 |
| 8 | female header pins 1x4 | H1,H6,H7,H8,H9 | 5 |
| 9 | female header pins 1x6 | H2,H4 | 2 |
| 10 | Male header pins_1x2 | J14,J17,J18,J19,J20,J21,J26,J27,J28,J29,J30,J31,J32,J33,J34,J35 | 16 |
| 11 | Male header pins_2x2 | J2,J3 | 2 |
| 12 | female header pins_1x6 | J6,J9,J10,P2 | 4 |
| 13 | female header pins_1x5 | J7,H3 | 2 |
| 14 | Male header pins 1x3 | J8,J11,J12,J13,J22,J23,J24,J25 | 8 |
| 15 | SLIDING SWITCH | SW1,SW2 | 2 |
| 16 | DC POWER-JACK Female | U2 | 1 |
| 17 | ATMEGA2560-16AU | U3 | 1 |
| 18 | JST 2.54mm male connector [3 Pin] | U6,U10,U11,U12,U7,U8 | 6 |
| 19 | JST 2.54mm Female connector [3 Pin] | 6 | |
| 20 | 7805 voltage regulator | U9 | 1 |
| 21 | AWSCR-16.00MTD-T SMD | Y2 | 1 |
| 22 | LED Green-0805 SMD | LED2,LED6,LED8,LED10,LED11,LED12,LED15,LED16,LED18,LED1,LED3,LED13,LED21 | 13 |
| 23 | LED Red -0805 SMD | LED7,LED9,LED14,LED17,LED19,LED4,LED5,LED20 | 8 |
| 24 | 1k SMD 1206 | R1,R2,R20,R21,R22,R23,R24,R25,R12,R26,R27,R28,R29,R30,R31,R32,R33,R34,R15,R18,R36,R11,R19,R37,R16,R17,R35 | 27 |
| 25 | 4.7k SMD 1206 | R3,R4,R5 | 3 |
| 26 | 10k SMD 1206 | R6,R7,R8,R9,R13 | 5 |
| 27 | Screw terminal 2 PIN 5.08mm | CN1,CN2,CN3,CN4,CN5,CN6 | 6 |
| 28 | 1N4007 diode | D2,D3,D4,D6,D7,D8 | 6 |
| 29 | Relay 5v spdt | K1,K2,K3,K4,K5,K6 | 6 |
| 30 | BC547 NPN Transistor | Q6,Q9,Q10,Q4,Q5,Q7 | 6 |
| 31 | EL817C SMD Optocouplers | U1,U5,U13,U8,U17,U19 | 6 |
| 32 | RTC DS3231 | U14 | 1 |
| 33 | Female Header pins 1x2 | J1,J4,J5 | 3 |
| 34 | IRF540 MOSFET N-Channel | Q1,Q2,Q3 | 3 |
| 35 | 8 PIN DIP SOCKET | U16 | 1 |
| 36 | SS36F SMD Schottky diode | D5 | 1 |
| 37 | HDR-M-2.54_1x15 | J15,J16 | 2 |
| 38 | PUSHBUTTON 4 PIN DIP 5.08mm | U15 | 1 |
| 39 | ESP32 DEVKIT V1 DOIT | U18 | 1 |
| 40 | 0.1uF/100nf 50V SMD1206 Electrolytic Capacitors | C2,C3,C8 | 3 |
| 41 | 10k SMD 1206 | R10 | 1 |
| 42 | EEPROM 24C04N DIP8 IC | 1 | |
| 43 | JUMPER SHORT 2.54mm | 30 | |
| 44 | CP2102 UART with DTR PIN | 1 | |
| 45 | 16MHz Crystal OscillatorDIP | 1 | |
| 46 | 22pF Ceramic Capacitor 50V | 2 | |
| 47 | SMPS | 1 | |
| 48 | DC POWER-JACK male | 1 | |
| 49 | Spacer | 8 |
System Integration