1600 Series. Impingement Technology

Transcription

1 Overview Background Oven with Impingement Technology Implementing Quest Energy Management System Background to the project Project Details(Functionality, Schematic, Signal Scenarios) Results Time/Cost Management Lessons Learned 1 2

2 1600 Series Impingement Technology Top View Side View 1600 Lo Profile Oven - Most Commonly Purchased Unit - Available as Gas or Electric Models - Both Domestic Units and Export Pressurized Plenum Finger Housings: 8 Total 3 4

3 Implementing Quest EMS Concept Variable Frequency Drive(VFD) System Variable Frequency Drive(VFD) System Two Induction VFD Driven Motors Induction Motor Specifications: 115VAC 60Hz 2.4A 3,000 RPM 1/6 HP SmartFan Variable Frequency Drive Specifications: 115 & 230 VAC ±10% Hz Single Phase Output Power ratings: 400 Watts for 120 VAC 0 to 400 Hz output frequency 5 (Courtesy of Kilowatt Classroom, LLC) VFD Fundamentals 6

4 Variable Frequency Drive(VFD) System Normal Mode Operation: Left Motor RPM 2971 Right Motor RPM 2897 Initializing Sleep Mode Operation Sharp Infrared Distance Sensors GP2Y0A02YK0F is a distance measuring sensor unit Sleep Mode Operation: Left Motor RPM 1631 Right Motor RPM 1622 Sensor 2- Input/Output to Cavity Sensor 3- Access Door Sensor 1- Input/Output of Cavity Results from Sleep Mode Operation: 25% Reduction in Energy Consumption based upon BTU/Hr comparison 7 8

5 Sleep Mode Operation Quest EMS Board (Input) Monitoring of Infrared Sensors If nothing crosses path for user defined time Unit will enter Sleep Mode Operation (Output) Signal to VFD Input to slow Main Fan Motors (Output) Energizes green light on side of unit to warn the user the unit is in Sleep Mode (Output) Energizes Electromechanical Relay Opens voltage to the conveyor motor (Output) 12VDC Signal to Feedback Simulator Board (Added as result of new signal simulator board) Addressing Issue Problem Conveyor belt operation must stop during Energy Savings Mode (Sleep Mode) Oven heating operations must continue (Requires conveyor motor feedback signal) Solution Maintain feedback signal from conveyor motor as if the conveyor belt operation was functioning while in Sleep Mode 9 10

6 Conveyor Motor Specifications Conveyor Motor Operation Single Phase Induction Motor: 1/20 HP Gear Ratio 120:1 Operating Voltage 120VAC 60Hz Operating Current 1.0A Conveyor Motor Location: Operates to move conveyor laterally through the oven with chain and sprocket attached Uses Hall Effect Sensor Circuit on the conveyor motor to produce the feedback signal to the main oven controller Frequency of Feedback Signal vs. User Defined Operating Time Slows down or Speeds up Conveyor Motor Vital to Oven Operation Unit control will shut down heating operation if feedback signal is lost 11 12

7 Conveyor Motor Operation Top View Frequency Vs. Time Table Hall Effect Sensor: Triggers Upon Pole Detection as Conveyor is Driven Hall Effect Sensor Rests Here Magnet Used to Trigger Hall Effect Sensor Hall Effect Output 13 14

8 Conveyor Motor Operation Hall Effect Output Signals 5:00 Conveyor Speed Operation 15:00 Conveyor Speed Operation 1 st Design Upon Entering Sleep Mode Simulated Feedback Signal to Main Oven Control is a 60 Hz Square Wave driven by 24VAC and transistor circuit 60 Hz Square Wave simulated by Transistor Circuit Shown: 15 16

9 Issues That Arise Unless the specified conveyor belt time is supposed to have a corresponding 60 Hz feedback signal the controller assumes there is a problem The Main Control tries to adjust the speed of the conveyor motor to achieve the correct feedback signal Upon coming out of sleep mode the control compensates for incorrect feedback signal and results in incorrect conveyor belt times Signal Comparison Feedback Signal at 5:00 Belt Time Current Design Simulated Feedback Signal During Sleep Mode Results In Poor Cooking In Normal Operation 17 5 msec/div. 10 msec/div. 18

10 Project Proposal Design new circuit to reproduce the conveyor motor feedback signal to maximize performance of conveyor oven with Quest Energy Management System (Quest EMS) Feedback signal will be a vital operation in both oven functionality and the newly designed EMS Resolution Implement new design of sampling circuit instead of transistor driven circuit Simulates corresponding feedback signal by sampling and recreating the same signal 19 20

11 Functional Requirements PCB Layout othe board shall be provided with the conveyor motor feedback signal othe corresponding simulated feedback signal shall provide a square wave signal with a peak voltage of 5 volts and a frequency between 10 Hz 600 Hz 21 22

12 Schematic Layout Schematic Breakdown Part C 23 24

13 Schematic Breakdown Part B Schematic Breakdown Part A PIC 18F258T (PIC16886) MAX667CPA 3.3VDC Voltage Regulator 25 26

14 Signal Simulation Scenarios Signal Simulation Scenarios Alternative control monitors the response time between switching from the simulated feedback signal to the actual conveyor motor feedback signal. 27 After time initialized as T3, if the conveyor motor feedback signal does not resume, the simulated feedback signal will cease and the conveyor oven control will display a Belt Jam 28

15 Signal Comparison New Design Signal Comparison New Design Feedback Signal at 5:00 Belt Time Simulated Feedback Signal During Sleep Mode Feedback Signal at 15:00 Belt Time Simulated Feedback Signal During Sleep Mode 5 msec/div. 5 msec/div msec/div. 10 msec/div. 30

16 Test Procedure 1. Allow the oven to be in Sleep Mode for 30 Minutes before each conveyor time test 2. Trigger the sensor to exit Sleep Mode 3. Time the conveyor belt from entrance to exit of the cavity 4. Calculate % Error from Actual Conveyor Belt Time to User Defined Belt Time Test Results Standard Conveyor Belt Times 31 32

17 Test Results Current (Transistor Circuit Design) Conveyor Belt Times Right Out of Sleep Mode Test Results (Sampling Circuit Design) Conveyor Belt Times Right Out of Sleep Mode 33 34

18 Project Timeline Overview Developed Transistor Circuit Early January 2010 Resolved problem oissue arose the oven must stop the conveyor during sleep mode othe solution appeared to be successful New problem Arised Late January February 2010 Solution oredevelop previous solution to stopping conveyor belt obrainstormed ideas otested theory and implemented test circuit oacquire PCB from outside resource through ATI Inc. Project Timeline Overview Implementation March 2010 Verification odevelop Prototype Board otest and incorporate prototype to Quest EMS overify Functionality Final Process April 2010 Acquire Professional Board oacquire resources from Lincoln to establish PCB owork with ATI Inc. to incorporate board design otest and Verify new finalized PCB 35 36

19 Resources Cost Management Prototype Board Soldering Station Fluke 199B Scope meter Serial # Fluke 87 V True RMS Multi meter Serial # AVR Studio Version 4.0 Software Lo Profile Oven Quest EMS Prototype ATI Inc. Production and Development of PCB Hours Lab Time 7 Hours Meetings 17 Hours Brainstorm/Discussion Total: 114 Hours At a going rate of $15.00, the total cost of labor, engineering, and testing comes to $1,

20 Problems That Arised Time was primary concern Production of PCB Code Process Reactive Engineering Isolating Board from Noise within the oven Conclusion Lessons Learned Value of Communication Understanding the Brainstorming Process Becoming more proactive Development Process within Lincoln Q/A 39 40