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Fermentation Vessel Automation

Fermentation Vessel Automation. SD Team: Dec06-07 December 12, 2006. Client: Stephanie Loveland Department of Chemical and Biological Engineering. Team Members: Andrew Arndt Adam Daters Brad DeSerano Austin Striegel. Advisor: Dr. Degang Chen. Presentation Outline.

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Fermentation Vessel Automation

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  1. Fermentation Vessel Automation SD Team: Dec06-07 December 12, 2006 Client: Stephanie Loveland Department of Chemical and Biological Engineering Team Members: Andrew Arndt Adam Daters Brad DeSerano Austin Striegel Advisor: Dr. Degang Chen

  2. Presentation Outline • Project Overview • Research Activities • Hardware Configuration • Software Development • Implementation • Resources and Scheduling • Lessons Learned • Closing Remarks • Questions

  3. Acknowledgements • Stephanie Loveland • Provided finances, design specifications, and requirements for the project • Dr. Degang Chen • Technical and practical advice

  4. 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

  5. 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

  6. 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

  7. Problem Solution-Approach Equipment Data Recorded

  8. 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

  9. 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

  10. Operating Environment • Location in 2059 Sweeney • Temperature controlled environment • 60°F to 80°F Laboratory Apparatus

  11. 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

  12. 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

  13. 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

  14. 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

  15. End Product and Deliverables • 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

  16. 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

  17. Future Required Activities • Review user manual with client • Review programmer’s manual with client

  18. Technology Considerations (1/4) • Data Acquisition Board • Signal Conditioning • Oxygen Concentration Meter

  19. Technology Considerations (2/4) Data Acquisition Board • USB DAQ • Inexpensive and Easy Connection • No Signal Conditioning Capability • PXI DAQ System • High Resolution/High Sampling Rate • High Cost • Signal Conditioning Capability Technology Selected: PCI DAQ Board • PCI DAQ Board • Moderate Resolution & Sampling Rate • Moderate Cost • Signal Conditioning Capability

  20. 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

  21. Technology Considerations (4/4) Oxygen Concentration Meter • Omega DOB-930 • 100 data point logging • RS232 Interface • Limited support and availability Technology Selected: Thermo Electron Orion 3-Star • Thermo Electron Orion 3-Star • 200 data point logging • RS232 Interface • 3-year Extended Warranty and availability up to 5 years

  22. Detailed Design (1/8) Hardware Data Flow Configuration

  23. 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

  24. 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

  25. 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

  26. 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

  27. Detailed Design (6/8) Data Acquisition Card • 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 • 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

  28. Detailed Design (7/8) Software Design and Implementation

  29. Detailed Design (8/8) Software Interface

  30. 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

  31. 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

  32. Resources Personnel Hours

  33. Resources Other Resources

  34. Resources Financial Resources

  35. Schedule

  36. Project Evaluation (1/2) • Technology Research and Selection • 100% Completed • Design • 100% Completed • Implementation • 100% Completed • Testing • 100% Completed • Documentation • 100% Completed

  37. Project Evaluation (2/2) With a score above 90%, the project has fully met and exceeded all expectations Making the project a complete success Legend: Greatly Exceeded (1.1) – Minimum expectations were met with the addition of several extra features Exceeded (1.0) – Minimum expectations were met with the addition of one or more extra features Fully Met (0.9) – Minimum expectation were met Partially Met (0.5) - Some of the minimum expectations were met Not Met (0.0) – None of the minimum expectations were met

  38. 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

  39. 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

  40. Lessons Learned (1/4) Successes • Client relationship • Time management • Project completed earlier than expected • Beta testing occurred early, allowed for more changes • Advisor Advice

  41. Lessons Learned (2/4) Setbacks • Incorrect SCC module purchased initially • Stirrer motor control pin out

  42. Lessons Learned (3/4) Experienced Gain • LabVIEW Programming • Data acquisition and signal conditioning • Troubleshooting problems • Client relations • Delegating responsibilities • Communication skills

  43. Lessons Learned (4/4) What we would do differently • More research into each piece of equipment • Obtain better LabVIEW reference

  44. 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

  45. 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

  46. Demonstration

  47. Questions?

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