Change of Resistance Test
Stand
PROJECT MEMBERS:
COLIN PAYNE-ROGERS
JACOB LENNOX
PROJECT GUIDE/MENTOR:
DR. BENJAMIN VARELA
PRIMARY CUSTOMER:
JOE MANAHAN
SPONSOR:
COOPER CROUSE-HINDS
Project Description
 Project Goal: To Design/Build a prototype test stand
to measure the temperature of a maximum of 6 coils
using a linear regression 4-wire resistance method.
 Project Overview: The test stand will include but is
not limited to a cart/apparatus, laptop with LabView,
data acquisition hardware, control circuitry and
switching hardware, power dissipation circuitry and
hardware. The apparatus is intended to use LabView
to allow the user to run the test with minimal
intervention. The prototype will be tested at RIT at
120VAC due to safety concerns.
Project Description
Customer Specifications
 Design and Build a Relay Circuit
 Operation: 120-480VAC, 50-60Hz
 Amphenol cable or similar connection
 Controls electrical power for the operation
 Select and Purchase a Digital Multimeter
 Resolution: 0.01Ohms
 Able to be calibrated
 Select and Purchase a Data Acquisition System
 Additional temperature measurement using
thermocouple
Customer Specifications
 Write a LabView program for the test stand


Communicate with and control measurement hardware
Measure the resistance of a maximum of 6 coils







40 readings every 30 seconds (one reading at a time)
Operator flexibility on coil selection (for measurements)
Plot Resistance versus Time for each coil
Make a Linear Regression of the data to calculate the temperature of the
data at the beginning of the test
Store the data in up to 9 different portable format files
Operator input: time, date, coil material
Selectable functions: pre-run test, run auto-test, view results, print results,
terminate
 All of the components must be contained in a rolling enclosure
 Test Stand must comply with UL 844
Meeting Priorities
 Proof-of-Concept Experimental Design
 Experimental results
 Proposed prototype relay circuit design
 Bill of Materials
 Test Plan
 Inquire about laptop and LabView licensing
Experimental Circuit Design
Experimental Circuit Design
Experimental Circuit Design
Experimental Results
Coil 1
Resistance
(Ω)
Direct-toBallast
Through
Relay Circuit
Coil 2
Resistance
(Ω)
3.798
2.678
3.801
2.677
RIT
Cooper
Rc from
DMM
Rc (Ω)
not from
DMM
4.1
3.66
Th (°C)
51.75
86.52
Rh (Ω)
4.57
4.57
Rc (Ω)
3.801
3.361
Th (°C)
55.92
93.94
Rh (Ω)
4.3037
4.3037
Experimental Results
Relay Circuit Design
Bill of Materials
Accessory
PXI Chassis
Chassis Power Cord
DMM
Relay Module
Relay Terminal Block
System Assurance
Power Circuit Relay
Power Circuit Relay
USB DAQ
Circuit Total
Labtop
Labview Lisence
Miscellaneous
Vendor
NI
NI
NI
NI
NI
NI
PN
781162-01
763000-01
780011-01
778572-66
778717-66
960903-02
Description Indv. Cost
NI PXIe-1073 $ 1,499.00
$
9.00
NI PXI-4065 $ 1,499.00
NI PXI-2566
$ 1,080.00
TB-2666
$ 277.00
$ 310.00
McMaster
Carr
Allied Elec
NI
7230K91
70198625
779051-01
4PST
DPST
USB-6008
NI
*Highlighted Boxes are approximate costs
Cart etc.
$
$
$
QTY Cost
1 $ 1,499.00
1 $
9.00
1 $ 1,499.00
1 $ 1,080.00
1 $ 277.00
1 $ 310.00
76.91
10.07
169.00
4
1
1
$ 500.00
$ 999.00
$ 1,000.00
1
1
1
Total
$ 307.64
$
10.07
$ 169.00
$ 5,160.71
$ 500.00
$ 999.00
$ 1,000.00
$ 7,659.71
Test Plan
Number
Description
1
Test the ballast temperature/resistance measurements with a borrowed 4-wire multimeter
but the updated relay circuit (using "final hardware" and one coil rather than "experimental
hardware"). Show the exponential decay, and the difference in resistance measurements
when measuring the ballast directly and through the circuit.
2
Test the ability to switch between different coil measurements using the NI switch, manually
and automatically, and then verify the results from test #1 for the same coil when switching to
the other coils inbetween each measurement (possibly taking all coil measurements)...with
the borrowed multimeter still?
3
Show that initial measurements are capable of being taken within 5 seconds, and that all 6
coil measurements are capable of being taken at the required rate. This would be a final
"proof-of-concept" test, showing that the LabView program can be used to measure 6 coils as
quickly as needed and can spit out the correct data (data compared to #1). The NI
multimeter used this time to show that it is calibrated as well as the borrowed multimeter.
4
Test the calibration routine by using a "correct" and "incorrect" calibration. The "correct"
calibration for the calibration routine should give the correct ballast (room temperature)
results while the "incorrect" calibration should offset the ballast resistance measurements?
This test depends on the final method for calibration.
Timeline
Task
Completed By
Select and Purchase Hardware
End of Week 11 of MSD I
First version of LabView Code Completed (using
simulated hardware)
End of Week 2 of MSD II
CAD Models (cart design)
End of Week 3 of MSD II
Order Cart Hardware
End of Week 4 of MSD II
Complete Testing with NI Hardware (not on cart)
End of Week 6 of MSD II
Assembled Electronics
End of Week 7 of MSD II
Complete any other testing at RIT (120 VAC, with
cart, full tests with LabView)
End of Week 8 of MSD II
End of Week 9 of MSD II
Finalize Senior Design Requirements
End of Week 10 of MSD II