Automated Data Extraction Unit for Fluke 80 Series VOM 6 of 35
Multidisciplinary Senior Design Project
TRANSCAT PROJECT 04039
Team Members:
Maham Suleman, EE
Jeffery Miller, EE
Joe Farnsworth, EE
Jerry Money, EE
Joshua Brown, ME
Anne Johnson, ME
Sanh Ha, ME
Faculty Advisors:
Dr. Sahin, EE
Dr. Kochersberger, ME
Faulty Coordinator:
Prof. George Slack
Rochester Institute of Technology
Kate Gleason College of Engineering
James E. Gleason Building
77 Lomb Memorial Drive
Rochester, NY 14623-5603
Figure 1:Final Assembly for the Automated Data Extraction Unit
Abstract:
A Multidisciplinary Engineering Design Team investigated viable methodologies and approaches to automate the “as received data” process for the Fluke 80 Series Multimeter for Transcat. Transcat is one of North Americas leading providers of calibration services and instrumentation. The project involved developing a device, the Automated Data Extraction Unit that acts as an interface between the multimeter and a PC running CalTrakÒ. The device analyzes the Fluke’s VOM digital display and transmits the display values to CalTrakÒ. The Automated Data Extraction Unit eliminates the need for a technician to sit through the entire fourteen minutes of the inspection process.
Table Of Contents
List of Figures 5
List Of Tables 6
1 Introduction 7
2 Recognize and Quantify Need 8
2.1 Project Mission Statement 8
2.2 Company Background 8
2.3 Calibration: An element of Metrology 9
2.4 Product Description 9
2.5 Scope Limitations 9
2.6 Stakeholders 10
2.7 Key Business Goals 10
2.8 Top Level Critical Financial Parameters 10
2.9 Financial Analysis 11
2.10 Primary Market 11
2.11 Secondary Market 11
2.12 Order Qualifiers 11
2.13 Order Winners 11
2.14 Formal Statement of Work 12
3 Concept Development 13
3.1 Concept Development Tools 13
3.2 Brainstorming Session 13
3.3 Conceptual Level Drawing 13
3.4 Final Concepts 14
3.4.1 Display Concept 14
3.4.1.1 Digital Video 14
3.4.1.2 Pen scanner 14
3.4.1.3 Phototransistors 15
3.4.2 Fixture Position 15
3.4.2.1 Mounting Fluke Upside Down 15
3.4.2.2 Mounting Fluke Right Side up 15
4 Feasibility Assessment 16
4.1 Microcontroller Feasibility 16
4.1.1 Pre-Designed Motor Control Board Feasibility 16
4.1.2 PIC Microcontroller Feasibility 17
4.1.3 Microcontroller Feasibility Results 17
4.2 Display Feasibility 17
4.2.1 Digital Video Feasibility 17
4.2.2 Pen Scanner Feasibility 18
4.2.3 Phototransistor Feasibility 18
4.2.4 Display Feasibility Results 19
4.3 Fixture Feasibility 19
4.3.1 Mounting the Multimeter Upside Down 19
4.3.2 Mounting the Fixture On Top of the Multimeter 19
4.3.3 Fixture Feasibility Results 20
4.4 Motor Feasibility 20
4.4.1 Servo Motor 20
4.4.2 Stepper Motor 20
4.4.3 Motor Feasibility Results 20
4.5 Relay Feasibility 20
4.5.1 Solid-State Relays 21
4.5.2 Mechanical Relays 21
4.5.3 Relay Feasibility Results 21
4.6 Feasibility Conclusion 21
5 Design Objectives and Specifications 22
5.1 Design Objectives 22
5.2 Design Specifications 22
5.2.1 Microcontroller Specifications 22
5.2.2 Digital Camera Specifications 22
5.2.3 Stepper Motor Specifications 22
5.2.4 Linear Actuators 22
5.3 Safety Issues 23
6 Analysis of Problem and Synthesis of Design 24
6.1 Final System Design 24
6.2 System Controls 24
6.3 Fixture Design 24
6.3.1 Optical Reader 24
6.3.1.1 Image processing 25
6.3.1.2 Microcontroller to camera communications 26
6.3.2 Dial rotator and push button controller 27
6.3.3 Test Lead Switcher 30
6.3.4 Interface Protocols 31
6.3.4.1 PC and Controller Communication 31
6.3.4.2 PC to Microcontroller Communication 31
6.3.5 Fluke Holding Fixture 32
7 Bill Of Materials 33
References 34
List of Figures
Figure 1: Final Assembly for the Automated Data Extraction Unit
Figure 2: Segments needed to recognize the digit
Figure 3: The display of the Fluke Multi-meter
Figure 4: Determining the Torque
Figure 5: Stepper Motor
Figure 6: Rotary Fixture
Figure 7: Solenoid Mounting Fixture
Figure 8: Linear Solenoid
Figure 9: Linear Actuator
Figure 10: Final Assembly
List Of Tables
Table 1: Brainstorming Session
Table 2: Preliminary cost associated with the camera concept
Table 3: Preliminary Cost associated with the pen scanner concept
Table 4: Preliminary Cost associated with the phototransistor concept
Table 5: Drive Format Truth Table
1 Introduction
The Automated Data Extraction Unit is designed to support the Fluke 80 series handheld Multimeter, which is a high volume unit in Transcat’s Rochester Calibration Laboratory. The Fluke 80 calibration process has been semi-automated through Transcat’s CalTrakÒ tool. CalTrakÒ is a database developed by Transcat to record the data received during the inspection.
Current testing procedure consists of continual interaction of the technician with the PC running CalTrakÒ. The software prompts the technician to manually configure the test leads from the Fluke 5500A calibration Instrument to the Fluke 80 series Multimeter under test. Once the technician confirms the meter’s setup, the CalTrakÒ software sends IEEE 488.2 commands to the GPIB port of the Fluke 5500 calibration instrument then the appropriate calibration signal is applied to the meter under test. For each mode and scale tested, the technician must also confirm and/or record the results. This process can consume fifteen minute for each meter tested.
The Automated Data Extraction Unit will only require the technician to verify that CalTrakÒ and the Fluke 5500A are ready and in the standby mode (during power up, the technician, and must verify the Rotary drive and the linear drive are in the home position. The Technician will rotate the Fluke 80 series selector switch to the off position, place it in the test fixture, clamp into position and, select start test on the PC running CalTrakÒ. After which, the test sequence begins. The test may still take 15 minutes, but the technician’s presence is not mandatory.
2 Recognize and Quantify Need
2.1 Project Mission Statement
The student engineering design team will investigate viable methodologies and approaches to semi-automate the “as received data” process for the Fluke 80 Series Multimeter. The final design will consist of an optical reader, a dial rotation and push button activation device, a method to toggle between test leads, and a process to enter the data acquired into CalTrak®.
2.2 Company Background
Transcat is one of North America’s leading providers of calibration services and instrumentations. Since its’ incorporation in 1964, Transmation (now Transcat) concentrated on developing, servicing and distributing electronic instrumentation used in the monitoring, calibration, and supervision. The primary markets for Transcat’s services are process, life sciences, manufacturing, communications, automotive, and aerospace industries.
Transcat, Inc.’s former manufacturing organization located in Rochester, New York, was comprised of the Transmation Instrument Division, established in 1964, and Altek Industries, which was purchased by Transmation, Inc. in 1996. The two groups combined in 1999 to form the Products Group in 1980, the Transcat (short for “Transmation Catalog”) Division was established as a catalog sales operation to offer customers a single source for calibration and test instrumentation. This operation has grown into a full-fledged industrial distribution network for not only Transmation and Altek products, but also those of more than 200 other manufacturers.
As catalog sales increased at a dramatic pace, it became evident that this type of equipment would require periodic recalibration and general maintenance in order to perform at peak level. Thus, in1988, Transcat opened the first of many calibration laboratories to service customer equipment. The purchase of E.I.L. in 1997 and MeterMaster in 1999 (both distributors & calibration service organizations with laboratories located throughout the United States and Canada) established Transcat as the leading calibration service provider in the U.S.
Finally, the newest business unit of Transcat established in 1999, MetersandInstruments.com, provides customers with an “Internet” channel for the purchase of calibration equipment and tools. In late 2001, as part of their strategy to divest non-core businesses, Transcat sold both the Products Group Division and the MAC (Measurement and Control) Division. This allowed them to focus on providing innovative, quality products and calibration services to their customers. Upon completion of the sale, the company name was changed from Transmation, Inc. to Transcat, Inc. Today, Transcat, Inc. employs 230 talented individuals throughout the U.S., Canada, and China.
2.3 Calibration: An element of Metrology
Metrology is the science of weights and measures. Metrology is required to ensure that the instrument or system can accurately and reliably perform the designated task. Laws to regulate measurement were originally developed to prevent fraud. However, units of measurement are now generally defined on a scientific basis, and are established by international treaties. Level of precision in measurements has greatly increased in the world due to the increased competition among the manufacturing industries.
One element of metrology is calibration. Calibration is the process of comparing measurements, made by an instrument with a standard. The instrument of unconfirmed accuracy is referred to, as the unit under test (UUT) and the instrument of known accuracy is known as a measurement standard. The process is performed to establish the accuracy of the equipment being used for measurements. Instruments that do not reach the standards are adjusted accordingly.
2.4 Product Description
The students on the Transcat’s design team will build a working prototype device that incorporates a majority of the design and features inputs as listed below.
· Optical Reader. An optical reader that reads the Fluke’s VOM digital display and then communicates the displayed value to CalTrak tool.
· Dial rotation and push button controller. An electro-mechanical scheme to turn the VOM rotary switch to the proper position and select the appropriate function selection pushbuttons.
· Test Lead switcher. An electro-mechanical method to select between voltage/resistance/capacitance and current test leads depending upon which calibration test is being run at a particular point in time.
· Automated digital controls for above and data interface to CalTrak®. (On-site Transcat software engineer to help define the interface requirements and make any updates to CalTrak tool.)
2.5 Scope Limitations
The project prototype will be fully designed by the end of winter quarter and a working device will be completed by the end of the spring quarter. At the end of the winter quarter the senior design team will present the preliminary design, detail sketches, and cost for the components needed to build the prototype. Also the design team will participate in on-site testing, data collection, and evaluation of the prototype device at the end of the spring quarter.
The design team will be responsible for a device that:
· Automates the display reading process
· Toggles the necessary push buttons
· Switches between test leads
· Rotates the VOM rotary switch
The design team will not be responsible for:
· Typing in or reading of the serial number of the unit
· Changing the UUT
· Starting the test
· Relieving the need for the technician
· Integration into the CalTrak® software
2.6 Stakeholders
The primary stakeholder for the research and development of the automation system is Transcat since the device will be connected to a computer running CalTrak®, The students are the secondary stakeholders in this project because it shall satisfy engineering curriculum requirements for the students in the design team and serve as a learning experience for them. Eventually the entire calibration industry could be a stakeholder if the device is modified to work in different environments.
2.7 Key Business Goals
As the need for precision is increasing in the industry, so is the need to for calibration. Everyday more and more companies providing calibration services are emerging. Increase in levels of services calls for an increased demand for calibration technicians. Currently the Fluke 80 series multimeter is a high volume unit at Transcat. The “as received data” process is currently labor intensive and requires a technician to do repetitive tasks to a large number of units. This device when successfully constructed can take away the need of having a technician sit through the entire calibration data process. This will give the technician time to perform other tasks while the test is running, thus providing Transcat with a more time efficient process.
2.8 Top Level Critical Financial Parameters
The top-level critical financial parameters related to the project are associated with the following components that are needed to build the device.
· The camera needed for analyzing the display
· The Evaluation Board to work with the microcontroller
· Stepper Motor to rotate the rotary switch
2.9 Financial Analysis
The team has not been given a definite budget by Transcat, but a low cost system is an important aspect of the project. The most costly component will be the camera used for analyzing the display. The total cost of the system will depend on the following components:
· The camera
· Evaluation Board
· Microcontroller
· Power Supply
· Stepper Motor
· Linear Actuators
· Miscellaneous electrical components
· Raw Material need to build the fixture
2.10 Primary Market
The primary market for this product will be Transcat, because the system is being customized for use in their lab with CalTrak®.
2.11 Secondary Market
Secondary market for this product can be any company that provides calibration services for the Fluke 80 series multimeter. In order for this system to be part of the secondary market some software modifications could be necessary.
2.12 Order Qualifiers
A system that analyzes the display and that mechanically performs the tasks necessary to complete the “as received data” process.
2.13 Order Winners
· System with reduced test time
· Reduced technician involvement
· Making a system that can be expanded in the future
o Possibility of multiple Flukes 80 Series Multimeters being analyzed at one time
· Meeting all the project requirements
2.14 Formal Statement of Work
The RIT engineering design team shall work closely with Transcat technical staff to understand customer’s needs and incorporate these requirements into the final product. In researching and assessing the design, the team will conduct appropriate literature, website, and manufacturer searches to identify various technical approaches for automating the Fluke 80 series multimeter “as received data” process. The design team shall engage in constructive and on-going discussion with company to understand the trade-offs between engineering desires, customer needs, product feasibility, and shall develop appropriate design and specification options for review by Transcat management. The primary goal of the design team is to build a working prototype that incorporates all of the project requirements that were requested/discussed with Transcat and to participate in on-site testing, data collection, and evaluation of the prototype device. The design team will prepare a written report including complete technical specifications, data, construction information, etc. for presentation to corporate managers.