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Multidisciplinary Engineering Senior Design 06421 Automated Plasma Generator Test System Preliminary Design Review 11/11/05. Project Sponsor: MKS, ENI Incorporated Team Members: John Dullea Christine Kuss Megan Suflita Team Mentor: Dr. Ferat Sahin Acknowledgements:
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Multidisciplinary Engineering Senior Design06421 Automated Plasma Generator Test System Preliminary Design Review11/11/05 Project Sponsor: MKS, ENI Incorporated Team Members: John Dullea Christine Kuss Megan Suflita Team Mentor: Dr. Ferat Sahin Acknowledgements: Dr. Paul Steibitz, Advisor Kate Gleason College of Engineering Rochester Institute of Technology
Project Background • Narrow band HF RF amplifier • Parallel devices with controller • Subcomponents of 3700 Watt amplifier
Current Situation • Tedious to test • Time consuming • Resource consuming • Interpolation issues • Result analysis is time consuming
Software Capabilities • LabVIEW code • Collect necessary data • Perform calculations • Generate graphs • Fully automated • Required tests
Needs Assessment • Customer’s Needs • Automated in LabVIEW • Graphical User Interface will be provided • Ability to vary input parameters • Ability to perform safety checks and take measurements • Potential for destructive testing • Our Needs • Access to MKS facility, equipment, and technical support • Defined work area at MKS • Results of past tests for comparison
Option 1 Concept Development
Concept Development • Option 2
Key Requirements & Critical Parameters • Repeatable Data • Safety Checks • Fully Automated
Overall System Diagram/Block Diagram • Software flow of overall LabVIEW program. • Contains 4 nested loops • Varies all necessary input parameters • Frequency • Impedance • Voltage • Amplitude
Analysis & Synthesis of Design • Project based upon generic platform • Easily adaptable for future considerations • Easily interchangeable with similar units • Customer specifications met • Integration of existing code
BOM & Costs • All equipment provided by MKS • Equipment list • Tektronix Digital Scope • Bird Power Meter • Bird Power Sensor • Agilent Power Meter • Agilent Power Sensor • ENI Load Simulator & RS232 Cable • ENI Matchwork Controller • ENI Fiber Optic Converter • Agilent Spectrum Analyzer • Dell PC • Agilent Signal Generator • Keithey Scanning Card • 4 RF Cables, DC Power Cable, & 6 GPIB Cables • Power Supply
Anticipated Design Challenges/Risk • Difficulty integrating software blocks • Creating user-friendly interface that is easily interpreted • UUT safety and control systems • Stability of amplifier signal • Debugging of code
SD II Project Plan • Automated Tests • Correlation Study • Corrective Actions • MKS onsite verifications
Deliverables • LabVIEW code • User manual • On site training
Smith Chart http://www.web-ee.com/primers/files/SmithCharts/smith_charts.htm
Cost – Benefit Analysis • Assumptions • For manual testing a technician requires 3 days for completion • Technician gets paid $15/hour. • Automated program can complete task in 24 hours with 1 hour set up. • ($15)*(8hrs/day)*(3 days) = $360 • ($15)*(1hr) = $15 • A cost difference of $345 per test • 3 tests * $360 = $1080 • 3 tests can be completed with the automatic test system in the same time that 1 test can be completed manually