Summer Internship 2016

Goodman Manufacturing

Friday August 5th 2016 Final Presentation

OverviewJeremy French• Education: University of Illinois Urbana-Champaign

• Expected Graduation: May 2018

• B.S. in Industrial and Systems Engineering

• Manufacturing Department- Ray Pitts

• Control Systems- Randy Spaulding

• Controls Engineering Intern

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On a weekly basis, I was able to work on projects that the controls group was doing at that time, along with seeing and learning from the situations they faced in the plant

Control systems engineering internship tasks

• HMIs (Human Machine Interface)

• Control Panels

• Heat Exchange Leak Tester

• Hands on manual labor

Projects

• Learned from colleagues how to diagnose and

solve control problems on the assembly lines

• Inputted questions and suggestions to the

problems at hand

Machinery Troubleshooting

© 2014 Daikin North America, LLC

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Human Machine Interface (HMIs)

Physical Construction• 80/20 extruded aluminum, bare bone

Key Points

Internal Makeup• E-stop, Ethernet, RTA module

Mainly used for all testers on Lines 1 and 7

© 2014 Daikin North America, LLC

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• Neat and clean• Labels and color code standard

• DC vs. AC• Terminate wires

Control panels from start to finish and everything in between

Concise statements with no fluff

Circuit Schematics The Layout

© 2014 Daikin North America, LLC

Heat Exchange Leak Tester

What is it?• A machine that tests the integrity of a heat exchange structure

by supplying air and measuring flow at the given air supply to determine if the unit is sufficient quality using the data given

What assembly lines is it used on?• Lines 1Why is it necessary?• Measures defects such as bad seals, cracked burners, and

missing parts

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The story of the heat exchange tester: one step at a time

1

2

3

Everything is manual, except for numatics which are controlled by the PLC

The next version has 4 drop down clamps with no other clamping mechanisms

The final version has a rear stop, front stop, 80% support, 7 drop down clamps, left and right clamps

From Beginning to End

© 2014 Daikin North America, LLC

As the machine was updated, the test became more efficient and there were less system leaks

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The early base form of the leak tester

• 7 drop down clamps• Left and right clamps• Front stop• 80% support

• Shannon Precision • Linear actuators

Front View Back View

Key Components

© 2014 Daikin North America, LLC

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The physical components of the leak tester

Linear Control Modules• Power Control (Pecans)• Control actuators

Numatics• Control numatics-actuate

clamps• Test numatics-actuate tests• Test, field, solenoid valves

© 2014 Daikin North America, LLC

Control Panel• Heart of machine• Controls clamping,

numatics, and all power• Receives limits• Collects and sends data

H.M.I.• Interface with operator• Master start, E-stop• Displays test data

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The digital side of the leak tester

• Controls the whole process

• Specialized computer

• Solves entire logic code

• Constantly looks at big

picture real time

PLC Logic

© 2014 Daikin North America, LLC

Communication amongst the leak tester is done via Ethernet IP at high speeds

Scan label (part no., serial no.) Read into PLC

Takes model no.to transaction manager via

trigger

Grabs info for model no. and goes to database

Searches server for all limits (recipes)

Sends limits back to transaction manager

then back to PLC

Limits includes: # burners, test/home

positions, etc.

Once test is complete all data is uploaded to data

base

Data consists of: pass/fail, pressure, flow

rate, # burners, limits tested at, and date/time

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The end result and functionality of the leak testerGoodman Video.m4v

© 2014 Daikin North America, LLC

Model is selected in manual or auto mode Scan specific part Part is loaded into test

position

User starts test by placing fingers on the 2

hand control

Machine clamps part into positionTest begins

Unit is filled with air from both test and field

valves for a period of time

Field valve closes, test valve remains open:

pressure check above .5 in of water column

Test proceeds to adjust air to 1 in of water

column +/- .5 and that flow is below the maximum limit

Machine checks that flow and pressure are

just right

Send data (model no., pressure, flow, date and

time) to database

Machine prints label and unclamps part

Operator removes part and places label on partCycle repeats again

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Looking ahead to improvements and research

Seals

Scanner/Hole Size

Insulation Bracket

• Seal material

• Pre-station to the leak tester• Automatic scanner and camera

sensor to determine hole size of burner

• Photo sensor to determine if the bracket is present

The future of the heat exchange leak tester

What parts of the machine could be improved for the

future?

© 2014 Daikin North America, LLC

THESOLUTION

Special Thanks • Human Resources

• Blake Miller• Manufacturing Department

• Ray Pitts-Supervisor• Controls Engineering Group

• Randy Spaulding-Manager• Mike Anders• Don Fenton• Shanthan Gambhir• David Haynes