This document summarizes a 3-month internship project involving programming tasks and plant visits. The internship focused on developing MATLAB applications for vibration data acquisition and analysis. Two key projects involved (1) creating a module to display real-time shaft centerline movement from proximity probe data and (2) designing a low-cost webcam-based system to remotely monitor analog meters. The webcam system used computer vision techniques to identify needle positions in images and calculate readings, allowing remote monitoring of meters located up to 100 meters from the control room. Overall, the internship provided hands-on engineering experience in condition monitoring.
TVS Scooty was a successful brand extension of Scooty Pep, a 4-stroke variant launched in 2003. It maintained the brand promise of style and convenience while adding features like increased speed and fuel efficiency. Scooty Pep saw high growth and market share. However, Scooty Teenz Electric, launched in 2007 focusing on the environment, failed due to technical issues like short battery life, slow charging, and frequent mechanical problems. It did not align well with the youthful brand image or fulfill customer needs.
What’s on your plate matters! It’s all about fuelling for results & in this case optimal lean muscle mass! It can be difficult to know what foods (& portions of), support your goals! The truth is, there is always a strategy in optimising your nutrition & it all starts with your 7-day program.
This document is a project report submitted by a group of students for their Design Engineering course. It details the development of an Automatic Railway Crossing System (ARC) over multiple semesters. In the 6th semester, the students developed a PLC circuit board and program to control the ARC. They tested the circuit and program on a DELTA DVP-14SS2 PLC. The report provides snapshots of the PLC program and discusses modeling software, engineering economics, prototyping, materials selection, and future improvements including using renewable energy sources.
IRJET- A Unique Methodology for Transmission Line Breakage Detection and ...IRJET Journal
This document describes a proposed system for detecting transmission line breakages and alerting relevant parties. The system uses voltage sensors along transmission lines to continuously monitor voltages between sections. If a rapid voltage change is detected between two sections, a signal is sent to trip the power supply and alert the public via buzzers. Data is communicated between sections using wireless sensor networks. The system is simulated using a PIC microcontroller and results are displayed on an LCD screen and transmitted to peripherals. The goal of the system is to quickly detect broken power lines to prevent electrical accidents and power outages.
Summer Training 2015 at Alternate Hydro Energy CenterKhusro Kamaluddin
This is the presentation i gave to "Defend" my Summer Training at AHEC IIT Roorkee During Summer 2015. I gave this presentation in my college during my final year. Indeed the most lengthy i ever gave .
IRJET- Design Analysis of Land Surveying Robot using Arduino UNOIRJET Journal
This document describes the design of a land surveying robot using an Arduino Uno microcontroller. The robot is intended to automatically survey and calculate the area of a given plot of land. It uses a Bluetooth module to control movement, and calculates distance traveled and area using a timer concept. The robot aims to reduce the manpower and equipment needed for land surveys compared to conventional methods, while improving accuracy and saving time. Key components include Arduino Uno, DC motors, an L293D motor driver, ultrasonic sensor, and Bluetooth module. The robot is designed to automatically measure land areas more efficiently than traditional manual surveying methods.
(https://www.indiamart.com/zreyastechnology) We are leading and trustworthy organization actively involved in manufacturing a vast collection of Vibration Analyzer, Power Analyzer and Network Gateway. We are manufacturing our offered products by using optimum grade input factors.
TVS Scooty was a successful brand extension of Scooty Pep, a 4-stroke variant launched in 2003. It maintained the brand promise of style and convenience while adding features like increased speed and fuel efficiency. Scooty Pep saw high growth and market share. However, Scooty Teenz Electric, launched in 2007 focusing on the environment, failed due to technical issues like short battery life, slow charging, and frequent mechanical problems. It did not align well with the youthful brand image or fulfill customer needs.
What’s on your plate matters! It’s all about fuelling for results & in this case optimal lean muscle mass! It can be difficult to know what foods (& portions of), support your goals! The truth is, there is always a strategy in optimising your nutrition & it all starts with your 7-day program.
This document is a project report submitted by a group of students for their Design Engineering course. It details the development of an Automatic Railway Crossing System (ARC) over multiple semesters. In the 6th semester, the students developed a PLC circuit board and program to control the ARC. They tested the circuit and program on a DELTA DVP-14SS2 PLC. The report provides snapshots of the PLC program and discusses modeling software, engineering economics, prototyping, materials selection, and future improvements including using renewable energy sources.
IRJET- A Unique Methodology for Transmission Line Breakage Detection and ...IRJET Journal
This document describes a proposed system for detecting transmission line breakages and alerting relevant parties. The system uses voltage sensors along transmission lines to continuously monitor voltages between sections. If a rapid voltage change is detected between two sections, a signal is sent to trip the power supply and alert the public via buzzers. Data is communicated between sections using wireless sensor networks. The system is simulated using a PIC microcontroller and results are displayed on an LCD screen and transmitted to peripherals. The goal of the system is to quickly detect broken power lines to prevent electrical accidents and power outages.
Summer Training 2015 at Alternate Hydro Energy CenterKhusro Kamaluddin
This is the presentation i gave to "Defend" my Summer Training at AHEC IIT Roorkee During Summer 2015. I gave this presentation in my college during my final year. Indeed the most lengthy i ever gave .
IRJET- Design Analysis of Land Surveying Robot using Arduino UNOIRJET Journal
This document describes the design of a land surveying robot using an Arduino Uno microcontroller. The robot is intended to automatically survey and calculate the area of a given plot of land. It uses a Bluetooth module to control movement, and calculates distance traveled and area using a timer concept. The robot aims to reduce the manpower and equipment needed for land surveys compared to conventional methods, while improving accuracy and saving time. Key components include Arduino Uno, DC motors, an L293D motor driver, ultrasonic sensor, and Bluetooth module. The robot is designed to automatically measure land areas more efficiently than traditional manual surveying methods.
(https://www.indiamart.com/zreyastechnology) We are leading and trustworthy organization actively involved in manufacturing a vast collection of Vibration Analyzer, Power Analyzer and Network Gateway. We are manufacturing our offered products by using optimum grade input factors.
This document is a project report submitted by four students at the Institute of Engineering and Technology in Lucknow, India. It describes their work to improve the gain of an operational amplifier designed using 90nm technology. The students declare that the work is original and was conducted under the guidance of Dr. Tanmay Dubey. The report includes an abstract, introduction on operational amplifiers, description of the CMOS design process, simulation results, and conclusions on matching calculations to simulations. The head of the electronics department certifies that the project fulfills requirements for a Bachelor of Technology degree.
Dynometer project data acquisition filteringRa'uf Tailony
This document describes a dynamometer project involving data acquisition and filtering of force data measured by a load cell. The load cell measures the force applied by an alternator connected to an engine. Software filters are used to filter noise from the load cell data. A Butterworth low-pass filter with a 25Hz cutoff frequency and order of 5 is used. The filtered and unfiltered force data are presented on graph indicators to compare the results and evaluate engine torque.
The document discusses various topics related to signal conditioning including:
1. Signal conditioning is the process of converting sensor signals into a format suitable for data acquisition and machine control. It involves signal amplification and conversion.
2. A data acquisition system collects signals from sensors, conditions the signals, converts them to digital values, and transfers the data to a computer for processing. It includes sensors, conditioning circuitry, analog-to-digital converters, and data acquisition hardware and software.
3. Microprocessors are now widely used in metrology and measurement systems as they provide accurate, fast measurements and allow automated error correction. Microprocessor-based systems can perform complex measurements and log errors in real-time.
3d printer electronics engineering live projects abstracts @1000KV Technologi...1000kv technologies
electronics engineering live projects abstracts
electronics projects, electronics projects for engineering final year students, electronics and communication engineering projects for final year students,100kv,1000kv,1000kv technologies,1000kv projects,technologies,live projects,Hyderabad live projects,live projects in, diploma low cost projects,1000kv projects, , academic projects,btech live projects,Hyderabad,1000kilovolts,1000kilovolts technologies ,btech main projects ,
This document proposes an automatic license issuing system that uses sensors to monitor a driver's behavior during a driving test. The system aims to replace the current manual process of evaluating driving tests. Sensors like force sensors, piezo sensors, MEMS accelerometers, smoke sensors, and an LCD display are mounted on a test vehicle. The sensors collect data on the driver's control of the vehicle and emissions. This data is sent wirelessly via a ZigBee module to a remote server for analysis. The server compares the test data to reference data to evaluate the driver's performance and determine if a license should be issued. The goal is to objectively assess driving ability and prevent illegal or unsafe licenses from being issued.
Research on Power Quality Real-Time Monitoring System For High Voltage Switch...IJRESJOURNAL
ABSTRACT: As an important equipment of high voltage switch cabinet distribution plays a key role in the power system of power generation, transmission and distribution of electricity, and monitoring the operation of electrical parameters, based on virtual instrument technology, make full use of the data processing, data analysis, data expression and network function and other advantages, build a set based on the LabVIEW real-time power quality monitoring system innovatively applied in high-voltage switch cabinet. Through building a power quality monitoring platform based on high voltage switchgear in the laboratory, the accuracy of the system measurement is verified. The experimental results show that the design of power quality real-time monitoring system has good performance, high accuracy, friendly interface, and has a good market prospect.
The document summarizes a test stand designed by Axis New England to test the effects of print head motion on print quality for large commercial inkjet printers. The test stand includes a two-axis gantry system with linear motors and encoders to induce acceleration up to 2G on a 4kg print head and reach velocities of 2m/s. A Delta Tau controller and Copley servo amplifiers provide precise position control within 1 micron repeatability. The system allows testing how head acceleration affects ink flow and output quality at high speeds.
Lingeswaran.P is an instrumentation and control engineer with over 8 years of experience in the power industry. He has expertise in commissioning, operating, and maintaining combined cycle power plants and their critical electrical and instrumentation systems. His resume provides details on his work experience with various power and industrial plants in India and Kuwait, highlighting his responsibilities in testing, commissioning, calibrating, and maintaining different types of field instruments and control systems.
IRJET- Vibration Analysis and Optimization of Housing for ECU in Automobile u...IRJET Journal
The document discusses the vibration analysis and optimization of an electronic control unit (ECU) housing for an automobile. The objectives are to design and optimize the ECU housing using CATIA and finite element analysis (FEA) in ANSYS to minimize vibration. Modal and harmonic analyses are conducted on the original housing and an optimized design with added cross ribs. The natural frequencies increase and acceleration amplitude decreases in the optimized design, improving stiffness and reducing vibration compared to the original housing.
Condition based monitoring of rotating machines using piezoelectric materialeSAT Publishing House
This document summarizes a study on using piezoelectric materials to monitor the condition of rotating machines. Piezoelectric crystals generate voltage when subjected to vibration or strain. The document details how piezoelectric sensors were attached to a lathe machine to measure voltages from vibrations during different operations. Voltage readings were taken and calibration curves were generated to relate voltages to frequencies for condition monitoring. The results demonstrate the potential of using inexpensive piezoelectric sensors as an alternative to conventional vibration sensors for machine monitoring.
Low cost Real Time Centralized Speed Control of DC Motor Using Lab View -NI U...IJPEDS-IAES
DC motors are an outstanding portion of apparatus used in automotive and automation industrial applications requiring variable speed and load characteristics, due to its ease of controllability. Creating an interface control system for multi DC motor drive operations with centralized speed control, from small-scale models to large industrial applications is in much demand. By using Lab VIEW (laboratory virtual instrument engineering workbench) as the motor controller, we can control a DC motor for multiple purposes using single software environment. The aim of this paper is to propose the centralized speed control of DC motor using Lab VIEW. Here, Lab VIEW is used for simulating the motor, whereas the input armature voltage of the DC motor is controlled using a virtual Knob in Lab VIEW software. The hardware part of the system (DC motor) and the software (in personal computer) are interfaced using a data acquisition card (DAQ) -Model PCI- 6024E. The voltage and Speed response is obtained using LABVIEW software. Using this software, the speed of a group of motors can be controlled from different locations using remote telemetry. The proposed work also focuses on controlling the speed of the individual DC motor using PWM scheme (Duty cycle based Square wave generation) and DAQ. With the help of the DAQ along with Lab VIEW front panel window, the DC motor speed and directions can be changed easily in remote way. In order to test the proposed system the laboratory model for an80W DC motor group (multi drive) is developed for different angular displacements and directions of the motor. The simulation model and experimental results conforms the advantages and robustness of the proposed centralized speed control.
This document presents an artificial intelligence and fuzzy logic based technique called Comprehensive Motor Testing Technique (CMTT) to comprehensively test motors and predict their performance and life. CMTT uses sensors to capture motor data during tests like design conformance, impedance analysis, current signature analysis, and reaction analysis. It then applies artificial intelligence and fuzzy logic methods to analyze the data, compare to historical data, and predict the motor's performance and estimate its life. This allows testing all motors without destructive testing, reduces total test time significantly, and provides higher confidence in motor quality and reliability.
INDUCTION MACHINES ANALYSIS USING LABVIEW SOFTWARE PACKAGE _Ijmet 10 04_085Isaac Samuel
Induction machines are widely used in many industries due to their robustness, ruggedness and easy maintenance feature. Due to the addition of power electronics devices and the complexity involved in the design of induction machines, their study and analysis can be very difficult. The use of software packages has been widely adopted to analyze and study the behaviours of induction machines. This work focused on the use
of an engineering software package known as Laboratory Virtual Instrument Engineering Workbench (LabVIEW). It is used in this work to study the behaviour and characteristics of induction machines. LabVIEW was utilized due to its cheap and userfriendly feature. This work shows that induction machines can be completely analyzed using related mathematical equations for performance analysis.
This document summarizes a research paper that proposes a novel low-cost WAMPAC system for power network monitoring and control. The system uses data sampling units to measure voltage, current, and frequency from distribution feeders. A data concentrator unit timestamps the measurements using a GPS module and stores them in a database. A master controller provides remote monitoring and control via wireless communication. Various protection schemes like distance, overcurrent, differential and synchronizing are implemented for feeder protection and coordinated between the feeder and master controllers. The proposed low-cost design aims to provide reliable monitoring and protection at an affordable price for all power sectors.
The document describes a PC-based oscilloscope that can display input waveforms on a computer screen. It includes a block diagram of the circuit which conditions input signals below 1 kHz and converts them to digital format for interfacing with a PC. Software written in Turbo C acquires and displays the data. The PC-based oscilloscope costs less than traditional models, can store multiple waveforms, and allows viewing on multiple PCs over a network. However, it has limitations such as low input frequency and voltage range and lacks multi-channel capability.
The document describes a project submitted for a diploma in mechanical engineering. It discusses developing an automatic inspection system for machining components using machine vision. The system would use a camera and image processing software to inspect parts on a conveyor belt for defects. Defective parts would be ejected by a pneumatic cylinder controlled by a microcontroller and computer system. The project aims to develop industrial automation and quality control by automatically checking parts throughout the manufacturing process.
Labview based rf characterization and testing of dual mode phase shiftereSAT Journals
Abstract R.F. characterization of C-band dual mode ferrite phase shifter cannot be done manually due to enormous and huge amount of data. So this paper provides the solution in term of automated procedure for testing of C-band DMPS in LabVIEW(Laboratory Virtual Instrument Engineering Workbench) software. Dual mode phase shifter is currently being used in phased array Radar and WLR (Weapon Locating Radar). The DMPS is in production to realize the exorbitant demand of these radars. The desirable characteristic of phase shifter for phased array radar as differential phase shift, insertion loss, return loss, Hi-low phase difference, insertion phase, Rx-Tx phase can be measured with high accuracy. The output can be presented in any desirable form such as concluded summary form, graphical form and in excel sheet for future reference purposes. Key words – Dual mode phase shifter, LabVIEW, GPIB, VNA, Hi-Low phase difference, Command generator
Design and Modelling of Automated Dimensional Check Conveyor Belt System for ...IRJET Journal
This document describes the design and modeling of an automated dimensional check conveyor belt system to categorize objects. The proposed system uses ultrasonic sensors and a microcontroller to simultaneously check three dimensions of an object passing on the conveyor belt. The system then uses a diverter to separate defective objects. The design calculations, circuit design, implementation of components like the conveyor belt, sensors and microcontroller are discussed. The experimental results show the system can successfully measure object dimensions and separate non-conforming objects in about 3 seconds.
Power Factor Detection and Data AnalyticsIRJET Journal
This document discusses a project that aims to provide a secure and efficient medium for transferring power factor and other power parameter data from a server to clients via an Android application. The project involves using smart meters to detect power factor values and other metrics through a zero-crossing method. An Android app is developed to allow users to access this encrypted data for analysis and comparison of load efficiency. Hardware is implemented using current and voltage sensors connected to a microcontroller. Calculations are performed to determine power, power factor, penalty costs, and consumption. Data is sent securely to a database and decrypted for viewing on the app. The goal is to allow real-time analytics of industrial power usage to improve efficiency.
The document describes the design and fabrication of an automated press machine controlled by a PLC. A pneumatic system is used for operation. Sensors and a PLC interface with the conventional punching process to achieve automation. The machine uses a stepper motor, 4 pneumatic cylinders and a vacuum unit. A proximity sensor, stepper motor, status light and relay are mounted on a wooden base along with limit switches. Directional control valves and a vacuum generator are mounted below. The pneumatic actuators and vacuum unit are controlled via directional control valves, while the stepper motor uses PLC control. Ladder logic is used for PLC programming.
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This document is a project report submitted by four students at the Institute of Engineering and Technology in Lucknow, India. It describes their work to improve the gain of an operational amplifier designed using 90nm technology. The students declare that the work is original and was conducted under the guidance of Dr. Tanmay Dubey. The report includes an abstract, introduction on operational amplifiers, description of the CMOS design process, simulation results, and conclusions on matching calculations to simulations. The head of the electronics department certifies that the project fulfills requirements for a Bachelor of Technology degree.
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The document discusses various topics related to signal conditioning including:
1. Signal conditioning is the process of converting sensor signals into a format suitable for data acquisition and machine control. It involves signal amplification and conversion.
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3d printer electronics engineering live projects abstracts @1000KV Technologi...1000kv technologies
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This document proposes an automatic license issuing system that uses sensors to monitor a driver's behavior during a driving test. The system aims to replace the current manual process of evaluating driving tests. Sensors like force sensors, piezo sensors, MEMS accelerometers, smoke sensors, and an LCD display are mounted on a test vehicle. The sensors collect data on the driver's control of the vehicle and emissions. This data is sent wirelessly via a ZigBee module to a remote server for analysis. The server compares the test data to reference data to evaluate the driver's performance and determine if a license should be issued. The goal is to objectively assess driving ability and prevent illegal or unsafe licenses from being issued.
Research on Power Quality Real-Time Monitoring System For High Voltage Switch...IJRESJOURNAL
ABSTRACT: As an important equipment of high voltage switch cabinet distribution plays a key role in the power system of power generation, transmission and distribution of electricity, and monitoring the operation of electrical parameters, based on virtual instrument technology, make full use of the data processing, data analysis, data expression and network function and other advantages, build a set based on the LabVIEW real-time power quality monitoring system innovatively applied in high-voltage switch cabinet. Through building a power quality monitoring platform based on high voltage switchgear in the laboratory, the accuracy of the system measurement is verified. The experimental results show that the design of power quality real-time monitoring system has good performance, high accuracy, friendly interface, and has a good market prospect.
The document summarizes a test stand designed by Axis New England to test the effects of print head motion on print quality for large commercial inkjet printers. The test stand includes a two-axis gantry system with linear motors and encoders to induce acceleration up to 2G on a 4kg print head and reach velocities of 2m/s. A Delta Tau controller and Copley servo amplifiers provide precise position control within 1 micron repeatability. The system allows testing how head acceleration affects ink flow and output quality at high speeds.
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IRJET- Vibration Analysis and Optimization of Housing for ECU in Automobile u...IRJET Journal
The document discusses the vibration analysis and optimization of an electronic control unit (ECU) housing for an automobile. The objectives are to design and optimize the ECU housing using CATIA and finite element analysis (FEA) in ANSYS to minimize vibration. Modal and harmonic analyses are conducted on the original housing and an optimized design with added cross ribs. The natural frequencies increase and acceleration amplitude decreases in the optimized design, improving stiffness and reducing vibration compared to the original housing.
Condition based monitoring of rotating machines using piezoelectric materialeSAT Publishing House
This document summarizes a study on using piezoelectric materials to monitor the condition of rotating machines. Piezoelectric crystals generate voltage when subjected to vibration or strain. The document details how piezoelectric sensors were attached to a lathe machine to measure voltages from vibrations during different operations. Voltage readings were taken and calibration curves were generated to relate voltages to frequencies for condition monitoring. The results demonstrate the potential of using inexpensive piezoelectric sensors as an alternative to conventional vibration sensors for machine monitoring.
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DC motors are an outstanding portion of apparatus used in automotive and automation industrial applications requiring variable speed and load characteristics, due to its ease of controllability. Creating an interface control system for multi DC motor drive operations with centralized speed control, from small-scale models to large industrial applications is in much demand. By using Lab VIEW (laboratory virtual instrument engineering workbench) as the motor controller, we can control a DC motor for multiple purposes using single software environment. The aim of this paper is to propose the centralized speed control of DC motor using Lab VIEW. Here, Lab VIEW is used for simulating the motor, whereas the input armature voltage of the DC motor is controlled using a virtual Knob in Lab VIEW software. The hardware part of the system (DC motor) and the software (in personal computer) are interfaced using a data acquisition card (DAQ) -Model PCI- 6024E. The voltage and Speed response is obtained using LABVIEW software. Using this software, the speed of a group of motors can be controlled from different locations using remote telemetry. The proposed work also focuses on controlling the speed of the individual DC motor using PWM scheme (Duty cycle based Square wave generation) and DAQ. With the help of the DAQ along with Lab VIEW front panel window, the DC motor speed and directions can be changed easily in remote way. In order to test the proposed system the laboratory model for an80W DC motor group (multi drive) is developed for different angular displacements and directions of the motor. The simulation model and experimental results conforms the advantages and robustness of the proposed centralized speed control.
This document presents an artificial intelligence and fuzzy logic based technique called Comprehensive Motor Testing Technique (CMTT) to comprehensively test motors and predict their performance and life. CMTT uses sensors to capture motor data during tests like design conformance, impedance analysis, current signature analysis, and reaction analysis. It then applies artificial intelligence and fuzzy logic methods to analyze the data, compare to historical data, and predict the motor's performance and estimate its life. This allows testing all motors without destructive testing, reduces total test time significantly, and provides higher confidence in motor quality and reliability.
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Induction machines are widely used in many industries due to their robustness, ruggedness and easy maintenance feature. Due to the addition of power electronics devices and the complexity involved in the design of induction machines, their study and analysis can be very difficult. The use of software packages has been widely adopted to analyze and study the behaviours of induction machines. This work focused on the use
of an engineering software package known as Laboratory Virtual Instrument Engineering Workbench (LabVIEW). It is used in this work to study the behaviour and characteristics of induction machines. LabVIEW was utilized due to its cheap and userfriendly feature. This work shows that induction machines can be completely analyzed using related mathematical equations for performance analysis.
This document summarizes a research paper that proposes a novel low-cost WAMPAC system for power network monitoring and control. The system uses data sampling units to measure voltage, current, and frequency from distribution feeders. A data concentrator unit timestamps the measurements using a GPS module and stores them in a database. A master controller provides remote monitoring and control via wireless communication. Various protection schemes like distance, overcurrent, differential and synchronizing are implemented for feeder protection and coordinated between the feeder and master controllers. The proposed low-cost design aims to provide reliable monitoring and protection at an affordable price for all power sectors.
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Labview based rf characterization and testing of dual mode phase shiftereSAT Journals
Abstract R.F. characterization of C-band dual mode ferrite phase shifter cannot be done manually due to enormous and huge amount of data. So this paper provides the solution in term of automated procedure for testing of C-band DMPS in LabVIEW(Laboratory Virtual Instrument Engineering Workbench) software. Dual mode phase shifter is currently being used in phased array Radar and WLR (Weapon Locating Radar). The DMPS is in production to realize the exorbitant demand of these radars. The desirable characteristic of phase shifter for phased array radar as differential phase shift, insertion loss, return loss, Hi-low phase difference, insertion phase, Rx-Tx phase can be measured with high accuracy. The output can be presented in any desirable form such as concluded summary form, graphical form and in excel sheet for future reference purposes. Key words – Dual mode phase shifter, LabVIEW, GPIB, VNA, Hi-Low phase difference, Command generator
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The document describes the design and fabrication of an automated press machine controlled by a PLC. A pneumatic system is used for operation. Sensors and a PLC interface with the conventional punching process to achieve automation. The machine uses a stepper motor, 4 pneumatic cylinders and a vacuum unit. A proximity sensor, stepper motor, status light and relay are mounted on a wooden base along with limit switches. Directional control valves and a vacuum generator are mounted below. The pneumatic actuators and vacuum unit are controlled via directional control valves, while the stepper motor uses PLC control. Ladder logic is used for PLC programming.
Similar to Internship report 2013 (Sri Wawadsan Sdn.Bhd) (20)
1. TABLE OF CONTENTS
Introduction 1
Company background 2
My projects outline 3
My project details 4-28
Working culture & management-labour relationship 29
Conclusion 30
Reference 31
Appendix 32
2. Introduction
This report is a compilation of the experience and work I have done during my 3 months
internship from 19th
Nov 2012 to 28th
Feb 2013. The internship is performed in order to fulfill the
requirements of the degree regulation, and the expectations of EAC, Engineers Australia, and
the Institution of Engineers Malaysia, and it’s usually done after completing three years (6
semesters) of studies during the year end vacation break. The objective of the internship is to
allow us to gain firsthand knowledge of the practice of engineering and to acquire skills and
experiences, which will be of value during subsequent studies and later employment.
Here, I would like to thanks my supervisor during my internship, Dr Chong Fei Seong for passing
his knowledge and experience to me during these 3 months in order for me to complete the
industrial training. Also, I would like to thanks Monash University for giving me the opportunity
to gain working experience before I graduate from the university. Besides, special thanks to my
colleagues who works with me and making my internship period a fun and enjoyable one.
The roles I play in this company as an intern are mostly dealing with programming tasks. Most of
the time, I use MATLAB as my programming tools to design applications for the company. Once
in a while, I also have to follow my supervisor to do plant visit and vibration testing. During the
visit, I gained a lot of firsthand practical experience as well as encounter many practical issues
that we solve together.
Overall, this internship was a success and I am glad that I am able to get the most out of it.
3. Company background
Sri Wawasan Sdn Bhd was established in 1991, to provide a comprehensive range of specialist
services and products in the fields of Vibration, Noise and Maintenance Engineering. Its
customers include offshore oil and gas, onshore petrochemical, power generation, marine,
manufacturing, food processing and others.
Sri Wawasan Sdn Bhd offers Maintenance Engineering Solutions that reduces maintenance costs,
increase equipment availability and reliability, improves safety, and enhances product quality.
They offer a wide spectrum of consultancy and engineering services in the fields of vibration,
noise and maintenance engineering.
Sri Wawasan Sdn Bhd has working relationships with major industries throughout the country
such as Petronas, Shell, Malaysia LNG, utilities, air-conditioner manufacturers and contractor. It
also has close coorperation with many specialist partners.
Sri Wawasan Sdn Bhd supplies a complete range of products for application in vibration, noise
analysis and machine condition and performance monitoring.
Vibration sensors and signal conditioning hardware
Portable dynamic signal analyzers and balancers
Online condition and performance monitoring system
Performance monitoring software (turbines, compressors, etc)
Offline condition monitoring systems
Condition monitoring & diagnostic software
Sri Wawasan Sdn Bhd also actively involved in machine monitoring and diagnosis, including a
wide spectrum of vibration and noise related problems such as:
On-line & off-line condition monitoring (predictive maintenance)
Transient analysis of machine startup/coast down
System integration, installation, and commissioning of integrated machinery
management information system
Gas turbine and turbo machinery consultancy in collaboration with Fern engineering,
United States of America
Vibration troubleshooting and faults diagnostics of machineries, structures, piping,
building & ground
In-situ dynamic balancing & alignment
Analytical modeling of machinery and machine design audit
Noise monitoring/analysis & noise control
Calibration of vibration transducers/instrumentation systems
5. My project details
1) DC gap voltage acquisition, processing & display module
Project background:
In machine condition monitoring, we often need to monitor turbo machinery with fluid film
bearing of pump, chiller, compressor etc. Some turbo machinery mechanical faults have
characteristic plot shapes. By comparing the acquired plots with any known characteristics we
can detect faults and diagnose machine problems.
To acquire the characteristic plot, namely orbit plot, time base plot, and shaft centerline plot,
we have to mount 2 proximity probes orthogonally on the fluid film bearing. Proximity probes
are devices that show different voltage reading as the distance between its tips and the object
varies. It has a linear voltage-distance characteristic over a specified range. The time base plot
displays the signals as a function of time in one or more revolutions with two separate plots, one
for x-axis and one for y-axis. A shaft centerline plot displays the shaft center DC position changes
within a bearing clearance range. An orbit plot represents the shaft center AC dynamic motion.
Both the orbit plot and shaft centerline plot is generated by plotting y-axis against x-axis signal
data. [1]
Figure 1: Two orthogonally-mounted proximity probes measure the shaft motion. The outer
circle depicts the bearing clearance. As the shaft speeds up in the counterclockwise (CCW)
rotation direction, the shaft center moves from the bottom of the bearing clearance to the
normal operational center, as the Shaft Centerline shows. As the shaft continues in normal
operation, the shaft center moves around the normal operating center, as the Shaft Orbit shows.
6. In many cases, we cannot mount probes easily in the desired 90 degrees out of phase horizontal
and vertical orientation. Probes often have a 45-degree deviation instead. The following
illustration shows the common mounting positions for X and Y probes.
Figure2: Common mounting positions for X and Y probes.
However, an orbit plot assumes that the signals are from probes in true horizontal and vertical
positions. To display data with respect to a true vertical and horizontal coordinate system, you
must rotate the data by the probe angular offset from the desired coordinates.
Figure 3: Time base plot of the X and Y axis.
7. Figure 4: Typical shaft centerline plot of a machine startup. The numerical values show the
rotational speed.
In this particular project, we only make a program for shaft centerline plot and time base plot,
which means it is only designed for DC vibration analysis.
Hardware used:
i) DATAQ (DI-149) data acquisition hardware [2]
ii) Laptop
8. Software used:
i) MATLAB
ii) DATAQ instrument data acquisition software
Description:
The purpose of this project is to make a standalone application that can display the real time
shaft centerline movement of the machine under test and time base plot on the laptop that runs
the application. The signal data in the form of electrical voltage is acquired using the DATAQ DI-
149 data acquisition hardware. After that, the acquired data is sent to the computer via USB
cable and the DATAQ instrument software as interface. A MATLAB standalone application
program was designed to receive the signal data, de-noise the data, and then finally the shaft
centerline plot is generated by plotting y-axis data against x-axis data. All the process described
is performed in real time and it can be depicted as follow:
Figure 5: Process flow of data acquisition module.
Coding detail:
Due to the massive length of the code, only important part of the code is presented here.
Firstly, the time base data is imported to MATLAB and the time base plot is generated.
Secondly, the time base signal is divided into 60 segments with each segment having the same
length. The average value of each segment is computed and the result stored in an array.
9. Thirdly, every individual data is compared with the average value of their respective segment. If
the data value differs from the average value of that segment by 2.5%, that particular data point
is modified to be equal to the average value. By doing so, all the spike (noise) that ‘’pollute’’ the
data will be eliminated and we end up with a ‘’clean’’ signal with useful data.
After that, we compressed the signal data so that the compressed signal has only 250 data
points. To do this, we divide the ‘’clean’’ data into 250 segments, and each segments is
combined into 1 point representing the average value of that segment. The reason we do this is
because the original data length is too big for real time processing. Besides, by compressing the
signal, we can see a more general movement of the motor shaft in real time when plotting the
shaft centerline movement.
After the data compression, we performed calibration to convert the data signal into distance.
This required user to key in sensitivity (mV/um) information of the proximity probes. Also, after
the conversion to distance, we shift the data with reference to the DC gap voltage by minus off
every data with the DC gap voltage of their respective axis. The formula to do the overall
conversion is as follow:
𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 =
𝐷𝑎𝑡𝑎 − 𝐷𝐶 𝑔𝑎𝑝 𝑣𝑜𝑙𝑡𝑎𝑔𝑒
𝑠𝑒𝑛𝑠𝑖𝑡𝑖𝑣𝑖𝑡𝑦
Finally, we perform axis transformation to the distance data if necessary and plot the shaft
centerline movement of each axes respectively on the MATLAB GUI in real time.
Figure 6: MATLAB GUI of the module.
10. 2) Low cost webcam data acquisition module
Project background:
In the process of condition monitoring, we have to run a series of vibration test and also
performance test for the machines. There are a lot of analogue meter mounted on the machine,
which their reading need to be taken and monitored when performing the test. However, the
machine is located in a remote location, where human are not allowed or easily allowed to
enter and take reading. Furthermore, the location of the machine is far away from the control
room where we gather and do the monitoring, thus provide difficulties when taking the reading
from the analogue meter. As a solution, I was asked by my supervisor to design a webcam
module so that we will place the webcam in front of the meter, and the image taken from the
webcam can be accessed in the control room and the webcam module will do the reading
automatically.
Hardware used:
i) USB webcam [3]
ii) USB hub
12. vi) Laptop
Software used:
i) MATLAB
ii) Team Viewer remote access software
Project description:
The purpose of this project is to design a standalone application using MATLAB so that we can
use a low cost USB webcam to read the needle reading of analogue meter, up to 4 webcams at
the same time, and at the end export all the reading acquired into Microsoft Excel for further
analysis. Basically, the project is divided into 2 parts. The first part of the project deal with image
processing, which comprises the computer vision technique to identifies the needle from the
image taken, calculate the needle reading after the needles position has been identified, auto
sampling module or manual sampling module, and exporting the data into Microsoft Excel up to
4 analogue meters at the same time. The second part of the project basically solve the problem
regarding image acquisition, which include setting up the entire network (the distance between
analogue meter and control room is about 100m) using network switch and Ethernet cables,
solving power issue (as distance increases, the image acquired is getting worse) by using a
powered USB hub, and other practical issues at the site.
For the first part of the project, I will describe the image processing technique I used in MATLAB.
Firstly, the webcam must be mounted in front of the analogue meter and remain static all the
time, otherwise the reading wouldn’t be accurate or sometimes not possible. After that, an
image of the analogue meter is captured, and the needle is removed from the image using Paint.
This image became the background image of the analogue meter.
13. Figure 7: Picture on the left shows the image captured of the analogue meter. Picture on right is
the image after needle being removed. It is used as a background image for webcam module.
After we have the background image of the analogue meter, we can start the calibration process.
The calibration process involves 2 parts, namely needles detection and needle value calculation.
Needle detection process starts with capturing the image of the analogue meter, subtract it
from the background image, and convert the subtracted image from RGB to grayscale. By doing
so, the subtracted image should be black with only the needles position showing a much higher
pixel value. This is because the only difference between the image captured and the background
image is the needles (provided the position of the analogue meter and webcam is static), thus
most of the subtracted pixel value should be 0 or close to 0 (due to some noise in the images as
well as environment noise) except the pixel position where the needles lie on. To increase the
contrast between the needles and the rest of the image, we manually calibrate a threshold
value such that if the pixel value is higher than the threshold, it will be modified to 255 (white),
otherwise it will be set to 0 (black). After this process, we will have a clear image of needles
position in white while the rest of the image in black. The diagram below illustrates this process.
Figure 8: Flow diagram of how the needle is detected from the image captured.
14. The 2nd
part of the calibration is to calculate the needles pointing value. To do this, it requires
user to pick the meter starting point, needle centre point, ending point and the range of the
analogue meter.
Figure 9: Example taken from MATLAB GUI showing the start point, ending point, center point
picked as well as all the range defined.
After all the required points are defined, we can find the point that represents the position of
the needle. The method I use is to firstly calculate the pixel length of the needle by calculate the
distance between start point and center point. After that, a for loop is made to inspect the
entire black and white image such that if the pixel position is at the needles length away from
the center point defined, and if its pixel value is 255 (white) which indicate it as a needle, that
pixel position will be picked as the point representing needle position. The pixel length to
inspect can be manually calibrated by user until a satisfactory position is found.
15. Figure 10: Example taken from MATLAB GUI showing the position of needle detected. The
threshold and radius to detect can be changed until a satisfactory point is detected.
The next and final step is to calculate the needle pointing value.
Figure 11: Figure showing how to divide the analogue meter to different region to calculate the
needle pointing value.
Needle vector = needle point − center point
Starting vector = starting point − center point
Needle angle = angle between needle vector and starting vector
16. 𝑵𝒆𝒆𝒅𝒍𝒆 𝒑𝒐𝒊𝒏𝒕𝒊𝒏𝒈 𝒗𝒂𝒍𝒖𝒆
=
{
𝑛𝑒𝑒𝑑𝑙𝑒 𝑎𝑛𝑔𝑙𝑒
𝑎𝑛𝑔𝑙𝑒 𝐼
× 𝑟𝑎𝑛𝑔𝑒 𝐼 𝑎𝑡 𝑅𝑒𝑔𝑖𝑜𝑛 1
𝑟𝑎𝑛𝑔𝑒 𝐼 +
𝑛𝑒𝑒𝑑𝑙𝑒 𝑎𝑛𝑔𝑙𝑒 − 𝑎𝑛𝑔𝑙𝑒 𝐼
𝑎𝑛𝑔𝑙𝑒 𝐼𝐼 − 𝑎𝑛𝑔𝑙𝑒 𝐼
× 𝑟𝑎𝑛𝑔𝑒 𝐼𝐼 𝑎𝑡 𝑅𝑒𝑔𝑖𝑜𝑛 2
𝑟𝑎𝑛𝑔𝑒 𝐼 + 𝑟𝑎𝑛𝑔𝑒 𝐼𝐼 +
𝑛𝑒𝑒𝑑𝑙𝑒 𝑎𝑛𝑔𝑙𝑒 − 𝑎𝑛𝑔𝑙𝑒 𝐼𝐼
𝑎𝑛𝑔𝑙𝑒 𝐼𝐼𝐼 − 𝑎𝑛𝑔𝑙𝑒 𝐼𝐼
× 𝑟𝑎𝑛𝑔𝑒 𝐼𝐼𝐼 𝑎𝑡 𝑅𝑒𝑔𝑖𝑜𝑛 3
The second part of the project is to set up the image acquisition network. In this particular
project, we have all together 6 analogue meters to monitor, with 4 located in the pump house
(100m away from the control room) and 2 in the electrical room (1 floor below the control
room). All image acquired must be send to control room in real time.
Figure 12: The entire network diagram of the webcam module to be setup.
Figure 13: Main menu of the Webcam module.
17. Figure 14: GUI of the background capture module.
Figure 15: GUI of the calibration module.
19. 3) XY-plot digitizing module
Project background:
We use a number of spectrum analyzer to capture the time domain data from the probe,
perform fast Fourier transform, and store the resulting spectrum in the analyzer. However,
when we want to extract the spectrum graph out from the analyzer to computer for further
analysis, some of the spectrum can only be extracted in the form of image file (image of the
spectrum), but not the X and Y data value. This causes some problem as we wanted to inspect
the spectrum data to calculate certain parameter such as the overall power of the spectrum.
Thus, I was asked by my supervisor to design a routine to digitize the spectrum graph from the
image file and export the X and Y data value into Microsoft Excel for further analysis.
Hardware used:
i) Spectrum image file
ii) Laptop
Software used:
i) MATLAB
Project description:
The purpose of this project is to digitize the image file of the graph to obtain the X and Y values.
2 types of digitizer were designed. The first type is to digitize the graph from image file to get
the X and Y value. The second type is to read the numerical Y value displayed in the image file
and digitize it.
For the first type of digitizer, we first import the image file into MATLAB. Then, the user have to
define the maximum X point and maximum Y point on the image graph as well as the graph
color to be detected. Also, the user has to specify the X data range and Y data range and the
number of data pair to be digitized to.
20. Figure 17: MATLAB GUI of the digitizer. The maximum X point, maximum Y point, color to the
detected, X range, Y range, and the number of data pair to be digitized to have to be specified
by user.
After all the required information is specified, the program will crop the image according to the
maximum X and maximum Y point selected. The cropped image is as show in the right hand side
image. Next, the program will digitize the image.
Figure 18: The result of graph digitization as shown by the right hand side plot.
The digitized data can be export to Microsoft Excel for further analysis.
21. The second type of digitizer is built to read the Y data value displayed in an image. The user have
to specify the region where the number to be read is located in the image. After that, the
program will do the reading automatically.
Figure 19: MATLAB GUI of the digitizer. User has to specify the region of the number to be
scanned. The digitized value is displayed on the GUI as 7.6e-005 for this particular example.
The above figure only shows the result of digitization of 1 particular value. Below is the
reconstruction of the graph from the digitization of an array of data.
Figure 20: Graph on right shows the reconstruction of the graph using the data obtained from
digitization. On the left is the original image from the analyzer.
From figure 20, it shows that the digitizer we made is perfectly accurate.
22. 4) FORTRAN to MATLAB code conversion
Project description:
This simple project is given by my supervisor for me to convert a script written in FORTRON
language into MATLAB so that its able to run in MATLAB. Before this, I have no experience in
working with FORTRAN programming. Throughout this project, I learn some programming
language about FORTRAN. Below is the original script given to me in FORTRAN.
23.
24. The resulting code after conversion into MATLAB is shown below:
function start
clear all
clc
set(0,'RecursionLimit',1000)
X=zeros(16384,1);
PT1=zeros(12);
PT2=zeros(12);
NPT=input('NPT=');
DIM=input('DIM=');
TAU=input('TAU=');
DT=input('DT=');
SCALMX=input('SCALMX=');
SCALMN=input('SCALMN=');
EVOLV=input('EVOLV=');
IND=1;
SUM=0;
ITS=0;
A=xlsread('data.xlsx');
for I=1:NPT
X(I)=A(I); %%%%%
end
for I=1:NPT
for J=1:DIM
if I+(J-1)*TAU<=NPT
Z(I,J)=X(I+(J-1)*TAU);
else
Z(I,J)=0;
end
end
end
NPT=NPT-DIM*TAU-EVOLV;
DI=1e38;
for I=11:NPT
D=0;
for J=1:DIM
D=D+(Z(IND,J)-X(I+(J-1)*TAU))^2;
end
D=sqrt(D);
if D<=DI || D>=SCALMN
DI=D;
26. DOT=0;
for J=1:DIM
DOT=DOT+(PT1(J)-Z(I,J))*(PT1(J)-PT2(J));
end
CTH=abs(DOT/(DNEW*DF));
if CTH>1
CTH=1;
end
TH=acos(CTH);
if TH<=THMIN
THMIN=TH;
DII=DNEW;
IND2=I;
end
end
end
end
if THMIN>=ANGLMX
ZMULT=ZMULT+1;
if ZMULT<=5
f_70(NPT,IND,EVOLV,DIM,PT1,Z,ZMULT,SCALMX,SCALMN,PT2,DF,ANGLMX,INDOLD,ITS,SUM,DT);
else
ZMULT=1;
ANGLMX=2*ANGLMX;
if ANGLMX<3.14
f_70(NPT,IND,EVOLV,DIM,PT1,Z,ZMULT,SCALMX,SCALMN,PT2,DF,ANGLMX,INDOLD,ITS,SUM,DT);
else
IND2=INDOLD+EVOLV;
DII=DF;
end
end
end
IND=IND+EVOLV;
if IND<NPT
DI=DII;
f_40(NPT,SCALMX,SCALMN,DIM,Z,IND,IND2,EVOLV,ITS,SUM,DI,DT,PT1,PT2);
end
end
27. 5) Proximity sensor calibration
Project background:
In condition monitoring, sensor plays an important role. Sensor must be ensure to function
correctly and accurately to ensure the accuracy of the analysis result. The type of sensors we
used in condition monitoring is proximity probe and accelerometer. Proximity probe changes
the voltage value as the gap between the sensor tips and the object varies. Accelerometer
changes the voltage value as the acceleration of the object with respect to the sensor tips varies.
One important parameter that defines the sensor properties is its sensitivity, which defines how
much the voltage value changes per unit measurement. For the proximity probe we use, its
sensitivity unit is V/mm, while for accelerometer, the unit is mV/G. Sensor calibration is a
common routine to make sure the sensitivity of the sensor still tally with the one specified in the
datasheet as well as to establish the range of operation for the sensor. The sensor need to be
calibrated often as the sensitivity may change a little bit over time due to ageing. The project
deal with the technique we used to calibrate the proximity sensor.
Hardware used:
i) Proximity probe
ii) Micrometer screw gauge
28. iii) Multimeter
Software used:
i) Microsoft Excel
Project description:
The purpose of this project is to calibrate a proximity probe using a micrometer screw gauge.
This is done to find out the sensitivity of the sensor and also to establish the operating range of
the probe. The method to calibrate is straight forward. The sensor is set up to be at a certain gap
distance away from an object, adjust using micrometer screw gauge. Then, the voltage value is
measured using a multimeter. The process is repeated for gap distance ranging from 0mm to
4mm, with each time increase the gap by 0.2mm. All the voltage value is tabulated in Microsoft
Excel and finally a voltage vs gap distance graph is plotted in Excel.
Figure 21: Result of the calibration is tabulated.
29. Figure 22: Graph showing voltage vs gap distance in mm.
From figure 22, we can see that the operating range of the proximity probe is 2.6mm. After
2.6mm, the voltage does not have linear characteristic.
The sensitivity of the proximity probe can be obtained by calculating the gradient of the linear
region. From Microsoft Excel built-in function, the sensitivity is calculated to be 7.628297V/mm.
0
5
10
15
20
25
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0
V
mm
V vs mm
30. Working culture & management-labour relationship
During my internship period, I observed a good working culture in the company. Everyone in the
company is committed to their work. Besides, all the workers are willing to help each other
when help is needed. They are hardworking and punctual, and willing to get their work done
even though it is outside the working hour. The management-labour relationship is good in the
company. We always have good communication with the management side, so that our job can
be done more efficiently.
The company is made up of a multi racial community. There are 3 races in the company, namely
Malay, Chinese and Indian. We are all working well together with tolerance. Besides, all the
races are willing to help each other when in need. For example, during Chinese New Year, most
of the Chinese in the company needed to take extra leave, causing a lack of human resources in
the company. However, the Malays and Indian in the company are willing to work during
Chinese New Year to help relieve the shortage of human power. We are like a big family,
respecting each other’s religious believe and culture, and never have any problem with racial
discrimination. I am glad that I have the chance to work in such an environment so that I learned
to work with peoples with different races and background. This company definitely
demonstrates the spirit of 1 Malaysia.
Figure 23: Picture taken during a lunch break with colleagues in a nearby restaurant.
31. Conclusion
In these three months industrial training in Sri Wawasan Sdn Bhd, I have learnt a lot of things
which cannot be learnt in University life. In terms of theory, I realized that not all the theories
can be directly applied in a real working environment. Indeed, theory part is the basic for us to
know more knowledge but hands-on experience is important as well. In real world there have
plenty of unforeseen factors can be occurred. As what I studied in university, most of the
theories are for ideal case, but when come to a real world, we need to modify and compensate
with certain factors so that the results we get are closest to the ideal.
Other than that, teamwork is one of the important key as well. I got a chance to work as a team
with other people. As what I mentioned before, teamwork is very important, it can determine
the successful of the given tasks. In real world, it is impossible for us to work alone. We might
need others’ helps in order we can complete the tasks.
Lastly, I realized the importance of the learning behaviors. It is an important attitude if you want
to be self-upgrade and it’s a key of success. Last time I do not have the initiative to learn a new
thing. However during these three months, I understand that if we do not have the initiative to
learn, then we will never learn a new thing and we will never ever able to equip ourselves with
the latest information. Egoism is the factor to block us to walking forward. Therefore we must
empty the cup in order to be filled.