ME4000 2006-2007Titan-40w AutomationDepartment of Mechanical EngineeringUniversity of Utah, Salt Lake City UT 84112-9208ME4000- Senior Project 12/5/06University of Utah Titan-40w AutomationPage 2 of 58DJ BURTONJUSTIN PRINCEJASON ENGLANDJUSTIN MCKINNON1 Front Matter1.1 Executive SummaryThe company EFI Electronics is a design, manufacturing, and testing facility that builds surgesuppression devices for various applications. One of their products, the Titan-40w, is designed toprotect a building from electrical surges. These buildings, usually commercial, utilize a largescale 3-phase power system.While building the Titan-40w, a test is completed to make sure that it will ground a 3-phaseelectrical surge. In the event of an electrical surge, the Titan-40w will ground the charge, savingthe remainder of the building’s electronics. The current testing procedure involves an operatorgoing step-by-step testing each phase, including full-power-up. This procedure is time consumingand can involve operator error.The goal for Team EFI is to redesign both the Titan-40w’s test procedure and its test fixture,making them completely automated. This will eliminate operator error as well as save more timefor the operator to continue building the product. The test fixture will also record results andnotify the operator of the results of the test.The Titan-40w project will incorporate the results of each test into a quality control system. EFIhas a strong need for quality control in order to guarantee a working and reliable product. Savingand analyzing the results of each test will help ensure this. This can be done either by saving theresults to a memory file or by attaching them directly to the product. Team EFI will evaluate thesedifferent methods and decide how best to incorporate the test results.ME4000- Senior Project 12/5/06University of Utah Titan-40w AutomationPage 3 of 58The Titan-40w Cell Redesign project will focus on improving the test quality of the Titan-40w.The improvements will be made in accuracy, time savings, result reporting, and safety. It is thegoal of Team EFI to complete the project by the Spring ’07 semester, and to produce a productthat can be applied to other products and testing procedures at EFI.1.2 Table of Contents1 Front Matter.................................................................................................................. 21.1 Executive Summary....................................................................................................... 21.2 Table of Contents........................................................................................................... 32 Context ......................................................................................................................... 72.1 Need Statement .............................................................................................................. 72.2 Problem Statement......................................................................................................... 82.3 Design Team..................................................................................................................92.3.1 Student Design Team Members.............................................................................................. 92.3.2 Teaching Team ................................................................................................................ 10Corporate Liaisons and Sponsors ..................................................................................................... 102.4 Team Circumstances.................................................................................................... 103 Design Requirements ................................................................................................. 123.1 Functional Requirements ............................................................................................. 123.2 Functional Constraints ................................................................................................. 123.2.1 External Constraints ............................................................................................................. 123.2.1.1 Time Requirements.......................................................................................................... 123.2.1.2 Wire Probe Accuracy....................................................................................................... 123.2.1.3 Operator Safety................................................................................................................ 123.2.1.4 Emergency Stop............................................................................................................... 123.2.2 Internal Constraints............................................................................................................... 133.2.2.1 Voltage/Current Supplier.................................................................................................133.2.2.2 Programmable Logic Controller ...................................................................................... 133.2.2.3 Record Keeping ............................................................................................................... 133.3 Assumptions................................................................................................................. 133.4 Opportunities................................................................................................................133.5 Physical Requirements................................................................................................. 133.6 Physical Constraints..................................................................................................... 143.6.1 Internal Constraints............................................................................................................... 143.6.1.1 Input Voltage Control...................................................................................................... 143.6.1.1.1 Connection to a Power Source.......................................................... 143.6.1.1.2 Use of PLC and PLC Program.......................................................... 143.6.2 External Constraints ............................................................................................................. 143.6.2.1 Total Size of Test Cell