Curriculum: Data Monitoring, Warning, Shutdown, Acquisition, and Logging in Industrial Applications

Course Objectives

1. Teach participants how to monitor, log, and analyze industrial process data.

2. Implement warning and shutdown mechanisms to prevent system failures.

3. Develop expertise in using WaveForms and LabVIEW for industrial data applications.

4. Design and execute robust systems for data acquisition, storage, and fault prevention.

Target Audience

• Engineers and technicians working in manufacturing or process industries.

• Researchers and developers of industrial automation systems.

• Advanced students of industrial or electrical engineering.

Module 1: Introduction to Data Acquisition and Industrial Processes

1. Basics of Industrial Data Acquisition
   
   

   • Role of data monitoring in factories and manufacturing processes.

   • Common industrial parameters: temperature, pressure, flow rate, voltage, current, etc.

2. System Overview
   
   

   • Components of a data acquisition and monitoring system:

     • Sensors/transducers.

     • Data acquisition hardware (Analog Discovery, DAQ cards).

     • Software platforms (WaveForms, LabVIEW).

3. Safety Systems
   
   

   • Warning systems for threshold breaches.

   • Shutdown mechanisms for critical fault prevention.

Module 2: Data Acquisition and Monitoring using WaveForms

1. Introduction to WaveForms Software
   
   

   • Overview of its tools: Oscilloscope, Logic Analyzer, and Data Logger.

   • Setting up the Analog Discovery for industrial data acquisition.

2. Configuring Inputs
   
   

   • Connecting sensors to the Analog Discovery device.

   • Configuring analog and digital channels for process monitoring.

3. Real-Time Monitoring
   
   

   • Using the Scope and Data Logger tools to monitor signals.

   • Setting triggers for alarms and warnings.

4. Warning Systems
   
   

   • Implementing warning triggers based on signal thresholds.

   • Configuring visual (on-screen alerts) and audio warnings in WaveForms.

5. Data Logging and Storage
   
   

   • Setting up the Data Logger for periodic signal recording.

   • Exporting data to CSV/Excel for industrial reporting and diagnostics.

6. Practical Activity
   
   

   • Configure a system to monitor the temperature of a motor.

   • Trigger warnings for high-temperature events and log data for analysis.

Module 3: Data Acquisition and Control using LabVIEW

1. Introduction to LabVIEW
   
   

   • Basics of the graphical programming environment.

   • Setting up LabVIEW for data acquisition systems.

2. Interfacing with DAQ Hardware
   
   

   • Using NI DAQ devices or Analog Discovery with LabVIEW.

   • Configuring channels, sampling rates, and data acquisition tasks.

3. Real-Time Monitoring
   
   

   • Developing a LabVIEW VI (Virtual Instrument) for live data visualization.

   • Configuring custom graphical dashboards with indicators and plots.

4. Warning Systems and Shutdown Logic
   
   

   • Designing logic to monitor data against thresholds.

   • Triggering alarms (visual, audible) and shutting down equipment via digital outputs.

5. Data Logging and Storage
   
   

   • Recording data to files (CSV, database, or cloud storage).

   • Managing large datasets and timestamps for long-term monitoring.

6. Practical Activity
   
   

   • Create a LabVIEW VI to monitor and log pressure in a pipeline.

   • Design a shutdown system for pressure breaches.

Module 4: Advanced Data Monitoring Systems

1. Multi-Parameter Monitoring
   
   

   • Simultaneous monitoring of multiple industrial parameters.

   • Combining WaveForms and LabVIEW for complex systems.

2. Integration with PLCs and Industrial Protocols
   
   

   • Interfacing DAQ systems with PLCs via Modbus or OPC.

   • Using LabVIEW for communication with SCADA systems.

3. Fault Diagnostics and Trend Analysis
   
   

   • Analyzing logged data to identify patterns and predict faults.

   • Implementing machine learning in LabVIEW for predictive maintenance.

4. Cloud Integration
   
   

   • Configuring LabVIEW to send data to cloud platforms for remote monitoring.

   • Developing a dashboard for factory supervisors.

Module 5: Final Project and System Deployment

1. Project Setup
   
   

   • Participants choose a real-world industrial scenario.

   • Examples: Conveyor belt monitoring, boiler temperature control, or motor vibration analysis.

2. Design and Implementation
   
   

   • Using WaveForms or LabVIEW to implement the monitoring, warning, and logging system.

   • Integrating alarms and shutdown mechanisms.

3. Evaluation
   
   

   • Demonstrate system functionality to peers and instructors.

   • Provide a report on system design, performance, and lessons learned.

Course Materials and Requirements

• Hardware:
  
  

  • Analog Discovery 2 or compatible DAQ hardware.

  • Sensors (e.g., thermocouples, pressure transducers, flow meters).

  • Industrial-grade actuators or simulated systems for shutdown logic.

• Software:
  
  

  • WaveForms (provided by Digilent).

  • LabVIEW Community or Professional Edition.

• Prerequisites:
  
  

  • Basic knowledge of sensors and industrial processes.

  • Familiarity with electrical measurements.

Outcome

By the end of the course, participants will:

• Be proficient in using WaveForms and LabVIEW for data monitoring, warning systems, and shutdown logic.

• Develop skills to acquire, log, and analyze industrial process data.

• Be able to design and deploy robust safety and monitoring systems in industrial environments.