Developing a Data Acquisition Platform Using LabVIEW Real-Time and FieldPoint

Author(s):
Tim Butterfield - Stress Engineering Services Inc.

Industry:
Machines/Mechanics

Products:
Compact FieldPoint, LabVIEW, FieldPoint

The Challenge:
Developing a real-time data acquisition (DAQ) platform that is user friendly, compact, cost effective, reliable, and Web accessible, to test mechanical power distribution products.

The Solution:
Using LabVIEW Real-Time and FieldPoint to implement a system that creates a generic DAQ platform that is easily adaptable.

Emerson Power Transmission (EPT) is a manufacturer of mechanical power distribution products. Over the years, EPT’s test facilities have grown and they have integrated a variety of DAQ systems. Because of the variety in DAQ systems, it was becoming increasingly difficult to train employees on the different systems. Such diverse systems also made service and maintenance complicated, creating a need for a single DAQ system adaptable to meet almost any need. An examination of the current DAQ systems revealed that the systems collected the same data - temperature, input power, output power, speed, and motor current - regardless of the product tested.

The FieldPoint Solution
After we examined EPT’s requirements for a DAQ system, we selected a FieldPoint system that contained five modules - an Ethernet controller, a relay module, an analog input module, and two thermocouple input modules. We mounted all modules in the optional FP-ENC1 enclosure, for easy viewing of the modules’ status. Because the FieldPoint modules are small, we were able to mount them on the EMT test station.
The FP-2010 Ethernet controller gathers and stores the data it collects on the test station. It also uses an Ethernet connection to transmit data back to a central computer saving EPT several thousands of dollars. In the past EPT used expensive sensor cabling that cost as much as $7 per foot with typical lengths of 150 to 200 feet between a test station and a data lab; but because we mounted the FP-2010 at the test station, the sensor cable lengths are now only 10-20 feet, and more inexpensive at $.05 per foot. Using Ethernet to transfer data eliminated electrical noise interference with the analog signal and ensured data integrity.

Creating an Interface with LabVIEW Real-Time and FieldPoint
Once we selected the hardware, our next challenge was creating a PC interface that was user friendly, had a consistent look and feel between stations, and adaptable enough to accommodate the different types of tests within EPT. In addition, the PC interface had to provide real-time access to the data for tests in progress as well as a PC interface accessible via the Web.

In order to meet the testing needs of EPT, SES developed two LabVIEW 6.1 applications. The first application, EPT_PC_DAQ, is an application that can run from any computer on the network and is responsible for test setup, monitoring, and control of each test station. The second application, FPRTDAQ, uses the LabVIEW Real-Time and runs stand alone on the FP-2010 real-time operating system. This application collects and stores test data from the test station.

With EPT_PC_DAQ, the user can enter test information, test parameters, and configure test channels to monitor during a test run on nine test stations. This test setup uploads to the FP-2010 module via file transfer protocol (FTP) functions from the LabVIEW Internet Developers Toolkit. We can then run start, pause, or stop a test from this interface. Once a test is running on the FP-2010, test data downloads from it and displays on the screen, and we can view, print, and save the data to disk for further analysis. We can view real-time test data from any station through a meter, graph, or data table screen. Once a test is complete, the data is formatted and stored into a test report for each test station.

The FPRTDAQ executable runs independent of the EPT_PC_DAQ application and starts when the FP-2010 powers up. This application collects data from the channels specified in the test setup file and stores it on the FP-2010 file system for the EPT_PC_DAQ application to retrieve when needed. Upon an alarm condition, the FPRTDAQ application will shut down the test station.

With the new remote monitoring and control features of LabVIEW 6.1, both applications are Web accessible from any Web browser so engineers in another building or off-site can check on the status of all the stations from the EPT_PC_DAQ application, or individually from the FPRTDAQ application.
Using LabVIEW Real-Time software and FieldPoint hardware we achieved a flexible, intelligent, and distributed DAQ platform. Currently EPT is designing new test stands that will utilize the new DAQ platform. There are also plans to begin phasing in the new DAQ platform on existing equipment. With the synthesis of LabVIEW Real-Time and FieldPoint EPT is achieving its goal of a feature rich, user friendly, reliable, and cost-effective DAQ system.

For more information, contact:

 Tim Butterfield

Stress Engineering Services, Inc.

5380 Courseview Drive

Mason, Ohio, 45040

Tel: 513-336-6701

Fax: 513-336-6817

E-mail: tim.butterfield@ses-oh.com

Browse All Case Studies »