Thermocouple Signal Simulator Sponsor Emerson Kent Burr Charles

Thermocouple Signal Simulator Sponsor: Emerson- Kent Burr, Charles Eastberg Advisor- Dr. Semih Aslan Group: NPPH(1. 7) Taylor Nash, Rey Perez, Victor Pinones, and Travis Howell

Why Emerson Needs A Thermocouple Signal Simulator ❖ Emerson has three different test teams in Round Rock ❖ They do different types of component testing, maxing out, and configurations ❖ Thermocouples is a very common component they test ❖ They want to be able to simulate thermocouple readings ❖ What does the Thermocouple Signal Simulator do?

Options ❖ Input ➢ Multiple inputs ➢ Configure thermocouple types ■ Input on DIP switches ■ Software implemented ❖ Output ➢ Have multiple outputs ➢ Have just one output Dataflow ❖ Hardware implemented ➢ Need 8 of each components, one for each of thermocouple types ➢ Too costly for hardware set up- not enough space, too many bugs ❖ Software implemented ➢ Only need one processor

Components ❖ Hardware ➢ Arduino Mega 2560 ➢ DAC, ADC ➢ Electrical Isolator ➢ 5 V power supply ➢ 4 -20 m. A input ➢ Power resistors ➢ Op Amp ➢ Printed Circuit Board (PCB) ❖ Software ➢ Program to execute all logic and arithmetic ➢ Thermocouple Polynomial Library ➢ Thermocouple look-up tables

❖ Input Proposal ➢ 4 -20 m. A, provided by Emerson ❖ Project: convert the 4 -20 m. A signal into an isolated m. V signal ranging from ± 100 m. V ❖ Combination of mostly software and some hardware ❖ Configuration to each type of thermocouple ➢ 8 synchronized output nodes

Demo: Dataflow Input 4 -20 m. A Find relative temp. for thermocouple Input range percentage conversion Map to PWM port range Use temp. for “look-up” value Output

Budget Device Price $200/member Total: $800 ❖ ❖ ❖ ❖ Arduino Mega 2560. ……………. . . $40 5 V High/Low Opto-isolator……. . $8 PCB by TXST………………. . . $0 24 bit ADC……………$11 20 bit DAC ……………. . $20 1 -8 demultiplexer………………. . $5 Project houseing………………. . TBA Total Estimated Price: $84

Test Plan ❖ Overview ➢ Input 4 -20 m. A signal ➢ Convert and isolate the input to eight ± 100 m. V outputs ➢ Outputs run to Emerson’s CHARM systems

Constraints ❖ Economical ➢ Hardware implementation would be costly ➢ Wasteful of resources, i. e. all hardware would result in multiple components ➢ Processor/software implementation was much more practical

Timeline Dataflow Schematic Output Isolation Hardware Selection Hardware Purchase

Timeline Write Program Progra Deviation Handling m Debug Circuit Assembly Testing Software e Circuit Testing System Verify System Testing

Demo and Progress ❖ Our demo simulates the type T thermocouple ❖ Input from Arduino’s serial interface ❖ Outputs analog signal on PWM port ❖ Similar to our completed system, except no isolation

References ❖ htatp: //community. emerson. com/cfs-file/__key/communityserver-blogscomponents-weblogfiles/00 -00 -00 -0292/3581. emerson_5 F 00_electric_2 D 00_logo. jpg ❖ http: //upload. wikimedia. org/wikipedia/en/e/ed/Thermocouple_%28 work_dia gram%29_LMB. png ❖ http: //www. ti. com/graphics/folders/partimages/ADS 1675. jpg ❖ http: //www. vetco. net/catalog/images/VET-SP-DIP 3 -1. jpg ❖ http: //media. digikey. com/Renders/~~Pkg. Case%20 or%20 Series/DIP 16_SO T 38 -1%20 Pkg. jpg

Questions?