Fermentation Vessel Automation

1
Fermentation Vessel Automation
SD Team Dec06-07 December 12, 2006
Client Stephanie Loveland Department of
Chemical and Biological Engineering
Advisor Dr. Degang Chen

• Team Members
• Andrew Arndt Adam Daters
• Brad DeSerano Austin Striegel

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
• 60F to 80F

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 programmers 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

• 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 VIs in LabVIEW define the operation of
  the DAQ card

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
Oxygen Concentration Meter 1500
Data Acquisition Unit 400
Signal Conditioning Unit 700
Cables 130
Project poster 20
Total 2750
34
Resources
Financial Resources
Labor Costs 9156
Other Resources 2750
Total 11906
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?