P15671: Expansion Joint Health Monitoring Data Acquisition Yousif Al-ali Nick D’Ermilio James Jewis Jesse Follman Matthew Sutton

Customer Needs

Engineering Specifications

Wifi Shield Compatible with Arduino Due Allows for simple wireless communication between board and network $80 Micro-SD slot on board

Microprocessor Selection —54 Digital I/O’s —12 Analog Inputs (Can have up to 12 sensor inputs) —84MHz Clock Speed —$50 (Already Owned)

LCD Display Allows us to display 4 lines of 20 characters each Runs on supply voltage from Arduino board Can be configured to run off of 4 Digital I/O pins Displays current readings of temperature, pressure, displacement as well as possible alarm indications Cheap and already owned ($25)

Pressure Sensor Selection •Very resistant to shock and vibration •We already own one (Saves $350) •Performs with 0.25% accuracy •Can be powered by 9 V supplied to Arduino while outputting 0-5 V analog voltage Validyne P2-3000-V Strain Gage Pressure Transducer

Temperature Sensor Selection Cheap – Can be found for around 30 dollars Already own one from previous group Accurate to +/- 2°C with ranges from -270°C to 1300°C Requires thermocouple amplifier breakout board. ($15)

Axial Displacement Sensor •Have an accuracy of .025% of full scale (10 in = +/- .0025in) •Lightweight and easy to mount •Ability for different types of outputs •Operation in temperatures -65°C to 125°C •We own one that meets the current requirements

Bill of Materials Item Cost (Retail) Cost (Owned) Pressure Transducer $350 $0 String Potentiometer $200 x 2 $200 Arduino Due Board $50 Arduino Wifi Shield $80 Thermocouple $40 1st Iteration Housing $10 2nd Iteration Housing LCD Display $25 Thermocouple Amplifier $15 MicoSD Card $20 Misc. Hardware Total Cost $1090 $425

Thread Research —Simulated an EJ under compression and tension in ANSYS Workbench —Displacement of ±1 inch —Used to determine where stress concentrations will be —Helps to determine sensor placement

Compression

Tension

Engineering Analysis —Avoid areas in the middle of EJ and areas right below or above flanges —Embed sensors in between these areas —Minimize risk of EJ leaking after sensors are embedded

Threaded Insert

Test Plan Power Test Water Resistance Test Load Testing Brightness Test (LED/LCD) Sound Level Test (Alarm) Vibration Test Drop Test*

Risk Assessment

Demo

Prototype Definitions 1st Iteration: (November-December 2014) Temperature, Pressure, Axial Displacement sensors Basic housing Wall-powered LED alarms With control bars (no lateral or angular movement) 2nd Iteration: (January-February 2015) All desired sensors and electronics boards Custom housing WiFi capable Mountable With/without control bars (lateral and angular movement) Wired data transfer 3rd Iteration/Imagine RIT: (March-April 2015) All desired sensors All desired alarms Battery and/or wall powered Wired and/or wireless data transfer Desired mounting structure

1st-Gen System mounted on a size 12, 200-style EJ.

Box mounting bracket String potentiometer mounting plate

Timeline