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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
Daimler Trucks and Buses
PROBLEM STATEMENT
Department 3
Daimler Trucks and Buses
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.
4
Biggest D.U.T.
Daimler Trucks and Buses
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.
5
Daimler Trucks and Buses
PROPOSAL AND SOLUTION
Department 6
Daimler Trucks and Buses
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)
7
4K Test 9K Test6K Nozzle
Daimler Trucks and Buses
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.
8
Daimler Trucks and Buses
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
Daimler Trucks and Buses
ELECTRICAL DESIGN
Department 10
Daimler Trucks and Buses
APPROACH
11
Daimler Trucks and Buses
SYSTEM OVERVIEW
12
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
Daimler Trucks and Buses
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
Daimler Trucks and Buses
SENSOR SUITE
• Thermocouple: to ensure that 9K test is at appropriate temperature
• Water leak sensors.
• Door lock
• Pressure switch
• Float level switch
14
Daimler Trucks and Buses
TURNTABLE
• Stepper motor (2 – 5 RPM)
• Stepper driver
• Double gear turntable
15
Daimler Trucks and Buses
POWER DEVICES
16
• Pumps
• Heater
• Stepper motor
• Solenoid Valve
Daimler Trucks and Buses
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
Daimler Trucks and Buses
FLOWCHART FOR THE PROGRAM
Department 18
Daimler Trucks and Buses
MECHANICAL DESIGN
Department 19
Daimler Trucks and Buses
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.
20
Daimler Trucks and Buses
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.
21
Daimler Trucks and Buses
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.
22
Daimler Trucks and Buses
FINAL DESIGN - PUMP SYSTEMS (cont.)
23
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
Daimler Trucks and Buses
LAST MINUTE CHANGE
Department 24
Daimler Trucks and Buses
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.
25
Daimler Trucks and Buses
CONCLUSION
Department 26
Daimler Trucks and Buses
CONCLUSION
27
Daimler Trucks and Buses
QUESTIONS
Questions?
Comments?
Concerns?
28
Daimler Trucks and Buses
BACKUP SLIDES
Department 29
Daimler Trucks and Buses
Current problem
9K test need more for 4 nozzle
Need a drainer for 6K and 9K test
Department 30
Daimler Trucks and Buses
More to add
Department 31