1. Path The purpose of this project is to design a universal data recording device to monitor the health of a Dresser-Rand compressor during operation. In particular, this device must be able to operate in a hazardous environment where traditional wired solutions are difficult or even impossible to implement. It will also need to record analog data from a variety of sensors, at multiple predefined sampling rates. Design Considerations: Power Source Sensor Connection Enclosure type Data Storage Processing Hardware Heat Analysis Expected Results Software Vibrations Analysis Ease of Use The device should be a small, easily mountable unit with no external wires and a variable sample rate. It should also offer universal sensing. Data Capture The device should be able to provide power to and store data collected from the sensors. It should be able to support multiple sample rates. Accuracy The device should provide an accurate timestamp with data collection. It should allow high frequency sampling with precision values. Durability The device should be able to withstand harsh environmental conditions and easily mountable on moving parts. Multiple Sensors The device should be able to allow multiple inputs from sensors simultaneously. Selected Components: LiPo Battery 3-Wire Audio Connector Aluminum Case microSD Card KL25z Microprocessor A heat analysis was performed in order to determine plausibility of high temperature applications. The limiting factor is the battery, with a maximum operating temperature of 140°F. Analysis was run and the results showed that even Another part of the device surviving a harsh environment is being capable of withstanding vibration from the compressor. The vibration of the compressor was analyzed and compared to the resonant frequency of the PCB and revealed no concern. A PCB board was designed as a daughter board that connects to the FRDM-KL25Z development board. Analog signal processing and battery charging are performed on this board. Analog peripherals include: sensor connectors, programmable gain amplifiers, and 8 th order low- pass filters. The device is powered by a single Li-Po battery and can be charged via the USB port. With ease of use in mind, a software program was designed to allow the user to configure the DAQ. A variety of settings are available, including: sample rate, accuracy, channel gain, as well as conversion factors for translating the analog voltages into measurable units. The device is to be placed into the finalized enclosure, and run through a rigorous suite of tests to verify functionality. This will ensure that it will be able to survive in various locations inside the compressor, while also being able to provide accurate sensor readings. Moving Forward This design can be optimized by being reduced to a single PCB that contains all of the analog processing, the battery charging circuitry and the microcontroller. Many of the components on the development board are not needed for proper functionality, and can be removed to further reduce board size. This would allow the overall device would be much smaller, and weigh less. A different case would then be required to compensate for the dimensions of the new board. Process Why? What? Mechanical Design Results Electrical Design Define Problem Design Systems Design Subsystems Detailed Design Stage 1 Stage 2 Build Test Customer Intro Define Systems Select Parts Make Concepts Final Decisions Analyze Solve Conclude Order Parts Build Product Test Product Conclude Create Specs Create Reqs Signal Capture and Storage Environmental 0-10V Input Range 10mV Accuracy 0-10kHz bandwidth 0.1-20kHz Sampling Rate 1+ hour of capture time Programmable start/stop timers In-order storage of data with accurate timestamps Specifications 0-160 F Operating Temp 0-100 PSI Pressure Handle 2-4 G of vibration in major axes Sealed to protect from oil User Interface Graphical User Interface for configuring device parameters Data stored in.CSV format on an SD family of memory Ability to retrieve data without removing SD Card with mass amounts of insulation, the device would not be able to run in these conditions. The customer then reduced the requirement to 140 °F. Team Members: Dennis Canosa [ME] Chris Stewart [ME] Matt Rodriguez[EE] Bryan Meyers [CE] Faculty Guide: Mr. William Nowak Primary Customer: Dr. Jason Kolodziej Acknowledgements: Mr. William Nowak Dr. Jason Kolodziej Dr. Adriana Becker-Gomez Mr. George Slack Mr. Jeff Lonneville