1. PROJECT MEMBERS: COLIN PAYNE-ROGERS JACOB LENNOX Change of Resistance Test Stand PROJECT GUIDE/MENTOR: DR. BENJAMIN VARELA PRIMARY CUSTOMER: JOE MANAHAN SPONSOR: COOPER CROUSE-HINDS

2. Project Description Project Goal: To Design/Build a prototype test stand to measure the temperature of a maximum of 6 coils using a linear regression 4-wire resistance method. Project Overview: The test stand will include but is not limited to a cart/apparatus, laptop with LabView, data acquisition hardware, control circuitry and switching hardware, power dissipation circuitry and hardware. The apparatus is intended to use LabView to allow the user to run the test with minimal intervention. The prototype will be tested at RIT at 120VAC due to safety concerns.

3. Project Description

4. Customer Specifications Design and Build a Relay Circuit  Operation: 120-480VAC, 50-60Hz  Amphenol cable or similar connection  Controls electrical power for the operation Select and Purchase a Digital Multimeter  Resolution: 0.01Ohms  Able to be calibrated Select and Purchase a Data Acquisition System Additional temperature measurement using thermocouple

5. Customer Specifications Write a LabView program for the test stand  Communicate with and control measurement hardware  Measure the resistance of a maximum of 6 coils  40 readings every 30 seconds (one reading at a time)  Operator flexibility on coil selection (for measurements)  Plot Resistance versus Time for each coil  Make a Linear Regression of the data to calculate the temperature of the data at the beginning of the test  Store the data in up to 9 different portable format files  Operator input: time, date, coil material  Selectable functions: pre-run test, run auto-test, view results, print results, terminate All of the components must be contained in a rolling enclosure Test Stand must comply with UL 844

6. Meeting Priorities Proof-of-Concept Experimental Design Experimental results Proposed prototype relay circuit design Bill of Materials Test Plan Inquire about laptop and LabView licensing

7. Experimental Circuit Design

10. Experimental Results Rc from DMM not from DMM Cooper Rc (Ω)4.13.66 Th (°C)51.7586.52 Rh (Ω)4.57 RIT Rc (Ω)3.8013.361 Th (°C)55.9293.94 Rh (Ω)4.3037 Coil 1 Resistance (Ω) Coil 2 Resistance (Ω) Direct-to- Ballast3.7982.678 Through Relay Circuit3.8012.677

11. Experimental Results

12. Relay Circuit Design

13. Bill of Materials AccessoryVendorPNDescriptionIndv. CostQTYCost PXI ChassisNI781162-01NI PXIe-1073 $ 1,499.001 Chassis Power CordNI763000-01 $ 9.001 DMMNI780011-01NI PXI-4065 $ 1,499.001 Relay ModuleNI778572-66NI PXI-2566 $ 1,080.001 Relay Terminal BlockNI778717-66TB-2666 $ 277.001 System AssuranceNI960903-02 $ 310.001 Power Circuit Relay McMaster Carr7230K914PST $ 76.914 $ 307.64 Power Circuit RelayAllied Elec70198625DPST $ 10.071 USB DAQNI779051-01USB-6008 $ 169.001 Circuit Total $ 5,160.71 Labtop $ 500.001 Labview LisenceNI $ 999.001 Miscellaneous Cart etc. $ 1,000.001 *Highlighted Boxes are approximate costsTotal $ 7,659.71

14. Test Plan NumberDescription 1 Test the ballast temperature/resistance measurements with a borrowed 4-wire multimeter but the updated relay circuit (using "final hardware" and one coil rather than "experimental hardware"). Show the exponential decay, and the difference in resistance measurements when measuring the ballast directly and through the circuit. 2 Test the ability to switch between different coil measurements using the NI switch, manually and automatically, and then verify the results from test #1 for the same coil when switching to the other coils inbetween each measurement (possibly taking all coil measurements)...with the borrowed multimeter still? 3 Show that initial measurements are capable of being taken within 5 seconds, and that all 6 coil measurements are capable of being taken at the required rate. This would be a final "proof-of-concept" test, showing that the LabView program can be used to measure 6 coils as quickly as needed and can spit out the correct data (data compared to #1). The NI multimeter used this time to show that it is calibrated as well as the borrowed multimeter. 4 Test the calibration routine by using a "correct" and "incorrect" calibration. The "correct" calibration for the calibration routine should give the correct ballast (room temperature) results while the "incorrect" calibration should offset the ballast resistance measurements? This test depends on the final method for calibration.

15. Timeline TaskCompleted By Select and Purchase HardwareEnd of Week 11 of MSD I First version of LabView Code Completed (using simulated hardware) End of Week 2 of MSD II CAD Models (cart design)End of Week 3 of MSD II Order Cart HardwareEnd of Week 4 of MSD II Complete Testing with NI Hardware (not on cart)End of Week 6 of MSD II Assembled ElectronicsEnd of Week 7 of MSD II Complete any other testing at RIT (120 VAC, with cart, full tests with LabView) End of Week 8 of MSD II End of Week 9 of MSD II Finalize Senior Design RequirementsEnd of Week 10 of MSD II