Micro/Nano Technology Sol-Gel Corrosion Sensor System Project

Transcription

1 Micro/Nano Technology Sol-Gel Corrosion Sensor System Project End of the Project Report Max Yen, Dong Chen, and Paul Lin College of Engineering, Technology, and Computer Science Indiana University-Purdue University Fort Wayne April 14, Micro-Nano Technology So-Gel Corrosion Sensor System End of Project Report 1. Sol-gel and Cylindrical Sensors Sol-gel Sensors: tar-coal epoxy coated and uncoated Cylindrical sensor: tar-coal epoxy coated and uncoated Sensor Testing and Calibration 2. Analog Signal Processing Circuits and Printed Circuit Board (PCB) 3. Corrosion Sensor Modules (Boxes) 4. Corrosion Monitoring Sensor System (CMS) 5. Deployment of Sensors and CMS at RIA, IL 6. Networking and Communication Subsystem 7. Remote Data Collection using Cloud-based Services 8. Sensor Data Analysis and Interpretation 9. Summary and Future Work 2 1

2 1. Sol-Gel and Cylindrical Sensors Cylindrical Corrosion Sensor A36 steel rod with diameter of 1.27 cm and height of 0.64 cm Electrical wire connected to the A36 steel rod 316 stainless steel ring with inner diameter of 2.22 cm, outer diameter of 2.54 cm, and height of 0.64 cm Electrical wire connected to the 316 stainless steel ring Connecting bridge insular with water-proof epoxy insulation 3 Lab Test of the Corrosion Sensor 4 2

3 Iron Loss of the Cylindrical Sensor due to Corrosion Accumulated Fe in solution (mg) Accumulated Fe in solution Fe lost rate in solution Fe loss rate in solution (g/(m 2 d)) Time in 0.2 M NaCl solution (hr) The iron loss rate and the accumulated iron loss in the solution during the test of the prototype corrosion sensor containing A36 steel in an aerated 0.2 M NaCl solution. 5 XRD of Iron Rust Intensity (degree) CuK XRD patterns of the corroded A36 steel samples. The identified crystals are 1: iron, 2: lepidocrocite, 3: magnetite

4 Table. Property of Iron Rust at Ambient Temperature Materials -Fe 2 O 3 -FeOOH Fe 3 O 4 -FeOOH amorphous Fe 2 O 3 iron air Electrical resistivity ( m) ( ) 10 4 [29] ( ) 10 5 [30] [31] ( ) 10 5 [30] [32] Dielectric constant [33] [34] Note: Data are from reference [35] unless otherwise noted. 7 The Capacitance of the Sensor C = 2πε 0h ε ln b a where: C = capacitance (F) ε 0 = free space permittivity, 8.85 pf/m h = height of the cylinder sensor (m) ε = dielectric constant of the material(s) between the A36 steel rod and the 316 stainless steel ring b = inner radius of the 316 stainless steel ring (m) a = radius of the A36 steel rod (m) 8 4

5 Increased Capacitance of the Sensor due to Corrosion Normalized capacitance in parallel (C/C 0 ) Corrosion sensor Reference sensor Time in 0.2 M NaCl solution (hr) Normalized capacitance in parallel (C/C 0 ) of the sensors vs. the accumulated time in an aerated 0.2 M NaCl solution. 9 Decreased Resistance of the Sensor due to Corrosion Normalized resistance in parallel (R/R 0 ) Corrosion sensor Reference sensor Time in 0.2 M NaCl solution (hr) Normalized electrical resistance in parallel (R/R 0 ) of the sensors vs. the accumulated time in an aerated 0.2 M NaCl solution. 10 5

6 Coal Tar Epoxy Coated vs. Not Coated A36 Cylindrical Sensor Capacitance change beore/after coating on A36 cylindrical sensor Capacitance in series (pf) A1 A1 coated A2 A2 coated 0 Coal tar epoxy coating 11 Coal Tar Epoxy Coated vs. Not Coated A36 Cylindrical Sensor Capacitance change beore/after coating on A36 cylindrical sensor Capacitance in series (pf) A3 A3 coated A3 coated cut A4 A4 coated A4 coated cut 0 Coal tar epoxy coating 12 6

7 Coal Tar Epoxy Coated vs. Not Coated Stainless Steel Cylindrical Sensor Capacitance change beore/after coating on stainless steel cylindrical sensor Capacitance in series (pf) SS1 SS1 coated SS2 SS2 coated 0 Coal tar epoxy coating 13 Coal Tar Epoxy Coated vs. Not Coated Stainless Steel Cylindrical Sensor Capacitance change beore/after coating on stainless steel cylindrical sensor Capacitance in series (pf) SS3 SS3 coated SS3 coated cut SS4 SS4 coated SS4 coated cut 0 Coal tar epoxy coating 14 7

8 Salt Fog Test of the A36 Cylindrical Sensor Coal Tar Coated A36 Cylindrical Sensor 800 Capacitance in series (pf) 700 A1 A2 A3_Cut A4_Cut Accumulated time in salt fog chamber (hr) 15 Salt Fog Test of the Stainless Steel Cylindrical Sensor Coal Tar Coated Stainless Steel Cylindrical Sensor 90 Capacitance in series (pf) SS1 SS2 SS3_Cut SS4_Cut Accumulated time in salt fog chamber (hr) 16 8

9 The Diagram of a Sol-Gel Corrosion Sensor Coal Tar Epoxy Coated vs. Not Coated Sol-Gel Sensor Capacitance change beore/after coating on sol-gel sensor Capacitance in series (pf) P1 P1 coated P2 P2 coated 0 Coal tar epoxy coating 18 9

10 Coal Tar Epoxy Coated vs. Not Coated Sol-Gel Sensor Capacitance change beore/after coating on sol-gel sensor Capacitance in series (pf) P1 P1 coated P2 P2 coated 0 Coal tar epoxy coating 19 Coal Tar Epoxy Coated vs. Not Coated Sol-Gel Sensor Capacitance change beore/after coating on sol-gel sensor Capacitance in series (pf) P3 P3 coated P3 coated cut P4 P4 coated P4 coated cut 0 Coal tar epoxy coating 20 10

11 Salt Fog Test of Coal Tar Epoxy Coated Sol- Gel Sensor Coal Tar Coated Sol-Gel Sensor 45 Capacitance in series (pf) P1 P2 P3_Cut P4_Cut Accumulated time in salt fog chamber (hr) Analog Signal Processing Circuit and Fabrication of Printed Circuit Boards Analog Signal Processing Circuits and Printed Circuit Board (PCB): a) Voltage regulator (± 22V DC input; ±15 V DC output) b) 1 khz sine wave generator c) Capacitance-to-voltage conversion d) Precision full-wave rectifier e) Signal amplifier f) Root-mean-square and final signal buffering g) Printed Circuit Board Design and Fabrication 22 11

12 2. Analog Signal Processing Circuit and Fabrication of Printed Circuit Boards Analog Signal Processing Sin Wave Generator (5V Pk- Pk) Capacitance to Voltage Conversion Precision Full-Wave Rectifier ADAM bit DAC Loading Effect Buffer Noise Filter Signal Amplifier & Processing CMS Analog Signal Processing Circuit and Fabrication of Printed Circuit Boards Fabricated PCB Boards and ADMA 4016 ADC 24 12

13 3. Corrosion Sensor Modules (Boxes) Corrosion Sensor Modules (Boxes): a) Power supply b) RS-485 communication c) Microcomputer with 16-bit ADC (analog-to-digital conversion) d) Sensor Box Packaging with Sensor s analog signal processing PCB e) Cabling f) Deployment of Six Sensor Boxes Corrosion Sensor Modules (Boxes) Corrosion Sensor Modules (Boxes): 5 PIN connector Pin 1: Ground Pin 2: Power +22V Pin 3: Power -22V Pin 4: Ground Pin 5: Power +22V P C B PCB OUT + PCB OUT - Vin- Vin+ Watertight Box 26 13

14 3. Corrosion Monitoring Sensor System Six RS485-based Sensor Nodes with 16-bit ADC: Sensor plus Sensor DAC box Inside view of sensor DAC box Mounted sensor box with Army S1 to S6 labels on all sides Corrosion Monitoring Sensor System Corrosion Monitoring Sensor System (CMS) a) Power supply system b) The Central Monitoring Computer (CMC) Fanless Embedded Computer, Windows XP OS setup and networking option configuration RS485 serial communication: CMS to Sensor Nodes Ethernet Ports for Internet communication c) Thermal Electric Cooler: mounted on the front-side of the CMC d) Six RS485-based Sensor Nodes with 16-bit ADC e) Packaging and Cabling f) Software for Polling Sensor Data Processing and Storage 28 14

15 4. Corrosion Monitoring Sensor System 16-bit A/D x 1 Analog AC 1 khz Signal Digital Source Processing Output x Unit 2 Built-In Sol-gel System Corrosion Program Sensor Power ADAM-4016 RSsupply 485 DAQ Node Corrosion Sensor Connected through RS-485- based DAQ Unit No. 1 Address #2 Corrosion Sensor DAQ Unit No. 2.. Corrosion Sensor DAQ Unit No. 5 Address #1 RS-485 Daisy Chain Link RS-485 Daisy Chain Link RS RS-232 CMS Programs/ Scripts Sensor Data Storage Windows XPembedded Ethernet/ RJ45 Internet Gateway Industrial Fanless PC Address #3 AC 1 khz Source Analog Signal Processing Unit 16-bit A/D x 1 Digital Output x 2 Address #6 Sol-gel Corrosion Sensor Built-In System Program Power ADAM-4016 RSsupply 485 DAQ Node Corrosion Sensor Connected through RS-485- based DAQ Unit No Corrosion Monitoring Sensor System a) The Central Monitoring Computer (CMC) UNO-2173 AF: Fanless Embedded Computer (Intel Atom N GHz processor), Windows XP OS 4 x USB 2.0 ports RS485 serial communication: CMS to Sensor Nodes Ethernet Ports for Internet communication Operating temperature range: -20 C to 70 C 30 15

16 CMS Wiring Diagram Power Supplies +22 V Gnd -22 V Fanless Embedded Computer/PC: UNO-2173A DC Power Input AC 120V Line For Faneless PC Power DC 24V/2.5A For sensor electronics DC 24V/1.7A For sensor electronocs DC 24V/1.7A CAT-6 RJ-45 Socket x 4 RS-485 Communication lines Pin 1: Power +22V (Orange / Orange White) Pin 2: Power +22V (Orange / Orange White) Pin 3: Ground (Green / Green White) Pin 4: Data+ (Blue) Pin 5: Data- (Blue White) Pin 6: Ground (Green / Green White) Pin 7: Power -22V (Brown / Brown White) Pin 8: Power -22V (Brown / Brown White) RJ-45 Connector for Sensor Electronics Circuit Board 23 AWG CAT-6 Cable +Vs: Power +22V GND 10: Ground Pin 1: Ground Sensor Pin 2: Power +22V Pin 3: Power -22V Electronics Pin 4: Ground + Pin 5: Power +22V PCB 5 PIN - connector Analog out Sol-Gel Sensor under Testing 8 Pin Weathersealed Connector Plug back-end viewed from cable side 4 5 Pin 1: Data+ (Blue) Pin 2: Data- (Blue White) Pin 3: Not use Pin 4: Power +22V (Orange / Orange White) Pin 5: Power -22V (Brown / Brown White) Pin 6: Ground (Green / Green White) Pin 7: Not use Pin 8: Not use Vin- Vin+ Analog Input Data Acquisition Unit Watertight Box Corrosion Monitoring Sensor System Packaging and Cabling Power Cable RJ 45 Internet Corrosion Sensor S1 S2 S3 Corrosion Sensor S4 S5 S

17 4. Corrosion Monitoring Sensor System Installation (May 2013) Power Supplies Thermal Electric Cooler (200 BTU) Central Monitoring Computer (Windows XP, embedded) Six Sensor Connection Suckets and Cabling Corrosion Monitoring Sensor System Installation May 2013 Power Supplies Thermal Electric Cooler Central Monitoring Computer (Windows XP, embedded) Six Sensor Connection Sockets and Cabling 34 17

18 4. Corrosion Monitoring Sensor System Server Scripts/Programs CMS sensor data polling program Every 30 minute, read sensors capacitance value: S1, S6 Add time stamps Store sensor data S1, S6 Sensor node control, data access Remote access to the CMS through a secured web client Deployment and Testing of Sensors at RIA Bridge, IL R Sensor #1 (coal tar epoxy coated sol-gel sensor) Sensor # 2 (coal tar epoxy coated sol-gel sensor) Sensor #3 (sol-gel sensor) Sensor #4 (sol-gel sensor) Sensor #5 (stainless steel cylindrical sensor, coal-tar epoxy coated) Sensor #6 (A36 cylindrical sensor, coaltar epoxy coated) 2 5&

19 Sensor Locations on the Government Bridge Deployment and Testing of Sensors at RIA Bridge, IL Sensor #1 (coal tar epoxy coated sol-gel sensor) at the lower car deck (31 inches above the deck, 2 ft above the car deck level, on the west side of the bridge) Sensor #1 Sensor DAQ Box #1 Box#1 (before installation) Sensor # 2 (coal tar epoxy coated sol-gel sensor) at the top of bridge control room (mounted on the vertically south side) Sensor #2 Sensor DAQ Box#

20 5. Deployment and Testing of Sensors at RIA Bridge, IL Sensor #3 (sol-gel sensor) on the ceiling of the car deck, or below train deck (west side) Sensor #3 and Sensor DAQ Box#3 Sensor #4 (sol-gel sensor) on the ceiling of the car deck, or below train deck (east side) Sensor #4 and Sensor DAQ Box# Deployment and Testing of Sensors at RIA Bridge, IL Sensor #5 Cylindrical Sensor (316 stainless steel cylindrical rod and ring, coal-tar epoxy coated) under the car deck (west side) Sensor #5 and Sensor DAQ Box#

21 5. Deployment and Testing of Sensors at RIA Bridge, IL Sensor #6 Cylindrical Sensor (A36 cylindrical rod sensor, stainless steel outer ring, coal-tar epoxy coated) under the car deck (east side) Deployment and Testing of Sensors at RIA Bridge, IL Testing RS 485 Communication Link from CMS to ADAM 4016 DAC Module 42 21

22 5. Deployment and Testing of Sensors at RIA Bridge, IL Initial Testing of Deployed Sensors using ADAM Utility & Spraying Water on Sensors Networking and Communication Subsystem (for Transporting Sensor Data) Networking and Communication Subsystem a) Fanless PC Two Ethernet b) Two RJ 45 Ethernet Ports Two Wireless N USB Adapters c) Two Wireless N USB Adapters (no Fixed IPs) Two WiFi Hotspots (3G) d) 3G Cellular Carrier Tower Internet 44 22

23 6. Networking and Communication Subsystem Arsenal Bridge, Rock Island, IL INTERNET AT&T DSL Modem Linksys 4 port switch CMS Arsenal Computer ARMY Corrosion Monitoring Sever Arsenal Bridge Control Tower Smart Phone Computer Initial Connection Setup Internet Remote Access using LogMeIn, through Hamachi Virtual VPN managed by Chandler. (tried but failed) Laptop Networking and Communication Subsystem Arsenal Bridge, Rock Island, IL INTERNET Sprint Cell Tower 3G Signal Internet on the Go 3G Mobile Hot Spot (Sprint) WIFI Signal Smart Phone Computer Laptop NENTGEAR WIFI Range Extender ARMY Corrosion Monitoring Sever Arsenal Bridge Control Tower Wi-Fi Hotspot for Internet Remote Accessing to the CMS (not reliable, failed a couple times) 46 23

24 6. Networking and Communication Subsystem Redundant WiFi Hotspots and LAN Adapters Hot Spot 1 USB WiFi Adapter 1 Hot Spot 2 USB WiFi Adapter Networking and Communication Subsystem Redundant WiFi Hotspots and LAN Adapters Arsenal Bridge, Rock Island, IL INTERNET Sprint Cell Tower 3G Signal Internet on the Go 3G Mobile Hot Spot (Sprint) Internet on the Go 3G Mobile Hot Spot (Sprint) WIFI Signal Smart Phone Computer Laptop NENTGEAR N300 Wireless-N USB Adapter ARMY Corrosion Monitoring Sever TP-LINK Wireless-N USB Adapter Current Connection Setup 48 Arsenal Bridge Control Tower 24

25 Redundant WiFi Hotspots and USB LAN Adapter 1 st WiFi HotSpot 2nd WiFi HotSpot Cooling Fan & Thermal Stat 2 WiFi HotSpot Computer Side Wireless LAN Adapter Networking and Communication Subsystem 50 25

26 7. Sensor Data and Remote Data Collection a) Data Collection and Storage Data saved (every 30 minutes) at the CMS system located at RIA bridge b) Cloud-based Remote Access: LogMeIn c) Move data to Cloud-based Data Store: Drop Box Sensor Data and Remote Data Collection b) Cloud-based Remote Access: LogMeIn 52 26

27 8. Sensor Data Analysis and Interpretation a) Data Analysis Data move to Excel Spread sheet Obtain humidity, temperature, and weather data of RIA from National Weather station Regression Analysis of the Sensors Capacitance Reading: y =β 1 x 1 + β 2 x 2 +α; y = estimated capacitance of y (capacitance); x 1 is temperature, x 2 is humidity 53 Capacitance of Sensor #1 (Coated Sol-Gel at the Car Deck Level) 54 27

28 Capacitance of Sensor #2 (Coated Sol-Gel outside the Control Room) 55 Capacitance of Sensor #4 (Uncoated Sol-Gel on the Ceiling of the Car Deck) 56 28

29 Capacitance of Sensor #5 (Coated Stainless Steel Cylindrical Sensor Under the Car Deck) 57 Capacitance of Sensor #6 (Coated A36 Cylindrical Sensor Under the Car Deck) 58 29

30 Data Interpretation The proposed formula is: Capacitance = β 1 *Temp + β 2 *Moisture + β 3 *Corrosion index + constant, where β 1, β 2 and β 3 are coefficients. Temp and moisture data are collected along with the capacitance readings. Dummy or reference sensors help to draw the baseline, including temp, moisture and surface fouling. Corrosion index is evaluated in lab tests, such as soaking in aerated NaCl solution and salt fog chamber. Multi-regression analysis is being conducted. 59 Primary Conclusions Corrosion triggered higher capacitance reading of the sensors, including both cylindrical and sol-gel sensors. Coating of coal tar epoxy decreased the capacitance of the sensors. This suggests that deterioration of the coating would increase capacitance, which is in consistence with the corrosion effect on capacitance. Moisture had much bigger impact on capacitance than temperature. Greater capacitance occurred at higher moist level

31 9. Summary and Future Work 1) Improved Internet and remote CMS system accessibility with at least one dedicated static IP address to provide better remote system access and maintenance support. 2) Improved Wireless Sensor Nodes and Networks to enhance the system reliability 3) Additional local temperature and humidity data collection Summary and Future Work Improved Wireless Sensor Nodes and Networks to enhance the system reliability Wired star network: RS-485, Wireless Mesh Network 62 31

32 9. Summary and Future Work Improved Wireless Sensor Nodes and Networks to enhance the system reliability Redundant measurement using an extra wireless sensor node running ZigBee sensor network protocol Mesh sensor network to provide maximum recheability and data routing for each sensor Arduino Uno with Xbee Shield Sensor ASP Unit Humidity Sensor Temperature Sensor Summary and Future Work Wireless Sensor Nodes and Networks to enhance the system reliability Arduino Uno with Xbee Shield Transmitter Mesh Wireless ZigBee Sensor ASP Unit ADAM-4016 DAQ Receiver (Coordinator) Sensor 1.. Arduino Uno with Xbee Shield RS-485 COM 3 CMS Server Connected and powered Via USB Transmitter Sensor ASP Unit ADAM-4016 DAQ Sensor

33 9. Summary and Future Work Experimental Testing of Wireless Sensor Nodes and Networks to enhance the system reliability Summary and Future Work Experimental Testing of Wireless Sensor Nodes and Networks to enhance the system reliability Arduino Uno with Xbee Shield Arduino Uno with Xbee Shield Sensor 1 Connected and powered Via USB ASP Unit XP Embedded Server Receiver (Coordinator) DSP Unit Battery (ADAM4016) Transmitter Sensor CMS Server RS

34 9. Summary and Future Work Experimental Testing of Wireless Sensor Nodes and Networks to enhance the system reliability IPFW ETCS Building 3F Outdoor LOBBY 100 FEET 2F Base Station Node (Coordinator) 1F 30 FEET Sensing Node 50 FEET Sensing & Routing Node FEET Sensing & Routing Node Summary and Future Work Experimental Testing of Wireless Sensor Nodes and Networks to enhance the system reliability Base Station node (Coordintor) 30 FEET 100 FEET Sensing & Routing node FEET Sensing node 50 FEET Sensing & Routing node