May03-12: Freeze-Thaw May03-12: Freeze-Thaw Concrete Chamber ControllerConcrete Chamber Controller

Team Members:Team Members: Craig RueterCraig Rueter Steven SpencerSteven Spencer Jason StoweJason Stowe Eric WulfEric Wulf

Faculty Advisor:Faculty Advisor: Dr. James A. DavisDr. James A. Davis

Client:Client: Iowa Department Iowa Department

of Transportationof Transportation

Date:Date: April 29, 2003April 29, 2003

Presentation OutlinePresentation Outline

IntroductionIntroduction Project Activities Project Activities Project Resources and SchedulesProject Resources and Schedules Closing Materials Closing Materials

TermsTerms DOTDOT

Department of TransportationDepartment of Transportation Programmable Logic Controller (PLC)Programmable Logic Controller (PLC)

A computer system designed to produce a desired A computer system designed to produce a desired set of outputs based on various inputs.set of outputs based on various inputs.

SolenoidSolenoid A device that uses an electromagnetic coil to A device that uses an electromagnetic coil to

operate another device, such as a valve or a relay.operate another device, such as a valve or a relay. ThermocoupleThermocouple

A device that measures differences in temperature A device that measures differences in temperature by measuring the voltage produced by the by measuring the voltage produced by the thermoelectric effect.thermoelectric effect.

IntroductionIntroduction

AcknowledgementAcknowledgement Problem StatementProblem Statement SolutionSolution Operating EnvironmentOperating Environment Intended Users and UsesIntended Users and Uses Assumptions and LimitationsAssumptions and Limitations End ProductEnd Product

AcknowledgementAcknowledgement

The May03-12 team thanks The May03-12 team thanks Stephen Upchurch, Materials Stephen Upchurch, Materials Laboratory Technician for the Iowa Laboratory Technician for the Iowa DOT, for his support and DOT, for his support and contributions to this project.contributions to this project.

BackgroundBackground

Employees of the Employees of the Iowa DOT use a Iowa DOT use a machine to freeze machine to freeze and thaw concrete and thaw concrete samples to simulate samples to simulate an Iowa winter to see an Iowa winter to see how the concrete how the concrete performs.performs.

These machines are These machines are known as freeze-known as freeze-thaw chambers.thaw chambers.

Problem StatementProblem Statement

Due to the age of the freeze-thaw chamber Due to the age of the freeze-thaw chamber controller in the materials lab, controller in the materials lab, replacements were determined to be a top replacements were determined to be a top priority. priority.

The current control system is running on The current control system is running on outdated hardware and is becoming outdated hardware and is becoming increasingly hard to maintain.increasingly hard to maintain.

The current software and hardware limits The current software and hardware limits the amount of control the user has with the the amount of control the user has with the actual chamber.actual chamber.

Current Control HardwareCurrent Control Hardware

The current The current control system control system consist of:consist of: IBM PC XTIBM PC XT Cyborg Cyborg

input/output input/output systemsystem

Relay PanelRelay Panel

Current Control SoftwareCurrent Control Software

The current The current software was software was written in Basic written in Basic 1.0 in the mid 1.0 in the mid 1980s and has 1980s and has never been never been documented.documented.

SolutionSolution

A new control system was created A new control system was created using a programmable logic using a programmable logic controller that controls the chamber controller that controls the chamber hardware and a Visual Basic hardware and a Visual Basic application running on a modern application running on a modern Windows based computer for data Windows based computer for data logging and remote control of the logging and remote control of the programmable logic controller.programmable logic controller.

Operating EnvironmentOperating Environment

The room that the The room that the freeze-thaw freeze-thaw chambers are chambers are located in is not air-located in is not air-conditioned.conditioned.

The control cabling is The control cabling is being run though the being run though the ceiling and is subject ceiling and is subject to electrical to electrical interference from interference from other cabling.other cabling.

Operating EnvironmentOperating Environment

The control room The control room is located is located approximately 100 approximately 100 feet away from the feet away from the freeze-thaw freeze-thaw chambers.chambers.

The control room The control room is a standard office is a standard office environment.environment.

Intended Users and UsesIntended Users and Uses

The freeze-thaw chambers and the The freeze-thaw chambers and the new control system will be used by new control system will be used by employees of the Iowa DOT employees of the Iowa DOT cement and concrete lab for the cement and concrete lab for the testing of concrete samples and for testing of concrete samples and for developing new testing developing new testing techniques.techniques.

AssumptionsAssumptions

Initially only one freeze-thaw chamber will Initially only one freeze-thaw chamber will be controlled.be controlled.

No more than two freeze-thaw chambers No more than two freeze-thaw chambers will be controlled by the same system. will be controlled by the same system.

The Iowa DOT will be able to order The Iowa DOT will be able to order required equipment in a timely manner.required equipment in a timely manner.

The hardware that will be reused is in The hardware that will be reused is in working order.working order.

The hardware that will be reused is The hardware that will be reused is already documented.already documented.

LimitationsLimitations Scheduling for time to use the freeze-thaw Scheduling for time to use the freeze-thaw

chambers.chambers. Scheduling conflicts between team Scheduling conflicts between team

members.members. Hardware ordering turnaround is dependent Hardware ordering turnaround is dependent

on the internal Iowa DOT ordering on the internal Iowa DOT ordering processes, supplier availability, and processes, supplier availability, and shipping delays.shipping delays.

Constraints of industry standard concrete Constraints of industry standard concrete freeze-thaw testing techniques. Specifically freeze-thaw testing techniques. Specifically the ASTM C 666 method B.the ASTM C 666 method B.

End ProductEnd Product

A new PLC that is properly A new PLC that is properly programmed to run freeze-thaw programmed to run freeze-thaw cycles in the concrete chamber.cycles in the concrete chamber.

A Visual Basic application that A Visual Basic application that gives the users greater flexibility, gives the users greater flexibility, more options, and communicates more options, and communicates with the PLC through a serial with the PLC through a serial connection.connection.

Project ActivitiesProject Activities

Present AccomplishmentsPresent Accomplishments Technical Approaches ConsideredTechnical Approaches Considered Technical Approach UsedTechnical Approach Used Research Research DesignDesign ImplementationImplementation Testing and ModificationTesting and Modification

Present Accomplishments Present Accomplishments

TASKTASK % ACCOMPLISHED% ACCOMPLISHED

Research Research 100%100%

Revised PLC Code Revised PLC Code 95% 95%

Visual Basic ProgramVisual Basic Program 100%100%

TestingTesting 90%90%

DocumentationDocumentation 95%95%

OverallOverall 95%95%

Technical Approaches Technical Approaches ConsideredConsidered

Upgrade the existing hardware and Upgrade the existing hardware and software.software. Existing hardware is antiquated.Existing hardware is antiquated.

Commercial control system.Commercial control system. Cost and lack of information.Cost and lack of information.

Custom system using a Custom system using a commercially available input/output commercially available input/output card for a PC.card for a PC. Future upgrade problems.Future upgrade problems.

Technical Approach UsedTechnical Approach Used

Duplicate the Duplicate the control system control system used in the used in the aggregates lab.aggregates lab. Existing code Existing code

reuse.reuse. Well documented.Well documented. Easy access to Easy access to

programming programming tools.tools.

Research Research

Decide on the most appropriate Decide on the most appropriate hardware hardware

Learn ladder logic and assembly Learn ladder logic and assembly language that is to be used in the PLClanguage that is to be used in the PLC

Go through old, uncommented code to Go through old, uncommented code to determine functionality that is still determine functionality that is still needed and what must be addedneeded and what must be added

Determine how a Visual Basic program Determine how a Visual Basic program can communicate with the PLCcan communicate with the PLC

Design OverviewDesign Overview

The design of the project is broken into The design of the project is broken into two parts.two parts.

A PLC that controls the freeze-thaw A PLC that controls the freeze-thaw chamber’s components and to handle chamber’s components and to handle error conditions.error conditions.

A PC application that communicates A PC application that communicates with the PLC in order to collect data and with the PLC in order to collect data and provide remote operation of the freeze-provide remote operation of the freeze-thaw chamber.thaw chamber.

PLC DesignPLC Design

The PLC has internal registers for The PLC has internal registers for storing data from the various sensors storing data from the various sensors attached to the freeze-thaw chamber.attached to the freeze-thaw chamber.

A programming language called ladder A programming language called ladder logic is used to program the PLC.logic is used to program the PLC. Ladder logic is a visual programming Ladder logic is a visual programming

language that is designed to mimic language that is designed to mimic physical switches and relays.physical switches and relays.

PLC DesignPLC Design

PC Software DesignPC Software Design

Ability to programmatically read and Ability to programmatically read and write any register within PLCwrite any register within PLC

Design of databaseDesign of database Functionality to graph temperatures Functionality to graph temperatures

of the tank and concrete samplesof the tank and concrete samples Provide interface for users to retrieve Provide interface for users to retrieve

data from prior samples and graph itdata from prior samples and graph it

Communication With PLCCommunication With PLCFX2NCommunications

OpenCOMPortCloseCOMPort

PerformIOFunction

PLC

Calling Program

Read Output Registers 000-027On, Off, etc.

“72A7C42BC2”

“000A00468”

Can Read/Write All RegistersCan Read/Write All Registers

Database DesignDatabase Design

Errors

U2,U1 Code

Description

Registers

U1,U2 Register

CommentDisplay

CurrentSample

I1 CurrentSample_IDInsertedStateCycleTankTemperatureBeamTemperature

HistoricalSummary

I1,U1 HistoricalSummary_ID

NameStartDateEndDateStartCycleEndCycleComment

HistoricalSamples

I1,U1 HistoricalSample_ID

I2 HistoricalSummary_IDI3 Inserted

StateCycleTankTemperatureBeamTemperature

Graphing of Current SampleGraphing of Current Sample

Graphing of Historical DataGraphing of Historical Data

Copy To Excel FeatureCopy To Excel Feature

Graphing of Historical DataGraphing of Historical Data

Error LoggingError Logging

Design ConstraintsDesign Constraints

The product should be easily understood The product should be easily understood by the intended users in order to easily by the intended users in order to easily modify the designmodify the design

Microsoft Graphing Control is not very Microsoft Graphing Control is not very flexible and very poorly documented, but flexible and very poorly documented, but was chosen over 3rd party controls due to was chosen over 3rd party controls due to budget constraintsbudget constraints

Microsoft Access was chosen as the data Microsoft Access was chosen as the data store despite its limitations also due to coststore despite its limitations also due to cost

Testing and Modification Testing and Modification

Simulate the different scenarios of the Simulate the different scenarios of the chamber manually from a homemade chamber manually from a homemade switchboxswitchbox Modify errors that occur from internal relays Modify errors that occur from internal relays

either being on or off in the PLCeither being on or off in the PLC Go through an entire freeze-thaw Go through an entire freeze-thaw

process in the chambersprocess in the chambers Make sure errors are being detected and Make sure errors are being detected and

shown to the administrator from the control shown to the administrator from the control stationstation

Resources and SchedulesResources and Schedules

Personal Effort RequirementsPersonal Effort Requirements Other Resource RequirementsOther Resource Requirements Financial RequirementsFinancial Requirements SchedulesSchedules

Personnel Effort BudgetPersonnel Effort Budget

TaskTask EstimatedEstimated To DateTo Date

MeetingsMeetings 80 hours80 hours 64 hours64 hours

ResearchResearch 77 hours77 hours 73 hours73 hours

DesignDesign 67 hours67 hours 26 hours26 hours

DocumentatiDocumentationon

77 hours77 hours 63 hours63 hours

TestingTesting 100 hours100 hours 50 hours50 hours

DevelopmentDevelopment 105 hours105 hours 76 hours76 hours

TotalTotal 506 hours506 hours 352 hours352 hours

Financial BudgetFinancial Budget

ItemItem Estimated Estimated CostCost

Cost to DateCost to Date

PCPC $1,500$1,500 $0$0

Misc. Cmpts.Misc. Cmpts. $100$100 $0$0

Control Control SystemSystem

$1,100$1,100 $1,100$1,100

Poster CostPoster Cost $50$50 $50$50

Misc. PrintingMisc. Printing $15$15 $10$10

TotalTotal $2,765$2,765 $1,160$1,160

Closing MaterialsClosing Materials

Project EvaluationProject Evaluation CommercializationCommercialization Recommendations for Additional Recommendations for Additional

WorkWork Lessons LearnedLessons Learned Risk and Risk ManagementRisk and Risk Management SummarySummary

Project EvaluationProject Evaluation Project success.Project success.

Project will be 100% complete by end of Project will be 100% complete by end of semester.semester.

Satisfaction of milestones.Satisfaction of milestones. Completion of Visual Basic GUI - 100%.Completion of Visual Basic GUI - 100%. Completion of PLC/GUI/hardware connections – Completion of PLC/GUI/hardware connections –

85% - serial comm.85% - serial comm. Completion of PLC/GUI interaction – 100%.Completion of PLC/GUI interaction – 100%. Run of test system with new code/GUI – 100%.Run of test system with new code/GUI – 100%. Implementation of design as new control – 80%.Implementation of design as new control – 80%.

CommercializationCommercialization

The potential production costThe potential production cost The cost of a disk and copying software.The cost of a disk and copying software.

The potential cost as commercial The potential cost as commercial itemitem $2600 – PLC/PC/Software development $2600 – PLC/PC/Software development

time.time. The potential marketThe potential market

Primarily DOT’s, but possibly Primarily DOT’s, but possibly construction companies.construction companies.

Recommendations for Recommendations for Additional WorkAdditional Work

Another PLC can be used to run a Another PLC can be used to run a different freeze-thaw chamber at different freeze-thaw chamber at the DOT with slight modifications to the DOT with slight modifications to the PLC code. the PLC code.

A second instance of the Visual A second instance of the Visual Basic GUI could be used on the Basic GUI could be used on the same PC to communicate with the same PC to communicate with the other PLC using a second serial port.other PLC using a second serial port.

Lessons LearnedLessons Learned

The project went well overall.The project went well overall. Satisfactory completion of milestones.Satisfactory completion of milestones. Primary difficulty is insufficient time for serial Primary difficulty is insufficient time for serial

communication conduit to be run.communication conduit to be run. Tech knowledge gained.Tech knowledge gained.

Understanding of PLC ladder logic.Understanding of PLC ladder logic. Better familiarity with Visual Basic coding.Better familiarity with Visual Basic coding.

Things to do differently.Things to do differently. Ask more questions early on instead of trying Ask more questions early on instead of trying

to solve issues with limited knowledge.to solve issues with limited knowledge.

Risks and Risk ManagementRisks and Risk Management AnticipatedAnticipated

Time to code is too long and gets into DOT’s Time to code is too long and gets into DOT’s primary test season – chosen design was primary test season – chosen design was completed within completion timecompleted within completion time

Loss of member due to unforeseen difficulties – Loss of member due to unforeseen difficulties – situation was dealt with proactively and problem situation was dealt with proactively and problem was avoidedwas avoided

Poor choice of approach – approach worked wellPoor choice of approach – approach worked well UnanticipatedUnanticipated

Insufficient time to run conduit – performed all Insufficient time to run conduit – performed all other possible tests and will finish when conduit other possible tests and will finish when conduit is doneis done

Closing SummaryClosing Summary Need for projectNeed for project

Previous code written in uncommented BasicPrevious code written in uncommented Basic Difficult to find replacement equipment Difficult to find replacement equipment No individual control of devices(valves, etc.)No individual control of devices(valves, etc.)

Chosen solutionChosen solution New control code in Visual Basic on modern PCNew control code in Visual Basic on modern PC Mitsubishi PLC used to replace old hardwareMitsubishi PLC used to replace old hardware

Effectiveness of chosen solutionEffectiveness of chosen solution – – Stephen Stephen UpchurchUpchurch ““The system that was chosen …is a vast improvement The system that was chosen …is a vast improvement

from what we had.” from what we had.” ““The project team has done an excellent job…I believe The project team has done an excellent job…I believe

they have exceeded our expectations.“they have exceeded our expectations.“

Questions?Questions?