National Conference ETEIC 2012 Proceeding, April 6-7, April, Anand Engineering College, Agra

Development of Labview DAQ for Static Test of Propulsion Motors Used in Missiles
Pavan Koundinya, Karthik Reddy B.M, Instrumentation Technology, R.V. College of Engineering,Bangalore-59 pavan.koundinya15@gmail.com +919972402342

ABSTRACT
The Network Integrated, Real-time, Multi signal Data Acquisition System is used for performing the static tests of propulsion motors used in missiles. The test bed comprises of data acquisition stations spread over an area of one square kilometre, which are integrated by Ethernet connectivity. The interconnectivity, control of acquisition, and data transfer between individual systems is achieved using TCP /IP protocol. The physical parameters acquired in Real-time are Pressure, Thrust, Temperature, Strain, Vibration, and Acoustic Signals. With this system, we can deterministically acquire more than 300 channels of data and make them available to the control via the Ethernet. The data is recorded, acquired and viewed in real-time and data analysis is performed offline. Keywords: Real Time, Static Test, Data Acquisition, TCP/IP, Test Bed, Physical Parameters

Lab VIEW is a graphical based dataflow programming language. Execution is determined by the structure of a graphical block diagram (the LV-source code) on which the programmer connects different function-nodes by drawing wires. These wires propagate variables and any node can execute as soon as all its input data become available. Since this might be the case for multiple nodes simultaneously, the code is inherently capable of parallel execution. The Lab VIEW data acquisition library has several options to control DAQ boards. Often one board can do variety of functions like analog-to-digital conversion (A/D), digital to analog conversion (D/A), digital input-output (I/O) & counter/timer operations. Testing aircraft components such as motors, turbines and generators requires dedicated test facilities that can subject the unit under test (UUT) to extreme pressures, temperatures, and other conditions similar to those encountered in real-life operating mode. Researchers initiate and monitor qualification tests from a control room, featuring multiple computer stations dedicated Sensors that convert physical parameters to electrical signals. Signal conditioning circuitry to convert sensor signals into a form that can be converted to digital values. Analog-to-digital converters, which conditioned sensor signals to digital values. convert

1 INTRODUCTION
to specific tasks such as pressure and flow control, safety monitoring and simulation. During a test run, teams of engineers, technicians, and analysts work together to collect and analyze real-time and historical data from various subsystems. The atmosphere is similar to that of a space flight control room everyone focuses on the UUT, but with a different perspective. A data acquisition system that acquires, displays, and records the critical test data is at the heart of this activity.

2 DATA AQUISITION SYSTEM:

Data acquisition is the process of sampling signals that measure real world physical conditions and converting the resulting samples into digital numeric values that can be manipulated by a computer. Data acquisition systems (abbreviated with the acronym DAS or DAQ) typically convert analog waveforms into digital values for processing. The components of data acquisition systems include:

Data acquisition hardware is either internal and installed directly into an expansion slot inside your computer, or external and connected to your computer through an external cable, which is typically a USB cable. At the simplest level, data acquisition hardware is characterized by the subsystems it possesses. A subsystem is a component of your data acquisition hardware that performs a specialized task. Common subsystems include Analog input 1

National Conference on Emerging Trends in Electrical, Instrumentation & Communication Engineering

National Conference ETEIC 2012 Proceeding, April 6-7, April, Anand Engineering College, Agra

Analog output Digital input/output Counter/timer

guarantee a maximum most of the time are referred to as "soft real-time". To fully grasp these concepts, it is helpful to consider an example. The main point is that, if programmed correctly, an RTOS can guarantee that a program will run with very consistent timing. Real-time operating systems do this by providing programmers with a high degree of control over how tasks are prioritized, and typically also allow checking to make sure that important deadlines are met. In contrast to real-time operating systems, the most popular operating systems for personal computer use (such as Windows) are called general-purpose operating systems. While more in-depth technical information on how real-time operating systems differ from general-purpose operating systems is given in a section below, it is important to remember that there are advantages and disadvantages to both types of OS. Operating systems like Windows are designed to smoothly run many programs and services at once, while realtime operating systems are typically designed to run one application very reliably and with precise timing.

3 PXI:
PXI (PCI eXtensions for Instrumentation) is a rugged PCbased platform for measurement and automation systems. PXI combines PCI electrical-bus features with the rugged, modular & software features. PXI is both a high-performance and lowcost deployment platform for measurement and automation systems. These systems serve applications such as manufacturing test, military and aerospace, machine monitoring, automotive, and industrial test.

5 TCP/IP:
The Internet Protocol Suite is the set of communications protocols used for the Internet and other similar networks. It is commonly also known as TCP/IP named from two of the most important protocols in it: the Transmission Control Protocol (TCP) and the Internet Protocol (IP), which were the first two networking protocols defined in this standard. Modern IP networking represents a synthesis of several developments that began to evolve in the 1960s and 1970s, namely the Internet and local area networks, which emerged during the 1980s, together with the advent of the World Wide Web in the early 1990s. The Internet Protocol Suite consists of four abstraction layers. From the lowest to the highest layer, these are the Link Layer, the Internet Layer, the Transport Layer, and the Application Layer. The layers define the operational scope or reach of the protocols in each layer, reflected loosely in the layer names. Each layer has functionality that solves a set of problems relevant in its scope.

Figure 1: PXI module

4 Lab VIEW REAL TIME SYSTEM

In general, an operating system (OS) is responsible for managing the hardware resources of a computer and hosting applications that run on the computer. An RTOS performs these tasks, but is also specially designed to run applications with very precise timing and a high degree of reliability. This can be especially important in measurement and automation systems where downtime is costly or a program delay could cause a safety hazard. To be considered "real-time", an operating system must have a known maximum time for each of the operations that it performs (or at least be able to guarantee that maximum most of the time). Some of these operations include OS calls and interrupt handling. Operating systems that can absolutely guarantee a maximum time for these operations are referred to as "hard real-time", while operating systems that can only

6 SYSTEM SETUP:

The hardware design is based on the PXI Platform for its ruggedness and multiple analog and digital I/O hardware offerings. A PXI controller running on Lab VIEW Real Time is chosen as the main data acquisition engine. This controller communicates with a host PC through the Ethernet interface. 2 National Conference on Emerging Trends in Electrical, Instrumentation & Communication Engineering

National Conference ETEIC 2012 Proceeding, April 6-7, April, Anand Engineering College, Agra

The host PC stores the data to a hard disk and, at the same time, makes it available to the client PCs for display. The software is based on the Lab VIEW platform for its ease of use and tight integration with the hardware. In addition, using Lab VIEW Real-Time, the control and acquisition program on the PXI controller runs as an embedded process without operating system overhead. With this system, we can deterministically acquire more than 300 channels of data and make them available to the control computer via the Ethernet. Normally, we would spend a year designing a system, such as this. However, using NI products, we can set up a data acquisition system in very less duration, reducing development time by more than 40 percent.

Temperature Sound Pressure Thrust Strain

Thermocouple(k-type) Microphone Piezo electric Transducer Load Cell Strain Gauge

7 SYSTEM DESCRIPTIONS:
The Data acquisition is based on a channel configuration file that the user creates. This configuration file is stored in a folder created with Test number. User has the option to Create, Open and Save Configuration files. Channel configuration consists of Channel Identifying name, Channel Description, Thermocouple Type, Temperature Unit and Scan Rate. Before the acquisition begins thermocouples are checked for continuity and noise level. This is achieved by viewing the acquired Temperature data and Average voltage of 8-channels at a time. This is also displayed on the host PCs so that technicians in the control room are aware of any defective thermocouples or open circuits before the start of any test. Data acquisition is performed based on the channel configuration file. The configuration information is transferred to the PXI-RT through TCP/IP protocol. Graphical displays are provided to the host computers with 4 charts. Each chart can have a maximum of 4-plots. The plots are user selectable for each chart. Thus the trend of up to 16 channels can be monitored on each PC. Digital displays are provided for each indicator channel, which is also user selectable.

Figure 2: Login Screen The System Utility is displayed in the Data Acquisition and Display main screen, which indicates the current Hard Disk space, free Hard Disk space and Total Hard Disk space of the Host and RT System as a pie chart Disk space and RT System. Configuration module is designed to configure the required channels for performing the Real Time Acquisition. Acquisition Module is designed to perform Real time data acquisition and display the acquisition data. This Module can be accessed by users having either administrator or user permission level. User Configuration is designed specifically to View, Add, Update and Delete users designated for operating this application. Computers are managing and controlling all the library activities. TCP/IP communication protocol is used for communicating RT and Host System. Thus our Data Acquisition System will employ following features: Real Time Data Display i.e. Online display Data storage in both Host (Client) and RT (Server). Automatic data file transferring. Offline Data processing and Analysis. Report Generation Data publishing on web

Table 1: Physical parameters & sensors used Physical parameter Sensor used 3

National Conference on Emerging Trends in Electrical, Instrumentation & Communication Engineering

National Conference ETEIC 2012 Proceeding, April 6-7, April, Anand Engineering College, Agra

through designed application automatically upon pressing a Report button.

Figure 4: Configuration Window

Figure 3: Block diagram of Real Time Data Acquisition System

8 OFFLINE ANALYSIS
Offline Analysis module will be designed to analyze acquired data. This module helps the user to verify the data recorded in a file. User having either administrator or user permission level can access this module. Analysis section will be designed for analyzing the acquired data. This can be done only with the data files, which are transferred to Host System from RT System. Initially Offline Analysis main screen will be displayed as shown. User has to select the required data file. In Offline Analysis module, provision to view data graphically or numerically is provided and displayed in Host PC continuously and simultaneously it is recorded.

Figure 5: Configuration Window

CONCLUSION
Graphical based programming using Lab VIEW Software is extensively used for time constraint acquisition and efficient transfer of data between the test bed & data acquisition stations. There is flexibility in choosing the required DAQ card depending on the requirement. The advantage of Real Time Operating System is in precise acquiring of data.TCP/IP communication is used for automatic data transfer between host & client.

ACKNOWLEDGEMENT
We are thankful to Dr. Padmaja .K.V of RVCE & Ms. Geetha, Senior Manager at Autotec Systems, for there information and guidance for successful completion of this paper.

REFERENCES
[1] www.autotecsystems.com Figure 3: Analysis Screen The acquired data is stored in the local drive and post analysis can be done through the application and MS word Waveform report of all the acquired signal has been taken [2] Modular Instrumentation by National Instruments [3] Virtual Instrumentation using Lab VIEW by Sanjay Gupta & Joseph John [4] NI Developer Zone [5] PXI Start up Guide 4

National Conference on Emerging Trends in Electrical, Instrumentation & Communication Engineering