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 • 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 • 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 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 • All hardware purchased and installed for automated data collection • 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) 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 • 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 • 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 Resources Personnel Hours 250 235 219 200 208 210 Hours 150 100 50 0 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 Resources Financial Resources Labor Costs $9156 Other Resources $2750 Labor Costs Oxygen Concentration Meter Total $11906 Data Acquisition Unit Signal Conditioning Unit Cables Project poster Schedule 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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