May03-12: Freeze-Thaw Concrete Chamber Controller Team Members: Team Members: Craig Rueter Craig Rueter Steven Spencer Steven Spencer Jason Stowe Jason Stowe Eric Wulf Eric Wulf Faculty Advisor: Faculty Advisor: Dr. James A. Davis Dr. James A. Davis Client: Iowa Department of Transportation Date: April 29, 2003

Presentation Outline Introduction Introduction Project Activities Project Activities Project Resources and Schedules Project Resources and Schedules Closing Materials Closing Materials

Terms DOT DOT Department of Transportation Department of Transportation Programmable Logic Controller (PLC) Programmable Logic Controller (PLC) A computer system designed to produce a desired set of outputs based on various inputs. A computer system designed to produce a desired set of outputs based on various inputs. Solenoid Solenoid A device that uses an electromagnetic coil to operate another device, such as a valve or a relay. A device that uses an electromagnetic coil to operate another device, such as a valve or a relay. Thermocouple Thermocouple A device that measures differences in temperature by measuring the voltage produced by the thermoelectric effect. A device that measures differences in temperature by measuring the voltage produced by the thermoelectric effect.

Introduction Acknowledgement Acknowledgement Problem Statement Problem Statement Solution Solution Operating Environment Operating Environment Intended Users and Uses Intended Users and Uses Assumptions and Limitations Assumptions and Limitations End Product End Product

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

Background Employees of the Iowa DOT use a machine to freeze and thaw concrete samples to simulate an Iowa winter to see how the concrete performs. Employees of the Iowa DOT use a machine to freeze and thaw concrete samples to simulate an Iowa winter to see how the concrete performs. These machines are known as freeze-thaw chambers. These machines are known as freeze-thaw chambers.

Problem Statement Due to the age of the freeze-thaw chamber controller in the materials lab, replacements were determined to be a top priority. Due to the age of the freeze-thaw chamber controller in the materials lab, replacements were determined to be a top priority. The current control system is running on outdated hardware and is becoming increasingly hard to maintain. The current control system is running on outdated hardware and is becoming increasingly hard to maintain. The current software and hardware limits the amount of control the user has with the actual chamber. The current software and hardware limits the amount of control the user has with the actual chamber.

Current Control Hardware The current control system consist of: The current control system consist of: IBM PC XT IBM PC XT Cyborg input/output system Cyborg input/output system Relay Panel Relay Panel

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

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

Operating Environment The room that the freeze-thaw chambers are located in is not air- conditioned. The room that the freeze-thaw chambers are located in is not air- conditioned. The control cabling is being run though the ceiling and is subject to electrical interference from other cabling. The control cabling is being run though the ceiling and is subject to electrical interference from other cabling.

Operating Environment The control room is located approximately 100 feet away from the freeze-thaw chambers. The control room is located approximately 100 feet away from the freeze-thaw chambers. The control room is a standard office environment. The control room is a standard office environment.

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

Assumptions Initially only one freeze-thaw chamber will be controlled. Initially only one freeze-thaw chamber will be controlled. No more than two freeze-thaw chambers will be controlled by the same system. No more than two freeze-thaw chambers will be controlled by the same system. The Iowa DOT will be able to order required equipment in a timely manner. The Iowa DOT will be able to order required equipment in a timely manner. The hardware that will be reused is in working order. The hardware that will be reused is in working order. The hardware that will be reused is already documented. The hardware that will be reused is already documented.

Limitations Scheduling for time to use the freeze-thaw chambers. Scheduling for time to use the freeze-thaw chambers. Scheduling conflicts between team members. Scheduling conflicts between team members. Hardware ordering turnaround is dependent on the internal Iowa DOT ordering processes, supplier availability, and shipping delays. Hardware ordering turnaround is dependent on the internal Iowa DOT ordering processes, supplier availability, and shipping delays. Constraints of industry standard concrete freeze-thaw testing techniques. Specifically the ASTM C 666 method B. Constraints of industry standard concrete freeze-thaw testing techniques. Specifically the ASTM C 666 method B.

End Product A new PLC that is properly programmed to run freeze-thaw cycles in the concrete chamber. A new PLC that is properly programmed to run freeze-thaw cycles in the concrete chamber. A Visual Basic application that gives the users greater flexibility, more options, and communicates with the PLC through a serial connection. A Visual Basic application that gives the users greater flexibility, more options, and communicates with the PLC through a serial connection.

Project Activities Present Accomplishments Present Accomplishments Technical Approaches Considered Technical Approaches Considered Technical Approach Used Technical Approach Used Research Research Design Design Implementation Implementation Testing and Modification Testing and Modification

Present Accomplishments TASK % ACCOMPLISHED Research100% Revised PLC Code 95% Visual Basic Program 100% Testing90% Documentation95% Overall95%

Technical Approaches Considered Upgrade the existing hardware and software. Upgrade the existing hardware and 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 commercially available input/output card for a PC. Custom system using a commercially available input/output card for a PC. Future upgrade problems. Future upgrade problems.

Technical Approach Used Duplicate the control system used in the aggregates lab. Duplicate the control system used in the aggregates lab. Existing code reuse. Existing code reuse. Well documented. Well documented. Easy access to programming tools. Easy access to programming tools.

Research Decide on the most appropriate hardware Decide on the most appropriate hardware Learn ladder logic and assembly language that is to be used in the PLC Learn ladder logic and assembly language that is to be used in the PLC Go through old, uncommented code to determine functionality that is still needed and what must be added Go through old, uncommented code to determine functionality that is still needed and what must be added Determine how a Visual Basic program can communicate with the PLC Determine how a Visual Basic program can communicate with the PLC

Design Overview The design of the project is broken into two parts. The design of the project is broken into two parts. A PLC that controls the freeze-thaw chamber’s components and to handle error conditions. A PLC that controls the freeze-thaw chamber’s components and to handle error conditions. A PC application that communicates with the PLC in order to collect data and provide remote operation of the freeze-thaw chamber. A PC application that communicates with the PLC in order to collect data and provide remote operation of the freeze-thaw chamber.

PLC Design The PLC has internal registers for storing data from the various sensors attached to the freeze-thaw chamber. The PLC has internal registers for storing data from the various sensors attached to the freeze-thaw chamber. A programming language called ladder logic is used to program the PLC. A programming language called ladder logic is used to program the PLC. Ladder logic is a visual programming language that is designed to mimic physical switches and relays. Ladder logic is a visual programming language that is designed to mimic physical switches and relays.

PLC Design

PC Software Design Ability to programmatically read and write any register within PLC Ability to programmatically read and write any register within PLC Design of database Design of database Functionality to graph temperatures of the tank and concrete samples Functionality to graph temperatures of the tank and concrete samples Provide interface for users to retrieve data from prior samples and graph it Provide interface for users to retrieve data from prior samples and graph it

Communication With PLC PLC Calling Program Read Output Registers On, Off, etc. “72A7C42BC2” “000A00468”

Can Read/Write All Registers

Database Design

Graphing of Current Sample

Graphing of Historical Data

Copy To Excel Feature

Graphing of Historical Data

Error Logging

Design Constraints The product should be easily understood by the intended users in order to easily modify the design The product should be easily understood by the intended users in order to easily modify the design Microsoft Graphing Control is not very flexible and very poorly documented, but was chosen over 3rd party controls due to budget constraints Microsoft Graphing Control is not very flexible and very poorly documented, but was chosen over 3rd party controls due to budget constraints Microsoft Access was chosen as the data store despite its limitations also due to cost Microsoft Access was chosen as the data store despite its limitations also due to cost

Testing and Modification Simulate the different scenarios of the chamber manually from a homemade switchbox Simulate the different scenarios of the chamber manually from a homemade switchbox Modify errors that occur from internal relays either being on or off in the PLC Modify errors that occur from internal relays either being on or off in the PLC Go through an entire freeze-thaw process in the chambers Go through an entire freeze-thaw process in the chambers Make sure errors are being detected and shown to the administrator from the control station Make sure errors are being detected and shown to the administrator from the control station

Resources and Schedules Personal Effort Requirements Personal Effort Requirements Other Resource Requirements Other Resource Requirements Financial Requirements Financial Requirements Schedules Schedules

Personnel Effort Budget TaskEstimated To Date Meetings 80 hours 64 hours Research 77 hours 73 hours Design 67 hours 26 hours Documentation 77 hours 63 hours Testing 100 hours 50 hours Development 105 hours 76 hours Total 506 hours 352 hours

Financial Budget Item Estimated Cost Cost to Date PC$1,500$0 Misc. Cmpts. $100$0 Control System $1,100$1,100 Poster Cost $50$50 Misc. Printing $15$10 Total$2,765$1,160

Closing Materials Project Evaluation Project Evaluation Commercialization Commercialization Recommendations for Additional Work Recommendations for Additional Work Lessons Learned Lessons Learned Risk and Risk Management Risk and Risk Management Summary Summary

Project Evaluation Project success. Project success. Project will be 100% complete by end of semester. Project will be 100% complete by end of 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 – 85% - serial comm. Completion of PLC/GUI/hardware connections – 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%.

Commercialization The potential production cost The potential production cost The cost of a disk and copying software. The cost of a disk and copying software. The potential cost as commercial item The potential cost as commercial item $2600 – PLC/PC/Software development time. $2600 – PLC/PC/Software development time. The potential market The potential market Primarily DOT’s, but possibly construction companies. Primarily DOT’s, but possibly construction companies.

Recommendations for Additional Work Another PLC can be used to run a different freeze-thaw chamber at the DOT with slight modifications to the PLC code. Another PLC can be used to run a different freeze-thaw chamber at the DOT with slight modifications to the PLC code. A second instance of the Visual Basic GUI could be used on the same PC to communicate with the other PLC using a second serial port. A second instance of the Visual Basic GUI could be used on the same PC to communicate with the other PLC using a second serial port.

Lessons 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 communication conduit to be run. Primary difficulty is insufficient time for serial 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 to solve issues with limited knowledge. Ask more questions early on instead of trying to solve issues with limited knowledge.

Risks and Risk Management Anticipated Anticipated Time to code is too long and gets into DOT’s primary test season – chosen design was completed within completion time Time to code is too long and gets into DOT’s primary test season – chosen design was completed within completion time Loss of member due to unforeseen difficulties – situation was dealt with proactively and problem was avoided Loss of member due to unforeseen difficulties – situation was dealt with proactively and problem was avoided Poor choice of approach – approach worked well Poor choice of approach – approach worked well Unanticipated Unanticipated Insufficient time to run conduit – performed all other possible tests and will finish when conduit is done Insufficient time to run conduit – performed all other possible tests and will finish when conduit is done

Closing Summary Need for project Need for project Previous code written in uncommented Basic Previous 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 solution Chosen solution New control code in Visual Basic on modern PC New control code in Visual Basic on modern PC Mitsubishi PLC used to replace old hardware Mitsubishi PLC used to replace old hardware Effectiveness of chosen solution – Stephen Upchurch Effectiveness of chosen solution – Stephen Upchurch “The system that was chosen …is a vast improvement from what we had.” “The system that was chosen …is a vast improvement from what we had.” “The project team has done an excellent job…I believe they have exceeded our expectations.“ “The project team has done an excellent job…I believe they have exceeded our expectations.“

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