Jeremy French completed a controls engineering internship at Goodman Manufacturing where he worked on various projects including HMIs, control panels, and a heat exchange leak tester. Over the course of the internship, he learned how to troubleshoot machinery issues, input questions to problems, and saw improvements to the leak tester to make the testing process more efficient with fewer leaks. The leak tester uses pneumatics, a PLC, HMI, and control panel to automatically clamp units, conduct tests by measuring pressure and flow, and send results to a database. Potential future improvements include updating seals, adding automatic scanning, and sensors to check for insulation brackets.

1. Summer Internship 2016
Goodman
Manufacturing
Friday August 5th 2016
Final Presentation

2. Overview
Jeremy French
• Education: University of Illinois Urbana-Champaign
• Expected Graduation: May 2018
• B.S. in Industrial and Systems Engineering
• Manufacturing Department- Ray Pitts
• Control Systems- Randy Spaulding
• Controls Engineering Intern

3. 3
On a weekly basis, I was able to work on projects that the controls group was doing at that time, along with seeing and
learning from the situations they faced in the plant
Control systems engineering internship tasks
• HMIs (Human Machine Interface)
• Control Panels
• Heat Exchange Leak Tester
• Hands on manual labor
Projects
• Learned from colleagues how to diagnose and
solve control problems on the assembly lines
• Inputted questions and suggestions to the
problems at hand
Machinery Troubleshooting
© 2014 Daikin North America, LLC

4. 4
Human Machine Interface (HMIs)
Physical Construction
• 80/20 extruded aluminum, bare bone
Key Points
Internal Makeup
• E-stop, Ethernet, RTA module
Mainly used for all testers on Lines 1 and 7
© 2014 Daikin North America, LLC

5. 5
• Neat and clean
• Labels and color code standard
• DC vs. AC
• Terminate wires
Control panels from start to finish and everything in between
Concise statements
with no fluff
Circuit Schematics The Layout
© 2014 Daikin North America, LLC

6. Heat Exchange Leak Tester
What is it?
• A machine that tests the integrity of a heat exchange
structure by supplying air and measuring flow at the given
air supply to determine if the unit is sufficient quality using
the data given
What assembly lines is it used on?
• Lines 1
Why is it necessary?
• Measures defects such as bad seals, cracked burners, and
missing parts

7. 7
The story of the heat exchange tester: one step at a time
1
2
3
Everything is manual, except for numatics which are controlled by the PLC
The next version has 4 drop down clamps with no other clamping mechanisms
The final version has a rear stop, front stop, 80% support, 7 drop down clamps, left and right clamps
From Beginning to End
© 2014 Daikin North America, LLC
As the machine was updated, the test became more efficient and there were less system leaks

8. 8
The early base form of the leak tester
• 7 drop down clamps
• Left and right clamps
• Front stop
• 80% support
• Shannon Precision
• Linear actuators
Front View Back View
Key Components
© 2014 Daikin North America, LLC

9. 9
The physical components of the leak tester
Linear Control Modules
• Power Control (Pecans)
• Control actuators
Numatics
• Control numatics-actuate
clamps
• Test numatics-actuate tests
• Test, field, solenoid valves
© 2014 Daikin North America, LLC
Control Panel
• Heart of machine
• Controls clamping,
numatics, and all power
• Receives limits
• Collects and sends data
H.M.I.
• Interface with operator
• Master start, E-stop
• Displays test data

10. 10
The digital side of the leak tester
• Controls the whole process
• Specialized computer
• Solves entire logic code
• Constantly looks at big
picture real time
PLC Logic
© 2014 Daikin North America, LLC
Communication amongst the leak tester is done via Ethernet  IP at high speeds
Scan label (part no.,
serial no.)
Read into PLC
Takes model no.to
transaction manager via
trigger
Grabs info for model no.
and goes to database
Searches server for all
limits (recipes)
Sends limits back to
transaction manager
then back to PLC
Limits includes: #
burners, test/home
positions, etc.
Once test is complete all
data is uploaded to data
base
Data consists of:
pass/fail, pressure, flow
rate, # burners, limits
tested at, and date/time

11. 11
The end result and functionality of the leak tester
© 2014 Daikin North America, LLC
Model is selected in
manual or auto mode
Scan specific part
Part is loaded into test
position
User starts test by
placing fingers on the 2
hand control
Machine clamps part
into position
Test begins
Unit is filled with air
from both test and field
valves for a period of
time
Field valve closes, test
valve remains open:
pressure check above .5
in of water column
Test proceeds to adjust
air to 1 in of water
column +/- .5 and that
flow is below the
maximum limit
Machine checks that
flow and pressure are
just right
Send data (model no.,
pressure, flow, date and
time) to database
Machine prints label
and unclamps part
Operator removes part
and places label on part
Cycle repeats again

12. 12
Looking ahead to improvements and research
Seals
Scanner/Hole Size
Insulation Bracket
• Seal material
• Pre-station to the leak tester
• Automatic scanner and camera
sensor to determine hole size
of burner
• Photo sensor to determine if
the bracket is present
The future of the heat exchange leak tester
What parts of the
machine could be
improved for the
future?
© 2014 Daikin North America, LLC
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13. Special Thanks
• Human Resources
• Blake Miller
• Manufacturing Department
• Ray Pitts-Supervisor
• Controls Engineering Group
• Randy Spaulding-Manager
• Mike Anders
• Don Fenton
• Shanthan Gambhir
• David Haynes