May 21st, 2012 Component Environmental Test Chamber Team Members Advisors Peter AdamThong Vo Dr. Robert Daasch - PSU Jeff HughesPhong 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 Department3

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 Department6

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 Test 6K 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 Department10

Daimler Trucks and Buses APPROACH 11

Daimler Trucks and Buses SYSTEM OVERVIEW 12

Daimler Trucks and Buses GUI - TOUCHSCREEN Department13 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 Department17 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 Department18

Daimler Trucks and Buses MECHANICAL DESIGN Department19

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 Department24

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 Department26

Daimler Trucks and Buses CONCLUSION 27

Daimler Trucks and Buses QUESTIONS Questions? Comments? Concerns? 28

Daimler Trucks and Buses BACKUP SLIDES Department29

Daimler Trucks and Buses Current problem 9K test need more for 4 nozzle Need a drainer for 6K and 9K test Department30

Daimler Trucks and Buses More to add Department31