Transcript Fermentation Vessel Automation

Fermentation Vessel
Automation
SD Team: Dec06-07
December 12, 2006
Client:
Stephanie Loveland
Department of Chemical and Biological Engineering
Advisor:
Dr. Degang Chen
Team Members:
Andrew Arndt
Brad DeSerano
Adam Daters
Austin Striegel
Presentation Outline
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Project Overview
Research Activities
Hardware Configuration
Software Development
Implementation
Resources and Scheduling
Lessons Learned
Closing Remarks
Questions
Acknowledgements
• Stephanie Loveland
– Provided finances, design specifications,
and requirements for the project
• Dr. Degang Chen
– Technical and practical advice
Definitions
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DAQ – Data acquisition
Flash – Animated graphics technology and format from
Macromedia
GUI – Graphical user interface
LabVIEW – Laboratory Virtual Instrument Engineering
Workbench
PPM – Parts per million
RPM – Rotations per minute
RS232 – Standard for serial cable interface
SCC – Signal conditioning system offered by National
Instruments
SLM – Standard liters per minute
VI (virtual instruments) – Sub-unit program in LabVIEW that
represents the appearance and function of a physical
implement
Problem Statement
• A mock fermentation vessel is available
for use by senior chemical engineering
students
• Simple methods were used to record
data (Paper and Pencil)
• An automated data collection system
needed to be developed to gather the
data
• Upgrade equipment as needed
Problem Solution-Approach
• Designed and installed new hardware for the
mock fermentation vessel apparatus
– Data acquisition card
– Signal conditioning modules
– Oxygen concentration meter
• Created automatic data collection software
with LabVIEW
• Recorded results with software to Excel
workbook
Problem Solution-Approach
Equipment Data Recorded
Intended Users
• Senior level students in the Department of
Chemical and Biological Engineering as well
as faculty in the department
• Users must have knowledge of safety
procedures and requirements while
conducting experiments within the lab
• Users will need to have been exposed to the
concepts that the lab is designed to simulate
Intended Uses
• Automate the collection of the data
from the mock fermentation vessel
apparatus
• Display data in real-time
• Record data into Excel workbook for
further analysis
• Use of this system is not supported on
any other equipment not supported
Operating Environment
• Location in 2059 Sweeney
• Temperature controlled environment
– 60°F 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
• All laboratory components will operate
within their given rated power values
Assumptions (2/2)
• A computer will be supplied by the
client with LabVIEW and Excel already
installed
• An extra PCI slot will be available on
the computer for data acquisition card
• The data acquisition card will supply its
own clock
Limitations (1/2)
• File format type is in Excel format
• Software shall be written using
LabVIEW
• One sample every five second must be
recorded from each specified device
• Maximum flow rate for the air/nitrogen
must be less than 6 SLM
• Motor speed must be kept less than
800 RPM
• Safety glasses must be worn at all
times when working in 2059 Sweeney
Limitations (2/2)
• No more than 4 significant digits stored
upon measurement
• The voltage signals from the stirrer
motor control must be electrically
isolated
• The oxygen concentration meter must
read from 0 to 9.5 PPM dissolved
oxygen
• The oxygen concentration meter must
be a benchtop unit
End Product and Deliverables
• A fully automated and integrated data
collection system
• A graphical user interface (GUI)
designed in LabVIEW
• Instruction manual and documentation
for the data collection system
Present Accomplishments
• Purchased and installed all hardware
for automated data collection
• Collected data from each piece of lab
equipment
• Tested functionality of software as a
team
• Tested functionality of software with
intended users, received feedback
• Delivered completed software with
software feedback implemented
Future Required Activities
• Review user manual with client
• Review programmer’s manual with
client
Technology Considerations (1/4)
• Data Acquisition Board
• Signal Conditioning
• Oxygen Concentration Meter
Technology Considerations (2/4)
Data Acquisition Board
USB DAQ
• Inexpensive and Easy Connection
• No Signal Conditioning Capability
PXI DAQ System
• High Resolution/High
Sampling Rate
Technology Selected:
• High Cost PCI DAQ Board
• Signal Conditioning Capability
PCI DAQ Board
• Moderate Resolution & Sampling Rate
• Moderate Cost
• Signal Conditioning Capability
Technology Considerations (3/4)
Signal Conditioning
No Signal Conditioning
• Less Cost
• Unable to interface directly with DAQ
board
Signal Conditioning
Technology Selected:
• Isolation requirements
Signal Conditioning
met for Stirrer
Motor Control
• Easy interface with DAQ board
• Extra cost of Signal Conditioning Carrier
Box
Technology Considerations (4/4)
Oxygen Concentration Meter
Omega DOB-930
• 100 data point logging
• RS232 Interface
• Limited support and availability
Technology
Selected:
Thermo Electron
Orion 3-Star
Thermo
• 200 data
pointElectron
logging Orion 3-Star
• RS232 Interface
• 3-year Extended Warranty and
availability up to 5 years
Detailed Design (1/8)
Hardware Data Flow Configuration
Detailed Design (2/8)
Oxygen Concentration Meter and Interface
InterfaceElectron Orion 3-Star
Thermo
• Onboard
Full ScaleRS232
Measurement
Connection
of Dissolved
port for data
Oxygen (0-9.5 PPM)
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
Interface
Full Scale
Measurement
of Gas
Flowoutput
from
• 9-Pin
D Connector:
Pins 2-3
voltage
0 to 10 SLM
• SCC-AI04
is used to isolate and condition
• Analog
Output Signal
the 0-5V0-5V
signal
• SCC Module is plugged into the SCC
Carrier for interface with the DAQ board
Detailed Design (4/8)
Signal Conditioning Carrier Unit
Interface
SCC
Carrier SC-2345
• Connects
Direct Cabling
to the
to DAQ
the M-Series
board via
DAQ
a 68
Board
pin
• shielded
Housing for
connector
up to 20cable
SCC Modules
• Powered by DAQ Board with 5V Signal
Detailed Design (5/8)
Stirrer Motor Control and Interface
Interface GKH-Stir Tester
Glas-Col
• 4
Two
pin
analog
terminal
voltage
connection
outputs (0-5V)
(Differential
• Voltage)
Operates with a floating ground at 70-90V
• SCC-AI04
60V fast transient
is usedspikes
to isolate
on voltage
the analog
lines
input up to 300V
• Voltages are measured differentially to
protect against transient spikes
• SCC Module is plugged into the SCC
Carrier to interface with the DAQ board
Detailed Design (6/8)
Data Acquisition Card
Interface
NI PCI-6221 M-Series DAQ Board
• Connects
the 2Signal
Conditioning
16 Analog with
Inputs,
Analog
Outputs, 24
Carrier
via Lines,
the 682pin
shielded cable
Digital I/O
Counters/Timers
• Supplies
internal clock
for data
16 Bit Resolution
– Accuracy
of acquisition
70μV
signals Rate: 250 kilo-samples/sec
• of
Sampling
• 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 (7/8)
Software Design and Implementation
Detailed Design (8/8)
Software Interface
Implementation Activities
• Determined scaling of devices for proper
measurement
• Determined proper connection for
obtaining stirrer motor control data
– No documentation
– Contacted manufacturer and obtained more
information
– Used multimeter to determine correct wiring
• Added multiple tab data writing after
obtaining beta testing feedback
Testing Activities
• Team Testing
– Individual unit testing
– Overall GUI functionality testing
• Beta Testing
– Student testing with actual laboratory
experiments
– Four groups of students tested
– Surveys filled out by each group
– Changes applied from feedback:
• Experiment data on a new worksheet in an Excel
file
Resources
Personnel Hours
250
Hours
200
208
219
235
210
150
100
50
0
Andrew
Brad
Adam
Team Member
Austin
Resources
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 (1/2)
• Technology Research and Selection
– 100% Completed
• Design
– 100% Completed
• Implementation
– 100% Completed
• Testing
– 100% Completed
• Documentation
– 100% Completed
Project Evaluation (2/2)
With a score above 90%, the project has
fully met and exceeded all expectations
Legend:
Making
the
project
a
complete
success
Greatly Exceeded (1.1) – Minimum expectations were met with the
addition of several extra features
Exceeded (1.0) – Minimum expectations were met with the addition of one
or more extra features
Fully Met (0.9) – Minimum expectation were met
Partially Met (0.5) - Some of the minimum expectations were met
Not Met (0.0) – None of the minimum expectations were met
Commercialization
• Project was not designed to be
commercialized
• With small software changes the
system would be extendable to collect
data from similar or newer equipment
Future Recommendations
• Total automation of the system via
computer controlled laboratory
equipment
– Current system would allow for computer
control following software changes
– Dependent upon client preference
Lessons Learned (1/4)
Successes
• Client relationship
• Time management
– Project completed earlier than expected
– Beta testing occurred early, allowed for
more changes
• Advisor Advice
Lessons Learned (2/4)
Setbacks
• Incorrect SCC module purchased initially
• Stirrer motor control pin out
Lessons Learned (3/4)
Experienced Gain
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LabVIEW Programming
Data acquisition and signal conditioning
Troubleshooting problems
Client relations
Delegating responsibilities
Communication skills
Lessons Learned (4/4)
What we would do differently
• More research into each piece of
equipment
• Obtain better LabVIEW reference
Risk and Risk Management
• Equipment damage
– Broken vessel overcome by team
– Replacement ordered by client
• Wrong module purchase
– Initial mass gas flow module wrong input
– Used stirrer motor control module during
development
• Team member loss
– No team member lost during duration of project
• Human injury
– Standard safety procedures are followed by
team while working in Sweeney lab
Closing Remarks
• Students collected by pencil and paper
data from each laboratory equipment
every 10-15 seconds
• An automatic data collection system was
successfully created using data
acquisition and LabVIEW software
• Users can view real-time data, and do
further analysis with electronically saved
data
Demonstration
Questions?