Thermocouple Signal Simulator Sponsor: Emerson- Kent Burr, Charles Eastberg Advisor- Dr. Semih Aslan Group: NPPH(1.7) Taylor Nash, Rey Perez, Victor Pinones, and Travis Howell

Why Emerson Needs A Thermocouple Signal Simulator ❖ Emerson has three different test teams in Round Rock ❖ They do different types of component testing, maxing out, and configurations ❖ Thermocouples is a very common component they test ❖ They want to be able to simulate thermocouple readings ❖ What does the Thermocouple Signal Simulator do?

Options ❖ Input ➢ Multiple inputs ➢ Configure thermocouple types ■Input on DIP switches ■Software implemented ❖ Output ➢ Have multiple outputs ➢ Have just one output Dataflow ❖ Hardware implemented ➢ Need 8 of each components, one for each of the thermocouple types ➢ Too costly for hardware set up- not enough space, too many bugs ❖ Software implemented ➢ Only need one processor

Components ❖ Hardware ➢ Arduino Mega 2560 ➢ DAC, ADC ➢ Electrical Isolator ➢ 5V power supply ➢ 4-20mA input ➢ Power resistors ➢ Op Amp ➢ Printed Circuit Board (PCB) ❖ Software ➢ Program to execute all logic and arithmetic ➢ Thermocouple Polynomial Library ➢ Thermocouple look-up tables

Proposal ❖ Input ➢ 4-20mA, provided by Emerson ❖ Project: convert the 4-20mA signal into an isolated mV signal ranging from ±100mV ❖ Combination of mostly software and some hardware ❖ Configuration to each type of thermocouple ➢ 8 synchronized output nodes

Demo: Dataflow Input 4-20mA Input range percentage conversion Find relative temp. for thermocouple Use temp. for “look-up” value Map to PWM port range Output

Budget Device Price ❖ Arduino Mega 2560.……………...$40 ❖ 5V High/Low Opto-isolator……....$8 ❖ PCB by TXST………………...…...$0 ❖ 24 bit ADC…………………………$11 ❖ 20 bit DAC ………………………..$20 ❖ 1-8 demultiplexer………………....$5 ❖ Project houseing………………....TBA Total Estimated Price: $84 $200/member Total: $800

Test Plan ❖ Overview ➢ Input 4-20 mA signal ➢ Convert and isolate the input to eight ±100 mV outputs ➢ Outputs run to Emerson’s CHARM systems

Constraints ❖ Economical ➢ Hardware implementation would be costly ➢ Wasteful of resources, i.e. all hardware would result in multiple components ➢ Processor/software implementation was much more practical

Dataflow Schematic Output Isolation Hardware Selection Hardware Purchase Timeline

Progra m Debug Circuit Assem bly Testing Softwar e Circuit Testing System Testing Write Program Circuit Assembly Deviation Handling Testing Software Verify System

Demo and Progress ❖ Our demo simulates the type T thermocouple ❖ Input from Arduino’s serial interface ❖ Outputs analog signal on PWM port ❖ Similar to our completed system, except no isolation

References ❖ htatp://community.emerson.com/cfs-file/__key/communityserver-blogs- components-weblogfiles/ /3581.emerson_5F00_electric_2D00_logo.jpg htatp://community.emerson.com/cfs-file/__key/communityserver-blogs- components-weblogfiles/ /3581.emerson_5F00_electric_2D00_logo.jpg ❖ gram%29_LMB.png gram%29_LMB.png ❖ ❖ ❖ T38-1%20Pkg.jpg T38-1%20Pkg.jpg

Questions?