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Automated Inspection Device for Electric Fan Clutch Actuators

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1. Design method to conduct circuit readings Research commercial meters and circuitry Order parts Build circuits Test circuits Make needed corrections ntt Er LabVIEW Interface Research LabVIEW abilities Order data acquisition module Build LabVIEVY VI Test circuit PC interface with LabVIEW VI Make needed corrections Tracking Design fan and meter housing Research electric motor to rotate fan Design motor housing Build motor housing Design meter housing Build meter housing Design fan clutch actuator housing Build fan clutch actuator housing EA RA Eg EN HEU E E EH REERI EJ REE EER EA peg EER EA E EH EA ER Ea EN ER ER EA EA EA Bi EA Ed ES E EA EA EA Ee E Prototyping Phase DEN Integrate all pieces Test prototype 100 Compare results with project specifications d Refine final design and make needed changes 100 Figure 2 8 2 Automated Actuator Inspection Device Gantt Chart Timeline Automated Actuator Inspection Device 16 BorgWarner Inc Figures 2 8 1 and 2 8 2 show ECE 480 Design Team 6 s Gantt Chart The Gantt Chart was used for tracking the design progress of the Automated Actuator Inspection Device It outlines the work breakdown structure of the project including assigned tasks and set milestones The Gantt Chart was continuously updated throughout the design process to gauge team progress and reorganize project priorities 3
2. 5v SS Out y MN 7 ora JE 5V 55 Low Voltage i LI Ta 0 5 Sy 55 In i 5V 55 Voltage x Time Delay Figure 3 4 2 Test Procedure Block Diagram 5V DC Speed Signal Automated Actuator Inspection Device 33 BorgWarner Inc Figure 3 4 2 shows the LabVIEW block diagram for test procedures specifically the 5V DC speed signal test A digital decoder signal is written out to the data acquisition module to trigger the specific test The analog input of the data acquisition module is then sampled for data The samples are then processed based on the equation corresponding to the test After processing a reset signal is written out to the decoder It is followed by a time delay for propagation after which another test can be run This is the standard procedure for every test with the only variations being the test decoder signal and its corresponding equation Figure 3 4 3 Database Recordset Entry Procedure Block Diagram Figure 3 4 3 shows the LabVIEW block diagram for recordset entry into the actuator test database in Microsoft Access A connection to the test database is created using the UDL file An INSERT SQL query is executed creating a recordset in the database with the completed test result values The recordset reference is then freed and the database connection is closed This procedure is executed every time the inspection process completes Appendix 6 3 12 shows a VI hierarchy of the LabVIEW softwar
3. 31 Test circuit PC interface with LabVIEW MI 32 Make needed corrections 33 34 Design fan and meter housing 35 Research electric motor to rotate fan 36 Design motor housing 37 Build motor housing 38 39 Design meter housing 40 Build meter housing 41 42 Design fan clutch actuator housing 43 Build fan clutch actuator housing 44 45 E Prototyping Phase 46 Integrate all pieces 47 Test prototype 48 Compare results with project specifications 49 Refine final design and make needed changes Duration 12 days E 1 day 1 day 5 days 5 days 22 days 5 days 12 days 5 days 18 days 18 days 5 days 5 days 2 days 3 days 3 days 18 days 5 days 5 days 2 days 3 days 3 days 18 days 2 days 5 days 6 days 3 days 3 days 18 days 5 days 1 day 5 days 1 day 5 days 1 day 5 days 18 days 3 days 6 days 3 days 6 days Start Fri 1 30 09 Fri 1 30 08 Mon 2 2 08 Tue 2 3 08 Tue 2 10 08 Tue 2 10 09 Tue 2 0 08 Tue 2A 7 08 Thu 3 5 08 Thu 342 09 Thu 3 12 09 Thu 342 08 Thu 3 19 09 Thu 3 26 08 Mon 3 30 08 Thu 4 2 08 Thu 342 09 Thu 3 12 08 Thu 3 19 09 Thu 3 26 08 Mon 3 30 08 Thu 4 2 08 Thu 342 09 Thu 3 12 08 Mon 3 16 08 Fri 3 20 08 Mon 3 30 08 Thu 4 2 08 Thu 3 12 09 Thu 3 12 08 Thu 3 19 08 Fri 3 20 08 Mon 3 30 08 Tue 3 31 08 Thu 3 2 08 Fri 3 13 08 Tue 4 7 09 Tue 4 7 08 Fri 4 10 08 Mon 4 20 09 Thu 4 23 08 Finish Mon 2 16 09 Fri 1 30 09 Mon 2 2 08 Mon 2 9 0
4. 500 00 Table 2 7 1 Automated Actuator Inspection Device Initial Budget Estimates ECE 480 Design Team 6 was presented with an initial budget of 500 00 for the Automated Actuator Inspection Device Table 2 7 1 shows the team s initial budget estimates Many of the components needed to develop the metering circuits and power supply in addition to PCB fabrication were assumed to be available free of charge courtesy of the MSU ECE Shop Automated Actuator Inspection Device BorgWarner Inc 14 2 8 Gantt Chart Task Name Initial Organization Phase Form team and trade contact information di Meet with Dr Ayres 4 Meet with BorgWarner to clarify project details EH Pick up test units 5 7 E Project Research 8 Define project specifications 8 Brainstorm and research for similar diagnostic devices 10 Decide on best solution and assign technical tasks 11 12 E Design Phase da Design power supply 14 Research transformers chips circuits etc 15 Order parts 16 Build power supply AT Test power supply 18 Make needed corrections 18 20 Design method to conduct circuit readings 21 Research commercial meters and circuitry 22 Order parts 23 Build circuits 24 Test circuits 25 Make needed corrections 26 E 27 LabVIEW Interface E 28 Research LabVIEW abilities P 28 Order data acquisition module d 30 Build LabVIEW VI
5. Actuator Date Code Actuator Model y E Database UDL 4 START TEST Figure 3 3 1 2 Automated Actuator Inspection Device Start GUI Automated Actuator Inspection Device 31 BorgWarner Inc Figures 3 3 1 2 shows the start graphical user interface GUI for the Automated Actuator Inspection Device interface The start GUI prompts the user for the actuator under test s serial numbers as well an actuator model selection from a drop down menu and a path to the test database s universal data link UDL file The UDL file specifies the type of connection to be established between the database and accessing application as well as the location of the database itself The Automated Actuator Inspection Device interface uses the Microsoft Jet 4 0 OLE DB Provider connection xj BorgWarner PEF 188 Back Actuated Fan Clutch Test Report 107 Test Date 5 Fan Drive Serial Actuator Date Code i e n Range Value 300v Current 30u 5 High SS Current gt 3ma 5 5v High SS Voltage 4 9V 5 Low 55 Current 12 m T ET n T D 10 1 i 0 100 Amplitude 5V Low SS Voltage 0 4V Coil Sup Diode Current 250 500 m 12 High 55 Current gt 3 m 12 High 55 Voltage gt 11 84 12V Low SS Current lt 12 m 12 Low 55 Voltage 0 4V Time Coil Current RT Coil Current 1 1 3A Resistance A B 10 Mohm Resistance A C gt 10 Mohm 3 Resis
6. It is close enough to the left wall such that an on off switch can be attached to the outside for easy access Located ten inches away from the power supply is the metering circuitry Much care is taken to secure the circuit board to the bottom section while protecting its fragile connections Spacers are attached to the bottom of the circuit and attached to the housing with screws The metering circuitry connects to the actuator during inspection through a one inch hole drilled in the back side of the aluminum base plate A single 1 1 8 hole on the left side of the bottom section provides a path to the outside for the stepper motor and power supply cords The data acquisition module s USB cable is also fed through this hole for connection to the PC The final aspect of the physical design for the product is with the stepper motor s safety mechanisms The power switch for the motor is located on the front side of the bottom enclosure while the power supply switch is on the left The hinge switch is located at the top of the shield where the lid meets the walls of the shield 3 3 Software and Interface Design 3 3 1 Automation and Database Storage VI Screenshot and Printout DI Conditioned Actuator Signals DAQ LabVIEW gt Access DB Input Circuit Switching Signals Figure 3 3 1 1 Automation and Database Storage Block Diagram Automated Actuator Inspection Device 30 Bo
7. 2 Data Acquisition and Processing The data acquisition and processing design emulates the functionality of metering systems by utilizing the PC to perform calculations Preconditioning circuits designed by ECE 480 Design Team 6 transforms and scale raw data signals from the electric fan clutch actuator into measurable waveforms These waveforms are communicated to the PC through USB using a data acquisition module from which calculations are made to derive voltage current resistance and capacitance measurements The cost of this design is relatively inexpensive in designing metering circuitry in house However accuracy may prove to be an issue for the same reason Additionally upgrading the system to take on new sets of measurements following the tenure of ECE 480 Design Team 6 may be problematic Automated Actuator Inspection Device 11 BorgWarner Inc 2 5 Feasibility Matrix Design Criteria Weight Commercial Meter Interfacing Data Acquisition and Processing Automation 5 5 5 Accuracy Expandability Data Storage Safety Cost Size Footprint Power Requirements www 2 IS U1 N N IR Ur coU SAUUWUIN W TOTALS 113 122 Table 2 5 1 Conceptual Design Feasibility Matrix Table 2 5 1 shows the rankings of ECE 480 Design Team 6 s initial conceptual designs through a feasibility matrix The design criteria are given weights based on an import
8. Other times the module analog inputs float when they seemingly should not The solutions are to get a more costly module with higher input impedance or use voltage follower OP AMP circuitry The decision was to go with OP AMP circuitry However a better solution is to use a better module The final challenge was how to measure the value of the 100nF capacitor in the actuator At this point there is not a way to do it with the current design of the metering circuitry 3 1 2 Power Generation The Automated Actuator Inspection Device s power supply needed to meet two main considerations robustness and low cost It needed to function properly during inspection with little monetary investment as the team s budget was small and spread thin throughout the project The planned design requirements for the power supply included steady 5V DC and 12V DC outputs and current output around 0 5A all from a 120V AC wall outlet input These outputs are required to power the metering circuitry as well as the fan clutch actuator The initial power supply design that was adopted was very robust It took in 120V AC and stepped it down through an F 90X transformer which gave the supply a solid 32V AC to be manipulated to obtain the desired outputs This output was then passed through a rectifier to attain a DC voltage Next the output of the rectifier was input to two LM78 voltage regulators at fixed output voltages of 5V DC and 12V DC The inputs of these
9. Wilson was responsible for designing the circuitry necessary to conduct fan clutch actuator tests This includes the design of methods to perform the measurements and merging them all into a single design using switching circuitry and digital control The circuit had to accept 4 bit digital codes from the data acquisition module and the output had to be either a voltage or frequency scaled to a range useable by the module The first thing Codie had to consider was how to use digital codes from the module as a control for each test The next thing he had to consider was what type of IC or circuitry would be controlled by that signal and how it would control what it does After having a rough outline of the design Codie had to consider the specifications for all the parts as components had to be not only compatible with each other but able to handle the types and magnitude of signals they are expected to operate on All throughout this process he was revising the ways to conduct the tests to match the specifications of the components used After coming up with a working design Codie s next task was to create a PCB so that all the components were not sitting on protoboards The team s design was too large for the typical Eagle PCB layouts that ECE 480 students commonly use for the MSU ECE Shop so he had to seek out other PCB software and use it to design a larger board The initial board Codie designed was meant for the PEF 188 model
10. actuator but he arranged the components such Automated Actuator Inspection Device 46 BorgWarner Inc that after working out any issues with it the team could easily create a new board and add the remaining tests without increasing the board size or moving any other components While the metering circuitry design works on the protoboards and mostly works on the PCB time consuming difficulties with the initial board prevented a second board from being designed Codie helped Stephen with the wiring of the switches for the housing He also helped Jacob with the automation While he did no actual programming automation in LabVIEW he was involved in the process of automating the design Automated Actuator Inspection Device 47 BorgWarner Inc 6 2 References 1N4148 Diode Datasheet http ronja twibright com datasheets diode 1N4148 1N4448 5 pdf 2N2222 NPN Transistor Datasheet http www fairchildsemi com ds PN PN2222A pdf ACS712 5A Current Sensor Datasheet http www allegromicro com en Products Part Numbers 0712 0712 pdf DB202B Analog Switch Datasheet http www vishay com docs 70037 dg201b pdf EC2 5NJ Relay Datasheet https www egr msu edu eceshop Parts Inventory datasheets 5v9620dpdt9620relay pdf F 90X Transformer Datasheet http triadmagnetics com pdf Page 2058 pdf LabVIEW Database Connectivity Toolkit User Manual http www ni com pdf manuals 321525c pdf LM317 Regular Datasheet http www national com ds LM LM117 p
11. between pin B and pin C Therefore there will be some voltage Vout at pin B after going through the 5600 resistor Automated Actuator Inspection Device 21 BorgWarner Inc Because the current at pin B is known by the equation above the resistance from pin B to pin C can then be calculated as V E pinB pinB resistor The 22nF capacitor test is controlled by decoder line S14 An LM555 timer is used in astable mode see LM555 datasheet When S14 goes high an analog switch closes connecting timer pin 6 to pin Dof the actuator which is the positive terminal of the 22nF capacitor see Appendix 6 3 7 S14 also connects pin E to ground through a 2N2222 transistor Once this happens the timer sends a frequency through timer pin 3 to the data acquisition module The frequency is proportional to the capacitance and the capacitance can be calculated by the equation 1 44 100KO 2 100kQ f The expected frequency is below 500Hz since the data acquisition module cannot sample fast enough for high frequency readings Adding test circuitry to the design was an easy task once the control framework was in place For example after completing the design for the speed signal tests the next test added was the coil suppression diode amperage test First a decoder control line was allocated to the new test and accordingly a 4 bit code The actual testing circuitry was already designed see Appendix 6 3 8 For new testing circuitry
12. current resistance and capacitance measurements as well as plots the desired statistics outlined in the design specification The derived information from LabVIEW is printed out in a format similar to the manual inspection method as well as input into Microsoft Access where an inspection history database is compiled The device will be powered through a power supply designed by the team It converts a standard wall outlet 120V AC into 5V DC 12V DC and 24V DC to power the actuator for inspection as well as to power the team s preconditioning circuits The Automated Actuator Inspection Device s housing consists of a bottom enclosure a rotating base and safety shield The bottom enclosure contains and isolates the device s power supply preconditioning circuits data acquisition module and induction motor The rotating base is powered by the induction motor for automated Hall Effect device inspection The safety shield covers the rotating base which spins only when the lid is closed to protect the user from moving parts Automated Actuator Inspection Device 13 BorgWarner Inc 2 7 Budget Total Part Name Cost ea Qty un Data Acquisition Module 150 00 1 150 00 Induction Motor 200 00 1 200 00 Device Housing Supplies 100 00 1 100 00 PCB Fabrication ECE Shop 0 00 1 0 00 Common Circuit Components ECE Shop 0 00 1 0 00 Specialized Circuit Components 50 00 1 50 00 TOTAL PROJECT COST
13. data acquisition module and from there conducts tests on the actuator Every test is given a specific code for example the four continuity tests are given binary codes 3 4 5 and 6 Once the code is given to the circuit the module can then read in a voltage or frequency from its analog inputs Software is used to convert this measurement into an actual component value When the module sends a binary code to the circuit the code is sent to the input control lines of a 4 to 16 decoder The number of decoder outputs equals 2 of control inputs and since 4 bit codes are used a 4 to 16 decoder was necessary When the decoder receives a code it forces one of its output lines to go to logic high voltage gt 2 5V while all others are low This signal is connected to all the components needed to be controlled for that specific test For the 5V DC speed signal test non inverting op amp circuitry is used The OP AMP is an LM358 because of its higher supply voltage rating running from the team s 24V DC supply and because it features 2 OP AMPs in a single 8 pin DIP saving space This test is given decoder code S1 When S1 is on the necessary analog switches are closed to conduct the speed signal test see Appendix 6 3 1 5V is applied at the non inverting terminal Because an OP AMP cannot have a voltage drop across its inverting and non inverting terminals the voltage at the non inverting terminal has to somehow become the voltage at the ot
14. it has to be decided where and how to connect the pins of the actuator For this new test a relay was used and controlled by the allocated decoder line The test point that connects to the analog input of the module is connected through an analog switch that is also controlled by the decoder line In this way test circuitry Automated Actuator Inspection Device 22 BorgWarner Inc can be added easily If more control lines are needed than what is available on a 4 to 16 decoder decoder arrays can be created using 5 bit codes allthe way up to 8 bit codes The main challenge with this design was getting a high level of accuracy and incorporating the circuitry to control and switch the different tests all while using common inexpensive components For example the speed signal test measures current in the 10mA range The solution to this problem came in different forms since there were a variety of tests performed For the example above OP AMP circuitry was used that can very accurately measure small currents in the 10MA range and is also very inexpensive cost of a common OP AMP and a few resistors capacitors The trade off for using this circuitry is that it is more complex than using a more expensive current sensor and the OP AMP configuration used in this way requires a voltage supply voltage output capability that is much higher possibly double than the voltage required for the speed signal tests It was easier to measure larger c
15. maintains or lowers the engine coolant fluid temperature inside the radiator Mechanical fan clutch actuators exist as bi metallic coils that contract when hot and expand when cold and in turn engage or disengage the radiator cooling fan BorgWarner Inc in partnership with ECE 480 Design Team 9 in the fall of 2007 has developed an electric fan clutch actuator that uses an electronic temperature sensor in place of the mechanical relay Electric actuators have a significant advantage over their mechanical counterparts in obtaining more accurate temperature readings therefore being able to engage or disengage the radiator cooling fan faster as well as run the fan at speeds commensurate to the temperature However electric actuators also have a greater design complexity than mechanical actuators and require more stringent inspection methods to verify proper operation BorgWarner s current inspection method for their electric fan clutch actuators is a manual process Isolated circuit metering systems are manually used to retrieve voltage current resistance and capacitance measurements These measurements are manually recorded on a system requirements sheet In the spring of 2009 ECE 480 Design Team 6 developed an automated inspection device for BorgWarner s electric fan clutch actuators The device interfaces with a PC through a USB connection and automatically takes required voltage current resistance and capacitance measurements for actu
16. of twelve inches Next he had to decide on a motor type weighing the various advantages and disadvantages of each Stephen s last responsibility was the housing shield safety features to ensure no damage or injury occurred For this he looked into what switches were available With the help of his team Stephen connected the switches to the wall and stepper motor to create the safety system In addition to the assigned tasks Stephen also aided Codie with the metering circuitry and Joshua with the power supply When the first few circuits were complete Stephen conducted some of the initial tests and aided in qualifying the results As the remaining metering circuits were designed he helped with the construction of the components and the testing of functionality When the metering circuitry PCB was fabricated he soldered many of the Automated Actuator Inspection Device 45 BorgWarner Inc components and analyzed the functionality of the design to ensure identical performance to that of the circuit during the prototyping phase Stephen aided Josh with the power supply by referencing information from past courses and lectures on possible components and theories When the power supply was to be built Stephen helped with the solder and testing When heat dissipation became a serious issue for the components he proposed the idea to mount an external fan which was later implemented 6 1 4 Codie Wilson Metering Circuitry Codie
17. regulators needed to be as close to DC signals as possible so 0 1uF capacitors were added These capacitors helped to eliminate oscillations within the signal Automated Actuator Inspection Device 24 BorgWarner Inc Once the power supply was built a problem came about in testing The current predicted in the initial design was too small for the working design of the metering circuitry Instead of 0 5A the circuitry required around 1 5A as well as another voltage supply of 24V DC This 24V DC was required to power the test switching circuitry and was also overlooked in the actuator test requirements Given this problem a different regulator was chosen to meet the new requirements The LM317 regulator provides an adjustable output that is varied by a change in resistance at the output The LM317 can be set to a range of 8V DC to 30V DC and has a current rating of 1 5A The LM317 is used to generate all three of the DC outputs Once the LM317 was added more problems arose The voltage output from the rectifier was not steady enough even with a 0 1uF capacitor at the input The oscillations in the output prevented the relays in the circuitry from switching Also too much heat was being dissipated from the 0 1pF capacitors Both of these problems were solved by putting a larger capacitor at the input diminishing the oscillations and cutting back on heat dissipation Once the larger capacitor was connected the oscillations at the output wer
18. the total components and cost to produce an Automated Actuator Inspection Device Many of the components were donated courtesy of BorgWarner and the MSU ECE Shop Although ECE 480 Design Team 6 s share of the total project cost was 253 34 it should be noted that the team spent a total of 540 33 throughout the design process These extra expenditures were a result of prototyping as well as failure of the data acquisition module leading to repurchase 5 3 Future Work Listed here are improvements recommended by ECE 480 Design Team 6 to the design of the Automated Actuator Inspection Device given relaxed time and budget constraints 5 3 1 Metering Circuitry Improvements For the speed signal test using a small signal current sensor instead of OP AMPs would make a simpler and cleaner although more costly solution For the tests using higher currents new relays should be used as the current ones handle a maximum of 2A For the 22nF capacitor test it is assumed that the connection of pin 6 of the timer to the actuator s capacitor has a series resistance of less than 1kO For example if in a future actuator design pin D of the actuator was connected to a 2kQ resistor before connecting to the capacitor then the frequency output of the timer will not be exactly proportional to the capacitance which is necessary for an accurate reading The larger the series resistance the worse the measurements will be This issue needs to be ad
19. 17 3 1 Hardware Design o ise dan t ee e ee lar dan to oiv adds P Rae ariana 17 3 1 1 Metering Circultiv iatale delie aaa 17 3 1 2 Power Generation iaia iaia it 24 3 1 3 Device Housing and Fan Rotation iii 26 3 2 Hardware Implementation EM RERRMMNI RE 29 3 3 Software and Interface Design ii 30 3 3 1 Automation and Database Storage iii 30 3 4 Software Implementation itc edes aaa 33 4 Functional Design Testing i 34 4 1 Current Method Comparison Procedure ii 34 4 2 Besull n socie cae oia EC rex Db aded UN ab enc pin M Da nd NM ER ERE DEN E 35 cM CONCIUSIONS gt ETT re aeree 36 5 1 SUMMA O N O E TI i 36 Automated Actuator Inspection Device BorgWarner Inc S2JFinal Costiari ee n re dcs Nicks decet 39 Bio Puture WOFPK usa retur EAS OS GN Een E EON era 40 5 3 1 Metering Circuitry IMprovemeEntSs enean nnne 40 5 3 2 Power Generation IMprovementSs nene 40 5 3 3 Device Housing and Fan Rotation Improvements 41 5 3 4 Automation and Database Storage ImprovementsS 41 Ge PRD DEI Lo eias Meter tesi estfecab passa acabe aos itane fut an Leite ien fatua atas Adeste etii aug 43 6 1 Technical Roles and Responsibilities i 43 6 1 1 Jacob Co Automation and Database Storage i 43 6 1 2 Joshua DuBois Pow
20. 4 Tur 100uF WF I E AC Automated Actuator Inspection Device 58 BorgWarner Inc 6 3 11 Automated Actuator Inspection Device Housing Draft Automated Actuator Inspection Device BorgWarner Inc 6 3 12 Automated Actuator Inspection Device LabVIEW VI Hierarchy Automated Actuator Inspection Device BorgWarner Inc 60
21. 6 81 42 96 24 75 38 37 Figure 2 3 1 Automated Actuator Inspection Device House of Quality The House of Quality for the Automated Actuator Inspection Device is shown in Figure 2 3 1 As a part of Quality Function Deployment QFD the House of Quality defines the relationship between Critical Customer Requirements CCRs and engineering design objectives ECE 480 Design Team 6 kept automation accuracy data storage and cost as objectives of high importance in the design of the Automated Actuator Inspection Device as seen in the House of Quality total importance weighting Automated Actuator Inspection Device 10 BorgWarner Inc 2 4 Conceptual Design Descriptions Listed are ECE 480 Design Team 6 s initial conceptual designs for the Automated Actuator Inspection Device 2 4 1 Commercial Meter Interfacing The commercial meter interfacing design improves upon BorgWarner s manual inspection method The PC interfaces with metering systems purchased off the shelf which are directly attached to the electric fan clutch actuator The PC stores the metering systems measurements in a database as well as on a hardcopy printout This ensures the measurement accuracy given by professionally developed metering systems However the cost in purchasing these metering systems is high Interfacing with the metering systems may also prove to be difficult if the user does not have a USB or GPIB mode control and measurement output 2 4
22. 8 Mon 2 16 09 Wed 3 11 09 Mon 2 16 09 Wed 3 4 08 Wed 3 11 08 Mon 4 6 09 Mon 4 6 09 Wed 3 18 08 Wed 3 25 08 Fri 3 27 08 Wed 4 1 09 Mon 4 6 09 Mon 4 6 09 Wed 3 18 08 Wed 3 25 08 Fri 3 27 08 Wed 4 1 08 Mon 4 5 08 Mon 4 6 09 Fri 343 09 Fri 3 20 08 Fri 3 27 09 Wed 4 1 09 Mon 4 6 09 Mon 4 6 09 Wed 3 18 08 Thu 3 19 09 Thu 3 26 08 Mon 3 30 09 Mon 4 5 08 Thu 3 12 08 Thu 3 19 08 Thu 4 30 09 Thu 4 9 08 Fri 4 47 08 Wed 4 22 08 Thu 4 30 08 Resource Names All All Stephen All Josh All All All Josh Josh Josh Josh Josh Josh Codie Codie Codie Codie Codie Codie Jacob Jacob Jacob Jacob Jacob Jacob Stephen Stephen Stephen Stephen Stephen Stephen Stephen Stephen All All All All Figure 2 8 1 Automated Actuator Inspection Device Gantt Chart Milestones Automated Actuator Inspection Device BorgWarner Inc 15 Task Mame Initial Organization Phase Form team and trade contact information Meet with Dr amp yres Meet with BorgWVarner to clarify project details Pick up test units Project Research Define project specifications Brainstorm and research for similar diagnostic devices Decide on best solution and assign technical tasks E Design Phase Design power supply Research transformers chips circuits etc Order parts Build power supply Test power supply Make needed corrections
23. Michigan State University ECE 480 DESIGN TEAM 6 Automated Inspection Device for Electric Fan Clutch Actuators For BorgWarner Inc Jacob H Co Joshua S DuBois Stephen J Sutara Codie T Wilson Dr Virginia M Ayres Facilitator Final Report Friday May 1 2009 x BorgWarner Executive Summary The inspection of fan clutch actuators is vital in ensuring the proper operation of radiator cooling fans in automobiles The current inspection method employed by BorgWarner Inc is manually driven each inspection task requires a different connection to the actuator and its measurement result is recorded by hand In the spring of 2009 BorgWarner tasked ECE 480 Design Team 6 with the design of an automated inspection device to replace their manual inspection method The team has successfully developed a device that automatically performs inspection tasks The device interfaces with the fan clutch actuator using a single connection and inspection is run through software on any USB enabled PC The measurement results are automatically gathered and are printed out for present validation as well as stored in a database for comparison This solution streamlines the inspection process increasing efficiency and eliminating human error As a result possible defects can be identified faster and more robust fan clutch actuators can be designed Automated Actuator Inspection Device 1 BorgWarner Inc Acknowledgements ECE 480 Desi
24. Technical Description The Automated Actuator Inspection Device is comprised of four key components the metering circuitry power supply device housing and fan rotation and automation and database storage 3 1 Hardware Design 3 1 1 Metering Circuitry Below is a list of the components used in the switching metering circuitry e NI USB 6008 Data Acquisition Module e DB202BDJ Analog Switch IC e MM74HC4514 4 to 16 Decoder IC e LM358 Dual OP AMP IC e LM555 Timer IC e ACS712 5A Current Sensor IC e 2N2222 NPN Transistor e 1N4148 Diode e 64W10K Precision Multi turn Potentiometer e EC2 5NJ 2A DPDT Relay e Various resistors capacitors One of the requirements for the new design was that it had to interface with a PC and be automated through software control The decision was made to use National Instruments USB 6008 Data Acquisition Module DAQ as the in between for the metering circuitry and the PC Since the module is produced by NI there is extensive support in the LabVIEW Automated Actuator Inspection Device 17 BorgWarner Inc environment The module itself is a small device that has a USB port in the back a terminal of analog I O on one side and a terminal of digital I O on the other side All I O operations from the PC to the circuit and back including running the tests and gathering results is controlled in LabVIEW through the module The basic function of the circuitry is to read in a binary code 4 bit from the
25. ance scale of 1 5 with 1 being slightly important and 5 being extremely important The initial conceptual designs are given rankings based on an effectiveness scale of 1 5 with 1 being slightly effective and 5 being extremely effective in fulfilling the design criteria Based on effectiveness totals the team continued with the data acquisition and processing design Considerations from the commercial meter interfacing design as well as from other ideas were taken into account throughout the design process 2 6 Implemented Design Solution Printout Unit Under Test Metering Circuits DAQ Module PC Database Figure 2 6 1 Automated Actuator Inspection Device Block Diagram Automated Actuator Inspection Device BorgWarner Inc 12 ECE 480 Design Team 6 implemented the Automated Actuator Inspection design shown in Figure 2 6 1 The unit under test interfaces directly with preconditioning circuits designed by the team These circuits transform and scale the raw signals received from the unit under test into usable inputs as defined by the data acquisition module specifications The data acquisition module interfaces with a PC using USB as the preconditioned inputs are communicated to a National Instruments LabVIEW environment The LabVIEW environment performs waveform analysis and other calculations to derive the desired voltage
26. andability was taken into consideration at the beginning of the design process However due to unfamiliarity with the actuator circuitry and a prolonged prototyping phase the customization GUI was not realized This proposed feature depends on the generic nature of the metering circuitry in being able to read actuator measurements of varying ranges However at present the metering circuitry has been tailored to accommodate PEF 180 and PEF 188 model actuators Only after the metering circuitry reaches a higher level of versatility can this expandability notion be entertained Automated Actuator Inspection Device 42 BorgWarner Inc 6 Appendix 6 1 Technical Roles and Responsibilities Each member of ECE 480 Design Team 6 is responsible for technical aspects of the Automated Actuator Inspection Device design Although they are responsible for overseeing the development of these aspects the project is a team effort as a whole and members work in conjunction with one another to facilitate completion Listed here are the team members technical roles and responsibilities 6 1 1 Jacob Co Automation and Database Storage Jacob Co was responsible for the automation backbone of the Automated Actuator Inspection Device His role was vital to the success of the project as the LabVIEW interface serves as the driving force behind the inspection procedures The interface is what the device user interacts with throughout inspection
27. ator units under test The measurements are stored in a database for later lookup and comparison as well as on a hardcopy printout similar to the system requirements sheets currently used under the manual inspection method The Automated Actuator Inspection Device significantly increases inspection efficiency and actuator design efforts in comparison to its manual counterpart Automated Actuator Inspection Device 5 BorgWarner Inc 1 2 Background b Viscous Couplings a Solenoid action Fluid Regulating Device c Hall Effect Device Element Figure 1 2 1 BorgWarner Generation Il Actuator Subassembly A cross sectional view of BorgWarner s Generation II electric fan clutch actuator system is shown in Figure 1 2 1 The actuator system consists of an electronic temperature sensor solenoid action fluid regulating device and a Hall Effect device The electronic temperature sensor monitors the temperature of the engine coolant fluid determining the engaging and disengaging of the radiator cooling fan The solenoid action fluid regulating device shown in a in Figure 1 2 1 is controlled by a variable current that proportionally regulates the amount of viscous fluid released into the clutch couplings shown in b in Figure 1 2 1 which solidifies under heat and links the couplings together to rotate the fan Automated Actuator Inspection Device 6 BorgWarner Inc The edge sensing Hall Effect device monitors the s
28. bles the fan clutch to be automatically rotated during inspection For safety purposes the enclosure has two Automated Actuator Inspection Device 36 BorgWarner Inc switches a power switch and a lid switch The device will not rotate until the lid is closed even if the power switch is on The team created a custom power supply that can output 5V DC 12V DC and 24V DC and is rated for 1 5A at each voltage It has a 2A fuse located before the regulators to safeguard from burning them out Although heat was previously an issue larger heat sinks ventilation holes anda large fan were added to the design to lower the temperature during operation The power supply is used to power the metering circuitry as well as to supply the actuator with test voltages The team s circuit design is able to interface with a PC It can run seventeen of the nineteen tests from the current PEF 188 model actuator checklist as well as new time plot inspections as mentioned previously The remaining two tests are for the same circuit component 100nF capacitor At this point the team s design is unable to retrieve a measurement The differences in the checklists for the PEF 180 and PEF 188 model actuators include a 24V DC coil test and extra continuity checks While the circuit design has not yet been tested on the PEF 180 its schematic is almost identical to the PEF 188 and should operate correctly Due to time constraints and technical difficulties t
29. convenient option when being placed in labs A larger concern deals with the stepper motor and the safety measures in place A better solution for protection would be to have electronic safety measures in addition to the mechanical switches Right now the PC controls inspection but not the rotation of the motor A software based speed control could provide more safety to the user In addition future inspection may require varying rotation speeds in which a speed control would prove beneficial 5 3 4 Automation and Database Storage Improvements Automation and database storage can be improved by continuing development of the Automated Actuator Inspection Device s LabVIEW interface A basic framework has been laid out in Vis created for automated testing of the PEF 188 model actuator Although this framework can be duplicated in order to fit future actuator models a more streamlined approach is desired A more streamlined approach can be implemented by further developing the device s interface for higher customization and ease of use A profile system can be developed and linked to the actuator model drop down seen in the device s start GUI This profile system would be powered by a customization GUI where the user would be able to create their own test Automated Actuator Inspection Device 41 BorgWarner Inc requirements citing desired measurements voltage current resistance capacitance and acceptable pass ranges This exp
30. cuits In addition the fan clutch must be rotated to simulate operation This is achieved through the powering of a motor attached to the clutch However a safety switch only allows power to be delivered to the motor if the lid of the device is closed From there a pass or fail declaration is made by comparing calculated voltage current resistance and capacitance measurements to the functional requirements of the actuator This comparison and calculation is done through a PC interface Automated Actuator Inspection Device 9 BorgWarner Inc 2 3 House of Quality Critical Customer Requirements Correlation matrix strong positive positive negative T strong negative n N oe Customer Rating Interrelationship matrix X 5 High 1 Low 2 9 AJIAJA UY Y Y amp c _ u Ch gt s S E I T E x D Z o t PIA E E 9 A AIT P R ol U N A F O Relationship vlt factors at E E i z Solc la s Q E Strong 9 THMICIBITIS TIRIo Moderate 3 S A U I O A P R Moderate 3 Diriritiririci rigit A Weak 1 GII A I A E O I EIR i o cjT GlT s N Qle Customer Requirements N Y Y E Y T T S E Automated Inspection e EX 5 High Meas Accuracy O 9 N 5 Test Result Printout e 4 Test Result Database g e 4 High Ease of Use 9 3 Small Device Footprint e 2 Calibration Ability 9 4 Wall Outlet Power e 3 Safety from Rotation e 2 Future Product Expansion e 114 3 Total Importance 9
31. df LM358 OP AMP Datasheet http www national com ds LM LM158 pdf LM555 Timer Datasheet http www national com ds LM LM555 pdf MM74HC4514 4 16 Decoder Datasheet http www fairchildsemi com ds MM MM74HC45 14 pdf NI USB 6008 DAQ Module Datasheet http www tau ac il electro pdf_files computer ni_6008 ADC manual pdf VHI590A 120U Stepper Motor Datasheet http www orientalmotor com products pdfs A_OM AcInd90 pdf Automated Actuator Inspection Device BorgWarner Inc 48 6 3 Technical Attachments 6 3 1 5V DC Speed Signal Test Circuit Schematic 5V Speed Signal Test 24V ikohm potentiometer 5V at Pin C Decoder I FOO i nn i AMO 1N4148 Tkohm 4 7kohm diode resistor resistor I I I Analog I Switeh 3 PhD AIO n T i I I Pin E 1N4148 diode rr 2N2222 transistor Automated Actuator Inspection Device 49 BorgWarner Inc 6 3 2 12V DC Speed Signal Test Circuit Schematic 12V Speed Signal Test 24V Analog Switch 1 1kohm potentiometer 12V at Pin B Analog Decoder ____________ l Switch 1 control S2 I I 1N4148 1kohm 4 7kohm diode resistor resistor Pin D PinE 1N4148 diode m 2N2222 transistor Automated Actuator Inspection Device 50 BorgWarner Inc 6 3 3 Coil Suppression Diode Amperage Test Circuit Schematic Coil Suppression Diode Amperage Test AIO Decoder control S9 Analog Switch 3 EC2 5NJ 10ohm 10W 2A relay power
32. dressed Overall using a better DAQ module would increase the device s accuracy and fix many of the problems with the current module However even a slightly better module costs significantly more so a trade off must be made 5 3 2 Power Generation Improvements For future designs a more reliable power supply needs to be acquired The power supply designed by ECE 480 Design Team 6 was completed quickly and although the power supply is robust it has not gone through rigorous testing A professionally manufactured power supply would provide a steadier more reliable power source with a longer lifespan This reliability would make it easier to implement the power supply into future tester designs Automated Actuator Inspection Device 40 BorgWarner Inc There is one test that was not implemented in the Automated Actuator Inspection Device due to time constraints This test required a 300V DC source to be applied through the fan clutch s solenoid to check its continuity This test should be implemented in future designs as it is important in fully verifying the proper operation of fan clutch actuators 5 3 3 Device Housing and Fan Rotation Improvements The physical design of the Automated Actuator Inspection Device requires no significant modification The dimensions can be adjusted so there is less open space This results in a less expensive housing since less material is required The footprint also decreases making it a more
33. e implementation 4 Functional Design Testing 4 1 Manual Method Comparison After developing circuits capable of running tests on the actuator it was necessary to check if the results had acceptable accuracy To do this the tests were run on the actuator with a high end multimeter whose results became the reference The meter does not perform capacitance measurements therefore a separate capacitance meter was used Automated Actuator Inspection Device 34 BorgWarner Inc 4 2 Results For the speed signal tests all the results for the current measurements were very close within 1mA The multimeter values were always slightly smaller than the team s design which is to be expected because of the way the multimeter calculates current as well as the errors introduced such as the multimeter s burden voltage It is possible that the results of the team s design are actually closer to the real current value The high signal state voltages for both tests were almost exactly the same The largest difference was with the 5V test where the difference was 0 03V The low signal states were both approximately 15mV different from the multimeter s results which may seem significant when the multimeter gives 65mV and the team s design gives 80mV However since the range of acceptable values for the low signal state is OV to 0 4V the difference in results leads to an error of only about 4 For the coil suppression diode amperage the multim
34. e minimal and little heat was dissipated As the power supply underwent more testing another problem came to the forefront The voltage output at the regulators began to steadily fall when the supply had been on a long time This was due to internal heat protection inside the regulators preventing them from melting The regulator dissipated too much heat and in turn activated the protection circuitry As such heatsinks were added to displace the heat and stop the protection circuitry from activating A fan was also attached to the power supply to further decrease the heat dissipation After further testing the power supply encountered no more problems The final power supply design can be seen in Appendix 6 3 10 Automated Actuator Inspection Device 25 BorgWarner Inc 3 1 3 Device Housing and Fan Rotation The physical layout for the AAID may be broken up into four sections the bottom shield baseplate and stepper motor Figure 3 1 3 1 Automated Actuator Inspection Device Housing Models Figure 3 1 3 1 shows CAD models of the Automated Actuator Inspection Device housing see Appendix 6 3 11 The bottom section measures 21 5 x 21 5 x 15 5 and is constructed from 1 2 plywood It houses the stepper motor power supply and metering circuitry The large size equates to a stable base during operation As heavy fan clutch actuators are tested this box is able to safely support the weight and momentum resulting from t
35. er Generation cessere 44 6 1 3 Stephen Sutara Device Housing and Fan Rotation 45 6 1 4 Codie Wilson Metering Circuitry iii 46 56 2 Referente AIROLA 48 6 3 Technical Attachments su rp RON pa M a pP ria e aaa 49 6 3 1 5V DC Speed Signal Test Circuit Schematic i 49 6 3 2 12V DC Speed Signal Test Circuit SchematiC i 50 6 3 3 Coil Suppression Diode Amperage Test Circuit Schematic 51 6 3 4 Coil Amperage Resistance Test Circuit SchematiC 52 6 3 5 Continuity Test Circuit SchematiC ii 53 6 3 6 Resistance Test Circuit Schematic 2 5 erae oi ien ro tnhe e oae I enin ha eodd nan 54 6 3 7 Capacitance Test Circuit SchematiC ii 55 6 3 8 Test Addition Circuit Schematic eu eco ane a peg ae p Ee ea Na SR Re Ipaa 56 6 3 9 PEF 180 Continuity Test Solution Circuit Schematic 57 6 3 10 Automated Actuator Inspection Device Power Supply Schematic 58 6 3 11 Automated Actuator Inspection Device Housing Draft 59 6 3 12 Automated Actuator Inspection Device LabVIEW VI Hierarchy 60 Automated Actuator Inspection Device BorgWarner Inc 1 Introduction and Background 1 1 Introduction The fan clutch actuator is responsible for engaging the radiator cooling fan in automobiles which
36. es this robust component an ideal choice The on off switch acts very much the same way it is rated for 2 5A well within the required limits When both switches are in the on position power is supplied to stepper motor The VHI590A 120U stepper motor is manufactured by Orientalmotor This 90W motor draws 1 56A at peak operation A gear ratio of 120 1 steps down the angular speed The 350 Ib in rated torque gives this motor versatility to be used in a number of applications Other notable specifications begin with the motor s power supply Its ability to be plugged directly into the wall outlet makes for seamless integration with the team s current power supply and choice of switches It possesses enough torque to rotate every fan clutch in BorgWarner s inventory with the capability to handle larger loads for potential future designs The motor operates at 15 rpm a perfect speed for inspection 3 2 Hardware Implementation Figure 3 2 1 Physical Device Hardware Layout Automated Actuator Inspection Device 29 BorgWarner Inc The physical layout of the Automated Actuator Inspection Device is shown in Figure 3 2 1 It provides a compressed protected shelter for the power supply metering circuitry data acquisition module and stepper motor Each device is carefully laid out so as to not damage another Because the power supply has an external fan it is oriented such that air is circulated throughout the bottom housing
37. esigned its housing and cooling system It consisted of a metal enclosure with a fan mounted on the side Throughout the project Joshua lent a hand wherever it could be used When he wasn t working on power generation Joshua was working with the metering circuitry PCB or the device housing Automated Actuator Inspection Device 44 BorgWarner Inc design The PCB needed to be built from the ground up and once the PCB was fabricated by the MSU ECE Shop the circuit elements had to be soldered to the board Since Joshua had prior soldering experience he did most of the initial PCB assembly Joshua also helped Stephen create the housing design by introducing valuable insights and ideas Joshua s role was vital in the success of the project 6 1 3 Stephen Sutara Device Housing and Fan Rotation Stephen Sutara was responsible for the housing design stepper motor and safety measures He first took measurements of Codie and Joshua s metering circuitry and power supply to have an idea as to how large the housing would need to be Using modeling software he designed and drew the schematics for the housing and worked with the MSU ECE Shop for fabrication The stepper motor required examination of many different quantities Stephen started by determining what requirements the motor would have to meet To accomplish this he worked with BorgWarner to learn that the largest fan clutch actuator weighed thirty five pounds with a diameter
38. eter gave a result of 375mA However using the same multimeter to measure the voltage at both terminals of the 100 resistor used in the test then using it to measure the resistance of the resistor the result is 401mA From this it can be seen that the multimeter introduces significant error As expected the error created result was smaller than the actual value This error is not enough to cause the test to fail however it is significant The team s design applies Ohm s Law in this test to produce a very accurate result 401mA The power supplies used for testing display the voltage and current output both of which agree with the results of the team s design For the coil current coil resistance test a Hall Effect IC is used to measure the current The IC s voltage output is a linear function of the current passing through it Once the equation is defined with exact values it is easy to calculate the current From calculations made with the IC measuring currents ranging from 0 25A to 1 35A the accuracy compared with the power supplies was at minimum 95 696 accurate and normally greater than 9796 accurate Because Ohm s Law is applied to get the coil resistance value the accuracy is the same Automated Actuator Inspection Device 35 BorgWarner Inc For the continuity tests the tests do not necessarily yield a value but rather a pass fail status All of the tests passed using the team s design and available test actuators A better
39. from the input of actuator identifying numbers and selection of the correct model to the display and storage of results in both printout and database form In the background the interface is sending decoder line outputs corresponding to specific actuator tests through the data acquisition module enabling the correct circuitry on the metering board for inspection In addition to facilitating the automation process Jacob s work was also responsible for processing the input signals from the metering circuitry into usable actuator measurements This conversion is crucial in being able to compare accurate results to actuator specification ranges Jacob made the graphical user interface GUI as user friendly and understandable as possible denoting inspection passes with green highlights and fails with red highlights As the automation interface drove the metering circuitry Jacob worked closely with Codie during development of the Automated Actuator Inspection Device Given the powerful versatility of the LabVIEW environment and the hurdles of circuit design Jacob structured the interface to work around the metering circuitry This was extremely beneficial through the Automated Actuator Inspection Device 43 BorgWarner Inc prototyping phase of the project where the metering circuitry would undergo major changes and automation needed to be kept intact Needing to know the metering circuitry thoroughly in order to successfully implement aut
40. gn Team 6 would like to thank the following people for their help in developing Automated Actuator Inspection Device e BorgWarner Stephen Bohan Jim Ignatovich and Al Dove for their background and guidance on fan clutch actuators and inspection e MSU ECE Technical Services Brian Wright Gregg Mulder and Roxanne Peacock for their support in procuring and fabricating necessary components e MSU College of Engineering Dr Virginia Ayres and Dr Erik Goodman for their support and guidance throughout the design process Automated Actuator Inspection Device BorgWarner Inc Table of Contents 1 Introduction and Background iii 5 T1 INFOduction alla SSR ri 5 BD DAG KOMI css ee cate elec eed etal cea onda eee seated eo 6 2 Solution Space and Specific Approach i 8 2 1 Design Specifications and Objectives casae cd oap aaa 8 22 FAST Diara MOMENT 9 2 3 House of Quality Critical Customer Requirements 10 2 4 Conceptual Design DescriptionS i 11 2 4 1 Commercial Meter Interfacing iii 11 2 4 2 Data Acquisition and Processing iii 11 2 5 Feasibility Matrix RH ROREM e ve Eve rv vei ER VERSUM ESOS 12 2 6 Implemented Design Solution ssssseesseeeeeeeeeeeeennn nnne nenne nennen nennen 12 PINAUTUDPIDPMAM EE em 14 2 8 Game Chet aaa d bea Read PAN NS Rota 15 3 Technical Description ii
41. he fans rotation The baseplate rests on top of the bottom structure Constructed from 21 5 x 21 5 x 1 8 aluminum its purpose is to support the weight of the fans during testing and hold the motor in place This is necessary because the stepper motor is built to rotate a shaft not act as a support for heavy loads If a large enough fan was placed on the motor directly it could tip or break due to the weight The rotation apparatus rests on the baseplate A more detailed look of this piece is shown In Figure 3 1 3 2 Automated Actuator Inspection Device 26 BorgWarner Inc Figure 3 1 3 2 Device Rotation Apparatus The stepper motor s shaft connects to the circular plate in the middle A threaded shaft is secured to this plate to securely fasten fans during rotation The circular plate rotates smoothly directly from the stepper motor shaft The top portion of the device housing is the shield resting on the aluminum baseplate A screw in each corner holds the shield baseplate and bottom sections together Constructed from the same 77 plywood as the bottom section the shield measures 20 5 x 20 5 x 8 The shield s purpose is to provide protection The fan clutch will be rotating while undergoing inspection raising the possibility of fingers clothing or other objects being caught in the motion The result could be damage or injury The shield features two Plexiglas pieces one as the lid and the other as a window Thi
42. her terminal With the non inverting OP AMP topology the OP AMP output voltage will be somewhere above 5V The voltage drop across the 1kO potentiometer will be enough so that regardless of what the output voltage is the voltage at its inverting terminal will be forced to 5V The inverting terminal in the schematic is directly connected to pin C of the actuator creating 5V there The current going into the actuator can be measured by Automated Actuator Inspection Device 18 BorgWarner Inc 5V out SS potentiom er The output voltage is measured after the switch so that the switch s non linear resistance around 45Q is not a factor The speed signal line of the actuator pin D is connected through a switch to the data acquisition module analog input The decoder signal is also connected to the base of an NPN transistor which grounds the sensor pin E For the 12V DC speed signal test it follows the same procedure as the 5V DC speed signal test except that 12V is applied to the non inverting terminal of the OP AMP and the inverting terminal is connected to pin B of the actuator instead of pin C as above see Appendix 6 3 2 To measure the coil suppression diode amperage instead of using analog switches like the ones used in the speed signal test it was decided to use a 2A DPDT double pole double throw relay Double pole double throw means that a single mechanism controls both switches inside the two switch relay Re
43. in B and the 8 2MQ resistor If there was a connection of 10M O between pin A and pin B then a voltage divider would be created with 10MQ in series with 8 2MO With these values there would be around 2 1V at the non grounded end of the 8 2MO resistor due to the equation M oma 4 6V 8 2MQ 8 2MQ R continuity where Rcontinuity is the resistance between pin A and pin B which is being calculated as 10MQ As the resistance between pin A and pin B increases the voltage between the two decreases and vice versa Therefore the voltage at the non grounded end of the 8 2MQ resistor can be read by the data acquisition module and if the voltage is less than or equal to 2 1V the test passes If it is greater the test fails The pin B to C resistance test is controlled by decoder line S7 This test is exactly like the coil suppression diode amperage test except that the software calculations are slightly different When the switches close 5V DC is connected to pin B of the actuator through a 5600 resistor and pin C is grounded 5600 was the value chosen for the fixed resistor because it is close to the expected resistance value from pin B to pin C so this voltage divider works well The voltage is read by the data acquisition module to the right of the resistor see Appendix 6 3 6 The current through that resistor can be calculated by SV Var resistor 560Q There is another resistance to factor in which is the resistance
44. lays have almost no resistance when connected and can handle a much larger current and more current is expected than what an analog switch can handle greater than 30mA Decoder signal S9 is used to control this test When it goes high the necessary switches are closed to activate the test see Appendix 6 3 3 The decoder is connected to an NPN transistor which will then connect 5V and the relay coil The other end of the relay coil is always grounded When S9 goes high current flows through the coil and the relay switches close When this happens 5V is connected to a 100 10W power resistor that is connected to pin F of the actuator Pin A becomes grounded and voltage is measured to the right of the resistor see Appendix 6 3 3 with the data acquisition module The amperage is then found by _5V V test diode 100 Automated Actuator Inspection Device 19 BorgWarner Inc For coil amperage and coil resistance both tests can be run simultaneously using decoder line S12 If 12V DC is applied to pin A of the actuator and the current at pin A is measured coil amperage test then the resistance is calculated as R 12V coil T pinA Once again for this test a 2A relay was used because up to 1 3A is expected When the relay switches close 12V is connected to pin A of the actuator and pin F is grounded However between 12V and pin A is the ACS712 current sensor IC see Appendix 6 3 4 It is a Hall Effect device that sense
45. omation Jacob also served as a hardware troubleshooter in the finalization stages of the device As metering components seemed to malfunction Jacob took a methodical approach in tracing signals from raw actuator input to component output isolating problems and working with Codie to brainstorm and implement design changes 6 1 2 Joshua DuBois Power Generation Joshua DuBois was responsible for the design and implementation of a reliable power supply The design had to be low cost due to budget constraints The power supply was needed to power the actuator under test as well as the circuitry used for taking measurements The measurement circuitry required 5V DC 12V DC and 24V DC supplies at 1 5A The fan clutch actuator required depending on certain models 5V DC and 12V DC supplies to operate Each voltage source needed to be designed and implemented The implementation of the designs did not always go smoothly but if any problems arose Joshua fixed or re designed the power supply to meet requirements This led to many design iterations to create a more reliable power supply Throughout the project the power supply had to be molded around the measurement circuitry power requirements These iterations required researching for parts as well as a re design of the power supply topography During each revision more parts were added which added to the complexity of Joshua s role After the power supply design was finalized Joshua d
46. on Device 55 BorgWarner Inc 6 3 8 Test Addition Circuit Schematic Adding a Test Module control Allocated decoder control line Actuator Module analog iL Automated Actuator Inspection Device 56 BorgWarner Inc 6 3 9 PEF 180 Continuity Test Solution Circuit Schematic Continuity checks for the PEF 180 proposed solution Decoder 2 control S1 S2 S3 r I I E fo Bes TOV vege 1N4148 I I diodes I I I I I Eod bd Li A E d nmm 2N2222 i l transistor I l I G I I B Nl I boo cio il cl lutti w Ee e e e a EET S a sic B S4 S5 S6 E I a o Test point 100kohm resistor SEEEN eel d 2N2222 transistor R Be Ww EER PE ISEE re ET EE os ee I ue B S7 8 o 1 I I ba 5V Test point i LI 100kohm diodes I I BEEP I Saia 4 2N2222 I I transistor I I I o I UO IUVOEVSGEUEWOEVOCUSGEWOENUESWSERNGENGENCIENWESME a M E i pe pe OSA Ww B Test point M og 100kohm resistor Automated Actuator Inspection Device 57 BorgWarner Inc 6 3 10 Automated Actuator Inspection Device Power Supply Schematic 2200 2 2KO 2200 f 8K42 2200 ATKO W LM317 LM317 LM317 100
47. owards the end of the project the team was unable to connect the extra tests for the PEF 180 to the PCB However proposed solutions with schematics for these tests have been drafted which will be given to BorgWarner see Appendix 6 3 9 The device s software created in LabVIEW allows the user to run the tests on the actuator with the click of a mouse The data is entered into a graphical output along with the time plots A passing or failing test is easily recognized in the output with passing results displayed in green and failed results in red The data is then made into a hardcopy printout as well as interfaces with Microsoft Access to create a database for test results Automated Actuator Inspection Device 37 BorgWarner Inc Once the framework for the design of the Automated Actuator Inspection Device was in place adding tests was an easy task under both hardware and software While the design is not entirely complete with some revision it can be a very robust design expandable to include new measurements ECE 480 Design Team 6 was able to show that it is possible to create an accurate low cost automated test device The team was able to demonstrate a functional although slightly incomplete automatic tester The team designed all the major components including the housing power supply hardware and software for the device It is a robust framework that is capable of being expanded as needed Automated Actuator Ins
48. pection Device 38 BorgWarner Inc 5 2 Final Cost Supplier E ECE Shop Total Part Name BW BorgWarner Cost ea Qty De T Team Metering Circuitry 10 ohm Power Resistor T 1 00 1 1 00 ACS712ELCTR 05B T Hall Sensor T 1 29 1 1 29 Chip Surface Mount E 0 42 6 2 52 DG202BD J Analog Switch T 1 26 4 5 04 Dual Operational Amplifier T 0 29 1 0 29 Inverter IC T 0 26 1 0 26 LM2917N 8 NOPB Signal Relay E 1 70 4 6 80 LM555 Timer T 0 42 1 0 42 MM74HC4514N Decoder IC T 1 11 2 2 22 National Instruments USB 6008 DAQ T 152 10 1 152 10 Terminal Blocks E 0 79 2 1 58 Transistor T 0 20 6 1 20 Power Generation 2 Amp Fuse E 2 61 1 2 61 DC Fan E 4 99 1 4 99 Heatsinks T 0 92 3 2 76 LM371 Voltage Regulators E 1 70 3 5 10 SPST Switch T 3 47 1 3 47 Transformer E 23 64 1 23 64 Device Housing and Fan Rotation 1 2 x 48 x 96 Inch Plywood T 31 96 1 31 96 21 5 x 21 5 x 1 8 Aluminum BW 20 00 1 20 00 3 16 x 24 x 48 Plexiglas T 51 33 1 51 33 Orientalmotor Stepper Motor BW 292 00 1 292 00 Snap Action Switch 2 15 1 2 15 Toggle Switch 2 34 1 2 34 Team Expenditures 253 34 ECE Shop Expenditures 51 73 BorgWarner Expenditures 312 00 TOTAL PROJECT COST 617 07 Table 5 2 1 Automated Actuator Inspection Device Project Expenditures Automated Actuator Inspection Device BorgWarner Inc Table 5 2 1 shows
49. peed of the radiator cooling fan through the number of passes of the Hall element shown in c in Figure 1 2 1 and regulates the speed in accordance with the desired engine coolant fluid temperature A general electrical schematic of the electric fan clutch actuator is shown in Figure 1 2 2 VPWR i o VBPWR OPT o ANN A 12V Reg OPT N C p x Ug ei COIL 100nF lt AR HED A lt FSS OPT j WR dex lt ANN qu 22nF i VBGND Ta FC V Figure 1 2 2 BorgWarner Generation II Actuator Electrical Schematic 1 As these devices are vital in the proper operation of the radiator cooling fan and in turn the automobile as a whole stringent inspection methods are required to ensure their correct functioning BorgWarner s current inspection method is a manual measurement of voltages currents resistances and capacitances through a device containing off the shelf metering systems This method involves multiple connections and the hand recording of measurements While this is suitable for validation a more unified and automated method is desired Automated Actuator Inspection Device 7 BorgWarner Inc 2 Solution Space and Specific Approach 2 1 Design Specifications and Objectives In designing the Automated Actuator Inspector the following design specifications must be followed Measurements Voltage current resistance and capacitance measurements as listed on sys
50. resistor 1 p Pin F Pin A 2N2222 Relay coil i transistor 45V Automated Actuator Inspection Device 51 BorgWarner Inc 6 3 4 Coil Amperage Resistance Test Circuit Schematic Coil Amperage and Resistance Test 0 1 uF capacitor 5 ACS712 5A current sensor AIO ink cca 1 capacitor I l 12V EC2 5NJ 2A relay I l Pin A l i Pin F I l l i 2N2222 Relay coil I transistor I i I l l l ov I 45V I l l l fe ntn es CR ND T I I Decoder control 812 Automated Actuator Inspection Device BorgWarner Inc 52 6 3 5 Continuity Test Circuit Schematic Tests Continui 5V 12V 2N2222 transistor Pin A Analog Pin B Pin C PinD Pin E AIO 1N4148 diodes Decoder control 53 Automated Actuator Inspection Device BorgWarner Inc 6 3 6 Resistance Test Circuit Schematic B to C Resistance Test AIO Decoder control S7 I Analog Switch 1 r Pin B Pin C 2N2222 Relay coil transistor 5V Automated Actuator Inspection Device 54 BorgWarner Inc 6 3 7 Capacitance Test Circuit Schematic 22nF Capacitor Test 5V 100kohm Analog I Switch 4 i Pin D I I I I I Analog Pin E Switch 4 porri ree et I I I I FERET i I I Decoder AIO control S14 Automated Actuator Inspecti
51. rgWarner Inc Figure 3 3 1 1 shows the implemented design for the Automated Actuator Inspection Device s automation and database storage interface The conditioned actuator signals from the metering circuitry serve as analog inputs to the data acquisition module and are processed in the LabVIEW VI The VI performs waveform measurements for values required by the metering circuitry equations for voltage current resistance and capacitance readings The equations are carried out and inspection result values are returned The results are then compared to the proper operation ranges for the actuator under test The VI then outputs a digital decoder signal to the data acquisition module which enables the switching circuitry and proceeds with the next test After the inspection process is complete the LabVIEW VI prints out a screenshot of itself for a hardcopy test report and also stores the results as a Microsoft Access database recordset for comparison with past and future test runs The software and interface design implementation requires the following components e National Instruments LabVIEW 8 5 Professional Development System e National Instruments LabVIEW Database Connectivity Toolkit e National Instruments USB 6008 Multifunction Data Acquisition Module e National Instruments DAQmx Software e Microsoft Office Access 2003 X BorgWarner Fan Clutch Actuator Test REA Number Fan Drive Number Actuator Part Number Fan Drive Serial Number
52. s combination allows the user to view the fan clutch while it is under test Automated Actuator Inspection Device 27 BorgWarner Inc In addition to ensuring safety while the fan clutch rotates the shield also provides protection as fan clutches are mounted and dismounted The circuit in Figure 3 1 3 3 accomplishes this feat AC p Figure 3 1 3 3 Device Housing Safety Switch Circuit One toggle switch acts as an on off control while the other completes the circuit This second switch depresses with a hinge lever This hinge switch is located on the shield when the lid is closed it depresses the switch s contact and completes the circuit path This means that even if the stepper motor is turned on the motor will not rotate while the lid is open Both switches act as single pull single throw components The hinge lever switch is a SS SLGT Snap Action Switch manufactured by Omron Its layout can be seen in Figure 3 1 3 4 COM NO NC Figure 3 1 3 4 SS 5LGT Snap Action Switch Circuit Layout Although designed for double pull double throw operation both switches are utilized as single pull single throw devices The normally open terminal connects to the on off switch while the common terminal connects to the wall outlet It is rated for 5A at 125V AC The internal resistance measures in the milliohm range and the 30 million operations lifecycle Automated Actuator Inspection Device 28 BorgWarner Inc mak
53. s current flowing through its terminals and its output voltage is a linear function of that current Vom sn V ffe coil slope Voffset is Vout When 1 0 which is usually half of the supply voltage to the chip The path the current takes through the IC has resistance of about 1mQ so its effect on the conduction path is undetectable When the test is on current flows through the circuit and the data acquisition module measures the output voltage of the current sensor The software converts the voltage value to its corresponding current value For continuity tests between the coil pin A of the actuator and any other pin to pass the measured resistance must be larger than 10MO For this test a voltage divider is set up using an 8 2MQ resistor as the fixed resistor on the board see Appendix 6 3 5 8 2M was chosen as the fixed resistor value because it is close to 10MQ so a voltage divider would work well Each continuity test is the same so the description of the test controlled by decoder line S3 is the same description for the other continuity tests as well S4 S5 and S6 When S3 goes high it connects pin A of the actuator to a voltage source through a 2N2222 transistor Because the Automated Actuator Inspection Device 20 BorgWarner Inc voltage at the base of the transistor is about 5V the maximum voltage across the transistor from the voltage source to pin A will be around 4 6V Also S3 closes an analog switch between p
54. tance A D gt 10 Mohm Resistance 4 E gt 10 Mohm Resistance A F 9 5 12O0hm Resistance B C 395 440 Ohm Capacitance B E 90 110nF Capacitance C E 90 110 nF 10 Capacitance D E 19 8 26nF 0 100 Time Speed Sensor Figure 3 3 1 3 Automated Actuator Inspection Device PEF 188 Test Report GUI Figures 3 3 1 3 shows the test report GUI for BorgWarner PEF 188 back actuated fan clutches Descriptive test information including the test date fan drive serial number and actuator date code are taken from the start GUI The inspection procedure is run and results are inserted into the test report as they are calculated The rows become colored green or red as the tests pass or fail respectively The coil current chart plots the step signature when 12V DC is applied Automated Actuator Inspection Device 32 BorgWarner Inc to the actuator The speed sensor chart plots the high and low speed signal voltages as the fan clutch rotates and passes through the Hall Effect device 3 4 Software Implementation Figure 3 4 1 Metering Circuitry DAQ PC Interfacing Figure 3 4 1 shows the connections between the metering circuitry board the data acquisition module and the PC The analog outputs from the circuitry are tied into the analog inputs of the data acquisition module for test processing and the digital outputs from the module are tied into the inputs of the decoder for test switching
55. tem requirements sheets for BorgWarner Inc Generation and Generation Il actuators Statistics Coil current time plot speed pulse rise and fall time speed sensor pulse time plot speed pulse edge to edge time coil magnetic field mechanical travel linear and angular versus coil current In addition the following design objectives must be met Automated Actuator Inspection Device Automation Automated measuring and storage process Accuracy Accurate voltage current resistance capacitance measurements in mV uA 10 nF scales respectively Expandability Future measurement additions Storage Sufficient database and hardcopy processing Safety Short circuits protection during speed sensor testing Cost Reasonable total device cost Size Workbench fitting footprint Power Efficient power consumption BorgWarner Inc 2 2 FAST Diagram Close Shield Lid Send High Low Signals Calculate Voltage Current Resistance and Capacitance Figure 2 2 1 Automated Actuator Inspection Device FAST Diagram The Function Analysis System Technique FAST Diagram for the Automated Actuator Inspection Device is shown in Figure 2 2 1 It organizes the purpose objectives and functions of the device In order to diagnose a fan clutch actuator data must be collected about it This is done by conducting various tests The tests are enabled and disabled through high and low signals sent by powered switching cir
56. test is to put a resistor across pin A of the actuator and one of the other pins to get a result It should fail if the resistor is less than 10MO which it did through the team s analysis For resistance between pins B and C of the actuator using the multimeter gives a value of 4160 The team s design yields 4150 which is greater than 99 accurate Further testing with other resistor values ranging from 1000 to 1kO were conducted all of the results were accurate For the 22nF capacitance test the capacitance meter used gave a value of 22nF while the team s design yielded about 20nF This is close but only about 9196 accurate A potentiometer was used in the design to tune the circuit to make it almost exactly in the range of capacitance the test specifies For the 100nF capacitance test the team does not yet have a circuit design in place pending implementation of a Wien bridge oscillator 5 Conclusions 5 1 Summary ECE 480 Design Team 6 was tasked with creating an automated test device for BorgWarner fan clutch actuators specifically the PEF 180 and PEF 188 models with the latter being the main focus The tests include specifications from the current test procedures as well as new inspections such as time plots of the coil current and speed sensor output The team has created a design that meets most of the design criteria The team designed an enclosure that uses an induction motor provided by BorgWarner that ena
57. urrents because current sensors are commonly made to measure greater than 1A A very inexpensive hall effect IC was used Another challenge came while trying to incorporate the switching mechanisms Sometimes relays were the best choice due to negligible contact resistance and high current capability However they are larger require more power to turn on and also cannot be directly driven by TTL use an extra transistor to turn on the relay from a logic signal Analog switch ICs were used many times because they are small and can be controlled directly from TTL The problem with analog switch ICs is that they cannot handle high voltage currents and they also have a non linear resistance associated with their contacts when the switch is closed The combination of these two switching mechanisms allowed us to run the tests An unexpected issue towards the end of the project was with the data acquisition module After further research it was discovered that while many commercial multimeters have internal Automated Actuator Inspection Device 23 BorgWarner Inc impedance greater than 10MO the module s is only 144kO As the circuit s impedance approaches that of the multimeter or data acquisition module the measurements become increasingly skewed to the point that they are not useful As an example measuring voltage in a voltage divider with a high end multimeter when the resistors are large greater than 1MQ creates significant error

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