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Graphical Output Package for Industrial Sensor May 00 - 12

Graphical Output Package for Industrial Sensor May 00 - 12. Team Members Steve Bower – CprE Ken Hall – CprE Roar Lien – CprE Jim Sproul – CprE Rich Matus - CprE. Graphical Output Package for Industrial Sensor May 00 - 12. Faculty Advisor Dr. Doug Jacobson Industrial Client

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Graphical Output Package for Industrial Sensor May 00 - 12

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  1. Graphical Output Package for Industrial SensorMay 00 - 12 Team Members Steve Bower – CprE Ken Hall – CprE Roar Lien – CprE Jim Sproul – CprE Rich Matus - CprE

  2. Graphical Output Package for Industrial SensorMay 00 - 12 Faculty Advisor Dr. Doug Jacobson Industrial Client Delavan Inc. – B.F. Goodrich Aerospace

  3. General Background • Delevan designs jet engine nozzles. • Lean Blow Out (LBO) • Incoming fuel rate too small • Incoming air velocity too great • Importance • Aircraft safety • Improved profitability • Improved data analysis

  4. Current Solution • Current test stand is completely manual. • Error is introduced when data is collected. • Complexity of situation may not allow for proper data gathering. • Collecting only fuel and air flow data has limited value. • Engineer must be in close proximity to the test stand to get the data.

  5. General Solution • Develop software that will… • Interface graphically • Automatically collect data • Multiple sensors • Improve accuracy of data collection • Electronically transfer test stand raw data • Manipulate data for analysis and presentation

  6. Design Objectives • Data acquisition component • LabVIEW front panel component • Data analysis component • E-mail component • Data visualization component

  7. Interface Diagram

  8. Design constraints • LabVIEW programming environment • Microsoft Excel installed • Data acquisition card installed • Internet access via modem • Windows NT, 95 ,or 98 • Software stubs to simulate sensors • Completed by April, 2000

  9. Intended Users and Uses • Intended for Aerospace and Mechanical Engineers in R&D. • Intended to cut down the design time of the jet nozzle being tested.

  10. End Product Description • Software package will… • Acquire data • Display data graphically • Electronically send data • Visually model data • Export to MS Excel

  11. Assumption and Limitations • Maximum number of sensors is twelve • Data precision is based on auxiliary computer. • Maximum of 600 data points per run. • Accuracy to three decimal places. • Will not perform statistical analysis.

  12. Milestones • Establish HART communication • Implement HART component • Implement Front Panel component • Implement E-mail component • Implement MS Excel component • Implement additional components • Document functionality

  13. Data Acquisition Options • FieldBus communications • HART communications

  14. FieldBus Communication • FieldBus communications protocol • Fast • Completely digital communication • Approximately three times more expensive than HART • Expensive 3rd party LabVIEW drivers • Determined to be outside project budget

  15. HART Communications • Highway Addressable Remote Transducer • Frequency shift key communications protocol • 1200 Hz = binary 1 • 2200 Hz = binary 0 • 1200 baud rate • Interface to PC via HART modem

  16. HART Communications • Proven technology • Inexpensive 3rd party LabVIEW drivers • Used by most industrial control manufacturers as a communications standard for "smart field devices." • The "smart field devices" use a embedded micro controller • Device power and communications use the same pair of wires

  17. Data Acquisition Module • Acquire data from… • HART device • Analog sensors • Configure the HART device. • Error detection for HART communications

  18. Hardware and software needed for HART communications • HART pressure transmitter • HART modem • 4 to 20 mA current source • "CARDIAC" LabVIEW driver

  19. HART configuration screen • Allows user to select one of twenty-two commands

  20. Reading Parameters • Reading data from HART pressure transmitter

  21. Writing Parameters • Writing configuration parameters

  22. Error Detection • Detect HART communication error • Display status from device • Allow user to retry communications

  23. Front Panel Module Component • Display multiple streams of data to user. • Terminate data acquisition upon flameout. • Display sensor values at flameout.

  24. Configuration Module • Write configuration Program will save its present configuration upon closure. • Read configuration Program will start in the configuration of last test.

  25. User Input Module • User must input proper documentation to proceed with test.

  26. Sensor Module • Design is scalable • User selects active sensors • User selects sensors to display on graph

  27. Program State Module • Active sensor states are written or read from a file.

  28. Excel Module • All data will be in Excel format with the date used as the file name.

  29. E-mail Module • User can select up to 200 recipients and send the data immediately after the test is complete.

  30. E-mail Attachments • User can send a text message as well as multiple attachments in .jpg and .png formats.

  31. Data Visualization Component • User can choose the sensors to display in a 3-D graph. • Data is sent to the 3-D graph in 2 dimensional arrays.

  32. Project Cost Analysis

  33. Personnel Original Estimated Effort (2 Semesters) Revised Estimated Effort (2 Semesters) Steve Bower 200 hours 120 hours Ken Hall 150 hours 82 hours Rich Matus 150 hours 85 hours Roar Lien 150 hours 98 hours Jim Sproul 150 hours 95 hours Total estimated effort 800 hours 480 hours Personnel Resources

  34. Problems Encountered • Software vendor backed out of software agreement • Software version incompatibility • Poster printing • Feature Creep • Time zone differences • Language barriers with tech support

  35. Future Work • Communication with multiple HART devices • Further development of 3-D modeling • Implementation of web based server

  36. Milestone Progress 100% 50% 80% 85% 100% 50% 10% • Establish HART communication • Implement HART component • Implement Front Panel component • Implement E-mail component • Implement MS Excel component • Implement additional components • Document functionality

  37. Summary • Current problem • Error prone manual data collection • Proposed solution • Accurate automated data collection • Implementation of solution • HART device • LabVIEW • What does this mean to Delavan?

  38. Questions ? ? ?

  39. For more information Visit our website at: http://seniord.ee.iastate.edu/may0012 Check out our poster:

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