Hello all,
I am currently running into a problem where the digital outputs of my cDAQ-9189 stop changing state.
Purpose of system: A test fixture designed to run pumps for a reliability test. This also controls several heaters, level sensors, and auxilary pumps to control the flow/temperature of water and cleaning solution being used to test the pump's long term reliability. The general state diagram is attached.
System overview:
cDAQ-9189 with 2x 9214 Tc modules (Only one used for this project), NI 9205 AI module, NI 9203 AI module, and NI 9375 DI/O module used as the output.
LabVIEW version 17.0 (64-bit) with 72640K memory allocated.
Code: See Attached
Hardware: All outputs to the test fixture are controlled through 12V relays with their coils controlled by the NI 9375 output card. The system is a mix of 24V and 240V power output through those relays to control 12 UUT pumps, two different heaters, and auxiliary pumps to move fluid between three tanks. The inputs to the system are level sensors and K-type TCs.
Problem:
Once in a while the output from the NI 9375 will stop changing state. This seems to happen when the software changes from one state to another, with the software continuing on to the next state while the hardware never stop executing the previous state. I.E: the hardware continues trying to drain an already empty tank after the software has commanded the tank be re-filled with the next fluid. The software is not frozen, and can continue to be interacted with but the hardware does not respond in any way. No error code occurs. The problem occurs at seemingly random intervals. Sometimes it runs for 2 days without issue, other times only a few hours.
Note: Resetting the cDAQ-9189 from NI MAX resolves the freeze, but requires the software to be restarted and we would like this test fixture to run continuously without direct monitoring.
I don't think this is a software issue as the code continues to function after the I/O freeze. No LabVIEW error code is recieved. I am currently monitoring the software's memory usage to determine if there is a problem with a memory leak or similar issue. So far no problems.
Any advice on resolving the issue or further troubleshooting steps to take?
Thanks,
Dylan