ARD, Carderock Division, Bayview,ID Project Professors: Dr. Herb Hess & Dr. Brian Johnson Jarred Coulter Vishu Gupta Zane Sapp Final Design Review December 5, 2008

Overview Project introduction DAQ Hardware Sensors Software Testing/Calculations Recommended System Future Work/Conclusions 2

Project Introduction 3

Background The Acoustic Research Detachment (ARD) of the Naval Surface Warfare Center, Carderock Division (NSWCCD) is located at Bayview, ID. The Advanced Electric Ship Demonstrator (AESD) is a ¼ scale destroyer used to monitor acoustics and test electric propulsion technologies. 4 AESD

Project Goals Design a Data Acquisition System (DAQ) to interface with the existing systems on the AESD to: Manage and display battery data from the propulsion and UPS systems Data for voltages, currents, and temperatures Correlate above data with the GPS data available Graphical display On board data storage buffer Expandable Architecture 5

Design specifications Ungrounded system 120 V AC 25Amps available Maximum 12 hours of data storage System needs to be space efficient/ rack mountable Expandable Architecture Integrate with existing sensors and GPS already in place on the AESD 6

System Architecture 7

DAQ Hardware 8

NI DAQ Lab Hardware 9 PXI/SCXI Combination Chassis (1) MXI Express Link (2) M-Series DAQ and PXI/SCXI Chassis Controller (3) 32-Channel Input Module/Multiplexer (4) I/O Connector M-Series DAQ (Not Shown) (5) Cast Screw Terminal Block for SCXI-1104C with Cold Junction Compensation (6) Data Acquisition System From National Instruments System Components

NI Hardware Features M-Series Data Acquisition Device 333 ks/s Up to 280 channels per DAQ device 16-Bit ADC resolution MXI-Express Connection Bandwidth: 110 Mb/s and up to 250 Mb/s PC and laptop compatible High bandwidth allows for large channel count through multiple chassis SCXI/PXI Variety of Input Modules for wide range of applications Rugged chassis for industrial applications 10

LabVIEW 8.2 Built in Virtual Instruments (VI) for data acquisition, analysis, storage and display Mathscript capabilities Stores all data in an ASCII text file called LabVIEW Measurement File (LVM) DAQmx and DAQ Assistant for easier programming 11

Sensors 12

Sensors Overview LEM Current Transducers Accurately measure wide range of currents Cost ≈ $400 per unit Hall Effect Voltage Transducers Capable of accurately handling very high voltages Cost ≈ $250 per unit Isolation Amplifier Type Voltage Transducers Designed Cost ≈ $5 per unit K-type Thermocouple Temperature Sensors Wide measurement range Cost ≈ $1.00 per ft 13

LEM Current Transducer 14 DC Current Transducer 3 Jumper Adjustable Ranges: 5, 10, 20 Amp Max Supply Voltage: VDC ±1% Accuracy at 25 ̊ C LEM DC-C10Features

ABB Voltage Sensor 15 Closed Loop Hall Effect Voltage Transducer Measuring Range: 0 to 500 V Output Voltage: 0 to 10 V (Max) Supply Voltage: ± 15 VDC ± 0.2% Accuracy at 25 ̊ C LEM CV 3-500Features

Designed Sensors Designed Voltage Sensors Low power consumption Only one voltage reference or ground reference Simple design Linear input to output 16 Voltage Sensor Schematic

Voltage Sensor Results 17 Horz = 12V Vert = 12V Simulation Results Experimental Results

Temperature Sensors K-type thermocouples used Temperature range: ˚F to 1562˚F SCXI Modules designed for Thermocouple inputs with integrated Cold Junction Compensation ICs Cost is approximately $1.00/ft for shielded thermocouple wire 18

Software 19

LabVIEW Control for the DAQ Program provides for: Easy control for data acquisition Real-time data display Save the data to a file in a specified location File can be opened with different analysis tools User comments can also be added to the file. Saved data is time and location stamped Errors observed on system are saved as a text file- ‘Error Log’ 20

Flow diagram of the code 21 Check for valid GPS signal Acquire data Display Voltage and Current data as graphs Numerical display for temperature Save data to file Check for stop condition

Designed for the user to control the System and test Divided into different tabs on the screen Instructions Control/Indicator System error Voltage graphs Current graph Temperature readings GPS 22 Front panel: Control/Indicator tab Front Panel: Control

TESTING & CALCULATIONS 23

Lab Setup 24 Designed sensors Current LEM ABB Voltage Sensor NI DAQ Battery Bank GPS Thermocouples

Testing Tests run on the system Period: 2 hours Measured Battery Voltage (V) String Current (A) Battery temperature (°F) Measurements taken on 9 channels Current LEM ABB Voltage Sensor Opto-coupler sensors : 3 Thermocouples : 4 Error observed: None 25

Test Results 26

Calculations LATENCY 1 sec with the GPS running. <100ms without GPS Dependant on sampling frequency POWER CONSUMPTION Lab Model: 510 Watts Including PC power consumption of 60Watts 27

Recommended System 28

System Architecture Flow: Recommended System 29

Recommended System: Calculations The cost analysis for a full system with all the required hardware and software was done Complete system includes: Data Acquisition Cards PC Controller and External Hard Drive Thermocouple/Voltage Input Modules Multi Chassis Adapter MXI Express Connector PXI and SCXI Chassis LabVIEW COST ANALYSIS Total system cost: $140, Cost per channel: $87.17 $68 per channel for additional channels POWER CONSUMPTION 1350 Watts Note: detailed cost analysis is provided in the final report. Also given at the end of the presentation 30

Future Work/ Conclusions 31

Future Work Integrate control of the sensors onto a Printed Circuit Board (PCB). Feedback from the ARD for actual integration with the GPS system on-board the AESD. Type of communication Data format Thermocouple Cards should be integrated into the lab model Integrating real-time system with charging schemes of the propulsion batteries Expanding LabVIEW Event triggering/alarms on the monitored channels For the recommended system Post processing 32

Conclusions System Capabilities: Monitoring propulsion batteries and UPS batteries Acquiring GPS data Data and Error Log saved as text files Sensors Voltage Current Temperature LabVIEW Control the DAQ Monitor the system 33

Acknowledgements ARD Alan Griffitts Frank Jurenka Karl Sette 34 University of Idaho Dr. Brian K. Johnson Dr. Herb Hess Dr. Chris Wagner Arleen Furedy Karen Cassil Beth Cree Dorota Wilk Research Group Justin Schlee John Finley Leo Luckose James Randall

Temperature sensors: Amplifier Amplifier adds a gain of This is then scaled in LabVIEW Explained later on in the presentation 35 Batteries Amplifier DAQ Thermocouple measurement LabVIEW (scale down) Amplified Thermocouple Voltage

Temperature data Modify amplified signal to obtain temperature readings. The amplified signal is scaled down by the gain factor Built in VI for converting voltage to temperature Outputs the temperature The units can be changed 36 Amplified signal from SCXI 1104-C Output temperature on thermocouple 1 Built –in VI for converting Voltage to temperature

Detailed cost analysis sheet of the recommended system 37

Detailed cost analysis sheet of the system used Put in the cost sheet that we had for the system we are using right now. 38