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