Fermentation Vessel Automation
Team Members:
Andrew Arndt Adam Daters
Brad DeSerano Austin Striegel
SD Team: Dec06-07
December 12, 2006
Client: Stephanie Loveland
Department of Chemical and Biological Engineering
Advisor:Dr. Degang Chen
Presentation Outline
• Project Overview• Research Activities• Hardware Configuration• Software Development• Implementation• Resources and Scheduling• Lessons Learned• Closing Remarks• Questions
Acknowledgements
• Stephanie Loveland– Provided finances, design specifications,
and requirements for the project
• Dr. Degang Chen– Technical and practical advice
Definitions
• DAQ – Data acquisition• Flash – Animated graphics technology and format from
Macromedia• GUI – Graphical user interface• LabVIEW – Laboratory Virtual Instrument Engineering
Workbench• PPM – Parts per million• RPM – Rotations per minute• RS232 – Standard for serial cable interface• SCC – Signal conditioning system offered by National
Instruments• SLM – Standard liters per minute• VI (virtual instruments) – Sub-unit program in LabVIEW that
represents the appearance and function of a physical implement
Problem Statement
• A mock fermentation vessel is available for use by senior chemical engineering students
• Simple methods were used to record data (Paper and Pencil)
• An automated data collection system needed to be developed to gather the data
• Upgrade equipment as needed
Problem Solution-Approach
• Designed and installed new hardware for the mock fermentation vessel apparatus– Data acquisition card– Signal conditioning modules– Oxygen concentration meter
• Created automatic data collection software with LabVIEW
• Recorded results with software to Excel workbook
Problem Solution-Approach
Equipment Data Recorded
Intended Users
• Senior level students in the Department of Chemical and Biological Engineering as well as faculty in the department
• Users must have knowledge of safety procedures and requirements while conducting experiments within the lab
• Users will need to have been exposed to the concepts that the lab is designed to simulate
Intended Uses
• Automate the collection of the data from the mock fermentation vessel apparatus
• Display data in real-time• Record data into Excel workbook for
further analysis• Use of this system is not supported on
any other equipment not supported
Operating Environment
• Location in 2059 Sweeney• Temperature controlled environment
– 60°F 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
• 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 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
800 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
• 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
End Product and Deliverables
Present Accomplishments
• Purchased and installed all hardware for automated data collection
• Collected data from each piece of lab equipment
• Tested functionality of software as a team
• Tested functionality of software with intended users, received feedback
• Delivered completed software with software feedback implemented
Future Required Activities
• Review user manual with client• Review programmer’s manual with
client
Technology Considerations (1/4)
• Data Acquisition Board
• Signal Conditioning
• Oxygen Concentration Meter
Data Acquisition Board
Technology Considerations (2/4)
USB DAQ• Inexpensive and Easy Connection• No Signal Conditioning Capability
PXI DAQ System• High Resolution/High Sampling Rate• High Cost• Signal Conditioning CapabilityPCI 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
Interface• Connects to the DAQ board via a 68 pin
shielded connector cable
Detailed Design (5/8)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 are measured differentially to
protect against transient spikes• SCC Module is plugged into the SCC
Carrier to interface with the DAQ board
Detailed Design (6/8)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 (7/8)Software Design and Implementation
Detailed Design (8/8)Software Interface
Implementation Activities
• Determined scaling of devices for proper measurement
• Determined proper connection for obtaining stirrer motor control data– No documentation– Contacted manufacturer and obtained more
information– Used multimeter to determine correct wiring
• Added multiple tab data writing after obtaining beta testing feedback
Testing Activities
• Team Testing– Individual unit testing– Overall GUI functionality testing
• Beta Testing– Student testing with actual laboratory
experiments– Four groups of students tested– Surveys filled out by each group– Changes applied from feedback:
• Experiment data on a new worksheet in an Excel file
ResourcesPersonnel Hours
ResourcesOther Resources
Oxygen Concentration Meter $1500
Data Acquisition Unit $400
Signal Conditioning Unit $700
Cables $130
Project poster $20
Total $2750
ResourcesFinancial Resources
Labor Costs Oxygen Concentration Meter
Data Acquisition Unit Signal Conditioning UnitCables Project poster
Labor Costs $9156
Other Resources $2750
Total $11906
Schedule
Project Evaluation (1/2)
• Technology Research and Selection– 100% Completed
• Design– 100% Completed
• Implementation– 100% Completed
• Testing– 100% Completed
• Documentation– 100% Completed
Project Evaluation (2/2)
Legend:Greatly Exceeded (1.1) – Minimum expectations were met with the addition of several extra featuresExceeded (1.0) – Minimum expectations were met with the addition of one or more extra featuresFully Met (0.9) – Minimum expectation were metPartially Met (0.5) - Some of the minimum expectations were metNot Met (0.0) – None of the minimum expectations were met
With a score above 90%, the project has fully met and exceeded all expectations
Making the project a complete success
Commercialization
• Project was not designed to be commercialized
• With small software changes the system would be extendable to collect data from similar or newer equipment
Future Recommendations
• Total automation of the system via computer controlled laboratory equipment– Current system would allow for computer
control following software changes– Dependent upon client preference
Lessons Learned (1/4)
• Client relationship• Time management
– Project completed earlier than expected– Beta testing occurred early, allowed for
more changes
• Advisor Advice
Successes
• Incorrect SCC module purchased initially• Stirrer motor control pin out
Lessons Learned (2/4)Setbacks
• LabVIEW Programming• Data acquisition and signal conditioning• Troubleshooting problems• Client relations• Delegating responsibilities• Communication skills
Lessons Learned (3/4)Experienced Gain
• More research into each piece of equipment
• Obtain better LabVIEW reference
Lessons Learned (4/4)What we would do differently
Risk and Risk Management
• Equipment damage– Broken vessel overcome by team– Replacement ordered by client
• Wrong module purchase– Initial mass gas flow module wrong input– Used stirrer motor control module during
development
• 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 Remarks
• Students collected by pencil and paper data from each laboratory equipment every 10-15 seconds
• An automatic data collection system was successfully created using data acquisition and LabVIEW software
• Users can view real-time data, and do further analysis with electronically saved data
Demonstration
Questions?
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