ARD, Carderock Division, Bayview,IDProject Professors: Dr. Herb Hess & Dr.

Brian Johnson

Jarred CoulterVishu GuptaZane Sapp

Final Design ReviewDecember 5, 2008

OverviewProject introduction

DAQ Hardware

Sensors

Software

Testing/Calculations

Recommended System

Future Work/Conclusions

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ProjectIntroduction

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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.

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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

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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

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System Architecture

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DAQ Hardware

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NI DAQ Lab Hardware

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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

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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

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Sensors

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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 ft13

LEM Current Transducer

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• DC Current Transducer• 3 Jumper Adjustable

Ranges: 5, 10, 20 Amp Max

• Supply Voltage: 20-50 VDC

• ±1% Accuracy at 25 IC

LEM DC-C10 Features

ABB Voltage Sensor

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• 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 IC

LEM CV 3-500 Features

Designed Sensors

Designed Voltage Sensors Low power consumption

Only one voltage reference or ground reference

Simple design

Linear input to output

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Voltage Sensor Schematic

Voltage Sensor Results

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Horz = 12VVert = 12V

Simulation Results Experimental Results

Temperature SensorsK-type thermocouples used

• Temperature range: -452.2˚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

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Software

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LabVIEW Control for the DAQProgram 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’

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Flow diagram of the code

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Check for valid GPS signalAcquire data

Display Voltage and Current data as graphs

Numerical display for temperature

Save data to fileCheck 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

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Front panel: Control/Indicator tab

Front Panel: Control

Front Panel: Control

TESTING & CALCULATIONS

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Lab Setup

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Designed sensors

Current LEM

ABB Voltage Sensor

NI DAQBattery Bank

GPS

Thermocouples

TestingTests run on the system

Period: 2 hoursMeasured

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

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Test Results

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CalculationsLATENCY

1 sec with the GPS running.<100ms without GPS Dependant on sampling frequency

POWER CONSUMPTIONLab Model: 510 Watts

Including PC power consumption of 60Watts

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Recommended

System

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System Architecture Flow: Recommended System

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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, 427.75 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

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Future Work/ Conclusions

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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

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ConclusionsSystem 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

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AcknowledgementsARD

Alan Griffitts

Frank Jurenka

Karl Sette

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University of IdahoDr. Brian K. Johnson

Dr. Herb HessDr. Chris Wagner

Arleen FuredyKaren Cassil

Beth CreeDorota Wilk

Research GroupJustin SchleeJohn Finley

Leo LuckoseJames Randall

Temperature sensors: AmplifierAmplifier adds a gain of 924.3 This is then scaled in LabVIEW

Explained later on in the presentation

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Batteries

Amplifier

DAQ

Thermocouple measurement LabVIE

W (scale down)

Amplified Thermocouple

Voltage

Temperature dataModify 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 temperatureThe units can be

changed

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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

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Detailed cost analysis sheet of the system used

Put in the cost sheet that we had for the system we are using right now.

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