Component Environmental Test Chamber

1. Component Environmental Test Chamber Team MembersAdvisors Peter Adam Thong Vo Dr. Robert Daasch - PSU Jeff Hughes Phong Ngo Justin Riel - DTNA May 21st, 2012

2. OVERVIEW • Problem Statement • Proposal and Solution • Electrical Design • Mechanical Design • Last Minute Changes • Conclusion • Questions

3. Problem statement Department

4. 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. Biggest D.U.T.

5. 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.

6. Proposal and Solution Department

7. 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) 9K Test 6K Nozzle 4K Test

8. 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.

9. 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.

10. Electrical Design Department

11. APPROACH

12. SYSTEM OVERVIEW

13. GUI - TOUCHSCREEN • 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 Department

14. SENSOR SUITE • Thermocouple: to ensure that 9K test is at appropriate temperature • Water leak sensors. • Door lock • Pressure switch • Float level switch

15. TURNTABLE • Stepper motor (2 – 5 RPM) • Stepper driver • Double gear turntable

16. POWER DEVICES • Pumps • Heater • Stepper motor • Solenoid Valve

17. CONTROLLER - PLC • Automation Direct DL06 • Discrete I/O, 0-24V • 20 Inputs/16 Outputs • Thermocouple external card • Program by Ladder logic • Support by John  Department

18. FLOWCHART FOR THE PROGRAM Department

19. Mechanical Design Department

20. 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.

21. 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.

22. 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.

23. FINAL DESIGN - PUMP SYSTEMS (cont.) • 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

24. Last minute change Department

25. 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.

26. conclusion Department

27. CONCLUSION

28. QUESTIONS • Questions? • Comments? • Concerns?

29. Backup slides Department

30. Current problem • 9K test need more for 4 nozzle • Need a drainer for 6K and 9K test Department

31. More to add Department