2. Graphical Output Package for Industrial Sensor May 00 - 12 Team Members Steve Bower – CprE Ken Hall – CprE Roar Lien – CprE Jim Sproul – CprE Rich Matus - CprE

3. Graphical Output Package for Industrial Sensor May 00 - 12 Faculty Advisor Dr. Doug Jacobson Industrial Client Delavan Inc. – B.F. Goodrich Aerospace

4. General Background Delevan designs jet engine nozzles. Delevan designs jet engine nozzles. Lean Blow Out (LBO) Lean Blow Out (LBO) –Incoming fuel rate too small –Incoming air velocity too great Importance Importance –Aircraft safety –Improved profitability –Improved data analysis

5. Current Solution Current test stand is completely manual. Current test stand is completely manual. Error is introduced when data is collected. Error is introduced when data is collected. Complexity of situation may not allow for proper data gathering. Complexity of situation may not allow for proper data gathering. Collecting only fuel and air flow data has limited value. Collecting only fuel and air flow data has limited value. Engineer must be in close proximity to the test stand to get the data. Engineer must be in close proximity to the test stand to get the data.

6. General Solution Develop software that will… Develop software that will… –Interface graphically –Automatically collect data –Multiple sensors –Improve accuracy of data collection –Electronically transfer test stand raw data –Manipulate data for analysis and presentation

7. Design Objectives Data acquisition component Data acquisition component LabVIEW front panel component LabVIEW front panel component Data analysis component Data analysis component E-mail component E-mail component Data visualization component Data visualization component

8. Interface Diagram

9. Design constraints LabVIEW programming environment LabVIEW programming environment Microsoft Excel installed Microsoft Excel installed Data acquisition card installed Data acquisition card installed Internet access via modem Internet access via modem Windows NT, 95,or 98 Windows NT, 95,or 98 Software stubs to simulate sensors Software stubs to simulate sensors Completed by April, 2000 Completed by April, 2000

10. Intended Users and Uses Intended for Aerospace and Mechanical Engineers in R&D. Intended for Aerospace and Mechanical Engineers in R&D. Intended to cut down the design time of the jet nozzle being tested. Intended to cut down the design time of the jet nozzle being tested.

11. End Product Description Software package will… Software package will… –Acquire data –Display data graphically –Electronically send data –Visually model data –Export to MS Excel

12. Assumption and Limitations Maximum number of sensors is twelve Maximum number of sensors is twelve Data precision is based on auxiliary computer. Data precision is based on auxiliary 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.

13. Milestones Establish HART communication Establish HART communication Implement HART component Implement HART component Implement Front Panel component Implement Front Panel component Implement E-mail component Implement E-mail component Implement MS Excel component Implement MS Excel component Implement additional components Implement additional components Document functionality Document functionality

15. Data Acquisition Options FieldBus communications FieldBus communications HART communications HART communications

16. FieldBus Communication FieldBus communications protocol FieldBus communications protocol –Fast –Completely digital communication –Approximately three times more expensive than HART –Expensive 3 rd party LabVIEW drivers Determined to be outside project budget Determined to be outside project budget

17. HART Communications Highway Addressable Remote Transducer Highway Addressable Remote Transducer Frequency shift key communications protocol Frequency shift key communications protocol –1200 Hz = binary 1 –2200 Hz = binary 0 1200 baud rate 1200 baud rate Interface to PC via HART modem Interface to PC via HART modem

18. HART Communications Proven technology Proven technology Inexpensive 3 rd party LabVIEW drivers Inexpensive 3 rd party LabVIEW drivers Used by most industrial control manufacturers as a communications standard for "smart field devices." Used by most industrial control manufacturers as a communications standard for "smart field devices." The "smart field devices" use a embedded micro controller The "smart field devices" use a embedded micro controller Device power and communications use the same pair of wires Device power and communications use the same pair of wires

19. Data Acquisition Module Acquire data from… Acquire data from… –HART device –Analog sensors Configure the HART device. Configure the HART device. Error detection for HART communications Error detection for HART communications

20. Hardware and software needed for HART communications HART pressure transmitter HART pressure transmitter HART modem HART modem 4 to 20 mA current source 4 to 20 mA current source "CARDIAC" LabVIEW driver "CARDIAC" LabVIEW driver

21. HART configuration screen Allows user to select one of twenty-two commands Allows user to select one of twenty-two commands

22. Reading Parameters Reading data from HART pressure transmitter Reading data from HART pressure transmitter

23. Writing Parameters Writing configuration parameters Writing configuration parameters

24. Error Detection Detect HART communication error Detect HART communication error Display status from device Display status from device Allow user to retry communications Allow user to retry communications

26. Front Panel Module Component Display multiple streams of data to user. Display multiple streams of data to user. Terminate data acquisition upon flameout. Terminate data acquisition upon flameout. Display sensor values at flameout. Display sensor values at flameout.

27. Configuration Module Write configuration Write configuration Program will save its present configuration upon closure. Read configuration Read configuration Program will start in the configuration of last test.

28. User Input Module User must input proper documentation to proceed with test. User must input proper documentation to proceed with test.

29. Design is scalable Design is scalable User selects active sensors User selects active sensors User selects sensors to display on graph User selects sensors to display on graph Sensor Module

30. Program State Module Active sensor states are written or read from a file. Active sensor states are written or read from a file.

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

33. User can select up to 200 recipients and send the data immediately after the test is complete. User can select up to 200 recipients and send the data immediately after the test is complete. E-mail Module

34. User can send a text message as well as multiple attachments in.jpg and.png formats. User can send a text message as well as multiple attachments in.jpg and.png formats. E-mail Attachments

35. User can choose the sensors to display in a 3-D graph. User can choose the sensors to display in a 3-D graph. Data is sent to the 3-D graph in 2 dimensional arrays. Data is sent to the 3-D graph in 2 dimensional arrays. Data Visualization Component

37. Project Cost Analysis

38. Personnel Resources PersonnelOriginal Estimated Effort (2 Semesters) Revised Estimated Effort (2 Semesters) Steve Bower 200 hours120 hours Ken Hall 150 hours82 hours Rich Matus 150 hours85 hours Roar Lien 150 hours98 hours Jim Sproul 150 hours95 hours Total estimated effort 800 hours 480 hours

39. Problems Encountered Software vendor backed out of software agreement Software vendor backed out of software agreement Software version incompatibility Software version incompatibility Poster printing Poster printing Feature Creep Feature Creep Time zone differences Time zone differences Language barriers with tech support Language barriers with tech support

40. Future Work Communication with multiple HART devices Communication with multiple HART devices Further development of 3-D modeling Further development of 3-D modeling Implementation of web based server Implementation of web based server

41. 100%50%80%85%100%50%10% Milestone Progress Establish HART communication Establish HART communication Implement HART component Implement HART component Implement Front Panel component Implement Front Panel component Implement E-mail component Implement E-mail component Implement MS Excel component Implement MS Excel component Implement additional components Implement additional components Document functionality Document functionality

42. Summary Current problem Current problem –Error prone manual data collection Proposed solution Proposed solution –Accurate automated data collection Implementation of solution Implementation of solution –HART device –LabVIEW What does this mean to Delavan? What does this mean to Delavan?

43. Questions ???

44. For more information Visit our website at: http://seniord.ee.iastate.edu/may0012 Check out our poster: