Power Control System for a Concrete Durability Test Cabinet – Phase 2 Jacob Jameson Madhav Kothapalli Thomas Persinger Andrew Versluys

Problem Statement The National Concrete Pavement Technology Center needs a system to perform temperature tests on concrete samples. ◦ The temperature test consists of 300 cycles between 0º and 40º F (±3ºF error). ◦ The client wants the system to be monitored and controlled with LabVIEW. ◦ There is existing hardware and software in place, but it does not achieve consistent results.

Need Statement We need to fix the existing system to run the tests consistently. ◦ Clean up the temperature sensors ◦ Re-write the software

Concept Sketch – Test Cabinet

Concept Sketch – Temperature Chart Recorder

Concept Sketch – User Interface

System Description LabVIEW Program ◦ In local computer ◦ Accessible by remote desktop ◦ Sends commands to temperature controller. Temperature Sensors ◦ Old system analog thermostat ◦ High temperature shut-off ◦ Circle graph recorder. ◦ New system thermocouple measuring the internal temperature of the concrete specimens within the cabinet. System Processes ◦ Measured temperature approaches 0 º, System activates a relay that shuts off the compressor and turns on the heater. ◦ Measured temperature approaches 40 º, System activates a relay that shuts off the heater and turns on the compressor. ◦ Cycle continues until the user ends it.

System Block Diagram

Operating Environment The system will operate in an indoor laboratory. This lab works with concrete so there is a chance of dust getting into the system. Water is poured into the system before running the freeze/thaw test, so the system must be sealed.

User Interface Records the data from the tests Allows the user to analyze data in graphical form Allows the user to change the freeze-thaw controls manually Accessible by remote desktop

Functional Requirements The freezing-thawing apparatus shall have automatic controls which are able to continuously reproduce cycles from 0±3°F to 40±3°F. The heat-cool cycle shall take between 2-5 hours. The time between freezing and thawing phases shall not exceed 10 minutes. The new system shall operate completely separate from the old system. All of the temperature data shall be recorded to an Excel spreadsheet.

Non Functional Requirements All of the electrical components shall be housed in a waterproof enclosure. The system shall not cause any fire hazards or electrical shocks. The user interface shall show a temperature vs. time graph of the current test.

Market/Literature Survey System Manufacturers ◦ Humboldt Manufacturing ◦ ScienTemp ◦ Schleibinger Buying a new system replacement is not an option because of the high cost.

Deliverables Computerized system ◦ Automatically controls the freeze-thaw cycle of the test cabinet ◦ Automatic system error adjustments ◦ Accurate temperature sensing User interface ◦ Allows users to input and analyze data ◦ Allows users to change the freeze-thaw controls manually System manual for reference

Work Breakdown Schedule Learn LabVIEW Group Website System Testing Test Temperature Probes Analyze Results of Temperature Probe Tests Test Freeze-Thaw Cabinet System Response Analyze Results of System Response Tests Project Design Develop Simulated Freeze-Thaw Cabinet in LabVIEW Develop New Control System in LabVIEW Simulated Testing and LabVIEW Program Revision LabVIEW Interface Bound Report/Final Website Implementation and Testing Implement New LabVIEW Program Test New LabVIEW Program LabVIEW Program Revision and Error Correction Documentation of Results Develop User Manual Final Report and Presentation Project Poster

Resource Requirements Hours: Jacob Jameson 181 Madhav Kothapalli 175 Thomas Persinger 184 Andrew Versluys 174 Project Labor Cost: Jacob Jameson $3620 Madhav Kothapalli $3500 Thomas Persinger $3680 Andrew Versluys $3480

Project Schedule

Questions?