To get data from Anodes (used in Aluminium smelting plants) on real time

Thread Starter

Meanalytix

Joined Nov 2, 2018
4
Hi,

We are looking into a solution to get the data on real time from Millivolt Anodes. Currently Engineers go and measure thru Fluke Multimeter. We need solution in terms of sensor to

1. Convert analog data to digital
2. Transmit data thru wireless for collection in real time

Thanks !

Deb
 

danadak

Joined Mar 10, 2018
4,057
Some questions -

1) Describe measurement(s) being done on Anodes. What is being measured ?
Temp, Voltage, Current, Conductivity, Pressure, Light.......
2) Desired accuracy of anode measurement ?
3) Factory floor size/dimensions ? Distance from WiFi collection point to furthest
sensor reading ?
4) Number of measurement nodes to service ?
5) Frequency of measurement ? How often do they need to be measured ?
6) Do you have staff that can design or are you looking for turnkey solution ?
7) Regarding 7 if turnkey would you hire a consulting firm to do this ?

Regards, Dana.
 
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Thread Starter

Meanalytix

Joined Nov 2, 2018
4
Some questions -

1) Describe measurement being done on Anodes. What is being measured ?
2) Desired accuracy of anode measurement ?
3) Factory floor size/dimensions ? Distance from WiFi collection point to furthest
sensor reading ?
4) Number of measurement nodes to service ?
5) Frequency of measurement ? How often do they need to be measured ?
6) Do you have staff that can design or are you looking for turnkey solution ?
7) Regarding 7 if turnkey would you hire a consulting firm to do this ?

Regards, Dana.
Hi Dana,

Many thanks for your reply. Please find reply in BOLD

1) Describe measurement being done on Anodes. What is being measured ?
voltage of Anode (Current distribution) in mv (millivolt )

2) Desired accuracy of anode measurement ?

Not got from client


3) Factory floor size/dimensions ? Distance from WiFi collection point to furthest
sensor reading ?

Will get later, however you can assume something and we can have multiple router to group locally

4) Number of measurement nodes to service ?

ACD value taken from approx. 20 POT ( metal furnace) per 8 hour and 40 point per pot, so approx. 40*20*3 = 2400 data point in a day

5) Frequency of measurement ? How often do they need to be measured ?

We can provide at 5/15 mins frequency

6) Do you have staff that can design or are you looking for turnkey solution ?

We need the sensor to make the data available, we have IoT platform to collect the data

7) Regarding 7 if turnkey would you hire a consulting firm to do this ?

Please provide me the cost for PoC with one pot, based on that I can take call. I don't have huge budget.

Thanks !

Deb
 

ArakelTheDragon

Joined Nov 18, 2016
1,353
Hello Meanalytix! Welcome to "AllAboutCircuits.com".

The system is simple but it will take time to develop.

Block 1 - amplifier for increasing the milivolt signal with minimum distortions.
Block 2 - processing the signal.
Block 3 - sending it over wifi.

Suggestions:
Block 1 - instrumentation amplifier.
Block 2 - PIC16/PIC18 or similar microprocessor.
Block 3 - any microchip wifi module suitable for you.

This is only the basics, we need details and requirements like mentioned by "danadak" in order to be able to provide the circuits.
 

danadak

Joined Mar 10, 2018
4,057
Low cost solution, depending on your accuracy, distance requirements,
is ESP8266 or ESP32 module. Processor + WiFi, tons of internet
activity/solutions, youtube full of applications and problem solving.
Uses Arduino or Lua platform to program.

https://www.espressif.com/en/products/hardware/esp8266ex/overview

https://en.wikipedia.org/wiki/ESP8266

https://www.esp8266.com/

https://blog.squix.org/2015/03/esp8266-module-comparison-esp-01-esp-05.html

https://hackaday.io/projects?tag=ESP8266


Regards, Dana.
 

Thread Starter

Meanalytix

Joined Nov 2, 2018
4
Hi Dana,

I really appreciate your support. Would you able to support on the design if I provide you all the questions what you have asked ? And what would be the cost for that ?

You can reply back with your proposal via PM.

Deb


Mods Note:
Please don't show your Email on forum, it will bring the Spambot to forum and your email address.
 

danadak

Joined Mar 10, 2018
4,057
Hi, no on doing the design. I am retired, help on forum at my leisure.

I think there is area on forum for seeking consultants, maybe moderator can
comment on that.

Regards, Dana.
 

ArakelTheDragon

Joined Nov 18, 2016
1,353
I can build it, but it will take at least a month. I also may need to actively work with you at your time zone. The materials depend on the requirements. Its not a problem for me to make only the circuits and let you produce them at any factory for PCBs.

Let me say that I make the hardware. You will need someone to program the MCU and/or wifi module.
 
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ArakelTheDragon

Joined Nov 18, 2016
1,353
As far as I understand these anodes are heated to a very high temperature, you need to replace them on a certain time and thats why you need to measure them life time? Maybe you are worried that someone is stealing from you or that they are not exploited properly?

Is there any way to get the signal from an already pre-installed system? How do you know its miliVolt? If there is a prepared cable from which to get the mV signal, than the rest will be faster, but if I have to detect this from the high temp anodes, it will take longer.
 
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