Component Environmental Test Chamber

May 21st, 2012

Component Environmental Test Chamber

Team Members AdvisorsPeter Adam Thong Vo Dr. Robert Daasch - PSUJeff Hughes Phong Ngo Justin Riel - DTNA

Daimler Trucks and Buses

OVERVIEW

• Problem Statement

• Proposal and Solution

• Electrical Design

• Mechanical Design

• Last Minute Changes

• Conclusion

• Questions

2


PROBLEM STATEMENT

Department 3


PRESENT SITUATION

• Daimler Trucks Product Validation Engineering (PVE) tests components to ensure they meet minimum specifications.

• More specifically, Mechatronics PVE tests the electrical components in trucks.

• 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.

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Biggest D.U.T.


PROBLEMS

• Current electrical component testing is done in the following method;

•While this may ‘get the job done’, there are a few concerns;

• There is no pre-determined pressure or exposure time (no standard).

• Repeatability is almost impossible.

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PROPOSAL AND SOLUTION

Department 6


DTNA PROPOSAL

• 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 spraying 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)

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4K Test 9K Test6K Nozzle


DTNA PROPOSAL (cont.)

• Currently, there is no company in the United Stated that specializes in equipment which conducts all the required tests.

• DTNA first contacted suppliers to estimate the cost of building a device to perform these three tests.

• Supplier Estimate = $40,000

• Daimler thought this was not a competitive estimate.

• Solution: Joint ECE-ME capstone project with a $10,000 budget.

• Due to the unique nature of this task, both ECE and ME students were recruited.

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ECE-ME JOINT SOLUTION

• As our capstone proposal, we created a testing chamber for DTNA

• The chamber can run all three tests (4/6/9K).

• Will come around $10,000 budget.

• Almost fully automated.

• PLC as the controller

• Touchscreen for the G.U.I

• 2 Separate pumps and water reservoirs.

• Steel Frame.9


ELECTRICAL DESIGN

Department 10


APPROACH

11


SYSTEM OVERVIEW

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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

Hot water route

Cold water route

Electric signal route

LEGEND


GUI - TOUCHSCREEN

Department 13

EZTouch Enhanced 6’’

• Directly Read/Write to PLC memory

• Multiples pages for different control, monitor situations

• Animation for operator

• Update status of the system

• Message, alarms


SENSOR SUITE

• Thermocouple: to ensure that 9K test is at appropriate temperature

• Water leak sensors.

• Door lock

• Pressure switch

• Float level switch

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TURNTABLE

• Stepper motor (2 – 5 RPM)

• Stepper driver

• Double gear turntable

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POWER DEVICES

16

• Pumps

• Heater

• Stepper motor

• Solenoid Valve


CONTROLLER - PLC

Department 17

Automation Direct DL06

• Discrete I/O, 0-24V

• 20 Inputs/16 Outputs

• Thermocouple external card

• Program by Ladder logic

• Support by John


FLOWCHART FOR THE PROGRAM

Department 18


MECHANICAL DESIGN

Department 19


FINAL DESIGN - TEST CHAMBER

• The test chamber consists of a large conical inductor tank.• Provides an easy

solution for draining and recirculating water.

• Plans to create a clear acrylic door for the chamber.

• Will contain nozzles and turntable inside.

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FINAL DESIGN - NOZZLES

• 4K nozzle:

• Will be bent out of aluminum pipe stock at Daimler.

• 6K nozzle:

• Will be machined in-house out of aluminum then welded together

• Slight dimension changes from DT Germany specifications to simplify manufacturing.

• 9K nozzle:

• Will be bought from supplier and modified to comply to spray geometry specifications from DT Germany.

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FINAL DESIGN - PUMP SYSTEMS (cont.)

• To use the pump for both the 4K and 6K test, a few steps had to be taken:

• A manifold had to be created for the pump system.

• A pressure regulator will enable the pump to operate at both the 4K and 6K specifications.

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FINAL DESIGN - PUMP SYSTEMS (cont.)

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9K Pump system:• Due to time and manpower

constraints, pump was

ordered from a DTNA supplier.

• Hotsy Model 1700 pump,

bought from American

Equipment co.

• Made specifically for high

pressure and high temp.

applications, with after-

market hot seals

• Water supplied from heated

Galvanized Steel Tank

• Single Phase


LAST MINUTE CHANGE

Department 24


LAST MINUTE CHANGES

• Initially, we explored two solenoid valves to control the draining from the test chamber.

• We found that the flow through the solenoid valves was not sufficient for the 6k test. We then investigated a larger actuated 3-way ball valve which was found to be cost prohibitive.

• The solution we settled on was a manually operated 3-way ball valve to reduce costs. The valve has mounting for an actuator.

• For the 9K tests, high pressure and high temperature solenoid valves were specified for use.

• We proposed that the operator move the position of the nozzle manually, rather than use 4 different solenoid valves to do this automatically.

• DTNA accepted this proposal, and it removed over $1000 of cost from the apparatus.

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CONCLUSION

Department 26


CONCLUSION

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QUESTIONS

Questions?

Comments?

Concerns?

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BACKUP SLIDES

Department 29


Current problem

9K test need more for 4 nozzle

Need a drainer for 6K and 9K test

Department 30


More to add

Department 31

Documents

Component Environmental Test Chamber