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PRAVEEN PARIHAR has successfully completed his Summer Training under the project "Study of Climatic Test Chamber" He has fulfilled the tenure successfully from 2 nd June to 30 th June 2014 with sincerity and regularity. He was good at understanding the concepts and shown efficient mutual understanding during his training.
PRAVEEN PARIHAR has successfully completed his Summer Training under the project "Study of Climatic Test Chamber" He has fulfilled the tenure successfully from 2 nd June to 30 th June 2014 with sincerity and regularity. He was good at understanding the concepts and shown efficient mutual understanding during his training.
PRAVEEN PARIHAR has successfully completed his Summer Training under the project "Study of Climatic Test Chamber" He has fulfilled the tenure successfully from 2 nd June to 30 th June 2014 with sincerity and regularity. He was good at understanding the concepts and shown efficient mutual understanding during his training.
A TRAINING REPORT On STUDY OF CLIMATIC TEST CHAMBER Submitted for Partial Fulfilment of the Requirement for the award of Degree of BACHELOR OF TECHNOLOGY In ELECTRICAL ENGINEERING
Submitted To: MR. DEEPAK GUPTA Scientist D Defence Laboratory Jodhpur (Raj.)
Submitted By: Praveen Parihar 4 th B.tech 2011-15 Electrical Engineering JIET Jodhpur CERTIFICATE This is to certify that PRAVEEN PARIHAR student of B.Tech IV th year VII th semester of Electrical Engineering of Jodhpur Institute of Engineering and Technology, Jodhpur, has successfully completed his Summer Training under the project Study of Climatic Test Chamber under my supervision Mr. DEEPAK GUPTA at Defense Research and Development Organization, Defense Laboratory, Jodhpur. He has fulfilled the tenure successfully from 2 nd June to 30 th June 2014 with sincerity and regularity. He was good at understanding the concepts and shown efficient mutual understanding during his training.
Mr. Deepak Gupta Date Scientist D 30 June 2014 Defense Laboratory Jodhpur (Raj.)
ACKNOWLEDGEMENT
It gives me immense pleasure in presenting my training report. I would like to take this opportunity to express my deepest gratitude to the people, who has contributed their valuable time for helping me to successfully complete this training.
With great pleasure and acknowledgement I extend my deep gratitude to Dr. S. R. Vadera, Director Defense Laboratory, Jodhpur for providing me an opportunity to accomplish training at this esteemed organization.
I am thankful to Mr. Deepak Gupta, Scientist D Diploma in Electronics, Post Diploma in computer applications, Engineering in Electrical and in Electronics, M.E. in Electrical Control Systems, also having experience of more than 18 years in the industry. He has provided me necessary guidance about instruments and gave me directions to proceed my training and helped me lot in enhancing my skills.
I would also like to thank my college and my colleagues who directly or indirectly helped me for providing this opportunity to nurture my professional skills at Defense Laboratory, Jodhpur.
Praveen Parihar 4 th B.Tech 2011-15 JIET, JODHPUR
ABSTRACT CONTENTS
S.No. Chapter No. Chapter Name Page No. 1 Certificate 2 Acknowledgement 3 Abstract 4 1 About defence research & development organization (DRDO)
5 2 Training Location 6 3 Introduction 7 4 Specifications 8 5 Types of Chambers and Parameters 5.1 Types of Chambers 5.2 Parameters 5.3 Types & Parameters Under Study
9 6 Bench- Top Climatic Test Chamber 6.1 Introduction 6.2 Constructional Details 6.3 Mechanical Diagram 6.4 Various Parts of a Bench- Top CTC 6.5 Types of Available Temperature Sensors 6.6 List of Components Used in the CTC 6.7 Operation and Controlling
10 7 Walk- In Chamber 7.1 Introduction 7.2 Specifications
11 8 Testing of a Product and Analyzing its Parameters 12 9 Other Types of Chambers 13 10 Conclusion 14 11 Bibliography
CHAPTER- 1
ABOUT DEFENCE RESEARCH & DEVELOPMENT ORGANIZATION (DRDO)
The Defence Research and Development Organisation (DRDO) is an agency of the Republic of India, responsible for the development of technology for use by the military, headquartered in New Delhi, India. It was formed in 1958 by the merger of the Technical Development Establishment and the Directorate of Technical Development and Production with the Defence Science Organisation. It is under the administrative control of the Ministry of Defence, Government of India. With a network of 52 laboratories, which are engaged in developing defence technologies covering various fields, like aeronautics, armaments, electronics, land combat engineering, life sciences, materials, missiles, and naval systems, DRDO is India's largest and most diverse research organisation.
Vision Make India prosperous by establishing world class science and technology base and provide our Defence services decisive edge by equipping them with internationally competitive systems and solutions.
Mission Design, develop and lead to production state-of-the-art sensors, weapon systems, platforms and allied equipment for our Defence Services. Provide technological solutions to the Services to optimise combat effectiveness and to promote well- being of the troops. Develop infrastructure and committed quality manpower and build strong indigenous technology base.
CHAPTER- 2 TRAINING LOCATION Defence Laboratory, Jodhpur (DLJ)
Defence Laboratory, Jodhpur was established on 16th May, 1959. DLJ is located at the gateway of Thar Desert of Rajasthan. It enhances the operational efficiency of troops in desert warfare and logistics support. The aim of the lab is to undertaken research studies in the following areas: 1. Camouflage & Low Observable Devices 2. Nuclear Radiation Management & Applications 3. Desert Environmental Science & Technologies
In addition to R&D activities in the above field, the lab conducts several training programs to the benefit of Services and Civil population, e.g. industrial radiography, NBC, radiation safety aspects, water desalination, quality, monitoring and desert meteorology. The lab has also been identified as a material development lab. The objective of DEST or HMG (Heat Management Group) is the removal of unwanted heat from man and machine, such as soldiers, electronic devices, systems and semiconductors without negatively affecting the performance or reliability of adjacent components. Thermal management addresses heat removal by considering the ambient temperature (and temperature gradients) throughout the entire product from an overall system perspective. Thermal removal solutions cover a wide range of options.
CHAPTER-3 INTRODUCTION Climatic Test Chamber (CTCs) are used for various types of testing procedures such as Prototype Evaluation, R&D Testing, Production testing, Accelerated Stress Testing, Reliability Testing, Failure Analysis, and other applications where environmental simulation is needed. It is used to stimulate temperature over a range of -30c to 120
C humidity from 10% to 90% as well as solar
radiation. A CTC is used to generate virtual environmental conditions for any product to be tested, so that its behaviour, operation, and reliability could be checked and analysed at extreme conditions. Manufactured samples, specimens, or components are placed inside the chamber and subjected to one or more of these environmental parameters such as extremely high or low temperature, various humidity levels, and solar radiations, to determine reliability or measure after-effects such as corrosion. In the case of machinery such as internal combustion engines, by products such as emissions are monitored. Test chambers are available from 1.2 cubic foot of interior workspace and up with temperature range capabilities of -184c (-300f) for cold chambers all the way to 350c (662f) for the extreme high temperature conditions.
CHAPTER- 4
SPECIFICATIONS
S.No. PART RATING/SPECIFICATION 1. CLIMATIC TEST CHAMBER
Model Number Sl. No.
CMEI-SPL CMEI/653/2004-05
2. WORK SPACE 560X750X750 mm
3. INNER MATERIAL Stainless Steel AISI 304
4. TEMPERATURE RANGE Accuracy & Resolution -30 o C to +120 o C 1 o C / 0.1 o C
5. HUMIDITY RANGE Accuracy 75% to 90% RH 3% RH
6. TEMPERATURE CONTROL By Eurotherm Make Model 2604 With ITOOLS Software
7. COMPRESSOR Make SR. No. CR42 (1 nos.) Kirlosker CBA-13434
8. REFRIGERATION R-404a
9. HEATER 2KW with safety Thermostat
10. POWER REQUIREMENT 380V- 440V AC, 50Hz, 4- Wire, 3- Phase with Neutral + Earth
CHAPTER-5
TYPES OF TEST CHAMBERS & PARAMETERS
5.1 TYPES OF CHAMBERS
Highly Accelerated Life Test (HALT) involves a combination of temperature, shock and vibration to locate a product weakness and assess the life of a product.
Highly Accelerated Stress Screening (HASS) involves fast temperature cycling and is performed on production units.
Thermal Cycling involves subjecting an object to extreme changes in temperature within an environmental chamber while ramping up and down in temperature.
Temperature Chambers simulate temperature and tests the effects on a product over a range of temperature conditions. Temperature cycling may be performed while combining environments such as humidity, altitude, and vibration.
Humidity Chambers simulate humidity and tests the effects on a product over range of humidity conditions. Humidity tests may be performed with or without temperature.
Bench top test chambers are used when testing small items and take up minimal floor space.
Thermal Shock chambers thermally shock and stress a product as a result of rapid temperature changes from extreme cold to hot environments.
Liquid-To-Liquid Thermal Shock chambers immerse a part/assembly in hot and cold fluids. Product is transferred between hot and cold baths without contamination.
Air-To-Air Thermal Shock chambers typically involve transferring the product from a hot chamber to a cold chamber. Configurations include two zone, three zone, and double duty.
AGREE Vibration Chambers can produce fast temperature changes. These chambers have removable floors and integrate with a variety of electrodynamic shakers for vertical and/or horizontal vibration. Temperature and/or humidity environments are also simulated in conjunction with vibration.
Altitude chambers simulate the effects of low pressure and are capable of altitudes of up to 200,000 feet above sea level.
Environmental Stress Screening (ESS) chambers are designed to test products for highly accelerated stress testing and fast ramp rates.
Walk-in chambers are environmentally conditioned rooms that may be configured to almost any size or footprint. Types of walk-in chambers include modular and welded (unitized) construction. Welded types are ideal for high temperature testing.
Drive-in chambers are similar to walk-in chambers and are designed for vehicle testing. Temperature, humidity, vibration, and solar may be simulated.
5.2 TEST PARAMETERS The parameters of performance testing for accurate environmental chambers are: Temperature range Accuracy of temperature control Humidity span and its Control Accuracy Vibrations Capacity of the chamber. Corrosion (Salt Fog/ Immersion)
5.3 TYPES OF CTC AND TEST PARAMETERS UNDER STUDY The following types of Climatic Test Chambers have been studied: Bench- Top Test Chamber Walk- In Test Chamber
The following parameters for product testing have been observed: Effect of Temperature Effect of Humidity Effect of Solar Radiations
CHAPTER-6 BENCH- TOP CLIMATIC TEST CHAMBER 6.1 INTRODUCTION This type of CTC is a smaller version of the conventional CTCs, which is mainly used to test products which are smaller in size, and within a specified limit of parameter changes. Its operating parameters and operating range is limited to a few values.
6.2 CONSTRUCTIONAL DETAILS A Bench- Top Climatic test Chamber has double wall construction of 6 thick fiber glass wool between the inner and the outer walls. Inner of the chamber is fabricated with mirror finished stainless steel and outer is CRCS with Electrostatic powder coating. A double lined silicon gasket is provided one on the door and other on the flange of the chamber. It has been provided with a glass window and a light for checking state of experiment being performed inside the chamber.
The above figure shows the Bench- Top Climatic Test Chamber. It consists of a main cabinet where the product to be tested is placed. On the right side, the control panel of the chamber is located which is both manual and software controllable. The left part of the chamber shows the cooling system, which consists of a fan having 1/5HP motor installed in it.
6.3 MECHANICAL DIAGRAM
6.4 VARIOUS PARTS OF A BENCH- TOP CTC
1. Temperature Controlling For gentle and uniform temperature in workspace, one 1/5 HP fan motor with a 94.5 width SS impeller is used.
2. Heaters This chamber provided with wet and dry heaters to control humidity inside the chamber so that the specimen could be tested in same environmental condition as that of field.
3. Solar Radiation Lamp The Metal Halogen lamp is used having radiation intensity of 100W/m 2 with a range of 280 to 3000 mm from a distance of 60 cms to stimulate solar radiation. This lamps radiation is very much figurative to suns radiation in field.
Fig.: A Solar Lamp
4. Refrigeration System The refrigeration system is a single stage eco-friendly system with air cooled condensing unit.
5. Temperature Sensors The temperature sensor used in this type of CTC is a class Pt-100 RTD (Resistance Thermometer Detector).
6.5 TYPES OF AVAILABLE TEMPERATURE SENSORS
1. Thermistor Thermistors are the Thermal Resistors and used fir precision temperature measurement, control and compensation. Their working principle is based on the change in the resistance of semiconductor materials with change in temperature. A thermistor is made up of semiconductor material and has a negative co-efficient of resistance, i.e., their resistance decreases with the increase in temperature. This negative temperature co-efficient of the resistance can be as large as several percent per degree Celsius, thus allowing the thermistor circuit to detect very small changes in the temperature.
2. Thermocouple A thermocouple is temperature transducer that s used for measurement of high temperatures. It works on the principle of Thermo- Electric Effect, which says that when two dissimilar metals are joined together so as to form a closed circuit, there will be two junctions where they meet each other. If one of these junctions is heated and other one is kept at fixed lower temperature, then a current flows in the circuit which can be detected by a galvanometer. The amount of current produced depends on the difference in the temperature between the two junctions and on the characteristics of the two metals.
3. Resistance Temperature Detector (RTD) This type of temperature transducer is use for the measurement of small temperature difference as well as for wide range of temperature. It works on the principle of the utilization of the change in resistance property of certain metals (conductors). With the increase of the temperature, the electrical resistance of the certain metals increases in direct proportion to the rise of temperature. Thus, if the resistance of a wire of known and calibrated material is measured, the temperature of the wire can be determined.
6.6 LIST OF COMPONENTS USED IN THE CHAMBER
S.No. PART RATING/SPECIFICATION Number 1. Chamber Fan Motor 1/5 HP, single phase 230V AC, 0.8 Amps
1 nos 2. Air Heater 0.5 KW Heater
4 nos 3. Controller Microprocessor based Eurotherm, make 2604 Dual Loop Programmable With iTools Software
1 nos 4. Blower 9 X 4.5 diameter SS Impeller
1 nos 5. Compressor
Model SR No
Make
CR42 CBA13434 3-phase, 440V AC Copeland
1 nos 6. Condenser Fan Motor Make FHP, 1400 RPM 230 V AC, 1 Phase, EBM NARDI
1 nos 7. Evaporator 20 X 14 X 17rows
1 nos 8. Refrigerant Gas R-404a
5 gm 9. Solenoid Valves
Make 3/8 Flair Flair Danfoss
2 nos 1 nos 10. Auto Oil Return Make OUB-1 Danfoss
1 nos 11. Accumulator 2 ton
1 nos 12. Liquid Drier Make 3/8 Flair Danfoss
1 nos
6.7 OPERATION AND CONTROLLING
Entire chamber is controlled using a State Of Art Eurotherm controller. Indicator cum controller is a programmable profile dual loop controller. This means that controller can be manually operated or can be interfaced with a system. Its interfacing facilitates automatic temperature control as preset by user and moreover readings can be automatically got stored; thus eliminating need of an attendant.
CHAPTER- 7 WALK- IN CLIMATIC TEST CHAMBER 7.1 INTRODUCTION Walk-In Environmental Test Chambers are Capable of testing large components, assemblies, and finished products. They simulate a wide range of temperature and humidity environments. These chambers can be used for testing and controlled storage as well as a versatile laboratory environment for conducting test procedures in the telecommunications, defence, aerospace, pharmaceutical, automotive, and electronics industries. Walk-in chambers consist of a self-contained conditioning module and a room constructed from interlocking panels or welded, insulated solid walls.
7.2 SPECIFICATIONS
S.No. PART RATING/SPECIFICATION 1. CHAMBER SIZE
8m x 5m x 5m (L x W x H) 2. MAX. TEST OBJECT SIZE 3m x 2.5m x 2.5m
3. TEMPERATURE RANGE
-10 o C to +80 o C
4. HUMIDITY RANGE
10% to 90% RH
5. SOLAR INTENSITY 300 to 1120 W/m 2
6. IRRADIATED AREA 3.2m x 2.4m
7. TEST PROFILES Desert Diurnal Cycle, Accelerated Cycle, and Tailor Made Cycle
CHAPTER- 8 TESTING OF PRODUCT AND ANALYZING ITS PARAMETERS
CHAPTER- 9 OTHER TYPES OF CHAMBERS
CONCLUSION
BIBLIOGRAPHY
1. Internet Sources a. http://en.wikipedia.org/Resistance_thermometer b. http://en.wikipedia.org/Thermistor c. http://en.wikipedia.org/Thermocouple d. http://cmeipl.com/products.html
2. Reference Books a. Power System Instrumentation- Ramnath (Genius Publications) b. Electrical and Electronics Measurements and Instrumentations- A. K. Sawhney