VI BASED TEMPERATURE SENSING AND CONTROLLING USING NI LABVIEW

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ACKNOwlEDGEmENT

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ACKNOWLEDGEMENT
First and foremost we wish to express our sincere gratitude and grateful acknowledgement to our institution, Channabasaveshwara Institute of Technology, for providing us the opportunity to do our project work. We take this opportunity to express our sincere thanks and deep sense of gratitude to our beloved Director, Dr. Suresh Kumar D.S, who is a perennial source of inspiration. His encouragement and valuable inputs helped us to complete our project successfully. We take this opportunity to express our profound and sincere gratitude to our beloved principal, Dr. Pradeep C.R, for facilitating a congenial academic environment in the college. Heartfelt thanks to our H.O.D Prof. V.C. Kumar, Department of Electronics and Communication, for his suggestions in the course of our project work.

valuable guidance, suggestions and encouragement throughout the project work. Our sincere thanks to all the staff members of Electronics and Communication department for their gracious support. Words are not enough to express our gratitude to our parents, for their moral support

indirectly helped us during our project work, to make it a great success.

and continuous encouragement.

Last but not the least we thank all our friends and well wishers who have directly or

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We express our immeasurable gratitude to our guide Dr. Suresh Kumar D.S for his

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pARENTs

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OUR BElOvED

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SYNOPSIS
Measuring and control is the quality of every precision Engineering work. Defining precision and accuracy is of utmost importance in every Engineering concern. A low-cost userfriendly programmable temperature controller compatible with the PC for industrial purpose which has to be monitored continuously in a remote place is required in many applications and it has been designed based on a VI (Virtual Instrument) program with minimum hardware design. Presently LabVIEW is fully featured VI programming language produced by NI (National Instruments). It is a graphical language by which code is constructed and saved automatically. There is no text-based code like any other programming language, but a

loved tool of the scientists and engineer who can often visualize data flow rather than how a text based conventional programming language must be built to achieve a task. The VI program measures and compares deviation between set/measured temperature values and alerts the user. It can also automatically correct the situation as required by the control function specified in graphical blocks. The programmable control function may be of any type like On/Off, P, PI, PD, PID (Proportional Integral Derivative), linear heating, onsweep measurement etc. In the meanwhile it provides on-line display of measuring temperature and plots of the control function output.

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diagrammatic view of how the data flows through the program. Thus LabVIEW is a much

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CONTENTs

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LIST OF CONTENTS
Chapter 1 Introduction .................................................................................................... 1 Chapter 2 Virtual Instrumentation ................................................................................. 4 2.1 Virtual Instrumentation Introduction .................................................................. 5 2.2 Virtual Instrumentation Applications .................................................................... 7 2.3 Integrated Hardware Platform ............................................................................... 8 2.4 The 3 Layers of VI Software ................................................................................. 9 2.5 LabVIEW makes ideal for VI ............................................................................... 9 2.6 Measurement and Control services software ....................................................... 11 2.7 The Philosophy of LabVIEW .............................................................................. 13 Chapter 3 Block Diagram ............................................................................................... 15 3.1 Block Diagram Introduction ............................................................................. 16 3.2 Block Diagram Description ................................................................................. 17 Chapter 4 Hardware ....................................................................................................... 19 4.1 Hardware Introduction ..................................................................................... 20 4.2 Hardware Description ......................................................................................... 20 4.2.1 Transducer ................................................................................................... 20 4.2.2 Temperature Sensing circuit ......................................................................... 23 4.2.3 Actuator circuit ............................................................................................ 25 4.2.4 Temperature Controllers .............................................................................. 26 Chapter 5 Software ......................................................................................................... 27 5.1 System Program .................................................................................................. 28 5.2 Flow Chart .......................................................................................................... 29 5.3 Front Panel ......................................................................................................... 30 5.4 Block Diagram ................................................................................................... 31 5.5 Building Application (.exe) ................................................................................. 32 5.6 Building Installer (setup.exe) .............................................................................. 32 5.7 Remote Controlling ............................................................................................ 33 Chapter 6 Advantages and Applications ....................................................................... 34 6.1 Advantages ......................................................................................................... 35 6.2 Applications ....................................................................................................... 36 Chapter 7 Tests and Results ........................................................................................... 37 Summary ......................................................................................................................... 39 Appendix ......................................................................................................................... 41 Appendix-I AD 590 ............................................................................................. 42 Appendix-II NI ELVIS ......................................................................................... 44 Appendix-III 741 .............................................................................................. 46 Appendix-IV Relays ............................................................................................... 49 Bibliography .................................................................................................................... 51

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LIST OF FIGURES & TABLES

Chapter 2 Virtual Instrumentation 2.1.1 Virtual Instrumentation Approach ...................................................................... 5 2.1.2 Functions of Virtual Instruments ........................................................................ 6 2.2.1 Table of Virtual Instrumentation Applications ................................................... 7 2.3.1 The NI Approach Integrated Hardware Platforms ............................................ 8 2.5.1 LabVIEW VI user Interface and Application Logic .......................................... 10 2.5.2 Virtual Instrumentation Software ..................................................................... 11 2.6.1 Table of NI-DAQmx features ........................................................................... 12 2.7.1 LabVIEW Development Platform .................................................................... 13

Chapter 3 Block Diagram 3.1.1 System Block Digram ....................................................................................... 16

Chapter 4 Hardware

Chapter 5 Software

5.2.1 Flow Chart ....................................................................................................... 29 5.3.1 Front Panel ...................................................................................................... 30 5.4.1 Block Diagram ................................................................................................. 31 5.7.1 Remote monitoring and controlling of the plant ............................................... 33

Chapter 7 Tests and Results 7.1 Tabular Column of Plants Controlling Status ..................................................... 38

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4.2.1 AD 590 Packages ............................................................................................. 21 4.2.2 AD 590 Metallic Package type Used in Project ............................................. 21 4.2.3 Pin-out and Functional diagram of AD 590 ...................................................... 21 4.2.4 741 op amp .............................................................................................. 23 4.2.5 Trim Pot . ......................................................................................................... 23 4.2.6 Temperature Sensing Circuit ............................................................................ 24 4.2.7 Block Diagram of the actuator circuit ............................................................... 25 4.2.8 Relay .. ......................................................................................................... 25 4.2.9 Heater . ......................................................................................................... 26 4.2.10 Cooler ........................................................................................................ 26

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Chapter 1

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INtrODUCtION

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V I based Temperature Sensing and Controlling With NI LabVIEW

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CHAPTER - I INTRODUCTION
Any industry will have various parameters that are to be continuously monitored and controlled from a remote place. In most of the cases the use of manpower becomes almost impossible and therefore remote monitoring and control systems are extensively developed and used. Consider a remote application in a process industry where the temperature of various

For such an application a low-cost user-friendly programmable temperature controller compatible with the PC for industrial purpose which has to be monitored continuously in a remote place is required.

All this features can be implemented easily with low cost by designing a temperature sensing and controlling unit based on a VI (Virtual Instrument) program with minimum hardware design to acquire, analyze the data and to initiate the control action accordingly. VI uses off-the shelf mainstream computer technologies combined with innovative, flexible software and modular high performance hardware technologies to create a powerful computer based instrumentation solutions. The objective in Virtual Instrumentation is to use a PC to mimic real instruments with their dedicated controls and displays, but with the added versatility that comes with software. LabVIEW is a graphical programming environment based on the G programming language for data acquisition and control, data analysis and data presentation. LabVIEW gives the flexibility of a powerful programming language without the associated difficulty and complexity due its graphical programming methodology. In this project the temperature of a plant at a remote place is acquired, analyzed and controlled by on/off controller using VI. The temperature to be controlled is acquired using AD590 temperature sensor having the ability to sense from -550C to 1500C and even up to 2000C HPK Kumar

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sources at different places, need to be monitored and controlled within an acceptable tolerance.

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for a short span of time. If the plant requires to sense at higher range than possible by AD590, then we can just replace the sensing unit by any other higher range temperature sensors. The design on a VI program minimizes the use of hardware. The hardware design is done on NI ELVIS (Educational Laboratory Virtual Instrumentation) and DAQ (Data Acquisition) with the maximum support of software written in NI LabVIEW (Laboratory Virtual Instrumentation Engineering Workbench). NI ELVIS is called as general hardware module by National Instruments, which supports maximum applications. The temperature sensing and controlling on NI ELVIS done here can also be done, using plenty of other modules manufactured by NI depending on the application area. But here we have specifically opted NI ELVIS because of its most flexible usage in educational

NI ELVIS is connected to DAQ board using a 68 wired cable and the DAQ System is connected to PCs PCI (Peripheral Component Interface) slot for PC interaction. This simple

cards or tailoring of the PCs hardware. That is PC is programmed using LabVIEW to acquire the temperature from the ELVIS. The control signal generated is given to actuator through Analog output Channel of ELVIS.

The basic idea is to design web page or an application which provides access to user to control the process plant parameters through the web. When user login to website with a valid

change the parameters according to the applications.

user ID, user will be able to view the front panel of the control room and it is also possible to

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design can be mounted on any higher version PCs port and does not require any interface add-on

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purpose and projects.

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INStrUMeNtatION

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Chapter 2

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CHAPTER - II VIRTUAL INSTRUMENTATION

2.1 Virtual Instrumentation - Introduction
Virtual Instrumentation uses off-the shelf mainstream computer technologies combined with innovative, flexible software and modular high-performance hardware technologies to create powerful computer based instrumentation solutions. The objective in virtual instrumentation is to use a PC to mimic real instruments with their dedicated controls and displays with the added versatility that come with software.

Virtual Instrumentation combines hardware and software with industrial standard computerized technologies to create user-defined instrumentation solutions. National Instruments

(DAQ), IEEE 488(GPIB), PXI, serial and industrial communications. The driver software is the application programming interface to the hardware and is consistent across National Instruments

deliver the sophisticated display and analysis capabilities that Virtual Instrumentation requires.

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Fig 2.1.1: Virtual Instrumentation Approach

Virtual Instrumentation can be used to create a complete and customized system for test, measurement and industrial automation by combining different hardware and software components. If there is any upgrade required in the process the same system can be used with some modifications, there is option of extending present components for the further use.
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application software, such as LabVIEW, Lab windows and Measurement Studio. These platforms

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specializes in developing plug-in, distributed hardware and driver software for data acquisition

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For more than 25 years, National Instruments has revolutionized the way engineers and

scientists in industry, government, academia approach measurement, automation. Leveraging PCs and commercial technologies, virtual instrumentation increases productivity and lowers costs for test, control, and design applications through easy-to-integrate software, such as NI LabVIEW, and modular measurement and control hardware for PXI, PCI, USB, and Ethernet. With virtual instrumentation, Engineers use graphical programming software to create userdefined solutions that meet their specific needs, which is a great alternative to proprietary, fixed functionality traditional instruments. Additionally, virtual instrumentation capitalizes on the everincreasing performance of personal computers. For example, in test, measurement and control, engineers have used virtual instrumentation to downsize automated test equipment (ATE) while experiencing up to a 10 times increase in productivity gains at a fraction of the cost of traditional instrument solutions. Last year 25,000 companies in 90 countries invested in more than 6 million virtual instrumentation channels from National Instruments.

measurement, and control systems. Since its introduction in 1986, engineers and scientists worldwide who have relied on NI LabVIEW graphical development for projects throughout the product design cycle have gained improved quality, shorter time to market, and greater engineering and manufacturing efficiency. By using the integrated LabVIEW environment to interface with real-world signals, analyze data for meaningful information, and share results, we can boost productivity throughout our organization. Because LabVIEW has the flexibility of a programming language combined with built-in tools designed specifically for test, measurement and control. We can create applications that range from simple temperature monitoring to sophisticated simulation and control systems.

National Instruments LabVIEW is an industry-leading software tool for designing test,

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11000111010110011110

Fig 2.1.2: Functions of Virtual Instruments

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Acquire

Analyze

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2.2

Virtual Instrumentation Applications

Virtual instrumentation is applicable in many different types of applications, starting from design to prototyping and deployment. The LabVIEW platform provides specific tools and models to solve specific applications ranging from designing signal processing algorithms to making voltage measurements and can target any number of platforms from the desktop to embedded devices with an intuitive, powerful graphical paradigm.

Design - Signal and Image Processing - Embedded System Programming (PC, DSP, FPGA, Microcontroller) - Simulation and Prototyping
And more..

Control - Mechatronics and Robotics

- Automatic Controls and Dynamic Systems

Measurements

- Circuits and Electronics

- Measurements and Instrumentation

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embedded targets from ruggedized toaster size prototypes to embedded systems on chips. LabVIEW streamlines system design with a single graphical development platform. In doing so, LabVIEW encompasses better management of distributed, networked systems because as the targets for LabVIEW grow varied and embedded, we will need to be able to more easily distribute and communicate between various LabVIEW code pieces in our system. The VI can be implemented in normal programming languages like C, C++, Pascal, VB, VC etc., but the advent of graphic languages (G languages) like LabVIEW, HP-Vee, Test point, Agilent VIEW etc., has made the VI implementation easier.

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Table 2.2.1: VI Applications

With version 8.6, LabVIEW scales from design and development on PCs to several

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And more..

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2.3

Integrated Hardware Platform

Fig 2.3.1: The NI Approach Integrated Hardware Platforms

A virtual instrument consists of an industry-standard computer or workstation equipped with powerful application software and cost-effective hardware such as plug-in boards, and driver software, which together perform the functions of traditional instruments. Virtual instruments represent a fundamental shift from traditional hardware-centered instrumentation systems to software-centered systems that exploit the computing power, productivity, display, and connectivity capabilities of popular desktop computers and workstations. Although the PC and integrated circuit technology have experienced significant advances in the last two decades, software truly offers the flexibility to build on this powerful hardware foundation to create virtual instruments, providing better ways to innovate and significantly reduce cost. With virtual instruments, engineers and scientists build measurement and automation systems that suit their needs exactly (user-defined) instead of being limited by traditional fixedfunction instruments (vendor-defined).

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2.4

The 3 Layers of Virtual Instrumentation Software

Virtual instrumentation software can be divided into several different layers. 1.

Application Software:
Most people think immediately of the application software layer. This is the primary development environment for building an application. It includes software such as LabVIEW, Lab Windows/CVI (ANSI C), Measurement Studio (Visual Studio programming languages), Signal Express and VI Logger.

2.

Test and Data Management Software:

Above the application software layer the test executive and data management software layer. This layer of software incorporates all of the functionality developed by the application layer and provides system-wide data management.

3.

Measurement and Control Services Software:

The last layer is often overlooked, yet critical to maintaining software development productivity. The measurement and control services layer includes drivers, such as NI-DAQmx, which communicate with all of the hardware. It

2.5

application development environment designed specifically for engineers and scientists. LabVIEW offers powerful features that make is easy to connect to a wide variety of hardware and other software. This ease of use and these features deliver the required flexibility for a virtual instrumentation software development environment. The result is a user-defined interface and user-defined application functionality. One of the most powerful features that LabVIEW offers is its graphical programming paradigm. With LabVIEW, engineers and scientists can design custom virtual instruments by creating a graphical user interface on the computer screen through which they:
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LabVIEW - Ideal for virtual instrumentation

LabVIEW is an integral part of virtual instrumentation because it provides an easy-to-use

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must access and preserve the hardware functions and performance. It also must be interoperable it has to work with all other drivers and the many modular I/O types that can be a part of the solution.

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Operate the instrumentation program Control selected hardware Analyze acquired data Display results

They can customize the LabVIEW user interface, or front panel, with knobs, buttons, dials, and graphs to emulate traditional instrument control panels of, create custom test panels, or visually represent process control and operation. Determine virtual instrument behavior by connecting icons to create block diagrams, which are natural design notations for scientists and engineers. With graphical programming, engineers and scientists can develop systems more rapidly than with conventional programming languages, while retaining the power and flexibility needed to create a variety of applications. LabVIEW is an open environment that includes readyto-use libraries for everything from serial, Ethernet, and GPIB communication to motion control, data acquisition, and image acquisition. Traditional instrumentation solutions, by nature of their fixed packaging and vendordefined nature, cant rapidly adapt to new software technologies. Because of its inherent flexibility, virtual instrumentation is much better suited to incorporating new tools and technology users can simply upgrade their software, rather than purchase a new system. Over the 20 plus years of its development, LabVIEW has tightly integrated cutting edge software
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Fig 2.5.1: LabVIEW VI User Interface and Application Logic.

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technology while still providing a seamless transition from version to version. With the long project lifetimes often found in the test and measurement industry, its critical that LabVIEW provide a stable platform for development over many decades.

Fig 2.5.2: Virtual Instrumentation software

However, to ensure maximum productivity of its users, LabVIEW must also take advantage of new technologies as they arise. Many software packages get caught in the trap of rapid adoption of new technology without regard to longevity. For example, software packages based primarily on the Microsoft platform of technology over the past 15 years have had several instances where their software had to be totally redefined due to the discontinuity of the latest technology, such as COM, ActiveX, and most recently .NET.

ensure that the user has access to the latest tools, but integrates them in such a way that there is no need to completely rework existing code. New technologies, such as .NET, can simply be added in to existing applications as needed.

2.6

However, it is much more than just drivers. Though often overlooked, it is one of the most crucial elements of rapid application development. This software connects the virtual instrumentation software and the hardware for measurement and control. It includes intuitive application programming interfaces, instrument drivers, configuration tools, I/O assistants, and
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LabVIEW has always incorporated and continues to incorporate these technologies to

Measurement and control services software

Measurement and control services software is equivalent to the I/O driver software layer.

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other software included with the purchase of National Instruments hardware. National Instruments measurement and control services software offers optimized integration with both National Instruments hardware and National Instruments application development environments. As an example, National Instruments raised the bar for data acquisition software when it introduced NI DAQmx for the Windows OS and increased the ease, speed, and power with which scientists and engineers take measurements. NI DAQmx leverages several technologies that legacy drivers do not exhibit including multithreading, simplified application programming interface (API), interactive configuration, and intelligent multi-device synchronization. Additionally, NI-DAQmx supports broad ranges of programming languages, devices, buses, sensors, and even mixed signal types. With NI DAQmx, a new user to data acquisition can easily create an application that leverages parallel processing and synchronizes multiple devices all with

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New Feature Best Good

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Table 2.6.1: NI-DAQmx with high-performance driver and additional software increase productivity

In addition to new technologies, every copy of NI-DAQmx ships with a collection of measurement services designed to save data acquisition system developers time and money. This collection of measurement services, in addition to NI-DAQmx, offer more software value than any other data acquisition vendor provides with a DAQ device. A few of these measurement services include, Measurement & Automation Explorer (MAX) for configuring, interacting with, HPK Kumar

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interactive, configuration-based programming.

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and testing our hardware; DAQ Assistant for configuration-based creation of data acquisition tasks; and VI Logger-Lite, FREE software specifically designed for data logging.

2.7

The Philosophy of LabVIEW

LabVIEW is an entirely graphical language which looks somewhat like an Electronic

Schematic diagram on the one hand and a 1950's vintage style electronic instrument on the other - these are the concepts of the block diagram and the front panel. LabVIEW is hierarchical in that any virtual instrument that we design (any complete functional unit is called a virtual instrument and is almost always referred to as a VI) can be quickly converted into a module which can be a sub-unit of another VI. This is entirely analogous to the concept of a procedure in conventional Programming. LabVIEW is also designed to be extendible. We can add modules through various means. A manufacturer of an interface card or an instrument may provide us details with a LabVIEW driver which appears as a VI representing the card and its functionality in the LabVIEW environment. We can also write a LabVIEW module using LabVIEW and present it as

with LabVIEW in other languages such as C and C++. These are known as sub-VIs and are no different from VIs except that the interface has been defined to the next level. Sub-VIs in C or C++ is very useful if we have a complex numerical procedure to perform on the data which is not covered in a standard LabVIEW routine. Since scientists are rather partial to complex numerical procedures, this can be a very useful property in our context.

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Fig 2.7.1: LabVIEW Development Platform

Programmers develop software applications every day in order to increase efficiency and productivity in various situations. LabVIEW, as a programming language, is a powerful tool that can be used to help achieve these goals. Its graphical nature makes it ideal for test and
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a VI to be used in other programs (re-usable code) or we can also write modules which interface

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measurement (T&M), automation, instrument control, data acquisition, and data analysis applications. This results in significant productivity improvements over conventional programming languages.

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Chapter 3

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BLOCK DIaGraM

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CHAPTER - III BLOCK DIAGRAM

3.1 Block Diagram - Introduction
This chapter explains clearly how actually the setup part looks like with the Block Diagram shown below in fig 3.1.1, which mainly consists of: Plant

o Heater / Cooler Sensing Circuit NI-ELVIS Actuator Circuit

Personal Computer

Data Acquisition Module (NI-DAQ)

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Actuator
Fig 3.1.1: System Block Diagram Dept. of ECE, CIT.

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NI-LabVIEW Software with NI-ELVIS Driver

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o Temperature Sensor

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3.2

Block Diagram Description

3.2.1 Plant:
The remote place at which the temperature is to be monitored and controlled is considered as a plant. It incorporates a temperature sensor AD590 which acquires live data and submit it to the sensing circuit. The Heater and Cooler are employed for controlling the varying temperature.

3.2.2 Sensing Circuit:

Temperature sensor AD590 produces a proportional current in accordance to the temperature in micro amperes. Sensing circuit consists of a widely used opamp , which converts current to proportional amplified voltage compatible

3.2.3 NI-ELVIS:

NI ELVIS uses LabVIEW-based software instruments and a custom-

of a suite of common laboratory instruments. NI ELVIS combines hardware and software into one complete laboratory suite.

3.2.5 Personal Computer:

A Personal Computer with Pentium-IV processor to which LabVIEW v8.6 software is loaded is used to monitor, generate control signal and to display temperature of the plant. A Graphical User Interface (GUI) has been designed using LabVIEW to interact with plant parameters. The Process parameters, setpoint temperature can be changed through input peripherals according to the requirement using GUI. The measured temperature of the plant is continuously displayed on the graph of GUI and the values are tabulated and written in a file to maintain a Database.

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respectively.

3.2.4 Actuator Circuit:

The actuator is used to switch ON/OFF the Heater/Cooler according to

control signals. A switch is implemented using two relays for Heater and Cooler

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designed benchtop workstation and prototyping board to provide the functionality

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3.2.6 Data Acquisition Module (NI-DAQ):

This NI module interconnects the PC and NI-ELVIS through a 68 wired cable. NI-DAQ is connected to PCI slot of the computer. This simple design can be mounted on any higher version PCs port and does not require any interface add-on cards or tailoring of the PCs hardware.

3.2.7 NI-LabVIEW Software with ELVIS Driver:

LabVIEW provides a powerful graphical programming tool for test and measurement (T&M), automation, instrument control, data acquisition, and data analysis applications. NI-ELVIS Driver software makes LabVIEW to interact with hardware by installing ELVIS compatible software library to LabVIEW installation parent folder.

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Chapter 4

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CHAPTER - IV

HARDWARE
4.1 Hardware Introduction

System Hardware consists of the following units: Transducer (Temperature Sensor - AD590) Temperature Sensing Circuit o op-amp o Trim Potentiometer Actuator Circuit o Relays Temperature Controllers o Heater o Cooler

4.2

HARDWARE DESCRIPTION

A transducer is a mechanism or an element of the sensor that transforms the energy

temperature into electrical signal. The features of this transducer are as follows: Linear current output Wide temperature range 2 - terminal device Wide power supply range Excellent linearity : : : : : 1 A/0K 55C to +150C voltage in/current out 4 V to 30 V 0.3C over full range (AD590M)

associated with, what is being measured into useful form of energy (Electrical energy). In this project, AD 590 M-series is used as the temperature sensor which converts

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4.2.1

Transducer

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Fig 4.2.1: AD 590 Packages

Fig 4.2.2: AD590 Metallic Package type (Used in Project)

AD 590 Description:

current proportional to the absolute temperature. The device acts as a high impedance constant current regulator, passing 1 A/ 0K for supply voltages between +4V and +30V. Laser trimming (250C). of the chip's thin film resistors is used to calibrate the device to 298.2 A output at 298.20K

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The AD590 is an integrated-circuit temperature transducer which produces an output

Fig 4.2.3: Pin-out and Functional diagram of AD 590

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The AD590 should be used in any temperature-sensing application between

to

in which conventional electrical temperature sensors are currently employed. The inherent low cost of a monolithic integrated circuit combined with the elimination of support circuitry makes the AD590 an attractive alternative for many temperature measurement situations. Linearization circuitry, precision voltage amplifiers, resistance measuring circuitry and cold junction compensation are not needed in applying the AD590. In the simplest application, a resistor, a power source and any voltmeter can be used to measure temperature. In addition to temperature measurement, applications include temperature compensation or correction of discrete components, and biasing proportional to absolute temperature. The AD590 is particularly useful in remote sensing applications. The device is insensitive to voltage drops over long lines due to its high-impedance current output. Any well insulated

characteristics also make the AD590 easy to multiplex: the current can be switched by a CMOS multiplexer or the supply voltage can be switched by a logic gate output.

AD 590 Highlights:

1. The AD590 is a calibrated two terminal temperature sensor requiring only a dc voltage supply (+4 V to +30 V). Costly transmitters, filters, lead wire compensation and linearization circuits are all unnecessary in applying the device. 2. State-of-the-art laser trimming at the wafer level in conjunction with extensive final testing ensures that AD590 units are easily interchangeable. 3. Superior interface rejection results from the output being a current rather than a voltage.

4. The high output impedance (>10 MW) provides excellent rejection of supply voltage drift and ripple. For instance, changing the power supply from 5 V to 10 V results in only a 1 A maximum current change, or 1C equivalent error. 5. The AD590 is electrically durable: it will withstand a forward voltage up to 44 V and a reverse voltage of 20 V. Hence, supply irregularities or pin reversal will not damage the device.

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In addition, power requirements are low (1.5 mW at 5V at +25C.) These features make

the AD590 easy to apply as a remote sensor.

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twisted pair is sufficient for operation hundreds of feet from the receiving circuitry. The output

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4.2.2

Temperature Sensing Circuit

Temperature sensor AD590 produces a proportional current in accordance to the temperature in micro amperes. Sensing circuit consists of a widely used op-amp A 741, which converts current to proportional amplified voltage compatible with NI-ELVIS. A 741 - Operational Amplifier: The A 741is a high performance monolithic operational amplifier constructed on a single silicon chip. It is intended for a wide range of analog applications.
Fig 4.2.4: A 741 Op-amp

Summing amplifier Voltage follower Integrator

Active filter Function generator

The high gain and wide range of operating voltages provide superior performances in integrator, summing amplifier and general

closed loop circuits. Potentiometer:

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Fig 4.2.5: Trim Pot

Trim type potentiometer is manually adjustable, variable, electrical resistor. It has a resistance element that is attached to the circuit by three contacts, or terminals. The ends of the resistance element are attached to two input voltage conductors of the circuit, and the third contact, attached to the output of the circuit, is usually a movable terminal that slides across the resistance element, effectively dividing it into two resistors. Since the position of the movable terminal determines what percentage of the input voltage will actually be applied to the circuit,
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feedback applications. The internal compensation network (6dB/octave) insures stability in

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the potentiometer can be used to vary the magnitude of the voltage; for this reason it is sometimes called a voltage divider. Typical uses of potentiometers are in radio volume controls and television brightness controls. The resistor R 1 present in the sensing circuit needs to be varied precisely for the current calibrations. Hence, a trim pot of 10 K is used in series with the constant 10 K resistor. Circuit Diagram:

V+ +

Circuit Description:

The temperature sensor AD 590s positive terminal is connected to the virtual ground of the op-amp. As the AD590 produces proportional current in A, op-amp input current at noninverting terminal is to be calibrated at desired current value by adjusting R 1 .

then adjusted for 100 mV out with the sensor at 100C. Other calculation pairs of temperatures may be used with this procedure as long as they are measured accurately by a reference sensor. Note that for 150 mV output (150C) the V+ of the op-amp must be lesser than +17V and greater
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Calculations:

273 A at 0 0C (273 0K)

R 1 = V/273 A = 18.31 K Ohms Input Voltage, V = +5V Now if we should get V out = 28 mV at 28 0C, Then, R f= 28mV/28 A = 1 K Ohms The circuit is trimmed by adjusting R 1 for a 0 mV output with the AD590 at 0C. R f is

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Fig 4.2.6: Temperature Sensing Circuit

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than +13V. Also note that V should be at least 4V; if V is ground, there is no voltage applied across the device. The temperature proportional output voltage of the sensing circuit is given to the analog channel of the NI-ELVIS to sense the plant temperature.

4.2.3

Actuator Circuit

After sensing of the temperature and its manipulation by LabVIEW, the digital ON/OFF control signal for the Heater/Cooler is generated and given to hardware through NI-ELVIS. The control signal is of low level DC voltage and Controllers operate on high AC voltages. Hence, the control from one level to another is given by actuator circuit using relays.

Relay:

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It is an electromechanical device to control the high level ac voltages using a TTL logic voltage levels. Relays are components which allow a low-power circuit to switch a relatively high current on and off, or to control signals that must be electrically isolated from the controlling circuit itself.
Fig 4.2.8: Relay

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Fig 4.2.7: Block Diagram of the Actuator Circuit

pull-in and holding current (DC) through its energizing coil. Generally relay coils are designed to operate from a particular supply voltage - often 12V or 5V, in the case of many of the HPK Kumar

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To make a relay operate, we have to pass a suitable

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small relays used for electronics work. In each case the coil has a resistance which will draw the right pull-in and holding currents when its connected to that supply voltage. So the basic idea is to choose a relay with a coil designed to operate from the supply voltage we are using for our control circuit (and with contacts capable of switching the currents we want to control), and then provide a suitable relay driver circuit so that our low-power circuitry can control the current through the relays coil. Typically this will be somewhere between 25mA and 70mA.

4.2.4

Temperature Controllers

The plant temperature is compared with the set-point temperature and output is given to a control element through NI-ELVIS. In this project LabVIEW is used to implement the ON/OFF controller, the high level voltage on which controllers work are produced by the actuator circuit

Here the controller is providing mainly 3 functions:

1. Provide one to one correspondence of the output.

3. Handle the fast process load changes.

Heater:

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Fig 4.2.9: Heater

controlling signals produced by LabVIEW.

Cooler:
If the temperature of plant is above the set point temperature then cooler will gets on and decreases the temperature of liquid in the system. Cooler also works by the same control mechanism as control signals given to heater.

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then heater will gets on and increases the temperature of liquid in the system. The coil type heater of 300W power, working at 230V AC/DC is used in the project, which is having the capability of heating the liquid in the system rapidly and having the feature of corrosion free material. The 230V AC is given by the actuator circuit as per the

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If the temperature of plant is below the set point temperature
Fig 4.2.10: Cooler

2. Eliminate the offset produced.

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using the low level voltage logic from LabVIEW / NI-ELVIS.

Chapter 5

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CHAPTER - V

SOFTWARE
5.1 System Program
Temperature Sensing and Controlling is done by Graphical programming language written in LabVIEW v8.6. This type of programming give rise to virtual instruments which mimics the real hardware without actually using it.

1. Front Panel:

Front Panel window is the interface to the VI code, containing visual waveform charts, knobs, switches, indicators, tables and all other virtual things needed for easy interaction with the project designed. 2. Block Diagram:

Block Diagram window contains graphical program code such as icons of different functionalities, wires, loops, sequences, structures, conditions, data and all the things needed for programming graphically. If LabVIEW does not contains the graphical code required for us, then it can be created by our self easily by graphical

which, it will be manipulated and shown in all 3 formats, that is in degree Celsius, Kelvin, Fahrenheit for ease of use by any user and also the readings will be plotted on the graph to observe the variations of temperature with respect to time and at the same time the acquired temperature reading will be tabulated and stored in database for every specified time interval given by the user, which helps to keep records of temperature continuously. After sensing the data, the next immediate part of the program is controlling, that is to keep the system temperature constant as specified in the field of set point temperature by user,
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codes provided by LabVIEW itself or even by other programming languages, without actually using that particular software.

In this project, software will get the sensed temperature details from NI-ELVIS after

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VIs when created popup two windows:

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means if the sensed temperature reading is below the set point temperature then the control signal is given to heater to turn-on, and at the same time to turn-off the cooler. If the sensed temperature reading is above the set point temperature then the control signal is given to heater to turn-off, and at the same time to turn-on the cooler. The method of controlling action explained is called ON-OFF Controlling.

5.2

Flowchart:
The flowchart of the Graphical programming language designed in LabVIEW for the

above sensing and controlling action is shown below:

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Fig 5.2.1: Flow Chart of the Project Dept. of ECE, CIT.

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5.3

Front Panel

shown in fig. 5.3.1. All input, intermediate and output status are available on front panel. In this project,

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The inputs are: Set Point Temperature Controlling Type Reset for Controlling Delay between each Execution Tabulation Controls Stop Execution

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The Front Panel which is having capable of providing flexible interaction to users is

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observing readings.
Dept. of ECE, CIT.

Fig 5.3.1: Front Panel of the Project

The set point and controlling type can be given according to the application by user. Virtual Indicators are used to show heater and coolers condition. Tabulation will help in

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The outputs are: Temperature Readings Its Graphical Indicator Heater Condition Cooler Condition Tabular Column Current date/time for database

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5.4

Block Diagram

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Fig 5.4.1: Block Diagram of the Project Dept. of ECE, CIT.

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The block diagram which contains graphical programming code is shown in fig. 5.4.1.

Acquisition of temperature data, manipulating it, generating corresponding control signals, storing to database, sending control signals to hardware, to execute the program as specified by the delay given by user and everything that comes under the programming part will be done by the graphical blocks and wires shown in the block diagram.

5.5

Building Application (.exe)

Building stand alone application is a method in LabVIEW for constructing the software

part which works independent of NI-LabVIEW installed in PC, but it will be the final part of the project where we cannot get the Block Diagram window to alter the graphical LabVIEW program. It will be helpful to designers who can sale their software in which user cannot change the program, but can use it.

Steps used in this project for building application:

Link all those VIs with in a project file (.lvproj). Build library for the corresponding project (.lvlib) optional step, but preferred.

Construct Application, by giving icons and key requirements to it.

installer is like designing complete software itself for building the project without the need of any driver software pre-installed in PC. All the steps involved in building application is needed, after which all the hardware drivers required are to be attached to the project and installer is build by giving right license file, readme file, icon file, installer key, project designer details and all other requirements. After building, installer can be provided to users, who can work with the designed project, even without a single pie of knowledge in LabVIEW.

5.6

Building Installer (setup.exe)

Application may need hardware driver software to be installed in the PC, but building

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Verify each and every links and set the main VI for user interaction.

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Construct all VIs needed for the final project (.vi).

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5.7

Remote Controlling

Either Application or installer of the final project is installed using setup.exe on controlling system attached to plant and also to the remote system. Connection can be created by internet/WAN/MAN/LAN or any kind of standard connectivity between the two system softwares.

Fig 5.7.1: Remote monitoring and controlling of the plant

Then main system at the plant area is set to be as master. Remote system can login to master by valid authentication and can view or control the status of plants temperature according to the type of authentication given. On either side of the PCs screen we can look the front panel (only), through controlling can be done easily.

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Chapter 6

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appliCations

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advantages &

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CHAPTER - VI

ADVANTAGES AND APPLICATIONS

6.1

Advantages
Complete analysis and flexible manipulation of the acquired temperature. Save development time. Graphical and Numerical Display of acquired data. Reduces maintenance cost. Increase Performance. Reuse of external code.

Easy Tabulation and maintenance of records by Database of Acquired Data.

Application and Installers can be built.

Remote controlling of the plant provides an easy access to the user. Flexible options for improving productivity.

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Different controlling options viz Heater/Cooler can be used based on application.

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6.2

Applications

In industrial plants Reactors (Nuclear, Thermal, Atomic) Automobiles Robotics Embedded Systems Structural Health Monitoring Environmental Monitoring Medical Field . Approximately in all fields.

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teStS & reSultS

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CHAPTER - VII

TESTS AND RESULTS

This project demonstrates the acquisition of temperature, measurement, analysis and controlling using virtual instrumentation. Various tests were conducted during the development and the final stages of the system design. The results obtained are satisfied with accuracy. The obtained results are tabulated below; here we can easily compare the system temperature read by the temperature sensor with the set point temperature to be obtained in the

Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Time (in sec) 0 5 10 20 30 40 50 60 70 80 90 100 110 120 130

Set Point Temperature 60 60 60 60 60 60 60 60 60 60 60 60 50 50 50

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System Heater Condition ON ON ON ON ON ON ON ON OFF OFF ON OFF OFF OFF OFF 26.321 30.124 33.526 39.510 45.685 51.621 56.780 59.813 60.923 60.105 59.941 60.735 58.387 56.916 55.032

system with respect to the time.

Cooler Condition OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF ON ON ON ON

Temperature

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Table 7.1: Plants Controlling Status up to 130 sec.

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SUMMARY

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SUMMARY
The temperature sensing and controlling system using LabVIEW is designed and listed with repeated measurements and the performance was satisfactory. The following conclusion can be drawn from the performance results: The overall project has gained a lot of importance as the data acquisition can be done from a remote place, which saves wiring and maintenance cost. Graphical Programming is simple and flexible. Program can be changed easily based on the user requirements. Heater and cooler controlling options can be used depending on the applications. The tabulation and storing of details in a database makes a good work for keeping record of the system.

The following suggestions are made for future development and further improvements of the presented project:

Different kind of controllers like P, PI, PD and PID can be implemented.

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validating the user.

The number of parameters to be measured can be increased like measuring of pressure and other parameters. Status of the temperature can be sent and controlled via e-mail and SMS after

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APPENDIX

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Appendix I AD 590

Wiring Configuration

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Appendix II - NI ELVIS

NI ELVIS uses LabVIEW-based software instruments and a custom-designed benchtop workstation and prototyping board to provide the functionality of a suite of common laboratory instruments. NI ELVISmx is the software that supports NI ELVIS II hardware. It provides the following LabVIEW soft front panels (SFPs): Arbitrary Waveform Generator (ARB) Bode Analyzer Digital Reader Digital Writer

Dynamic Signal Analyzer (DSA) Function Generator (FGEN) Impedance Analyzer Oscilloscope (Scope)

Two-Wire Current Voltage Analyzer

Three-Wire Current Voltage Analyzer

NI ELVIS Hardware

shows a typical diagram of an NI ELVIS II system.

NI ELVIS combines hardware and software into one complete laboratory suite. Figure

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Variable Power Supplies

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APPENDIX: CASE STUDY

Digital Multimeter (DMM)

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Fig: Typical NI ELVIS System

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NI ELVIS Benchtop Workstation

The workstation control panel provides easy-to-operate knobs for the variable power supplies and function generator, and offers convenient connectivity and functionality in the form of BNC and banana-style connectors to the function generator, scope, and DMM instruments. Figure shows the control panel parts locator diagram.

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Fig: Top View of NI ELVIS II Benchtop Workstation with Prototyping Board

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Appendix III

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Appendix IV Relays

It is an electromechanical device to control the high level ac voltages using a TTL logic voltage levels. Relays are components which allow a low-power circuit to switch a relatively high current on and off, or to control signals that must be electrically isolated from the controlling circuit itself. To make a relay operate, you have to pass a suitable pull-in and holding current (DC) through its energizing coil. Generally relay

12V or 5V, in the case of many of the small relays used for electronics work. In each case the coil has a resistance which will draw the right

pull-in and holding currents when its connected to that supply voltage.

So the basic idea is to choose a relay with a coil designed to operate from the supply voltage you are using for your control circuit (and with contacts capable of switching the currents you want to control), and then provide a suitable relay driver circuit so

be somewhere between 25mA and 70mA.

Relay Design ID:

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that your low-power circuitry can control the current through the relays coil. Typically this will

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Relays are either Normally Open or Normally Closed. Notice the position of the switches in the two relays shown below. Normally open relays have a switch that remains open until energized (ON) while normally closed relays are closed until energized. Relays are always shown in the de-energized position (no current flowing through the control circuit OFF).
APPENDIX: CASE STUDY

coils are designed to operate from a particular supply voltage - often

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Normally Open Relays:

DE-ENERGIZED (OFF)

ENERGIZED (ON)

Normally Closed Relays:

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BIBLIOGRAPHY

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BIBLIOGRAPHY
1) NI Educational Laboratory Virtual Instrumentation Suite mx (NI ELVIS mx) User Manual by National Instruments. 2) LabVIEW User Manual April 2003 Edition, Part Number 320999E-01. 1992 2003 National Instruments Corporation. All rights reserved. 3) Two Terminal IC Temperature Transducer, AD 590 Datasheet 2003 by Analog Devices, Inc. USA. 4) Introduction to LabVIEW Graphical Programming for Engineers and Scientists by National Instruments.

5) LabVIEW 8.6 User manual, Measurement & automation, National Instruments Inc. (2008).

6) LabVIEW: Advanced Programming Techniques, 2nd Edition, by Rick Bitter (Motorola), Taqi Mohiuddin (Mindspeed Technologies), Matt Nawrocki (Motorola). 7) LabVIEW in Digital Signal Processing and Digital Communication, 2nd Edition, by Corry. L. Clark.

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8) LabVIEW Exercises, by A. Fakheri. 9) Image Processing with LabVIEW and IMAQ Vision by Thomas Klinger Thomas, Ph.D., 2003 Pearson Education Inc. 10) http://www.ni.com by National Instruments. 11) G Programming Reference Manual Part Number 321296B-01, by National Instruments, 1998. 12) Getting Started for LabVIEW with Data Acquisition, by National Instruments. 13) A Software Engineering Approach to LabVIEW by Jon Conway Steve Watts. HPK Kumar

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14) Introduction to LabVIEW Six-Hour Course September 2003 Edition, Part Number 323669B-01, 2003 National Instruments Corporation. 15) LabVIEW Fundamentals August 2005 Edition, Part Number 374029A-01. 2005 National Instruments Corporation. All rights reserved. 16) Sensors, Transducers, and LabVIEW by Barry Paton. 17) LabVIEW Help, LabVIEW --> Help, Help and Examples. 18) Learning LabVIEW 8.6 Video Toolkit, by National Instruments Corporation. 19) LabVIEW Quick Reference Card, 2006 National Instruments Corporation.

21) LabVIEW Signal Processing by Mahesh L. Chugani Abhay R. Samant Michael Cerra.

22) Analog Electronics with LabVIEW by Kenneth L. Ashley. 23) Hands-On Exercise Manual for LabVIEW Programming, Data Acquisition, and Analysis by Jeffrey Y. Beyon. 24) LabVIEW for Electric Circuits, Machines, Drives, and Laboratories by Nesimi Ertugrul. 25) NI

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LabVIEW

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Database HPK Kumar

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Connectivity

20) Using External Code in LabVIEW, by National Instruments Corporation.

Toolset

User

Manual,

http://www.ni.com/pdf/manuals/321525c.pdf

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