Small Hydro Power Plants with Elixir

We have been exploring methods for using Elixir in industrial applications and challenging ourselves to use it to control several small hydroelectric power plants. In the latest project, we explored the appropriate industrial approach, not just using Elixir.
In this presentation, we will first provide an overview of the control system for small hydroelectric power plants, followed by an explanation of the system architecture with Nerves. We will then discuss the issues encountered during the on-site installation.
The subsequent presentation by KINUKAWA Ryota, also known as @pojiro, will introduce details of the technical methods applied. See also the following URL.
https://docs.google.com/presentation/d/1otmg2S6qY57G7VuXssd-2BViKfDPzmJQ5XQK-futhfI/

Transcript

1. Small Hydro Power Plants with Elixir Part 1 by KIKUCHI Yutaka @kikuyuta part 2 by pojiro 2025.09.10 KIKUCHI Yutaka 1
2. Special Thanks from kikuyuta myasu nishiuchikazuma 32hiro takasehideki pojiro satorumatsushima 2025.09.10 KIKUCHI Yutaka 2
3. Concept To make industrial machinery easy and fun to build and maintain 2025.09.10 KIKUCHI Yutaka 3
4. Contents • Background (by kikuyuta) – Introduction to SHP, History • Hardware implementation (by kikuyuta) – Development of Nerves machine – Hardware configuration in the latest case • Software implementation (by pojiro) 2025.09.10 KIKUCHI Yutaka 4
5. SHP Overview 2025.09.10 KIKUCHI Yutaka 5 Penstock Powerhouse Flood way Conduit Intake weir Head tank Gross head (m) Flow (or discharge) (m3/s)
6. SHP Overview: inside powerhouse 2025.09.10 KIKUCHI Yutaka 6 Turbine Generator Regulation Protection OAM Transformer Switch Board Power Grid
7. History 2025.09.10 KIKUCHI Yutaka 7 2016 2018 2020 2022 PLC Ladder 1st Original box Python 2nd Original box (not used for real applications) 3rd Original box Elixir Nerves 2024 Hardware: Language:
8. Latest case: Honsawa location (world) 2025.09.10 KIKUCHI Yutaka 8
9. Latest case: Honsawa location (Japan) 2025.09.10 KIKUCHI Yutaka 9
10. Latest case: Honsawa location (Nagano) 2025.09.10 KIKUCHI Yutaka 10
11. Latest case: Honsawa location (Vill.) 2025.09.10 KIKUCHI Yutaka 11
12. Honsawa SHP layout 2025.09.10 KIKUCHI Yutaka 12 Top
13. Honsawa SHP: Spec 2025.09.10 KIKUCHI Yutaka 13 • Head ≒ 80m • Flow ≒ 90L/s (max) • Turbine: Pelton – Vertical axis – Nozzles: 4 actuators – Output: ≒ 55kW • Sync. Gen: 60kVA • Battery: 54.6kWh • Grid: 6600V 60Hz
14. Robust box for Nerves • Not many products in 2019 – Linux in industrial atmosphere • low and high temperature, humidity, vibration, dust • Development ourselves – Beaglebone based (thanks open source hardware) – Operating environment testing based on IEC 61131-2 2025.09.10 KIKUCHI Yutaka 14
15. 3rd generation Nerves box: ExiBee 2025.09.10 KIKUCHI Yutaka 15 Octavo OSD335x C-SiP inside
16. IEC 61131-2 Temperature and Humidity stress test 2025.09.10 KIKUCHI Yutaka 16
17. IEC 61131-2 Vibration and Shock test 2025.09.10 KIKUCHI Yutaka 17
18. Control system hardware overview 2025.09.10 KIKUCHI Yutaka 18 MODBUS TCP Erlang Cluster MODBUS RTU MODBUS TCP Powerhouse Turbine / Generator Nagasaka Ski house Power Grid / Battery Digital I/O Analog I/O Digital I/O Other types RTU/TCP converter Erlang Cluster MODBUS/TCP MODBUS/TCP Erlang Cluster TCP/IP/Ethernet Optical Fiber L2SW L2SW Digital I/O Digital I/O
19. Against Discontinuance 2025.09.10 KIKUCHI Yutaka 19 • SHP systems runs over decades – How to maintain them after the devices would be gone? • Our solution – MODBUS and TCP/IP/Ethernet will live on for a long time – Independency from Linux box = Don’t use IFs of box • All I/Os on Modbus – almost on Modbus/TCP, a few on Modbus/RTU – Linux boxes use Modbus/TCP (not their own I/O IFs)
20. Inside Powerhouse 2025.09.10 KIKUCHI Yutaka 20
21. Coming up next about Software 2025.09.10 KIKUCHI Yutaka 21 by pojiro