ii
AUTOMATIC DETECTION TEMPERATURE TRANSMITTER FOR CALIBRATION
PROCESS USING RTD
MUSTAQIM BIN HAZMI
This thesis is submitted as partial fulfillment of the requirements for the award of the
Bachelor of Electrical Engineering (Electronics)
Faculty of Electrical and Electronics Engineering
UNIVERSITI MALAYSIA PAHANG
29 NOVEMBER 2010
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“I hereby acknowledge that the scope and quality of this thesis is qualified for the award of
the Bachelor Degree of Electrical Engineering (Electronics)”
Signature
: ______________________________________________
Name
: NAJIDAH BINTI HAMBALI
Date
: 29 NOVEMBER 2010
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“All the trademark and copyrights use herein are property of their respective owner.
References of information from other sources are quoted accordingly; otherwise the
information presented in this report is solely work of the author.”
Signature
: ____________________________
Author
: MUSTAQIM BIN HAZMI
Date
: 29 NOVEMBER 2010
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ACKNOWLEDGEMENT
First of all, I am grateful to ALLAH S.W.T for blessing me in completion of my
final year project (PSM) with success in achieving my objectives to finishing this project.
The project also has been complete on the time given.
Secondly, I want to thank my family for giving morale support and encouragement
in completing my project. I also would like to thank my supervisor Puan Najidah Bt
Hambali for guiding and supervising my final year project. I really apologize to her for any
mistakes, and things that I done wrong while doing my project.
I, myself are fully in dept with Faculty of Electrical and Electronics Engineering
(FKEE) for providing me the necessary instruments, hardware and all information for my
project. Without their helped, this project was deeming to be unfinished.
Last but not least, I want to thank my entire friend especially Muhamad Farid Bin
A. Wahab, that given me advice, helps, and encouragement in completing my project. To
En. Shahrizal Bin Saat and En. Muhammad Hamka Bin Embong, thanks for your support
and your time to teach us about calibration of the instruments and all connection of the
hardware. Thank you very much to all and May ALLAH bless you.
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ABSTRACT
The purpose for this project is to detect temperature for Calibration Process using
Resistive Thermal Device (RTD) automatically. This project will be used Visual Basics
(VB) programmed to develop Graphical User Interface (GUI). An RTD will be use as
temperature sensor in this Calibration Process. The software and the temperature sensor
will be interfaced by using a Data Acquisition (DAQ) card. Proportional–Integral–
Derivative (PID) controller will be purpose for automatic detection for temperature system.
The expected result for this project is an automatic detection system for temperature
measure during the Calibration Process. The accuracy of the measurement will be monitor
beside the analysis of uncertainty and confidence limit.
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ABSTRAK
Projek ini adalah bertujuan untuk mengesan suhu bagi proses kalibrasi
menggunakan Thermal Device Resistive (RTD) secara automatik. Projek ini akan
menggunakan Visual Basics (VB) yang diprogram untuk membina Graphical User
Interface (GUI). Sebuah RTD akan digunakan sebagai pengesan suhu dalam proses
kalibrasi. Perisian dan pengesan suhu akan dihubungkan dengan menggunakan kad Data
Acquisition (DAQ). Proportional Integral Derivative (PID) bertujuan untuk pengesanan
automatik kepada sistem suhu. Keputusan yang dijangkakan dalam projek ini adalah sistem
pengesanan automatik pengukuran suhu dalam proses kalibrasi. Ketepatan pengukuran
akan dipantau, di samping analisis ketidakpastian dan had keyakinan.
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TABLE OF CONTENTS
ELEMENTS
PAGES
TITLE
ii
SUPERVISOR’S DECLARATION
iii
STUDENT’S DECLARATION
iv
DEDICATION
v
ACKNOWLEDGEMENT
vi
ABSTRACT
vii
ABSTRAK
viii
TABLE OF CONTENTS
ix
LIST OF TABLES
xii
LIST OF FIGURES
xiii
LIST OF SYMBOLS
xv
LIST OF ABBREVIATIONS
xvi
CHAPTER 1
INTRODUCTION
1.1 Background
1
1.2 Introduction to the Project
2
1.3 Problem Statement
3
1.4 Objectives
4
1.5 Scope of the Project
5
1.6 Thesis Overview
6
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CHAPTER 2
CHAPTER 3
LITERATURE REVIEW
2.1 Infrared Temperature Detection
8
2.2 Temperature Transmitter
9
2.3 Temperature Measurement and Control System
9
2.4 ULTRA-Accurate Temperature Measurement
10
2.5 Temperature Coefficient
10
2.6 Ge-Film Resistance and Si-Based Diode sensors
12
2.7 Temperature Measurement via Laser Fluorescence
12
2.8 Thin Film Resistance Temperature Sensors
13
METHODOLOGY
3.1 Introduction
14
3.2 Resistance Temperature Detector (RTD)
15
3.3 Four Wires RTD
17
3.4 Dry Block Calibrator (furnace)
17
3.5 Temperature Transmitter
19
3.6 Calibrate a HART Temperature Transmitter
20
3.7 Advantech USB-4716, PC-Lab Card.
21
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3.8 Visual Basic (VB)
28
3.9 Software Development
29
4.0 Calibration Technique
42
CHAPTER 4
RESULT AND DISCUSSION
48
CHAPTER 5
CONCLUSION AND RECOMMENDATION
5.1 Conclusion
58
5.2 The Obstacles and Recommendations
59
REFERENCES
APPENDICES
61
A
Student’s t-distribution table
63
B
Advantech USB-4716 specification
64
C
HART Calibration Data Sheet
67
D
Furnace Data Sheet
69
E
Pt100 Resistance Table
73
F
Yokogawa YTA110 Data Sheet
75
G
Source Code for the Software
80
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LIST OF TABLES
TABLE NO.
TITLE
PAGES
3.1
Pins Function of every port in DAQ card.
24
3.2
Table of draft UUT calibration data.
43
3.3
Five point calibration table.
44
4.1
Result from software implementation
54
4.2
The comparison between software and manual calculation
56
xiii
LIST OF FIGURES
FIGURE NO.
TITLE
PAGES
2.1
Sensitivity as a function of temperature for sample low,
moderate, and high resistance CX-1030s samples and CX1050s samples used in this analysis.
11
3.1
The system roughly interconnection base on picture and
the flow of the data.
15
3.2
Circuit design for 4-wires RTD Pt100.
17
3.3
Isotech Jupiter 650B, the Dry Block Calibrator as a
furnace.
18
3.4
The temperature controller of Isotech Jupiter 650B.
18
3.5
Yokogawa YTA110, temperature transmitter.
19
3.6
HART documenting process calibration by section
20
3.7
HART calibrator.
21
3.8
Data Acquisition (DAQ) card.
22
3.9
Software installation for Advantech USB-4716.
22
3.10
Pins Assignments for DAQ card Advantech USB-4716.
23
3.11
The Advantech Device Manager.
25
3.12
Advantech Device Test, Analog Output.
26
3.13
Advantech Device Test, Analog Input reading.
27
3.14
Connection of instruments, hardware and software.
28
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3.15
Selecting device.
30
3.16
Capture data for Data Analog in Voltage and Degree
Celsius data.
31
3.17
GUI for Data Storage for the software system.
34
3.18
GUI for generate graphs for the project.
35
3.19
Average graph for the calibration.
36
3.20
Error graph.
37
3.21
Voltage input versus Temperature.
38
3.22
Data Progress shows the input data in volts.
39
3.23
Uncertainty calculation in the software.
40
3.24
Flow chart for software implementation.
41
3.25
Calibration technique.
42
3.26
Flow chart of the project.
47
4.1
Data Storage as a last result after running the system.
49
4.2
Average graph from the data storage.
50
4.3
Error graph.
51
4.4
Voltage input versus average temperature.
52
4.5
Uncertainty value for 95.45% of confident interval.
53
4.6
Uncertainty for 99.00% of confident interval.
54
xv
LIST OF SYMBOLS
γ
Degree of Freedom
Ω
Ohms
∞
Infinity
xvi
LIST OF ABBREVIATIONS
RTD
Resistance Temperature Detector
DAQ
Data Acquisition
VB
Visual Basic software
USB
Universal Serial Bus
GUI
Graphical User Interface
HART
Highway Addressable Remote Transducer
3D
Three Dimension
PID
Proportional Integral Derivative
Ni
Nickel
Pt
Platinum
Ge
Germanium
PSM
Power Sensor Microsystem
PSM
Final Year Project (Projek Sarjana Muda)
PV
Process Variable
LRV
Lower Range Value
URV
Upper Range Value
PC
Personal Computer
AGND
Analog Ground
AI0
Analog Input 0
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LED
Light Emitting Diode
V
Volts
mA
Mille-Ampere
IDE
Integrated Development Environment
MSU
Master Standard Unit
UUT
Unit Under Test
Std Dev
Standard Deviation
Mean
Median or Average
TUR
Test Uncertainty Ration
U
Uncertainty
A
Maximum Error
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CHAPTER 1
INTRODUCTION
1.1
BACKGROUND
In this thesis there is a basic idea to recognize a temperature measurement system
that has instrumentation or control considerations in addition to simple temperature
measurement considerations. The need for temperature calibration is obvious, and the
need for instruments to bring about that calibration control is also obvious. The limits of
calibration control, the acceptable variations in temperature for process, are less obvious.
The types of instrumentation involve so many combinations of precision, cost, reliability,
and utility that is impossible to present a suitable analysis without analyzing a particular
system to make sure the temperature calibration system is accurate [1].
Although temperature sensors are usually checked as part of a calibration of the
connected device, it may be necessary to check a suspect temperature sensor or to verify
the accuracy of a new RTD. The principles of this Automatic Detection Temperature
Transmitter for Calibration process using RTD, would apply to any sensor type. All
modern test equipment performs the temperature compensation, but it is important to
verify. The calibration process in this thesis is used RTD that connected to the transmitter
to make sure resistance value of RTD are converted into ampere value. In order to
interfacing, using DAQ card that only receive voltage, a 250 Ω resistor needed to make
2
sure the voltage reading is from 1V minimum and 5V maximum, with it respect current 4
mA until 20 mA. 1V will represent minimum temperature and 5V represent maximum
value of temperature.
When the calibration is heading for measurements, there is a chance that errors in
the measurement influence the decision. The primary purpose of uncertainty analysis is to
provide a measure of that influence and likelihood of presented a wrong decision.
Uncertainty analysis requires understanding of the measurement, usually in terms of
mathematical models of the various influence effects that cause errors. This thesis is
running a systematic error that occurs when the value is recorded in repeatedly. The
result of the accuracy of the RTD is present with it uncertainty to make sure the error is
estimated in the result.
1.2
INTRODUCTION TO THE PROJECT
Temperature is the one parameter that needs to measure their value and the
accuracy in the calibration process. A system must be developing using software to make
the system to detect and calculate all the uncertainty and provide the value of temperature
with it accuracy. The major change occurring at the present is the increasing number of
user friendly software that make it possible for user to experience new and fast ways of
learning. In minutes, simulation, controller and real world interfacing can be created
instantly. In this project, the software is developed to help user to learn and explore the
calibration and uncertainty process with an interesting and interactive way in order to
reduce the human error.
The Data Acquisition (DAQ) card will be use for interfacing process between
temperature instrumentation and the software. Besides that, the temperature measurement
calibration will consume a long process compared to pressure measurement calibration
due to measurement repeatability and therefore, it needs the monitoring of the operator
until the process is finish. Therefore, the automatic detection temperature measurement
3
from the temperature source using the Resistance Temperature Detector (RTD) is
proposed in this project. The computer software is menu-based to give the user flexibility
and ease of use. The user needs no programming experience to operate the systems. This
project is to detect temperature for Calibration Process using RTD sensor automatically.
All the reading that comes from the calibration system will be display by the computer.
The best measurement capabilities in temperature calibrations by comparison
strongly relate to some particular and some typical uncertainty contributions. In general
there are four main uncertainty contributions in calibration of thermometers;
repeatability, uncertainty of a calibration furnace, uncertainty of a reference thermometer
and uncertainty of a measuring devices [2]. All the uncertainty need to measure to know
the accuracy of the value that has been provided.
1.3
PROBLEM STATEMENT
Most of the industry using a machine that provide heating process whether it to
soldering, melting an iron or just to provide the optimum temperature for the element.
Temperature is one of the most frequently measured parameters in process system. The
electrical thermometer is used, to sense and control the process temperatures. Regular
calibration of these thermometers is critical to ensuring consistent quality of product
manufactured, as well as providing regulatory compliance for some industries.
The industry needs an automatic detection for the temperature sense by the
electrical thermometer. Thus, this project comes to solve the problem in industrial by
provided temperature detection using electrical thermometer, this project used RTD and a
system that provided the measurement of the uncertainty to make sure the degree of
accuracy is high.
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1.4
OBJECTIVES
The objectives of this project are:
i.
To develop software application to help in student learning process.
Visual Basic (VB) 2008 Express Edition will be used as a main
programming language. The software is developed to be interactive and user
friendly for student. Student can understand well about the flow of the program
when it’s running.
ii.
To interface the temperature transmitter output using Resistance
Temperature Detector RTD to Visual Basic application.
The interface process is done with Data Acquisition process (DAQ).
Advantech USB-4716 DAQ card will be used to interface between instrument and
the computer. All the hardware is connected to input of the DAQ and then the
USB to the computer. The value of the temperature can be received by the
computer after interfacing is done properly.
iii.
To design an automatic detection of temperature measurement in the
software from the temperature source port within the range of the setting
temperature.
All the complete set of the temperature readings will be used directly for
the calibration and uncertainty calculation process. The program is developed to
make sure all the data can be captured by the software and it can transfer it to
calculate the uncertainty for the calibration.
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1.5
i.
SCOPES OF PROJECT
Develop a programming language using Visual Basic in software application
for the project.
The software is to develop GUI to describe how the program runs. It will
help the person to save all the data needed. The data is saved in the table and also
can be saved in Microsoft Office Excel. The software also can generate all the
graph needed from the data obtain. It also develops to calculate the uncertainty for
three reading; each reading is in five point calibration.
ii.
DAQ card is used to interface between computer and temperature
instrument such as temperature transmitter, HART communicator, etc.
The DAQ card is to connect inputs or outputs for the hardware to interface
with the software. So, the software can receive the reading from the hardware.
DAQ card can receive a change of voltage only. So, transmitter is needed to
convert the resistance reading from RTD to current and then the converter is used
to convert the current to voltage before connected to the DAQ card.
iii.
The Resistive Temperature Detector (RTD) will use as an input device to
detect temperature changes.
RTD is a sensor to detect the change of the temperature. The RTD will be
inserted into the furnace to read the value of the temperature inside it. RTD Pt100
is giving the reading in value of resistance. When it gives 100 Ω reading it mean
the temperature is at 0 oC. That is how the RTD Pt100 works.
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1.6
THESIS OVERVIEW
This thesis is consist seven chapters. There are the topics that include in this
thesis:
CHAPTER 1: Introduction
This chapter introduce about the thesis is all about. Why the thesis is
operated. It also includes the objective of the project and all the scope in
this project.
CHAPTER 2: Literature review
This chapter discuss about published information from other experiment in
this subject area.
CHAPTER 3: Methodology
All the method used to construct the project is arranged in the flow of the
step that is consisted all the important point below:
i.
It included how the hardware, software and the GUI work. How to
interface between software and hardware; get the value of the temperature.
It also includes mathematical method use in this project.
ii.
Introduction of the instruments used in the project.
iii.
Hardware Implementation.
It discussed about the interface used and how it implements.
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iv.
Software Development.
It discussed about the software use and how it implements.
v.
Formulas use in this project especially for the development of the
software. Uncertainty calculation.
CHAPTER 4: Result and discussion
It presents the result from this experiment and the related discussions on
the result obtain in this project.
CHAPTER 5: Conclusion
This chapter discussed the project overview and how to improve the
project.
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CHAPTER 2
LITERATURE REVIEW
2.1
3D Device of Infrared Temperature Detection.
In a certain field, it is important to measure temperature information in variable
direction at the same time. However, there are few instruments to accomplish the
function now. To implement the measure in 3 dimensions, an experimental table of
temperature detection by infrared is designed. It is the integration of detection, control
and monitor. The infrared device in the table can detect and measure temperature in real
time and the three dimension electric motional device can adjust the detection distance by
the user. The mechanical bar for displacement is controlled by a circuit with the control
button. The infrared temperature sensor is fixed on the bar, so it can move along with the
bar controlled by the circuit. The method of temperature detection is untouched, so it can
detect small object and its tiny variable temperature, which cannot be detected by the
thermometer or the electronic temperature sensor. In terms of the 3-D parallel motion
control, the device can implement temperature measurement in variable directions.
According to the results of the temperature values, the 3-D temperature distributed curve
can be described. By using of the detection device, temperature of some special objects
can be detected, such as the live anatomical animal, small sensor, nondestructive object,
and so on [3].
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2.2
Temperature Transmitter with On-Line Calibration Using Johnson Noise.
The relationship between resistance of a RTD and temperature tends to change
over time. These changes can be periodically calibrated out of the system to maintain
accuracy of the temperature measurement. For example, periodically an operator may be
required to journey into the field to calibrate the transmitter. The transmitter is calibrated
by placing the RTD sensor in a bath of a known temperature and monitoring output from
the temperature transmitter. The difference between the actual temperature of the
temperature bath and the output temperature is used as a calibration factor and stored in
memory for subsequent use by the microprocessor. The transmitter injects a current into
the RTD and the resultant voltage drop across the RTD is used to measure resistance. The
voltage is converted into a digital format using an analog to digital converter and
provided to a microprocessor. The microprocessor converts the measured voltage into a
digital value representative of temperature [4].
2.3
Designing a Temperature Measurement and Control System for Constant
Temperature Reciprocator Platelet Preservation Box Based on LabVIEW.
On LabVIEW, a temperature measurement and control system for constant
temperature reciprocator platelet preservation box is designed based on Fuzzy-PID
control. For temperature measurement part, we use multi-sensor data fusion algorithm to
optimization data, and output fault early warning signal for sensors; Using Fuzzy-PID
control algorithm to control the system, that will make the system has good dynamic
characteristics, and has more ideal steady-state quality; Using LabVIEW software
developing the temperature measurement and control system, that will make the
measurement and control charts real-time display; Real-time state monitoring functions
guarantee system security operation. And compared with traditional design method, using
virtual technology allows the system to operation simply, to set up or reconstruct easily,