Lab #7: Strain Gauges with LabView

EET3131 - Instrumentation Lab #7: Using Strain Gauges with LabView

Conducted: Monday 3/17 Due: Monday 3/24 Purpose: Using strain gauges with LabView signal conditioning, also methods for calibration of sensors will be studied.

DESCRIPTION:
Strain Gauges have been used in Experiment 5 with the Logger Pro hardware and the need for signal conditioning for practical use of these sensors was identified. Now the same strain gauges will be used with LabView where the required signal conditioning will be performed inside LabView and the usability will be studied again. For more information about Strain Gauges or LabView refer to descriptions in Experiments 5 and 6 respectively. Sensor Calibration: Every sensor on a machine contributes to the accuracy of the machine or process of operation. Therefore, an analog sensor that is providing improper information will cause whatever is being manufactured to be done incorrectly. Further, since some sensors are used for data collection, the records of the manufacturing process will be incorrect as well. Once the characteristics of the sensor have been established, preliminary sensor calibration can proceed. The sensor can be connected into an electrical test circuit or a test bench. After the sensor is connected and the circuit is determined to be electrically valid, the next challenge is to find an accurate reference source. If, for example, the sensor is a pressure transducer with a range of 200 pounds per square inch, then a source of pressure will need to be provided. Further, the source must be accurate enough and adjustable enough to ensure that the proper reference can be given to the sensor. Continuing with the example of the pressure transducer, we will need a variable source of pressure capable of delivering 0-200 psi with a percentage of accuracy equal to that of the sensor. An alternative for most types of sensors is to have several fixed-calibration standards. These standards would deliver a single point of exact measurement. By having one at a low point on the sensor range and one at the high point of the sensor range, the sensor can be calibrated to operate in a linear region using this simple two point calibration. To return to our example, if we are measuring O-200 psi with our pressure transducer, we would perhaps want a fixed standard at 10
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Lab #7: Strain Gauges with LabView or 20 lbs. and a fixed standard at something toward the high end of the sensor range, perhaps even exactly 200 lbs. Because the accuracy of the measurement source is so important, many machine builders and maintenance departments often choose to send sensors for calibration to certified calibration labs. It is typically advantageous to perform these repairs and calibrations in-house. There are several applications however, which require the calibrations to be performed by a certified authority, for example the aviation and the pharmaceutical industries. The ability to perform general calibration checking is important in order to determine which sensors may need more detailed maintenance or whether other items on the machine are in need of maintenance. Once the sensors are electrically connected into the test circuits and measurement standards, the next work is done with a calculator. Using the range of the sensor and the maximum signal of the electrical output, the amount of measured electrical signal can be calculated. (See the equations at left for voltage or current sample calculations.) Once this calculation is done, the next step is to apply a measured standard amount to the sensor and confirm that the sensor provides the electrical output to match the portion of the measured range. Using our pressure transducer example, if we were to apply 100 lbs. to the transducer, we would expect to see half of the electrical signal output assuming linear operation. Setting zero and span If calibration is being performed, the first step is to set the zero point on the transducer. Using the calibrated measurement standard of zero, you would then adjust the zero adjustment on the sensor to provide the zero electrical signals from the sensor. After this is accomplished, the measurement standard should be adjusted to provide full scale, or 100%, of range, and the span adjustment should be set to provide the maximum electrical signal. If you are unable to provide a maximum signal range, you can adjust the measurement standard to the maximum you have available and then mathematically calculate the difference from the maximum electrical range, and then proceed to adjust the span to that amount. This process of setting a calculated span may be necessary, but it will also be less accurate. The closer the measurement standard can be set to the sensor "full" range, the more accurate this process will be. Obviously, this also depends upon the sensor being linear across its range. After the zero and span have been set, it is usually wise to repeat the settings several times to make sure that they are repeatable. Having a written calibration procedure for each type of sensor helps provide a record of calibration requirements and history. If significant or frequent calibrations are required, there may be other issues with the sensor that should be investigated.

OBJECTIVES
Using LabView to provide the necessary signal conditioning for the strain gauges

connected in a Wheatstone bridge. Calibrating the Strain Gauges inside the LabView Environment Using the Calibrated strain gauges to find the unknown number of pennies in a bag.
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Lab #7: Strain Gauges with LabView

MATERIAL
Windows PC Lab-View NI PCI-6024E DAQ Board Strain Gauge with Platform and cup Known number of pennies for calibration Oscilloscope Function Generator CB-68LPR Terminal Board Connecting wires Bag of unknown number of pennies

Lab #7: Strain Gauges with LabView

PROCEDURE
Part I: LabView Setup 1. This lab is to be set up to obtain a VI that has all the components represented in Figure I.

Figure I: VI Front Panel. 2. The external connections for this experiment are described in Figure II.

Figure II: Required External Connections.

Lab #7: Strain Gauges with LabView 3. The complete block diagram for this setup looks like Figure III.

Figure III: Complete Block Diagram. 4. This block diagram has 3 main parts. a. First is the DAQ Assistant which is meant to sample 2 voltage waveforms. These correspond to the bridge voltage and the Voltage across the White Gauge. b. Adjust the input range for both the channels such that there is no waveform clipping. The range being sampled should be as close as possible to the range of the signal. Record these input voltage ranges in the Sign-off sheet. c. Set the sampling to Continuous, Number of samples to be read to 500 and Sampling Rate to 2.5 KHz. For both the channels. These values are not the only values which will work, but they have been shown to work. d. Both the waveforms are to be displayed in their native form. split waveform object. This e. To split the waveforms, you need to utilize a object takes the two channels sampled by the DAQ assist and splits them into the two discrete channels (i.e. white gauge and bridge). This object can be found in the express->signal manipulation palette. f. The second part is the Filter and the filtered waveform display. The block diagram for this is as shown in Figure IV.

Lab #7: Strain Gauges with LabView

Figure IV: Signal Processing Block Diagram. g. The Filter Module is available from Express > Signal Analysis menu. h. Set this filter to be a smoothing rectangular filter with the half width of moving average to be 50. i. This Filtered waveform is to be displayed as a graph, a Meter and as a numeric output. j. For Meter and Numeric Display, the Dynamic Data Converter will have to be used. This is available in Express > Signal Manipulation menu. k. The Signal Merge and Signal Split modules are also available in the Express > Signal Manipulation menu. 5. Before energizing the circuit and passing current through the strain gauges, please get the signoff of the instructor to verify proper circuit connections. At this time raw signals should be visible on the front panel. Part II: Calibrator Setup 6. The next part of the experiment is to setup the calibrator for the signal received from the strain gauge. 7. The Front Panel for the calibrated meter looks like the Figure V and the block diagram of the same looks like Figure VI. a. The components used in the front panel of the Calibrator are Toggle Buttons, Numeric Displays, and Gauge. These modules can be found through the front panel window in LabView.

Lab #7: Strain Gauges with LabView

Figure V: Calibrated meter Front Panel.

b. The components used in the block diagram of the calibrator are Signal Merge, Numeric Subtraction, Numeric Division, Convert From Dynamic Data, Index Array, and Bool To. These modules can be found through the block diagram window of Labview.

Figure VI: Block Diagram of Calibrated Meter. c. For example: the object is the index array object. This object can be found on the block diagram page through programming -> array -> index array palette. This object selects between the current value (index 1 as shown) and the currently set calibration value (index 0 as shown) d. is the dynamic data converter, this converts between the The object dynamic data type on the left hand side, and the array data type on the right hand side. This object should automatically be added for you when you wire from a dynamic data type (blue block line) to the array input of the index array object.
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Lab #7: Strain Gauges with LabView

e. The object is a merge signals operator which combines two data elements (on the left) into a single multi-dimensional data element (on the right). This object can be found in the express->signal manipulation palette. In this application this object joins the calibration value (index 0) and the current value (index 1) into the multidimensional array, such that the index array operator can select between them using the toggle button. f. The object is a loop carried variable which can only be created within a loop. This should be created automatically when you wire from the output of the index array object to the input of the merge signal operator, provided the other connections have been established first. LabView knows to create a loop carried variable whenever a given signal may be dependant upon itself. is a Bool to converter, which converts from a boolean on g. The object the left to an integer on the right. This object can be found in the mathematics -> numeric -> conversion palette. The index array object requires an integer index into the multi-dimensional array, while the toggle button produces a bBoolean output. This converter addresses this discrepancy. Other objects (i.e. the use of a dial instead of toggle button) could eliminate the need for this converter. h. The objects , , and are subtract, divide and integer constants respectively. Each of these objects can be found in the mathematics -> numeric palette. These objects will perform the calculations require 8. Take the instructors signature on the properly constructed calibration block diagram. 9. Explanation of the Calibration Method. a. First we store the inputs that are received when the strain gauge is subjected to the weight of 0 pennies and 50 pennies (0 scale and full scale). b. Then the final reading is obtained using Equation I where O is the output value, I is the real time input signal and F and Z are the stored Fifty Calibration and Zero Calibration readings respectively. I O = ---------------(F Z) / 50 Equation I: Calibration Formula. c. Since there are no memory elements in LabView an array index and a loop is used as a memory element. The Array Index module can be accessed from the Array Menu. 10. Place the empty plastic cup on the hook of the strain gauge and wait for the reading to stabilize.
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Lab #7: Strain Gauges with LabView 11. When the reading is stabilized press the Calibrate Zero button so that the value is gated to the zero memory element. Once a stabilized value is visible in the zero display press the Zero Calibrate button once again to store the reading. 12. Count 50 pennies and put them in the cup. Put the cup back on the hook and wait for the reading to stabilize. 13. Repeat step 11 with the Calibrate 50 button to store the full scale reading. 14. Now the experimental setup is ready for measuring unknown load weighing between 0 and 50 pennies. 15. Acquire the unknown weight and find out how many pennies is that weight equivalent to. Record this reading in the sign-off sheet. 16. Get the instructor signoff on the recorded reading.

CONSIDERATION QUESTIONS
1. Is the complete input range of the DAQ card being used in this application setup? What steps can be taken to improve the accuracy of the readings? 2. What elements utilized in Lab 7 allow greater precision resulting from the strain gauge output than was available in Lab # 5. 3. What steps can be taken to improve the calibrated output of this VI? (Changes in the calibration process only.) 4. Did you like this Lab? What would you change? What would you keep the same?

DELIVERABLES
1. Report as described in the Lab Policies & Guidelines document, including answers to all the Consideration Questions. 2. Signoff sheet (page 11) duly signed and dated by the lab instructor. 3. Screen Shots of the Block Diagram and Front Panel windows where only these windows and their title bars and nothing else is visible. Points will be deducted if the components are not clearly visible in these windows or of any of the Windows screen components like the Start Button or Task Bar are visible.

Lab #7: Strain Gauges with LabView

PRELAB

Name ______________________________
1. What are the limitations of LabView in creating instrumented systems?
(i.e. what range of systems will Lab View accommodate, what range of systems will the Vernier LabPro support that Lab View ay not, and with type(s) of systems will neither support? for example open-loop systems, closed-loop systems, analog, digital, process control, unattended, low-power, etc)

2. What are the assumptions being made when the zero and span method is used for calibration of a sensor?

3.

What methods can be used for calibrating sensors with non linear outputs such that the measurand value can be easily determined?
(NOTE : a mechanism for producing non-linear outputs with LabView is given http://zone.ni.com/devzone/cda/tut/p/id/3738#toc4, this is different than the question being asked)

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Lab #7: Strain Gauges with LabView

TEAM MEMBERS: ______________________________ ______________________________

Instructor Sign-off prior to energizing circuit: _____________________________________ Part I Bridge Voltage Value (V) Maximum Nominal Minimum Voltage across White Gauge Value (V) Maximum Nominal Minimum The data above is to be used to calibrate the 6024E Using the DAQ Assistant settings Instructor Sign-off operation of the basic VI: _____________________________________ Part II Bridge Voltage Zero Pennies Penny Quantity #1 Penny Quantity #2 Fifty Pennies Penny Quantity #3 Penny Quantity #4 Penny Count 25 Bridge Voltage Pennies from VI

Signature of Instructor _______________________________

Date_____________

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