Graphical Output Package Graphical Output Package for Industrial Sensorfor Industrial Sensor

May 00 - 12May 00 - 12Team MembersTeam Members

Steve Bower – CprESteve Bower – CprE

Ken Hall – CprEKen Hall – CprE

Roar Lien – CprERoar Lien – CprE

Jim Sproul – CprEJim Sproul – CprE

Rich Matus - CprERich Matus - CprE

Graphical Output Package Graphical Output Package for Industrial Sensorfor Industrial Sensor

May 00 - 12May 00 - 12Faculty AdvisorFaculty Advisor

Dr. Doug JacobsonDr. Doug Jacobson

Industrial ClientIndustrial Client

Delavan Inc. – B.F. Goodrich AerospaceDelavan Inc. – B.F. Goodrich Aerospace

General BackgroundGeneral Background

Delevan designs jet engine nozzles.Delevan designs jet engine nozzles. Lean Blow Out (LBO)Lean Blow Out (LBO)

– Incoming fuel rate too smallIncoming fuel rate too small– Incoming air velocity too greatIncoming air velocity too great

ImportanceImportance– Aircraft safetyAircraft safety– Improved profitabilityImproved profitability– Improved data analysis Improved data analysis

Current SolutionCurrent Solution

Current test stand is completely manual.Current test stand is completely manual. Error is introduced when data is Error is introduced when data is

collected.collected. Complexity of situation may not allow Complexity of situation may not allow

for proper data gathering.for proper data gathering. Collecting only fuel and air flow data Collecting only fuel and air flow data

has limited value.has limited value. Engineer must be in close proximity to Engineer must be in close proximity to

the test stand to get the data.the test stand to get the data.

General SolutionGeneral Solution

Develop software that will…Develop software that will…– Interface graphicallyInterface graphically– Automatically collect dataAutomatically collect data– Multiple sensorsMultiple sensors– Improve accuracy of data collectionImprove accuracy of data collection– Electronically transfer test stand raw dataElectronically transfer test stand raw data– Manipulate data for analysis and Manipulate data for analysis and

presentationpresentation

Design ObjectivesDesign Objectives

Data acquisition componentData acquisition component LabVIEW front panel componentLabVIEW front panel component Data analysis componentData analysis component E-mail componentE-mail component Data visualization componentData visualization component

Interface DiagramInterface Diagram

D ata analysis com ponentExcel and Text F ile

E-m ail com ponent

D ata v isualization com ponent3 dim enional graphing

LabVIEW front panel com ponentGU I

D ata Acquisiton C om ponentH art C om m unications

Test station

Design constraintsDesign constraints

LabVIEW programming environmentLabVIEW programming environment Microsoft Excel installedMicrosoft Excel installed Data acquisition card installedData acquisition card installed Internet access via modemInternet access via modem Windows NT, 95 ,or 98Windows NT, 95 ,or 98 Software stubs to simulate sensorsSoftware stubs to simulate sensors Completed by April, 2000Completed by April, 2000

Intended Users and UsesIntended Users and Uses

Intended for Aerospace and Mechanical Intended for Aerospace and Mechanical Engineers in R&D.Engineers in R&D.

Intended to cut down the design time of Intended to cut down the design time of the jet nozzle being tested.the jet nozzle being tested.

End Product DescriptionEnd Product Description

Software package will…Software package will…– Acquire data Acquire data – Display data graphicallyDisplay data graphically– Electronically send dataElectronically send data– Visually model dataVisually model data– Export to MS ExcelExport to MS Excel

Assumption and LimitationsAssumption and Limitations

Maximum number of sensors is twelveMaximum number of sensors is twelve Data precision is based on auxiliary Data precision is based on auxiliary

computer.computer. Maximum of 600 data points per run.Maximum of 600 data points per run. Accuracy to three decimal places.Accuracy to three decimal places. Will not perform statistical analysis.Will not perform statistical analysis.

MilestonesMilestones Establish HART communicationEstablish HART communication Implement HART componentImplement HART component Implement Front Panel componentImplement Front Panel component Implement E-mail componentImplement E-mail component Implement MS Excel componentImplement MS Excel component Implement additional componentsImplement additional components Document functionalityDocument functionality

Data Acquisition Options Data Acquisition Options

FieldBus communications FieldBus communications HART communicationsHART communications

FieldBus CommunicationFieldBus Communication

FieldBus communications protocolFieldBus communications protocol – Fast Fast – Completely digital communicationCompletely digital communication – Approximately three times more expensive Approximately three times more expensive

than HARTthan HART– Expensive 3Expensive 3rdrd party LabVIEW drivers party LabVIEW drivers

Determined to be outside project budgetDetermined to be outside project budget

HART CommunicationsHART Communications

HHighway ighway AAddressable ddressable RRemote emote TTransducer ransducer

Frequency shift key Frequency shift key communications protocolcommunications protocol– 1200 Hz = binary 11200 Hz = binary 1– 2200 Hz = binary 02200 Hz = binary 0

1200 baud rate1200 baud rate Interface to PC via Interface to PC via

HART modemHART modem

HART CommunicationsHART Communications

PrProven technologyoven technology Inexpensive 3Inexpensive 3rdrd party LabVIEW drivers party LabVIEW drivers Used Used by most industrial control by most industrial control

manufacturers as a communications manufacturers as a communications standard for "smart field devices."standard for "smart field devices."

The The "smart field devices" use a embedded "smart field devices" use a embedded micro controllermicro controller

Device power and communications use the Device power and communications use the same pair of wiressame pair of wires

Data Acquisition ModuleData Acquisition Module

Acquire data from…Acquire data from…– HART deviceHART device– Analog sensorsAnalog sensors

Configure the HART device.Configure the HART device. Error detection for HART communicationsError detection for HART communications

Hardware and software needed Hardware and software needed for HART communicationsfor HART communications

HART pressure transmitterHART pressure transmitter HART modemHART modem 4 to 20 mA current source4 to 20 mA current source "CARDIAC" LabVIEW driver"CARDIAC" LabVIEW driver

HART configuration screen HART configuration screen

Allows user to Allows user to select one of select one of twenty-two twenty-two commands commands

Reading Parameters Reading Parameters

Reading data from Reading data from HART pressure HART pressure transmittertransmitter

Writing ParametersWriting Parameters

Writing Writing configuration configuration parametersparameters

Error DetectionError Detection

Detect HART Detect HART communication errorcommunication error

Display status from Display status from devicedevice

Allow user to retry Allow user to retry communicationscommunications

Front Panel Front Panel Module Module

ComponentComponentDisplay multiple Display multiple streams of data to user.streams of data to user.

Terminate data Terminate data acquisition upon acquisition upon flameout.flameout.

Display sensor values Display sensor values at flameout.at flameout.

Configuration Configuration ModuleModule

Write configurationWrite configuration

Program will save Program will save its present its present configuration upon configuration upon closure.closure.

Read configurationRead configuration

Program will start in Program will start in the configuration of the configuration of last test.last test.

User Input User Input ModuleModule

User must input User must input proper documentation proper documentation to proceed with test.to proceed with test.

Design is scalableDesign is scalable

User selects active User selects active sensorssensors

User selects sensors User selects sensors to display on graphto display on graph

Sensor ModuleSensor Module

Program Program State ModuleState Module

Active sensor Active sensor states are written or states are written or read from a file.read from a file.

Excel Excel ModuleModule

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

User can select User can select up to 200 up to 200 recipients and recipients and send the data send the data immediately after immediately after the test is the test is complete.complete.

E-mail ModuleE-mail Module

User can send a User can send a text message as text message as well as multiple well as multiple attachments attachments in .jpg and .png in .jpg and .png formats.formats.

E-mail E-mail AttachmentsAttachments

User can User can choose the choose the sensors to sensors to display in a 3-D display in a 3-D graph.graph.

Data is sent to Data is sent to the 3-D graph in 2 the 3-D graph in 2 dimensional dimensional arrays.arrays.

Data Data Visualization Visualization ComponentComponent

Project Cost AnalysisProject Cost AnalysisOriginal Client

Revised Client

Original Team

Revised Team

Estimated Cost

Actual Cost Estimated Cost

Actual Cost

Equipment and parts

HL-Link Software $1,200 $1,200 $0 $0

LabVIEW SE. Software $150 $190 $0 $0

Rosemount Pressure Sensor $2,000 $3,000 $0 $0

Power Supply $250 $0 $0 $0

Digital Read Out for Sensor $400 $400 $0 $0

Internet Development Kit $1,000 $1,000 $0 $0

Data Rate Flow Computer $3,000 $3,000 $0 $0

HART Modem $750 $390 $0 $0

Telephone and postage $0 $30 $100 $10

Poster Printing $0 $0 $80 $54

Total Estimated cost $8,930 $9,210 $180 $64

Item

Personnel ResourcesPersonnel ResourcesPersonnel Original

Estimated Effort(2 Semesters)

RevisedEstimated 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

Problems EncounteredProblems Encountered

Software vendor backed out of software Software vendor backed out of software agreementagreement

Software version incompatibility Software version incompatibility Poster printingPoster printing Feature CreepFeature Creep Time zone differencesTime zone differences Language barriers with tech supportLanguage barriers with tech support

Future WorkFuture Work

Communication with multiple HART devicesCommunication with multiple HART devices Further development of 3-D modelingFurther development of 3-D modeling Implementation of web based serverImplementation of web based server

100%100%

50%50%

80%80%

85%85%

100%100%

50%50%

10%10%

Milestone ProgressMilestone Progress Establish HART communicationEstablish HART communication Implement HART componentImplement HART component Implement Front Panel componentImplement Front Panel component Implement E-mail componentImplement E-mail component Implement MS Excel componentImplement MS Excel component Implement additional componentsImplement additional components Document functionalityDocument functionality

SummarySummary Current problemCurrent problem

– Error prone manual data collectionError prone manual data collection Proposed solutionProposed solution

– Accurate automated data collectionAccurate automated data collection Implementation of solutionImplementation of solution

– HART deviceHART device– LabVIEWLabVIEW

What does this mean to Delavan?What does this mean to Delavan?

QuestionsQuestions

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For more informationFor more informationVisit our website at:

http://seniord.ee.iastate.edu/may0012

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