design specifications and requirements for a mobile data

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Open Access Theses & Dissertations

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Design Specifications and Requirements for a Mobile Data Design Specifications and Requirements for a Mobile Data

Acquisition System Acquisition System

Corey Garrett Hansen University of Texas at El Paso

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DESIGN SPECIFICATIONS AND REQUIREMENTS FOR A MOBILE DATA

ACQUISITION SYSTEM

COREY GARRETT HANSEN

Master’s Program in Mechanical Engineering

APPROVED:

Jack Chessa, Ph.D., Chair

Ahsan Choudhuri, Ph.D.

Luis Rene Contreras, Ph.D.

Stephen L. Crites, Jr., Ph.D.

Dean of the Graduate School

Copyright ©

by

Corey Hansen

2019

Dedication

I would like to thank my Mom and Dad, first and foremost, for supporting me in everything I do.

I would not have made it this far without y’all. Second, I’d like to thank my girlfriend for helping

to keep me motivated when school or work got tough. Lastly, I’d like to thank all my friends and

colleagues who suffered through the hard times and enjoyed the good times alongside me.

DESIGN SPECIFICATIONS AND REQUIREMENTS FOR A MOBILE DATA

ACQUISITION SYSTEM

by

COREY GARRETT HANSEN, B.S.

THESIS

Presented to the Faculty of the Graduate School of

The University of Texas at El Paso

in Partial Fulfillment

of the Requirements

for the Degree of

MASTER OF SCIENCE

Department of Mechanical Engineering

THE UNIVERSITY OF TEXAS AT EL PASO

December 2019

v

Acknowledgements

To Jack Chessa, Ph.D., Ahsan Choudhuri, Ph.D., Luz Bugarin, Gloria Salas, Charles Hill,

Jason Adams, Marissa Garcia, Marianna Chaidez, Adrian Welsh, Ray Rojo, Rene Miranda, Jerry

Ramirez, and so many others for their help and support in getting the MICIT up and running.

vi

Abstract

This Thesis will discuss the design, use, and maintenance of the Mobile Instrumentation

and Control Interface Trailer (MICIT) housed at tRIAc HQ in Fabens, TX. The design of the

MICIT, as it pertains to this thesis, reflects the “as-built” configuration, which, in some cases,

strays significantly from the original design. These design changes are noted in detail, as are the

reasons for the changes. Appendix A contains a BOM complete with vendor information, part

numbers, and prices where available. Appendix A is provided in an attempt to streamline the

repair/replacement/expansion process for the components in the MICIT. Original AutoCAD

schematics are available in the MICIT schematic library on the SVN.

As a continuation of the “future work” proposed in the original design thesis (Chaparro

2017), the design intent behind each sub-assembly is outside the scope of this thesis, but may be

referenced in some sections. Design intent for new or largely altered sub-assemblies will be

addressed. The LabVIEW, or software interface, side of the MICIT is outside the scope of this

thesis, as it was recently covered by another publication (Rojo, 2019)

Future work proposed in this publication includes compartmentalizing each sub-assembly

and re-termination of system harnessing. Compartmentalization is intended to ease the burden of

troubleshooting and verifying sub-assembly functionality. Re-termination is intended to ease the

daily set-up and tear-down burden on research assistants, technicians, and laboratory personnel.

vii

Table of Contents

Dedication ................................................................................................................................. iii

Acknowledgements ..................................................................................................................... v

Abstract ..................................................................................................................................... vi

Table of Contents ......................................................................................................................vii

List of Tables ............................................................................................................................. ix

List of Figures ............................................................................................................................. x

List of Illustrations ..................................................................................................................... xi

Chapter 1: MICIT Development and Evolution ........................................................................... 1

MICIT Description and Organization Scheme .................................................................... 1

MICIT Layout .................................................................................................................... 3

Chapter 2: MICIT Sub-Assemblies.............................................................................................. 5

MICIT-L1: Motor Valve Panel ........................................................................................... 5

MICIT-L2: Igniter Panel..................................................................................................... 6

MICIT-L3: 120V AC Solenoid Valve Panel ....................................................................... 7

MICIT -L4: 120V AC Solenoid Valves Cont’d................................................................... 8

MICIT-L5: 12V DC Solenoid Valve Panel ......................................................................... 9

MICIT-L6: 12V DC Solenoid Valve Cont’d ..................................................................... 10

MICIT-L7: Warning Lights and Bell ................................................................................ 11

Power Supply Sub-assembly............................................................................................. 12

Trailer Warning Lights and Bell ....................................................................................... 13

MICIT-R1: Cryo PT’s, Differential PT’s, and Turbine Flow Meters ................................. 15

MICIT-R2: Load Cells ..................................................................................................... 16

MICIT-R3: Venturi Flow Meters ...................................................................................... 17

MICIT-R4: Single Ended Static PTs ................................................................................. 18

MICIT-R5: High Speed Instrumentation ........................................................................... 19

MICIT-R6: Unused BNC Connectors ............................................................................... 20

MICIT-R7: K-Type Thermocouples ................................................................................. 20

MICIT-R8: E-Type Thermocouples .................................................................................. 22

viii

MICIT-R9: Communications Panel .................................................................................. 23

Emergency Stop Button .................................................................................................... 23

Chapter 3: Component Specifications ........................................................................................ 24

UPS: APC Model Number SMT1500RM2U .................................................................... 24

8VDC Power Supply: Acopian Model Number A8MT500 .............................................. 28

Relay Card: Omega Model Number OME-DB-24PRD/24/DIN ........................................ 29

Cryo PT Amplifiers – Omega DP25B-E-A ....................................................................... 30

NI cRIO-9066: Control System ........................................................................................ 32

NI cDAQ-9189: Data Acquisition System ........................................................................ 34

NI Module Specifications ................................................................................................. 36

NI9344 .................................................................................................................... 36

NI9403 .................................................................................................................... 37

NI9269 .................................................................................................................... 38

NI9214 .................................................................................................................... 39

NI9205 .................................................................................................................... 40

NI9361 .................................................................................................................... 41

Chapter 4: Current System Advantages and Limitations ............................................................ 43

Current System ................................................................................................................. 43

Future Work ..................................................................................................................... 43

References ................................................................................................................................ 47

Glossary .................................................................................................................................... 48

Appendix A............................................................................................................................... 52

Appendix B ............................................................................................................................... 55

Vita 56

ix

List of Tables

Table 3.1: UPS Output Specifications ....................................................................................... 24 Table 3.2: UPS Input Specifications .......................................................................................... 24

Table 3.3: UPS Battery Specifications ....................................................................................... 25 Table 3.4: UPS Unit Specifications ........................................................................................... 27

Table 3.5: UPS Unit Specifications ........................................................................................... 28 Table 3.6: Relay Card Specifications ......................................................................................... 29

Table 3.7: Baseline Cryo PT Amp Configuration ...................................................................... 30 Table 3.8: DP25B-E-A Specifications ....................................................................................... 31

Table 3.9: cRIO Specifications .................................................................................................. 33 Table 3.10: cRIO Slot Population .............................................................................................. 33

Table 3.11: cDAQ Specifications .............................................................................................. 35 Table 3.12: cDAQ Slot Population ............................................................................................ 35

Table 3.13: NI9344 Specifications ............................................................................................ 36 Table 3.14: NI9403 Specifications ............................................................................................ 37



x

List of Figures

Figure 1.1: Front Panel Layout ....................................................................................................3 Figure 1.2: Back End Layout .......................................................................................................4

Figure 2.1: MICIT-L1 Photo .......................................................................................................5 Figure 2.2: MICIT-L2 Photo .......................................................................................................6

Figure 2.3: MICIT-L3 Photo .......................................................................................................7 Figure 2.4: MICIT-L4 Photo .......................................................................................................8

Figure 2.5: MICIT-L5 Photo .......................................................................................................9 Figure 2.6: MICIT-L6 Photo ..................................................................................................... 10

Figure 2.7: MICIT-L7 Photo ..................................................................................................... 11 Figure 2.8: Power Supply Sub-Assembly Photo ........................................................................ 12

Figure 2.9: Trailer Warning Lights and Bell .............................................................................. 13 Figure 2.10: MICIT-R1 Photo ................................................................................................... 15

Figure 2.11: MICIT-R2 Photo ................................................................................................... 16 Figure 2.12: Original MICIT-R3 Photo ..................................................................................... 17

Figure 2.13: Current MICIT-R3 Photo ...................................................................................... 18 Figure 2.14: MICIT-R4 Photo ................................................................................................... 18

Figure 2.15: MICIT-R5 Photo ................................................................................................... 19 Figure 2.16: MICIT-R6 Photo ................................................................................................... 20

Figure 2.17: MICIT-R7 Photo ................................................................................................... 20 Figure 2.18: MICIT-R8 Photo ................................................................................................... 22

Figure 2.19: MICIT-R9 Photo ................................................................................................... 23 Figure 2.20: Emergency Stop Button Photo ............................................................................... 23

Figure 3.1: UPS Photo ............................................................................................................... 24 Figure 3.2: UPS Runtime Graph ................................................................................................ 26

Figure 3.3: UPS Efficiency Graph ............................................................................................. 27 Figure 3.4: 8VDC Power Supply Photo ..................................................................................... 28

Figure 3.5: Relay Card Photo .................................................................................................... 29 Figure 3.6: Cryo PT Amplifier Panel ......................................................................................... 30

Figure 3.7: cRIO Photo ............................................................................................................. 32 Figure 3.8 cDAQ Photo ............................................................................................................. 34

Figure 3.9: NI9344 Drawing ..................................................................................................... 36 Figure 3.10: NI9403 Photo ........................................................................................................ 37

Figure 3.11: NI9269 Photo ........................................................................................................ 38 Figure 3.12: NI9214 Photo ........................................................................................................ 39

Figure 3.13: NI9205 Photo ........................................................................................................ 40 Figure 3.14: NI9361 Photo ........................................................................................................ 41

Figure A1: NEMA 5-15 Picture................................................................................................. 55

xi

List of Illustrations

Illustration 2.2: MICIT-L2 Schematic .........................................................................................6 Illustration 2.3: MICIT-L2 Schematic .........................................................................................7

Illustration 2.4: MICIT-L4 Schematic .........................................................................................8 Illustration 2.5: MICIT-L5 Schematic .........................................................................................9

Illustration 2.6: MICIT-L6 Schematic ....................................................................................... 10 Illustration 2.7: MICIT-L7 Schematic ....................................................................................... 11

Illustration 2.8: Power Supply Sub-Assembly Schematic........................................................... 12 Illustration 2.9: Trailer Warning Lights and Bell Schematic ...................................................... 14

Illustration 2.10: MICIT-R1 Schematic ..................................................................................... 15 Illustration 2.11: MICIT-R2 Schematic ..................................................................................... 17



Illustration 3.1: cRIO Slot Population ........................................................................................ 32 Illustration 3.2: cDAQ Slot Population ...................................................................................... 34

1

Chapter 1: MICIT Development and Evolution

Data acquisition is an integral part of any hardware testing operation. This requires both a

hardware and software component. The Mobile Instrumentation and Control Interface Trailer, or

MICIT for short, is the hardware side of the data acquisition scheme developed for use with the

LO2/LCH4 projects at tRIAc HQ in Fabens, TX. The main objective of MICIT development is to

provide an expandable one-size-fits-all solution for data acquisition with the LO2/LCH4 projects.

Historically, these projects have each used their own custom developed hardware and software

solutions which make data verification, system maintenance, and system operation procedures

very unique to the individual project. By developing a universal hardware and software solution,

we hope to decrease the learning curve associated with starting work on a project/switching

between LO2/LCH4 projects at tRIAc HQ. This decreased learning curve is important, as there is

an inherent high turnover rate in the academic research environment as compared to the research

and development that goes on in industry. Industry side projects can span decades with largely

the same engineering team, so six months to a year of training on a given system isn’t a deal

breaker. Students working on an academic research projects, in contrast, spend two to six years

on average working at the research center, and much of that time is spent on multiple projects.

By easing the transfer into a new project, at least from a data collection standpoint, the MICIT

project helps to increase researcher productivity in the academic environment.

MICIT DESCRIPTION AND ORGANIZATION SCHEME

The main objective of MICIT development is to create a data acquisition system which is

independent of the experiment for which data is being collected. Rocket engine tests, heat transfer

characterization tests, fluid delivery system tests, and many other experiments share similar

requirements in terms of the data that needs to be collected during the test. This commonality is

2

what drove the idea behind the MICIT. While a data acquisition system with as much hardware

support as the MICIT is by no means the lowest cost plan, the single-experiment DAQ systems

that have conventionally been used at cSTER quickly become more expensive when considered

as a whole. The MICIT system allows one cRIO and cDAQ to interface with many different

experiments, which leads to less hardware duplication across the center as a whole – saving money

overall.

The clusters of components that make up the MICIT have been divided into subsystems

based on the harness interface panel that they feed on the front side of the server racks. MICIT

subsystems were named according to a hierarchical scheme beginning with the system name and

followed by the server rack identifier, panel identifier, connection identifier, and pin identifier. By

chaining the identifiers in descending order, a user or technician can refer to any component or

group of components with whatever level of generality or specificity the task at hand requires. As

an example, a user could refer in general to the entire K-Type TC subsystem as MICIT-R7, or go

all the way down to the single positive lead in the 6th K-Type TC by specifying MICIT-R7_6_+.

This scheme allows for connectors with many pins to be easily addressed. MICIT-L1_2, for

example, is the entire DB9 connector on the left-hand side of the MICIT-L1 panel and MICIT-

L1_2_9 is the 9th pin in the MICIT-L1_2 connector. The cRIO, cDAQ, and assorted hardware on

the backend side of the racks follow a similar naming scheme starting with the highest-level

component, usually a cRIO or cDAQ, and ending with the module and module connection

identifiers. The drawings discussed in Chapter 2 follow this same naming scheme.

3

MICIT LAYOUT

There are two main racks in the MICIT system. They are designated MICIT-L and MICIT-

R. MICIT-L houses most of the power distribution and valve interface hardware, including the

motor valve sub-assembly, the igniter sub-assembly, and all 4 of the solenoid valve sub-

assemblies. MICIT-R houses most of the data acquisition hardware, including the cryo PT sub-

assembly, the differential PT sub-assembly, the turbine flow meter sub-assembly, the load cell

sub-assembly, the static PT sub-assembly, the high speed instrumentation sub-assembly, the K-

Type sub-assembly, the E-Type sub-assembly, and the communication sub-assembly. The power

and data systems are in separate racks to limit the amount of electrical noise that the power system

can induce in the data system.

Figure 1.1: Front Panel Layout

4

Figure 1.2: Back End Layout

5

Chapter 2: MICIT Sub-Assemblies

The sub-assemblies described in this chapter serve as the connection point between the test

hardware and the LabView control and acquisition software. As of the writing of this document,

the sub-assemblies share power sources, and a few subassembly panels share modules in the cRIO

and cDAQ. This isn’t the most modular solution, but it does allow for the greatest level of hardware

use as nearly every NI module is wired to capacity. The merits and shortcomings of this solution

will be discussed in detail in Chapter 4.

The current configuration of the sub-assemblies within the MICIT is laid out in support of

the 500lb and RCE test programs. Additional functionality can be added in support of other

projects, if needed in the future. Removal or modification of existing sub-assemblies in order to

support new programs is discouraged, as doing so may negatively impact the MICIT system’s

ability to support existing testing programs. The MICIT shall maintain support for existing

programs until such a time as the program(s) in question have reached end of life and have been

discontinued.

MICIT-L1: MOTOR VALVE PANEL

Figure 2.1: MICIT-L1 Photo

The MICIT-L1 Panel, shown in Figure 2.1, is tailored more for the 500lb engine test than

many of the other MICIT system panels because of the wiring requirements for the motors that set

the position of the main valves. This panel accommodates two motor valves and is broken into two

connector clusters accordingly; one made up of MICIT-L1_1 and -L1_2, and the other of -L1_3

and 4. -L1_1 is a standard banana plug pair which provides 24VDC power from FPS-T1U_1 to

6

the motor valve, and -L1_2 is a DB9 which provides analog and digital communication with the

motor controller. Together, -L1_1 and -L1_2 provide support for a single motor valve. Support for

the second motor valve is provided in the second cluster on the panel, which is set up the same

way as the first. The tailored nature of the MICIT-L1 panel showcases the flexibility in the design

of the MICIT system, wherein each panel can be set up as a general use panel or in support of a

specific subsystem.1

MICIT-L2: IGNITER PANEL


Illustration 2.2: MICIT-L2 Schematic

1Moving forward, use of the unique system support panel configuration is discouraged. See NOTE 1 in Appendix A

for more information.

7

The MICIT-L2 panel, shown in Figure 2.2, has capacity for four igniters, however as of

the writing of this report, only two are wired and operational as shown in Illustration 2.2. Each

connector cluster on the panel is made up of 3 connectors; a single BNC connector and a banana

plug pair. The BNC connector supplies the trigger frequency from the signal generator module

(NI9269-1) to the igniter coil pack out at the test article. Signal frequency can be set through

LabVIEW. The banana plug pair provides 8VDC power from the A8MT500 to the coil pack at the

test article.

MICIT-L3: 120V AC SOLENOID VALVE PANEL



The MICIT-L3 panel, shown in Figure 2.3, contains 16 banana plug pairs. These banana

plug pairs are set up in a high side switch configuration, wherein the hot leg of the 120V AC

8

facility power is fed through a relay in the 3rd relay board (OME-DB-24PRD/24/DIN – 3) before

running to the positive (red) banana plug connector. The neutral leg of the 120V AC facility power

runs to the negative (black) banana plug connector. This connection method ensures that until the

relay is powered on through LabView, the positive banana plug connection is not powered. While

the alternative connection method (known as a low-side switch) would cycle the valve in the same

way once it was connected, a low-side switch configuration would leave the positive banana plug

connection energized when an SV is not plugged in, which presents a safety hazard for personnel

interacting with the panel.

MICIT -L4: 120V AC SOLENOID VALVES CONT’D



The MICIT-L4 panel, shown in Figure 2.4, contains 16 banana plug pairs in much the same

configuration as those in MICIT-L3, with the only exception being that the connections are split

9

between relay boards 2 and 3 (OME-DB-24PRD/24/DIN – 2 and OME-DB-24PRD/24/DIN – 3,

respectively) as shown in Illustration 2.4. MICIT-L4 is connected in the same high-side switch

configuration as MICIT-L3.

MICIT-L5: 12V DC SOLENOID VALVE PANEL



The MICIT-L5 panel, shown in Figure 2.5, contains 16 banana plug pairs in much the same

configuration as the 120V AC variants in -L3 and -L4, with two key differences. 1) The power

feeding the high side of the switch comes from the 12 DC power supply (FPS-T1U_2), and 2) the

positive (red) banana plugs are connected to the relays in relay card 1 (OME-DB-24PRD/24/DIN

– 1) as shown in Illustration 2.5.

10

MICIT-L6: 12V DC SOLENOID VALVE CONT’D



The MICIT-L6 panel, shown in Figure 2.6, contains 16 banana plug pairs in the same

configuration as MICIT-L5 with the exception that the high side is switched by the 2nd relay card

(OME-DB-24PRD/24/DIN – 2). -L6 initially supported 24V DC SV’s, however at the time of

writing no systems which used the MICIT had any 24V DC SV’s and RCE required 18 12V DC

SV’s. In order to accommodate the extra two SV’s that RCE needed, -L6 was converted to 12V

DC with the intent of adding a 4th relay card (to be designated OME-DB-24PRD/24/DIN – 4)

should the need for 24V DC SV’s arise.

11

MICIT-L7: WARNING LIGHTS AND BELL



The MICIT-L7 panel, shown in Figure 2.7, supports the trailer warning lights and bell, and

is different from the other interface panels in that its operation is usually internal to the MICIT.

Other panels usually connect to harnessing which interfaces with hardware outside the MICIT, but

-L7’s connection routs back into the bell and lights on the trailer. The connections were left

accessible on the front panel, as it may be advantageous to connect auxiliary lights to these same

connections to allow for remote warning lights to be placed away from the MICIT. In the event

that auxiliary warning lights or bells are used, take care to ensure that the total current through any

one relay (read current through any one banana plug pair) does not exceed the relay card’s stated

switching current of 5A@30VDC. The bell’s hookup location is labelled “Buzzer” as the MICIT

12

was originally slated to have a buzzer type audible indicator, however the buzzer was not loud

enough at a distance and was switched over to a fire alarm bell.

POWER SUPPLY SUB-ASSEMBLY

Figure 2.8: Power Supply Sub-Assembly Photo

Illustration 2.8: Power Supply Sub-Assembly Schematic

13

The Power Supply Subsystem, Shown in Figure 2.8, consists of the SMT1500RM2 UPS,

A8MT500 power supply module, and the FPS-T1U rack mount power supply unit. The A8MT500

has an input of 105-125VAC and an output of up to 5A at 8V DC. The FPS-T1U has an input of

85-250VAC. FPS-T1U_1 has an output of 21.5-29VDC at a maximum of 40A. FPS-T1U_2 has

an output of 10.5-13.2VDC at a maximum of 72A. This system supplies power to all the

instrumentation in the MICIT system. Future work includes migrating the 120VAC SV power

source from the UPS to a separate 120VAC power assembly to reduce demand on the UPS and

increase battery based operating time.

TRAILER WARNING LIGHTS AND BELL

Figure 2.9: Trailer Warning Lights and Bell

14

Illustration 2.9: Trailer Warning Lights and Bell Schematic

The MICIT is equipped with three warning lights and a bell as safety measures. By

triggering the green, amber, or red lights the operator is able to inform others visually and from a

distance as to what the status of the MICIT is. The lights flash on their own, and as such the

operator can only turn them on or off; the color is the only indicator of system status. Speed and

pattern of flashing is not determined by the operator and does not have a set meaning. The warning

bell serves as an audible alert to catch the attention of anyone not in visual range of the lights, and

is to be activated before any test goes active. The operator is able to control the duration and pattern

of bell activation through LabView, which allows for several different audible alarms.

The lights and bell are to be connected to MICIT-L7, with red connected to -L7_1, amber

to -L7_2, green to -L7_3, and the bell to -L7_4 as shown in Illustration 2.9. The lights have a

nominal input of 12 V DC and pulls 2.8A each when active. The bell has a nominal input of 12 V

DC and pulls 0.45A when active. Connection paths are explained in detail in the MICIT-L7 Panel

section.

15

MICIT-R1: CRYO PT’S, DIFFERENTIAL PT’S, AND TURBINE FLOW METERS

Figure 2.10: MICIT-R1 Photo

Illustration 2.10: MICIT-R1 Schematic

The MICIT-R1 panel is different than most other panels in that it houses multiple

subsystems. -R1’s front interface consists of a 3U panel, and the 3 subsystems installed in this

panel are separated by row. All connections in this panel use 4-pin speaker connectors, however

16

each row is wired differently due to the different sensor requirements, so care must be taken to

ensure that instruments do not get cross connected or connected to the wrong places. Connections

in this panel share the same connector type, as it was not economically viable to source enough

distinct connectors to prevent cross connection.

The first row (-R1_1 through -R1_12) is designated MICIT-R1_A and houses connections

for Omega PX1005 Series Cryo PTs. The sensor model is important in this row because each plug

is wired to provide the input power (24VDC from FPS-T1U_1) the PX1005 requires, and to

amplify the output voltage of the PX1005 through the bank of DP25B-E-A amplifiers and

ultimately back to NI9205-3. Different sensors may have different inputs and outputs, and may or

may not need to be amplified, thus it is imperative that these parameters be checked if different

instrumentation is to be used in this first row.

The second row (-R1_13 and _14) is designated as MICIT-R1_B and houses connections

for Stellar Technologies DT1400-30BD-233 differential PTs. At the time of writing, these PTs are

only used on the 500lb test stand, and there are only 2 of them, which is why -R1_13 and _14 are

the only two wired connections in this row. If more DT1400s are added in the future, or if another

system uses more of them, connectors can be added to this row to accommodate. The DT1400s

take a 14 to 32VDC input and output 0-5VDC, and the connectors are wired accordingly, with

power coming from FPS-T1U_1, and the differential signal feeding into NI9205-3.

The third row (-R1_25 through _32) is designated as MICIT-R1_C and houses connections

for COX CLF6AN turbine flow meters. This panel supports 8 turbine flow meters. Each connector

is wired to provide power (24VDC) from FPS-T1U_1 and to send the signal returned from the

instrument to NI9361_1.

MICIT-R2: LOAD CELLS


17


The MICIT-R2 panel is intended to house connections for PCB Piezotronics brand load

cells, but as of writing, the load cells are not in use in any test article and have not been incorporated

into the system. Each connector in this panel is a DB9, with pins 1-4 wired to supply power and

receive signal from the load cell. Illustration 2.11 shows the wiring that is planned should these

load cells come into use.

MICIT-R3: VENTURI FLOW METERS

Figure 2.12: Original MICIT-R3 Photo

18

Figure 2.13: Current MICIT-R3 Photo

The MICIT-R3 panel originally housed connectors for the two venturi flow meters (as

shown in Figure 2.12) on the 500lb test stand. Each connector cluster consisted of a standard cryo

PT, a differential PT, and an E-type TC connector, which are each already housed in other panels.

The PT connectors were moved to MICIT-R1. The E-type TCs were moved to MICIT-R8. See

NOTE 1 in Appendix A for details. The location is currently occupied by a blank panel (as shown

in Figure 2.13), and is available for future expansion.

MICIT-R4: SINGLE ENDED STATIC PTS


19


The MICIT-R4 panel houses connections for 22 single ended static pressure transducers.

The connection is wired to supply the instrument with 24VDC power and to accept a single 0-

5VDC signal which is routed to NI9205-1 and NI9205-2. The signal is split and transmitted to

both the cDAQ for data acquisition and to the cRIO for use as a redline. The standard PTs were

chosen as redlines, as they do not require amplification or postprocessing like the cryo or

differential PTs do. This leaves less room for error due to calibration, which makes these sensors

better candidates for system critical redline data sources.

MICIT-R5: HIGH SPEED INSTRUMENTATION


20


The MICIT-R5 panel consists of 8 BNC connectors, and is designed to accept signal from

dynamic PTs and accelerometers. The panel connects to the PCB_483C05 signal conditioner

mounted in the top of the MICIT-R rack. As of the writing of this document, MICIT-R5 is wired

and ready, but has remained unused.

MICIT-R6: UNUSED BNC CONNECTORS


The MICIT-R6 panel consists of 8 BNC connectors, identical to those in -R5. At the time

of writing, all connectors in -R6 are available for use in future expansion.

MICIT-R7: K-TYPE THERMOCOUPLES


21


The MICIT-R7 panel houses connections for 32 K-Type TCs. MICIT-R7_1 through -

R7_16 are connected to both the cRIO and cDAQ for use as redlines and as data collection sensors.

MICIT-R7_17 through -R7_32 are only connected to the cDAQ and therefore only function as

data collection sensors. K-Type TCs are suitable for measuring temperatures from -454°F to

+2300°F (-270°C to 1260°C) with higher accuracy at the top end of the operating range. K-Type

TCs are commonly used to monitor high temperature surfaces such as rocket engine or combustor

chamber surfaces.

22

MICIT-R8: E-TYPE THERMOCOUPLES



The MICIT-R8 panel houses connections for 32 E-Type TCs. All E-Type TCs are

connected to the cDAQ and only function as data collection sensors. E-Type TCs are suitable for

measuring temperatures from -454°F to +1600°F (-270°C to +870°C) with higher accuracy at the

low end of the operating range. E-Type TCs are commonly used to monitor low temperature

surfaces or fluids such as liquid nitrogen, liquid methane, and liquid oxygen delivery lines.

23

MICIT-R9: COMMUNICATIONS PANEL


The MICIT-R9 panel houses the fiberoptic connection that allows for communication

between the main control computer and the cRIO and cDAQ in the MICIT. The yellow fiber optic

cable is to be routed through the strain relied bracket (pictured in Figure 2.19) to prevent the weight

of the cable from pulling on the connectors.

EMERGENCY STOP BUTTON

Figure 2.20: Emergency Stop Button Photo

The MICIT system includes an emergency stop button, located in the top frame panel of

the MICIT-R rack. The e-stop button is wired into the cRIO, and functionality is defined in the

LabVIEW VI. The e-stop button is intended to be used as a safety contingency in the event that

personnel are in the MICIT when the system begins hazardous operations.

24

Chapter 3: Component Specifications

This chapter discusses the specifications and usage instructions for many of the

components in the MICIT system. This chapter is intended to make repairs easier by simplifying

the procurement and replacement process.

UPS: APC MODEL NUMBER SMT1500RM2U

Figure 3.1: UPS Photo

The SMT1500RM2U is a 120V AC battery backup by APC which switches power delivery

from mains power to its internal battery pack, without cutting power to the equipment it supplies,

should the mains power cut out.

Table 3.1: UPS Output Specifications

SPECIFICATION VALUE

Output Power Capacity 1000 W

Output Voltage 120VAC (Nominal)

Output Voltage Distortion <5% at full load (114VAC to 126VAC)

Output Frequency 50 to 60Hz +/- 3 Hz (Auto Sync to mains)

Output Connections 6 (NEMA5-15R)

Surge Protection Rating 459 Joules

Table 3.2: UPS Input Specifications

SPECIFICATION VALUE

Transfer Time (Mains to Battery) 4ms typ : 8ms max

Input Voltage 120VAC (Nominal)

Input Voltage Range 82 to 144V

25

Input Frequency 50 to 60Hz

Input Connection 1 (NEMA 5-15P)

Cord Length 8’ (2.44m)

Table 3.3: UPS Battery Specifications

SPECIFICATION VALUE

Battery Type Leak Proof Sealed Lead-Acid w/ suspended

electrolyte

Typical Recharge Time 3 hr

Expected Battery Life 3 to 5 yr

Battery Volt-Amp-Hour Capacity 432

Net Weight 26.32 lb (11.96 kg)

Operating Temperature +32 to +104 °F (0 to +40 °C)

Operating Humidity 0 to 95%

Operating Elevation 0 to 10,000 ft (0 to 3000 m)

Storage Temperature +5 to +13 °F (-15 to +45 °C)

Storage Elevation 0 to 50,000 ft (0 to 15000 m)

Battery Disposal Prepaid postage

26

Figure 3.2: UPS Runtime Graph

27

Figure 3.3: UPS Efficiency Graph

Table 3.4: UPS Unit Specifications

SPECIFICATION VALUE

Audible Alarm Battery supply mode and low-battery alarms

Weight2 63 lb (28.6 kg)

Rack Width 19”

Rack Height 2U

Operating Temperature +32 to +104 °F (0 to +40 °C)

Operating Humidity 0 to 95%

Operating Elevation 0 to 10,000 ft (0 to 3000 m)

Storage Temperature +5 to +113 °F (-15 to +45 °C)

2Due to the unit weight, OSHA recommends the use of two or more people when lifting or moving the unit.

28

Storage Elevation 0 to 50,000 ft (0 to 15000 m)

Noise Level 46.0 dBA @1m

Online Thermal Dissipation 90.0 BTU/hr

8VDC POWER SUPPLY: ACOPIAN MODEL NUMBER A8MT500

Figure 3.4: 8VDC Power Supply Photo

The Acopian A8MT500 is an 8VDC power supply. It takes one 120VAC output from the

APC UPS and converts it to 8VDC power, currently used for the igniters in MICIT-L2.

Table 3.5: UPS Unit Specifications

SPECIFICATION VALUE

Input Voltage Range 105 to 125 VAC

Input Voltage Frequency 50 to 400Hz; Single Phase

Polarity3 Output is floating, positive or negative

terminal may be grounded or floated up to 300

volts above ground.

Temperature Coefficient 0.015%/°C

Ambient Operating Temperature -4 to +159.8 °F (-20 to 71 °C)

Storage Temperature -67 to +185 °F (-55 to +85 °C)

Response Time <20 microseconds

Mounting DIN Rail

3Always connect -8V lines back to the negative terminal on the A8MT500. Negative connected to ground cannot be

assumed to produce an 8VDC delta between positive and negative.

29

Case Size M6

Overvoltage Protection None

RELAY CARD: OMEGA MODEL NUMBER OME-DB-24PRD/24/DIN

Figure 3.5: Relay Card Photo

The OME-DB-24PRD/24/DIN is an Omega relay card with 16 NC relays, and 8 selectable

(NC or NO) relays. There are 3 of them in the system, each connected to its controlling module in

the cRIO by a (DB37) cable.

Table 3.6: Relay Card Specifications

SPECIFICATION VALUE

Control Logic Input TTL High (+5VDC)

Maximum Switching Voltage/Current 250VAC/5A, 30VDC/5A

Number of Channels 24

Ambient Operating Temperature Range +32 to +140 °F (0 to +60 °C)

Storage Temperature Range -4 to +158 °F (-20 to +70 °C)

Relay Response Time 10 ms

Max Power Consumption Voltage/Current 24VDC/0.8A

30

CRYO PT AMPLIFIERS – OMEGA DP25B-E-A

Figure 3.6: Cryo PT Amplifier Panel

The MICIT system currently uses 12 Omega DP25B-E-A units to amplify the signals from

the Omega PX1005 Series pressure transducers. The DP25B-E-A is configurable and can be

calibrated to amplify signals from other instrumentation. Table 3.7 lists the configuration settings

for use with the PX1005 PT. Table 3.8 lists the specifications for the DP25B-E-A.

Table 3.7: Baseline Cryo PT Amp Configuration

GROUP SPECIFICATION VALUE DESCRIPTION

Main Inpt 100M Specifies input range

Main Decp FFFF Specifies the location of the decimal point on the

display.

RDSO In1 0138 Signal from instrumentation at input setpoint 1

RDSO RD1 0014 Reading, in PSI, correlated to In1 (Ambient

pressure PSIA)

RDSO In2 3320 Signal from instrumentation at input setpoint 2

RDSO RD2 PT Max4 Reading, in PSI, correlated to In2 (PT max

pressure PSIA)

4PT Max varies based on the instrumentation used. Configuration should read 1000 for a PT with a 1000 PSI rating,

500 for a 500PSI rating, etc.

31

RDCF R.1 N

RDCF R.2 4

RDCF R.3 F

OTCF O.1 E

OTCF O.2 V Sets the output type to voltage

OTSO RD1 0000 Reading for output setpoint 1

OTSO OUT1 0000 Output correlated to RD1

OTSO RD2 PT Max Reading for output setpoint 2 (Should match RD2

in the RDSO menu)

OTSO OUT2 10 Output correlated to RD2

LkcF Rs E

Table 3.8: DP25B-E-A Specifications

SPECIFICATION VALUE

Display digits 4

Display Colors Red, Amber, Green5

Voltage Output Option 0 to 10V

Current Output Option 4 to 20mA or 0 to 20nA

Read Rate 3/s

Power 115 VAC or 230 VAC ± 10%; 11 W Max; 240

Vrms overvoltage protection

Input Ranges 0 to 100mV; ±50 mV; 0 to 10 V; ±5 V; 0 to 20

mA; 4 to 20 mA

Max Error Strain / Process ±0.03% rdg

Accuracy 0.02% rdg

5Amber and green display colors can not be used concurrently with high display brightness unless connected

instrumentation is on a separate power supply.

32

Span Temperature Coefficient ±50 ppm/°C

Warm-Up Time (to rated accuracy) 30 min

Excitation Voltage Options 24V@25mA; 12V@50mA; 10V@120mA;

5V@60mA

NI CRIO-9066: CONTROL SYSTEM

Figure 3.7: cRIO Photo

Illustration 3.1: cRIO Slot Population

cRIO9066-1 is the control side of the MICIT, and contains modules with a variety of

control and data collection functions. cRIO9066-1 (colloquially known as “the cRIO”) has 8

module slots which are designated cRIO9066-1_1 through _8. Table 3.9 lists the specification the

cRIO9066. Table 3.10 lists the modules which are installed in each slot on the cRIO. In similar

fashion to the connectors within each sub-assembly, the cRIO modules have a dash followed by a

number appended to the model number. This aids in identification of which module is in each sub-

assembly. While a cRIO can be used to collect data, this is limited to redline data to reduce the

33

load on the cRIO and in doing so increase the responsiveness of the system. This minimizes the

time it takes for the system to react to a redline condition, and reduces the change of damage to or

failure of a test article.

Table 3.9: cRIO Specifications

SPECIFICATION6 VALUE

CPU Core Count 2

CPU Speed 667 MHz

DRAM 256 MB

Onboard Storage 512 MB

Operating Temperatures -4°F to +131°F (-20°C to +55°C)

Compatible Software LabVIEW 2014 or later; LabVIEW Real-Time

Module 2014 or later; LabView FPGA Module

2014 or later

Driver Software NI-RIO Device Drivers 14.0 or later

Timing Accuracy 5 ppm

Internal Battery Life (Unit Powered) 10 yr

Internal Battery Life (Unit Unpowered) 5 yr

Internal Battery Replacement Method RMA

Voltage Input Range 9 VDC to 30 VDC

Reverse Voltage Protection 30 VDC Maximum

Maximum Altitude 16404 ft (5000 m)

Weight (Unloaded) 36.97 oz (1048 g)

Sleep Mode Compatible Yes

Table 3.10: cRIO Slot Population

CRIO SLOT MODULE

6Additional Specifications Available in the cRIO9066 Spec Sheet

34

cRIO9066-1_1 NI9344-1

cRIO9066-1_2 NI9403-1

cRIO9066-1_3 NI9403-2

cRIO9066-1_4 NI9403-3

cRIO9066-1_5 NI9269-1

cRIO9066-1_6 NI9214-1

cRIO9066-1_7 N/A

cRIO9066-1_8 NI9205-1

NI CDAQ-9189: DATA ACQUISITION SYSTEM

Figure 3.8 cDAQ Photo

Illustration 3.2: cDAQ Slot Population

cDAQ9189-1 is the data acquisition side of the MICIT, and contains modules with a variety

of data collection functions. cDAQ9189-1 (colloquially referred to as “the cDAQ”) has 8 module

slots which are designated cDAQ9189-1_1 through _8. Table 3.11 lists the specifications of the

cDAQ9189. Table 3.12 lists the modules which are installed in each slot on the cDAQ. In similar

35

fashion to the cRIO modules, the cDAQ modules have a dash followed by a number appended to

the model number. This aids in identification of which module is in each sub-assembly. Large

quantities of incoming data can cause the cDAQ data log to lag behind real time, sometimes

reportedly taking 10 to 15 minutes to finish compiling data once a test has finished.

Table 3.11: cDAQ Specifications

SPECIFICATION7 VALUE

Maximum Sample Rate Determined by modules

Timing Accuracy 50 ppm of sample rate

Input Voltage Protection -20V min; +25V max

Output Voltage Protection -15V min; +20V max

Input Voltage Range 9V to 30V DC

Maximum Power Consumption 16W

Operating Temperature Range -40°F to +158°F (-40°C to +70°C)

Maximum Altitude 16404 ft (5000 m)

Weight (Unloaded) 37.6 oz (1065.9 g)

Sleep Mode Compatible No

Table 3.12: cDAQ Slot Population

CDAQ SLOT MODULE

cDAQ9189-1_1 NI9214-2

cDAQ9189-1_2 NI9214-3

cDAQ9189-1_3 NI9214-4

cDAQ9189-1_4 NI9214-5

cDAQ9189-1_5 NI9205-4

cDAQ9189-1_6 NI9205-2

cDAQ9189-1_7 NI9361-1

7Additional Specifications Available in the cDAQ9189 Spec Sheet.

36

cDAQ9189-8 NI9205-3

NI MODULE SPECIFICATIONS

NI9344

Figure 3.9: NI9344 Drawing

The NI9344 is an IO module with 4 physical input switches and 4 output LEDs. This

module can be used both to collect user input and display that said input has been received.

Table 3.13: NI9344 Specifications

SPECIFICATION VALUE

Operating Temperature Range -40°F to 158°F (-40°C to +70°C)

LED Solid On This channel has been programmed to be in the

on state

LED Off This channel has been programmed to be in the

off state

Digital Input 4 switches

Digital output 4 channels, LEDs

Switch Life Expectancy 50,000 operations

Power Consumption 145 mW max (Active mode); 25 µW (Sleep

Mode)

37

Weight 5.3 oz (150 g)

NI9403

Figure 3.10: NI9403 Photo

The NI9403 is a digital IO module with 32 channels. This module can be used to

communicate with other hardware such as, in the case of the MICIT, a relay control board.


SPECIFICATION VALUE


Input/Output Type TTL/single ended

Input Current ±250 µA Maximum from 0 V to 4.5 V

Output Current 64 mA

Input Voltage -0.25 V to 5.25 V

Input High 2.2 V Minimum

Input Low 0.8 V Maximum

Power Consumption 1 W Maximum (Active Mode); 25 µW

Maximum (Sleep Mode)

Channel to COM Safety Voltage No Greater Than ±30 V on up to 8 channels at

a time

Channel to Earth Ground Safety Voltage 60 VDC

38

Operating Temperature -40°F to 158°F (-40°C to +70°C)

NI9269


The NI9269 is an analogue output module with a nominal output of ±10V.


SPECIFICATION VALUE


Output Range ±10V Nominal; ±10.38 V Min; ±10.47 Typ;

±10.56 Max

Current Drive ±20mA all channels max; 10mA per channel

Overvoltage Protection ±30 V

Short Circuit Protection Indefinitely

Power Consumption 1 W Max (Active Mode); 120 µW (Sleep

Mode)


Channel to Channel Safety Voltage 250Vrms continuous

Channel to Earth Ground Safety Voltage 250 Vrms Continuous

Operating Temperature -40°F to 158°F (-40°C to +70°C)

39

NI9214


The NI9214 is a TC terminal block with capacity for 16 TCs. Figure 3.12 shows the NI9214

with the terminal block (TB-9214). Every NI9214 in the MICIT system is equipped with a TB-

9214.


SPECIFICATION VALUE

Number of Channels 16 TC Channels; 1 internal autozero channel; 3 internal

cold-junction compensation channels in TB-9214

Compatible TC Types J, K, T, E, N, B, R, S

Conversion Time 52ms in High Resolution Mode; 735 µs in High Speed

Mode

Sample Rate 1

(𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 𝑇𝑖𝑚𝑒 ∗ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶ℎ𝑎𝑛𝑛𝑒𝑙𝑠 𝑖𝑛 𝑢𝑠𝑒)⁄

or 100 S/s, whichever is smaller.

Warm Up Time 15 min to full rated accuracy

Overvoltage Protection ±30 V between any two inputs


40

Gain Error (Within Operating Temp.

Range)

0.15% Max (High Resolution Mode); 0.16% Max (High

Speed Mode)

Power Consumption 300 mW Max (Active Mode); 30 µW Max (Sleep Mode)

Thermal Dissipation 630 mW Max (Active Mode); 450 mW Max (Sleep

Mode)

Weight 5.0 oz (141 g) for NI9214; 3.6 oz (102 g) for TB-9214

NI9205


The NI9205 is an analogue input module with 16 double ended or 32 single ended channels.

It is available win both spring channel and D-Sub variants. The spring terminal variant has the

advantage of being easier to assemble than the D-Sub variant, however the spring terminal variant

is not suited to repeated connect/disconnect cycles. The MICIT currently uses the spring terminal

variant.


SPECIFICATION VALUE

Number of Channels 16 differential / 32 single ended

Conversion Time (Max Sample Rate) 4.00 µs (kS/s)

Nominal Input Ranges ±10 V; ±5 V; ±1V; ±0.2 V

41

Max Working Voltage Each Channel Must Stay Within ±10V of

COM

Power Consumption 625 mW (Active Mode); 15 mW (Sleep Mode)


Weight 5.7 oz (163 g) w/ spring terminal

NI9361


The NI9361 is a counter module which counts the frequency of a signal. In the MICIT

system, this module is used to count the frequency signal from the RCE turbine flow meters.


SPECIFICATION VALUE

Number of Inputs 8

I/O Signal Rate 1 MHz Max

Differential Input Voltage Range 0 V to 5 V

Single Ended Voltage Range 0 V to 24 V

Maximum Input Current 50 µA Max Per Terminal @5V Input; 1.5 mA

Max Per Terminal @ 24 V Input

42

Power Consumption 0.92 W Max (Active Mode); 53 µW Max

(Sleep Mode)



43

Chapter 4: Current System Advantages and Limitations

CURRENT SYSTEM

The current MICIT system allows for subsystems to share NI Modules in both the cRIO

and cDAQ. This was done to ensure that each module was filled as close to capacity as possible,

as installing duplicates of the same module solely to ease sub-assembly removal and installation

leads to a massive increase in the cost and complexity of the system. This layout works, however

it introduces several problems when troubleshooting a sub-assembly. Without a connector in

between the NI Module and the sub-assembly front panel, modules which share connections with

multiple sub-assemblies cannot be removed for troubleshooting without disconnecting adjacent

sub-assemblies as well. This increases the workload on the technician and introduces sources of

error when reassembling the system after troubleshooting has been completed. The “Box-style”

solution presented in the next section contains mitigation for this ‘multiple disconnect’

complication.

This ‘multiple disconnect’ complication has, at least once, caused a waterfall effect while

troubleshooting, wherein the investigation of a fault in one sub-assembly required disconnection

of another sub-assembly, which in turn introduced a fault in that sub-assembly upon reassembly.

One instance in particular, troubleshooting the connections to the bank of cryo PT amplifiers, led

to the removal and reinstallation of not only the cryo PT connections, but also the differential PTs

which share connections in NI9205-3. Breaking the connections to the NI Modules with a multipin

connector (DB9 or similar) on a sub-assembly basis would mitigate this problem by allowing for

single sub-assembly removal without affecting adjacent hardware.

FUTURE WORK

The current MICIT System meets the requirements set for it, however ease of use for the

people using and troubleshooting the system could be much improved. From an end user

perspective, there are several challenges to easy day to day operations that could be overcome in

44

future work. From a troubleshooting perspective there are several barriers to easy identification of

the problem source.

As an end user, the main barrier to easy use of the system on a day to day basis comes in

the form of cable management and connection. The quantity of instrumentation in any one setup

combined with the mobile nature of the MICIT means that any given test day begins with plugging

in up to 200 individual connectors. This presents an enormous drain on personnel and imparts a

significant delay to the beginning of the test day. One suggested solution is to re-terminate the

harnessing, so that the connection/disconnection point is located at the outer wall of the MICIT

and is accomplished through the use of 48-pin cannon plugs. This strategy would bring that 200-

connection number down to approximately 6, depending on pinout configuration in the cannon

plugs. Thermocouple connections would still need to be made individually, as thermocouple

cannon plugs are prohibitively expensive. The same could be done at the other side of the

harnessing, further reducing the number of man-hours consumed by harnessing set-up. While this

seems like an easy solution, implementation requires several weeks of time from a trained

technician who would be tasked with splicing into the existing harnesses and assembling the

connectors.

As a technician working to troubleshoot a problem and/or verify correct operation of the

system, the main barrier to ease of work presents itself in the complexity of the wiring behind the

front panels. While most sub-assemblies are only connected to one front panel, the wiring in the

rack is not confined to the area behind that panel. Wiring for every sub-assembly shares a sort of

common area in the rack as it makes its way over to the cRIO and cDAQ. This complicates

troubleshooting efforts, as the technician working the problem has to work in cramped conditions

within the rack and must work around the wiring for the other sub-assemblies. All of this must be

done without disturbing the other sub-assembly wiring, so as not to introduce another potential

issue to troubleshoot.

One solution to this problem, and the solution proposed for future work, is to isolate each

sub-assembly to a 1U, 2U, or 3U rack mount ‘box’ that can be pulled out of the system in one

45

piece so that problems may be worked on a lab bench. Take the UPS as an example. Should a

technician or user notice a problem in power delivery when on battery power, one approach could

be to remove the UPS from the rack, which would isolate the work to the UPS alone. A similar

style box, containing all the wiring for a sub-assembly, with a front panel exactly like the ones in

the current setup and a single connector (DB37 or similar) on the back would simplify the

troubleshooting process. The technician could remove the box in question and take it to a bench

where he/she could work the problem without fighting cramped conditions and the wiring from

other sub-assemblies. The technician would also avoid tampering with other subsystems, as

disconnecting from the cRIO or cDAQ at the connector on the box eliminates the need to remove

the NI Module it connects to. This solution also dramatically improves the cable management

situation in the rack, as the large volume of common wiring area would be broken up into discrete

units for each sub-assembly.

Obstacles to implementation of this system presents themselves in the time, money, and

labor required to locate all of these subsystems in rack mount boxes. One way to reduce the cost

would be to remove the existing wiring from the racks, place it into boxes, and then reinstall the

boxes in the racks. This comes with the downside of requiring that the MICIT be offline during

the rework. Another option, which doesn’t require that the MICIT be taken offline for as long, is

to purchase new wiring, connectors, and hardware so that the box-style sub-assemblies could be

built up while the MICIT is operational. With this strategy, the sub-assemblies could be assembled

and tested prior to taking the MICIT offline for installation. The existing wiring and hardware

could then be reworked into box-style modules in similar fashion to first method, allowing for

doubled capacity in the current MICIT, or for a duplicate MICIT to be constructed. The obvious

downside to this second method is cost, as the hardware in the trailer accounts for the majority of

the cost of the system. Despite the cost, a backup MICIT, however, may be an invaluable asset for

continued testing operations in the future. In fulfilling its purpose as a one-size-fits-all one-stop-

shop for data acquisition and system control, the MICIT did introduce a bottleneck into the testing

scheme out at the Fabens facility. This bottleneck is that there is only one MICIT. Only one test

46

can be performed at a time anywhere on site, and one team cannot work on setting up their test

while another team is testing, or preparing to test. This bottleneck also means that, should the

MICIT experience a fault and go offline, all testing that relies on the MICIT stops dead. Having a

duplicate or backup system would allow for testing to continue while the fault is worked out.

47

References

Omega.com, Multiple Product Specification Sheets and Pricing Information. Retrieved

from https://www.omega.com/en-us/

TDK Lambda, Product Specifications. Retrieved from https://www.us.tdk-lambda.com/

Acopian Power supplies, Product Specifications and Pricing. Retrieved from

https://www.acopian.com/

Mouser.com, Multiple Product Specification Sheets and Pricing Information. Retrieved

from https://www.mouser.com/

McMaster.com, Multiple Product Specification Sheets and Pricing Information. Retrieved

from https://www.mcmaster.com/

NEMA 5-15 image, Image retrieved from https://images-na.ssl-images-

amazon.com/images/I/81HYb1h78QL._SL1500_.jpg

APC UPS, Product Specifications and Pricing. Retrieved from https://www.apc.com/

National Instruments, Multiple Product Specification Sheets and Pricing Information.

Retrieved from https://www.ni.com/en-us/

Thermocouple temperature ratings, K-Type and E-Type data. Retrieved from

https://www.thermocoupleinfo.com/type-e-thermocouple.htm

Chaparro, Javier, “The Development of a Data Acquisition and Control System for Rocket

Propulsion Research” (Masters Thesis)

Rojo III, Raymundo Mendivil, “Development and Implementation of the tRIAc Data

Acquisition and Control System” (Masters Thesis)

https://www.omega.com/en-us/

https://www.us.tdk-lambda.com/

https://www.acopian.com/

https://www.mouser.com/

https://www.mcmaster.com/

https://images-na.ssl-images-amazon.com/images/I/81HYb1h78QL._SL1500_.jpg

https://images-na.ssl-images-amazon.com/images/I/81HYb1h78QL._SL1500_.jpg

https://www.apc.com/

https://www.ni.com/en-us/

https://www.thermocoupleinfo.com/type-e-thermocouple.htm

48

Glossary

TERM DEFINITION

(‘) or (ft) Foot; Units of length

(“) or (in) Inches; Units of length

µ Micro; x10^-6

4-Pin Speaker Connector Conxall/Switchcraft HPCC4FT and compatible variants. These

are available in cable mount M and F connectors as well as panel

mount F connectors, all of which are used in the MICIT system.

See parts list for model numbers and sources.

A Amps (Amperes); Units of electrical current

A8MT500 8VDC power supply module by Acopian. Input 105-125VAC,

output 8VDC @ up to 5A.

BTU Units of Heat

cDAQ NI Compact DAQ

cRIO NI Compact RIO

Cryo Common abbreviation for cryogenic, i.e. very low temperatures.

In this document, cryogenic refers to temperatures in the range at

which liquid nitrogen, oxygen, and methane boil (at standard

atmospheric pressure).

DAQ Data Acquisition System

DB37 37-Pin variant to the common D-Sub connector

DB9 9-Pin variant of the common D-Sub, or D-Subminiature,

connector

dBA Decibel; Units of sound intensity

49

FPS-T1U A rack mount power supply product manufactured by TDK-

Lambda. The unit has 3 slots which can each accommodate one

of the several power supply units supplied by TDK-Lambda. Our

unit contains a 24V and a 12V unit at the time of writing. One slot

remains open.

FPS-T1U_1

24VDC power supply in the first slot (on the left) of FPS-T1U.

Output: 24VDC @40A

FPS-T1U_2

12VDC power supply in the second slot (middle) of FPS-T1U.

Output: 12VDC @72A

FPS-T1U_3 Empty bay in the 3rd slot (on the right) of FPS-T1U

g Grams (Units of weight)

hr hours

IO Input/Output

J Joules; Units of energy

kg Kilograms; Units of mass

lb Pounds; Units of weight

LO2/LCH4 Liquid Oxygen and Liquid Methane Propellant Combination

(Commonly pronounced Lox Methane)

m meter

mA milliamp

MB Megabytes (Units of data storage)

MHz Megahertz (Units of frequency)

MICIT Mobile Instrumentation and Control Interface Trailer

min minutes

ms millisecond

50

NC Normally Closed

NEMA 5-15P Standard US grounded wall plug for 120VAC power (See Figure

A1)

NEMA 5-15R Standard US grounded wall socket for 120VAC power (See

Figure A1)

NO Normally Open

OME-DB-24PRD/24/DIN A 24-Channel Power Relay Output board from Omega. This unit

can switch up to 5A@250VAC or 5A@30VDC. This unit uses a

DB37 to connect to the cRIO module that controls it.

oz Ounces (units of weight)

ppm Units of timing accuracy; seconds of drift per million seconds of

operating time

PT Pressure Transducer

RMA Return Material Authorization (Hardware Repair or

Replacement)

s second

S/s Samples per second

SMT1500RM2U UPS that provides 120V AC power to the system.

SV Solenoid Valve

TC Thermocouple

TTL Transistor-Transistor Logic

UPS Uninterruptable Power Supply

V Volts; Units of Voltage; VAC is used for AC Voltage; VDC is

used for DC Voltage

Volt-Amp-Hour Units of power output; describes the theoretical max power output

of a battery; calculated by multiplying voltage * current * time

51

yr year

52

Appendix A

PART NAME MODEL NUMBER MANUFACTURER PRICE

UPS SMT1500RM2U APC.com $730.00

UPS Replacement

Battery

APCRBC133 APC.com $219.99

8VDC Power Supply A8MT500 Acopian.com $300.00

Rack Mount Power

Supply Housing

FPS-T1U Mouser.com $717.10

Male Banana Plug 565-MDP-02 Mouser.com $7.18

Female Banana Plug 565-2269-0 Mouser.com $4.50

48-Pin Cannon Plug

Box Mount

654-UPT00D-24-48S Mouser.com $13.12

48-Pin Cannon Plug 654-UPT06D-24-48P Mouser.com $13.04

Male 4-Pin Speaker

Connector

502-HPCC4FT Mouser.com $6.61

Panel Mount Female

4-Pin Speaker

Connector

568-NL4MD-V-2 Mouser.com $3.64

Cable Mount Female

4-Pin Speaker

Connector

502-HPCI4F Mouser.com $9.60

Male DB9, Plastic

Housing

2146T11 McMaster.com $2.18

Female DB9, Plastic

Housing

2146T12 McMaster.com $2.39

Panel Mount BNC 530-VB1094 Mouser.com $2.60

53

2 Wire Cable,

SJOOW, Black

Insulation, 18AWG

7422K2 McMaster.com $0.62/ft

2 Wire Cable,

16AWG, Gray

Insulation, 1000ft

566-5200FE-U1000-

08

Mouser.com $336.45

3 Wire Cable,

SJOOW, Black

Insulation, 18AWG


4 Wire Cable,

SJOOW, Black

Insulation, 18AWG


Flexible K-Type TC

Extension wire,

yellow polyvinyl

insulation, 500ft

EXPP-K-24S-500 Omega.com $249.37

Abrasion resistant K-

Type TC wire, 1000ft

TFE-K-20S-1000 Omega.com $1072.00

Flexible E-Type TC

Extension wire,

purple polyvinyl

insulation, 500ft

EXPP-E-24S-500 Omega.com $238.13

Abrasion resistant E-

Type TC wire,1000ft

TFE-E-20S-1000 Omega.com $1072.00

E-Type Male

Connector

SMPW-E-M Omega.com $2.28

54

E-Type Female

Connector

SMPW-E-F Omega.com $2.70

K-Type Male

Connector

SMPW-K-M Omega.com $2.28

K-Type Female

Connector

SMPW-K-F Omega.com $2.70

BNC Back-to-Back 568-NBB75FA Mouser.com $8.28

Relay Card OME-DB-

24PRD/24/DIN

Omega.com $415.00

Relay Card

Connection DB37

Cable

OME-CA-3710 Omega.com $52.00

Cryo PT Amplifier DP25B-E-A Omega.com $393.75

NI cRIO-9066 cRIO-9066 NI.com $2269.00

NI cDAQ-9189 cDAQ-9189 NI.com $1724.00

NI9344 NI-9344 NI.com $146.00

NI9403 NI-9403 NI.com $459

NI9269 NI-9269 NI.com $1022

NI9214 NI-9214 NI.com $1719

NI9205 NI-9205 NI.com $930

NI9361 NI-9361 NI.com $720

PCB Piezotronics

Amplifier

Model 483C Series Pcb.com $1345.00

Warning Light 5808T92 McMaster.com $58.79

Alarm Bell, 96dB 5658T66 McMaster.com $179.06

55

Appendix B

NOTE 1: While it may be tempting to add new capability to the MICIT system in the form of

unique system support panel format like MICIT-L1, keep in mind that a unique cluster of

connectors like this will be hard to make use of in any other experiment. As a result, unique support

panels like -L1 are a step back towards the ‘DAQ for each experiment’ format, which drives up

system cost. Support for unique panels is included for the rare situation where the instrumentation

has no generic connection format, but it is advised that the engineer attempt to come up with a

generic interface panel, should new instrumentation support be required.

Figure A1: NEMA 5-15 Picture

56

Vita

Corey Garrett Hansen has a Bachelor of Science in Mechanical Engineering from the

University of Texas at El Paso and has worked a combined 10 months as a Pathways Intern at

NASA Johnson Space Center in Houston, Texas. He has training on the safe operation of high

intensity laser, cryogenic fluid, high pressure gas, and vacuum systems as well as training on safe

handling of flight rated spacecraft window panes and hardware. He has also received training on

Geometric Dimensioning and Tolerancing (GD&T) and Tolerance Stack Analysis.

His experiences at the University of Texas at El Paso grew his skills in automotive

prototype vehicle design through the Shell EcoMarathon program, as well as rocket engine design,

rocket propulsion fuel feed system design and testing, high powered laser system operation, and

data acquisition system design through his work as a Graduate Research Assistant with the Center

for Space Exploration and Technology Research (cSETR).

His work at NASA JSC has involved a variety of disciplines including propulsion,

spacecraft structures, and hardware development. He has gained experience in reaction control

engine (RCE) design and testing, spacecraft weight estimation and structure optimization,

spacecraft window material testing, ground support equipment (GSE) design, and spacecraft

window inspection.

Contact Information: <[email protected]>

design specifications and requirements for a mobile data

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