Fermentation Vessel
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
•   Project Overview
•   Research Activities
•   Hardware Configuration
•   Software Development
•   Implementation
•   Resources and Scheduling
•   Questions
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
• 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
•   Senior level students in the Department of Chemical and
    Biological Engineering as well as faculty within the department

•   The users must have knowledge of safety procedures and
    requirements while conducting experiments within the lab

•   Students will need to have been exposed to the concepts that
    the lab is designed to simulate
Intended Uses
•   The intended use of this project is to automate the collection of
    data from the mock fermentation vessel apparatus

•   The automation process will yield data in a real-time display as
    well as saved file format for further data analysis by the users

•   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)
•   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 per 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 600 RPM

•   Safety glasses must be worn at all times when working in 2059
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
Present Accomplishments

•   All hardware purchased and installed for automated data

•   Able to collect data from each piece of lab equipment
Technology Considerations (1/4)
•   Data Acquisition Board

•   Signal Conditioning

•   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)

 • 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

 • 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
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


 • 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

• 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

•   4 Gauges represent
    various real-time test
•   Main graph shows
    waveform of
    currently selected
•   Selectable results
    path for saving of
    data results
•   Selectable
    experiment time
Implementation Activities
•   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

•   Determined scaling of devices for proper measurement
Testing Activities
•   Team Testing
     – Individual unit testing
     – Overall GUI functionality testing

•   Beta Testing
     – Student testing with actual laboratory experiments
     – Scheduled for October 24
 Personnel Hours


               200     208              210





                     Andrew   Brad    Adam    Austin
                              Team Member
Other Resources

Oxygen Concentration Meter   $1500
Data Acquisition Unit        $400
Signal Conditioning Unit     $700
Cables                       $130
Project poster                $20
Total                        $2750
     Financial Resources

                                                     Labor Costs       $9156
                                                     Other Resources   $2750

Labor Costs             Oxygen Concentration Meter
                                                     Total             $11906
Data Acquisition Unit   Signal Conditioning Unit
Cables                  Project poster
Project Evaluation
•   Technology Research and Selection
     – 100% Completed
•   Design
     – 100% Completed
•   Implementation
     – 90% Completed
•   Testing
     – 60% Completed
•   Documentation
     – 30% Completed
Additional Work
•   Final GUI implementation

•   Beta testing

•   End-user documentation and manual
Lessons Learned
•   Double-check all specifications before purchasing

•   Motor balance is important to accurately take measurements

•   LabVIEW programming
Risk and Management
•   Equipment Damage
     – Broken vessel overcome by team
     – Replacement ordered by client

•   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 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 ?

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