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Component Environmental Test Chamber Jeff Hughes 1 , Peter Adam 1 , Thong Vo 2 and Phong Ngo 2
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Transcript of Component Environmental Test Chamber Jeff Hughes 1 , Peter Adam 1 , Thong Vo 2 and Phong Ngo 2
Component Environmental Test ChamberJeff Hughes1, Peter Adam1, Thong Vo2 and Phong Ngo2
1. Department of Mechanical and Material Engineering, 2. Department of Electrical and Computer EngineeringAdvisor: Dr. W. Robert Daasch
Introduction Daimler Trucks Product Validation Engineering (PVE) tests components to ensure they meet minimum specifications. Some electrical components are attached under the hood, and other areas where they may be exposed to the outside environment. In some cases, this may include exposure to water, especially in vocational models built for heavy duty applications.
Products
ConclusionsThis project is our first large corporate project. We gain lots of valuable skills in cross functional engineering as well as electrical controls engineering.
More work need to be done to assembly the chamber, ensure water pressure and flow rate . The system can be connected to the network to send email, alarms, update status to operator.
GUI EZTouch Enhanced 6’’•Directly Read/Write to PLC
memory•Multiples pages for different
control, monitor situations
Design
Department of Electrical and Computer Engineering
In an attempt to set a testing standard, Daimler Trucks Germany provided their testing specifications. This document highlights E.U. standards for testing of electrical components at varying levels of intensity. Three water spray tests to be conducted:- 4K – Low pressure (~60 PSI), Low flow (~0.15 GPM
per hole), Room Temperature- 6K – Medium pressure (~145 PSI), High flow (~20
GPM), Room Temperature- 9K – High Pressure (~1300 PSI), Medium flow
(~4.0GMP), High Temperature (~180 ⁰F)
Background
The top of the chamber• Large conical inductor tank: easy for
draining and recirculating water•Nozzles: fabricated base on Daimler’s
spec document•Turn table: Stepper motor turns the
table at require speeds•Water collector: drains the water to
suitable tanks during tests.
The base of the chamber•Hot water pump: High pressure, high
water temperature pump•Hot water tank: able to heat up and
keep water at desired temperature•Cold water pump: roller pump can
provide high flow rate•Cold water tank: store room water,
able to alarm when the water temp. is out of range.
Department of Mechanical and Materials EngineeringDaimler Trucks North America
Controller Automation Direct DL06•Discrete I/O, 0-24V• 20 Inputs/16 Outputs• Thermocouple external card• Program by Ladder logic
Hot water tankHeating element: 3000W •Heat water up to 1800 F•Measure temperature by
thermocouple•Water level detection
TurntableStepper motor•Double gear turn table : two
different RPM (2 and 5)• Proximity sensor for velocity
feedback
UserTest Selection 4,6,9
Command Start, Stop…Test conditions
GUIControl PanelSystem statusTemp. graph
PLCControls solenoid valves, pumps, heater, turn tableMonitors turntable, water temp, interlock conditions
Update data to GUI
Power DevicesPumps, Valves,
Heater
SensorsRotation, Pressure, Door lock, Water
leak, Temperature
Approach
Controller•Reads values from the thermo couple,
converts them to BCD•Communicates with GUI (touchscreen)• Sequentially control power devices to
complete different tests• Issues commands for stepper motor
driver to archive appropriate speed•Monitor safety conditions and
interlock conditions. Turn off power device appropriately when there is any hazard.
GUI•Control Panel: Start/Stop, Test
selection, Pre-Heat the tank•Animation instructions, real time
system status•Temperature graph
Sensor suite•Thermocouple: to ensure that 9K test
is at appropriate temperature•Proximity sensor: to ensure the turn
table is turning at the right speed•Water leak sensors.• Pressure sensors.
Typical device under test
(DUT)
TestingThere are many mechanical parts , high power devices in this system must be fabricated, assembled together to get the full version of the chamber. While finishing the chamber, we test our algorithm with smaller scale devices. We successfully control power devices following sequences in the tests’ spec.
9K Pump
4k/6K Cold Tank
Filter
Water collecter
46K Pump
Level detector
Filter
Rotation sensor
Motor
PLC
Heating Element
6K Nozzle
4K Nozzle
9K Nozzle
Turn table
Thermocouple
Level detector
UserTest Selection 4,6,9
Command Start, Stop…Test conditions
GUIControl PanelSystem statusTemp. graph
PLCControls solenoid valves, pumps, heater, turn tableMonitors turntable, water temp, interlock conditions
Update data to GUI
Power DevicesPumps, Valves,
Heater
SensorsRotation, Pressure, Door lock, Water
leak, Temperature
User Test selection 4k,6k,9k
Command Start, Stop... Test conditions
GUI Control Panel System Status
Temperature graph
Sensor suiteRotation, Pressure,
Door lock, Water leak, Temperature.
Power Devices Pumps, Valves,
Heater
PLC Controls solenoid valves, pumps, heater, turn table
Monitors turn table, water temperature, interlock
conditionsUpdate data to GUI
Hot water route
Cold water route
Electric signal route
LEGEND
DUT
6K Nozzle 4K Nozzle 9K Nozzle