Transcript FINANCIAL PERFORMANCE - Iowa State University

Fermentation Vessel
Automation
Team Members:
Client:
Andrew Arndt
Stephanie Loveland
Adam Daters
Chemical Engineering
Brad DeSerano
Advisor:
Austin Striegel
Dr. Degang Chen
Team: Dec06-07
October 12, 2006
Presentation Outline
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Project Overview
Research Activities
Hardware Configuration
Software Development
Implementation
Resources and Scheduling
Questions
Definitions
COM – Serial communications port
DAQ – Data acquisition
Flash – Animated graphics technology and format from Macromedia,
which can be viewed with a web browser plug-in
GUI – Graphical user interface
I/O – Input/Output
LabVIEW – Laboratory Virtual Instrument Engineering Workbench
PCI – Peripheral component interconnect
PPM – Parts per million
PXI – PCI extensions for instrumentation
RPM – Rotations per minute
RS232 – Standard for serial cable interface
SCC – Signal conditioning system offered by National Instruments
SLM – Standard liters per minute
USB – Universal serial bus
VI (virtual instruments) – Sub-unit program in LabVIEW that
represents the appearance and function of a physical implement
Acknowledgements
• Stephanie Loveland - of Iowa State University
Department of Chemical and Biological Engineering
for providing finances, design specifications, and
requirements for this project
• Dr. Degang Chen - of Iowa State University for
technical and practical advice
Problem Statement
• A mock fermentation vessel is available for use by senior
chemical engineering students
• Archaic methods were used to record data (Paper and Pencil)
Previous Design Layout
Problem Solution-Approach
• Designed and installed new hardware for the mock fermentation
vessel apparatus
• Created an automatic data collection software to display and record
real time results
Intended Users
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Senior level students in the Department of Chemical and
Biological Engineering as well as faculty within the department
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The users must have knowledge of safety procedures and
requirements while conducting experiments within the lab
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Students will need to have been exposed to the concepts that
the lab is designed to simulate
Intended Uses
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The intended use of this project is to automate the collection of
data from the mock fermentation vessel apparatus
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The automation process will yield data in a real-time display as
well as saved file format for further data analysis by the users
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The end system is not intended to be used on any other
equipment that is not supported
Operating Environment
• Located in 2059 Sweeney
• Temperature controlled environment 60˚ to 80˚ F
Laboratory Apparatus
Assumptions (1/2)
• The end-user of this project will be someone who is familiar
with the fermentation process
• Only one experiment will be conducted at a time
• Environmental stability of 2059 Sweeney will be maintained
• All new components and cables will be paid for by the client
• The end-user understands basic computer terminology
(double-click, scroll, etc)
• All laboratory components will operate within their given rated
power values
Assumptions (2/2)
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A computer will be supplied by the client with LabVIEW and
Excel already installed
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An extra PCI slot will be available on the computer for data
acquisition card
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The data acquisition card will supply its own clock
Limitations (1/2)
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File format type is in Excel Format
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Software shall be written using LabVIEW
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One sample per every five second must be recorded from each
specified device
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Maximum flow rate for the air/nitrogen must be less than 6 SLM
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Motor speed must be kept less than 600 RPM
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Safety glasses must be worn at all times when working in 2059
Sweeney
Limitations (2/2)
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No more than 4 significant digits stored upon measurement
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The voltage signals from the stirrer motor control must be
electrically isolated
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The oxygen concentration meter must read from 0 to 9.5 PPM
dissolved oxygen
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The oxygen concentration meter must be a benchtop unit
End-Product and Deliverables
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A fully automated and integrated data collection system
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A graphical user interface (GUI) designed in LabVIEW
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Instruction manual and documentation for the data collection
system
Present Accomplishments
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All hardware purchased and installed for automated data
collection
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Able to collect data from each piece of lab equipment
Technology Considerations (1/4)
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Data Acquisition Board
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Signal Conditioning
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Oxygen Concentration Meter
Technology Considerations (2/4)
Data Acquisition Board
USB DAQ
PXI DAQ System
• Inexpensive and Easy Connection
• High Resolution/High Sampling Rate
• No Signal Conditioning Capability
• High Cost
• Signal Conditioning Capability
PCI DAQ Board
• Moderate Resolution & Sampling Rate
• Moderate Cost
• Signal Conditioning Capability
Technology Selected
PCI DAQ Board
Technology Considerations (3/4)
Signal Conditioning
No Signal Conditioning
• Less Cost
• Unable to interface directly with DAQ board
Signal Conditioning
• Isolation requirements met for Stirrer Motor Control
• Easy interface with DAQ Board
• Extra cost of Signal Conditioning Carrier Box
Technology Selected
Signal Conditioning
Technology Considerations (4/4)
Oxygen Concentration Meter
Omega DOB-930
• 100 data point logging
• RS232 Interface
• Limited support and availability
Thermo Electron Orion 3-Star
• 200 data point logging
• RS232 Interface
• 3-year Extended Warranty and availability up to 5 years
Technology Selected
Thermo Electron Orion 3-Star
Detailed Design (1/8)
Hardware Data Flow Configuration
Detailed Design (2/8)
Oxygen Concentration Meter and Interface
Thermo Electron Orion 3-Star
• Full Scale Measurement of Dissolved
Oxygen (0-9.5 PPM)
Interface
• Onboard RS232 Connection port for data acquisition
• Meter is configured to transfer data every 5 seconds to the PC
• Data is acquired using the onboard COM port of the computer supplied
Detailed Design (3/8)
Mass Gas Flow Meter and Interface
Omega FMA-5610
• Full Scale Measurement of Gas Flow from 0
to 10 SLM
• Analog 0-5V Output Signal
Interface
• 9-Pin D Connector: Pins 2-3 voltage output
• SCC-AI04 is used to isolate and condition the 0-5V signal
• SCC Module is plugged into the SCC Carrier for interface with the DAQ board
Detailed Design (4/8)
Signal Conditioning Carrier Unit
SCC Carrier SC-2345
• Direct Cabling to the M-Series DAQ Board
• Housing for up to 20 SCC Modules
• Powered by DAQ Board with 5V Signal
Detailed Design (5/8)
Signal Conditioning Carrier Unit Interface
• Connects to the DAQ board via a 68 pin shielded connector
cable
Detailed Design (6/8)
Stirrer Motor Control and Interface
Glas-Col GKH-Stir Tester
• Two Analog voltage outputs (0-5V)
• Operates with a floating ground at 70-90V
• 60V fast transient spikes on voltage lines
Interface
• 4 pin terminal connection (Differential Voltage)
• SCC-AI04 is used to isolate the analog input up to 300V
• Voltages is measured differentially to protect against transient spikes
• SCC Module is plugged into the SCC Carrier to interface with the DAQ board
Detailed Design (7/8)
Data Acquisition Card
NI PCI-6221 M-Series DAQ Board
• 16 Analog Inputs, 2 Analog Outputs, 24 Digital
I/O Lines, 2 Counters/Timers
• 16 Bit Resolution – Accuracy of 70μV
• Sampling Rate: 250 kilo-samples/sec
Interface
• Connects with the Signal Conditioning Carrier via the 68 pin shielded cable
• Supplies internal clock for data acquisition of signals
• 6 Channels of Analog Inputs are used for acquiring mass gas flow, torque,
and speed
• Automatic VI’s in LabVIEW define the operation of the DAQ card
Detailed Design (8/8)
Software Interface
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4 Gauges represent
various real-time test
data
Main graph shows
waveform of
currently selected
data
Selectable results
path for saving of
data results
Selectable
experiment time
Implementation Activities
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Applied capacitor to motor controller output signal
– Precision of module recorded all noise seen on signal
– Contacted manufacturer for recommendation
– Applied proper sizing by calculating time constant for settling
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Determined scaling of devices for proper measurement
Testing Activities
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Team Testing
– Individual unit testing
– Overall GUI functionality testing
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Beta Testing
– Student testing with actual laboratory experiments
– Scheduled for October 24
Resources
Personnel Hours
250
Hours
200
208
219
235
210
150
100
50
0
Andrew
Brad
Adam
Team Member
Austin
Other Resources
Oxygen Concentration Meter
$1500
Data Acquisition Unit
$400
Signal Conditioning Unit
$700
Cables
$130
Project poster
Total
$20
$2750
Resources
Financial Resources
Labor Costs
Other Resources
Labor Costs
Data Acquisition Unit
Cables
Oxygen Concentration Meter
Signal Conditioning Unit
Project poster
Total
$9156
$2750
$11906
Schedule
Project Evaluation
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Technology Research and Selection
– 100% Completed
Design
– 100% Completed
Implementation
– 90% Completed
Testing
– 60% Completed
Documentation
– 30% Completed
Additional Work
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Final GUI implementation
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Beta testing
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End-user documentation and manual
Lessons Learned
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Double-check all specifications before purchasing
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Motor balance is important to accurately take measurements
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LabVIEW programming
Risk and Management
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Equipment Damage
– Broken vessel overcome by team
– Replacement ordered by client
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Team Member Loss
– No team member lost during duration of project
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Human Injury
– Standard safety procedures are followed by team while
working in Sweeney lab
Closing Summary
A mock fermentation vessel is available for use by senior
chemical engineering students to conduct experiments in their
final laboratory course. This vessel currently uses archaic
methods to operate the equipment and to collect data. The
objective of this project is to design an automated system to
collect the necessary data for the user. This system will involve
the use of data acquisition cards to interface with the current lab
equipment, and LabVIEW software will be used to collect the
data. When completed, the entire system should allow end
users complete access to data collection from all laboratory
equipment. This will ensure a deeper more complete
understanding of the fermentation process, and will culture a
better environment for learning.
Questions ?