multidisciplinary engineering senior design 06421 automated plasma generator test system preliminary...
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Multidisciplinary Engineering Senior Design06421 Automated Plasma Generator Test System Preliminary Design Review11/11/05
Project Sponsor:MKS, ENI Incorporated
Team Members:John Dullea
Christine KussMegan Suflita
Team Mentor:Dr. Ferat Sahin
Acknowledgements:Dr. Paul Steibitz, Advisor
Kate Gleason College of EngineeringRochester Institute of Technology
Project Background
Narrow band HF RF amplifier Parallel devices with controller Subcomponents of 3700 Watt
amplifier
Current Situation
Tedious to test Time consuming Resource consuming Interpolation issues Result analysis is time consuming
Software Capabilities
LabVIEW code Collect necessary data Perform calculations Generate graphs Fully automated
Required tests
Needs Assessment Customer’s Needs
Automated in LabVIEW Graphical User Interface will be provided Ability to vary input parameters Ability to perform safety checks and take measurements Potential for destructive testing
Our Needs Access to MKS facility, equipment, and technical support Defined work area at MKS Results of past tests for comparison
Concept Development Option 1
Signal Generator
Variable DC Supply
Coupler Load Simulator
Spectrum Analyzer Oscilloscope
Amplifier UUT
HP 4418B Power Meter
Bird Power Meter Sensor
Coupler
Power Meter
Concept Development Option 2
Control BoardGenerator Driver
Amplifier
Generator PSV
UUT Generator CouplerPC Pin Pout Load Simulator
Project ScheduleID Task Nam e Durati on
1 Obtain/Write driv ers for giv en hardw are 17 days
2 Obtain dri vers needed to begin wri ti ng l oops 10 days
3 Obtain/Write other dri vers 10 days
4 Code Loops in LabVIEW 22 days
5 Input Dri ve 7 days
6 Rai l Voltage 7 days
7 Load Impedance 7 days
8 Frequency 7 days
9 Fail S afe 43 days
10 File Input 10 days
11 File Input GUI 28 days
12 File Output 7 days
13 Data Collection 30 days
14 Correlation S tudy 17 days
15 Data Processing 17 days
16 Debug 32 days
17 Documentation 59 days
18 Users' Manual 10 days
19 Rev iew of Code Comments 10 days
20 Input Dri ve 4 days
21 Rai l Voltage 4 days
22 Load Impedance 4 days
23 Frequency 4 days
24 Meeting Notes 59 days
25 Websi te 5 days
26 Presentati on 10 days
All
All
JD
MS
CK
CK
JD
JD
MS
CK
All
All
All
All
All
CK/MS
CK/JD
JD/MS
JD/MS
CK
MS
All
11/13 11/20 11/27 12/4 12/11 12/18 12/25 1/1 1/8 1/15 1/22 1/29 2/5 2/12 2/19 2/26 3/5 3/12 3/19
Overall System Diagram/Block Diagram Software flow of
overall LabVIEW program. Contains 4 nested
loops Varies all
necessary input parameters
Frequency Impedance Voltage Amplitude
File Input
Frequency
Impedance
Voltage
Amplitude
Analysis & Synthesis of Design
Project based upon generic platform Easily adaptable for future
considerations Easily interchangeable with similar
units Customer specifications met Integration of existing code
BOM & Costs All equipment provided by MKS Equipment list
Tektronix Digital Scope Bird Power Meter Bird Power Sensor Agilent Power Meter Agilent Power Sensor ENI Load Simulator & RS232 Cable ENI Matchwork Controller ENI Fiber Optic Converter Agilent Spectrum Analyzer Dell PC Agilent Signal Generator Keithey Scanning Card 4 RF Cables, DC Power Cable, & 6 GPIB Cables Power Supply
Anticipated Design Challenges/Risk
Difficulty integrating software blocks
Creating user-friendly interface that is easily interpreted
UUT safety and control systems Stability of amplifier signal Debugging of code
Input Parameters
User input state:Input fields will be displayed for user
Did user save file with unique
name?
File name state:User will select the input file to test the
unit
Did user select a file?
Display parameters:
Display input file parameters for
user
Are these parameters
acceptable to the user?
Pre-Test:Parse input file into format for
LabVIEW processing
YES
NODEFAULT
ENTRANCE
TO TEST STRUCTURE
NONO
YESYES
Signal Generator Frequency Flow
Read and compare input
frequency
Is frequency in range?
Set signal generator frequency
Is there an output
amplitude present?
Set signal generator amplitude
FROM FILE INPUT NO
YES
NO
YES
GO TO LOAD SIMULATOR STATE
Communications with Load Simulator
Call load simulator software
Has load simulator data
been recorded?
Wait and scan for software to complete
FROM SIG GEN FREQUENCY
NO
YES
GO TO POWER SUPPLY
Power Supply Handling
Read and compare voltage and current level
Are levels in acceptable
ranges
Set power supply voltage and
current
Did output settle?
Wait until output settles
FROM FILE INPUT AND LOAD SIMULATOR
NO
YES
NO
YES
GO TO LOAD SIMULATOR STATE
Determine safe level to cut back to and set variables
Signal Generator Amplitude Handling
Read and compare input
amplitude
Is amplitude in range?
Set signal generator amplitude
FROM FILE INPUT AND POWER SUPPLY
NO
YES
GO TO LOAD SIMULATOR STATE
Cost – Benefit Analysis Assumptions
For manual testing a technician requires 3 days for completion
Technician gets paid $15/hour. Automated program can complete task in 24 hours with 1
hour set up. ($15)*(8hrs/day)*(3 days) = $360 ($15)*(1hr) = $15 A cost difference of $345 per test 3 tests * $360 = $1080 3 tests can be completed with the automatic test
system in the same time that 1 test can be completed manually
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