P10503 Preliminary Test Plan Document
Top Customer Needs: Ensure Safety, Functional Subsystems, Ease of Use, Hardware Specifications
I)
Ensure Safety
a. Determine safe high voltages
b. Determine velocity of carriage and lifting systems to avoid damage to operator or
product
II) Functional Subsystems, Hardware Specifications
a. Determine nominal values
b. Determine if ‘expose in dark’ concept chosen adequately fits project needs in terms of
stray light, allowed wavelengths
III) Ease of Use
a. Ensure that operator can easily use user interface with minimal to no documentation
although documentation will be provided
Test Plans to meet above Needs:
I)
Perform Experiment (generally for testing mechanical parts/wiring)
Sample of an experiment:
EXPERIMENT PERFORMED BY: Jeff Robble
PROBLEM: After DAQ hook-up, both paper feed and transfer drum would activate
simulataneously. Reason why is what needs to be found out by this
experiment.
HYPOTESIS: Possibly some wires were crossed or both paper feed/transfer drum
hooked up to same relay.
OBSERVATIONS:
NI DAQ 6602
PFI36 / CTR0 out (pin 5) - paper feed control
PFI32 / CTR1 out (pin 9) - transfer drum control
When both controls hooked from DAQ to respective relays the following
behaviors are observed:
1. Generating continuous pulses
[EXPECTED]
2. Generating continuous pulses
[EXPECTED]
3. Generating N pulses on PFI36
[NOT EXPECTED]
4. Generating N pulses on PFI32
[NOT EXPECTED]
on PFI36 activates paper feed only.
on PFI32 activates transfer drum only.
activates both paper feed and transfer drum.
activates both paper feed and transfer drum.
When the transfer drum control is disconnected the following behaviors are
observed:
1. Generating
[EXPECTED]
2. Generating
3. Generating
4. Generating
continuous pulses on PFI36 activates paper feed only.
continuous pulses on PFI32 does nothing. [EXPECTED]
N pulses on PFI36 activates paper feed only. [EXPECTED]
N pulses on PFI32 activates paper feed only. [NOT EXPECTED]
When the paper feed control is disconnected the following behaviors are
observed:
1. Generating
2. Generating
[EXPECTED]
3. Generating
4. Generating
EXPLANATION:
continuous pulses on PFI36 does nothing. [EXPECTED]
continuous pulses on PFI32 activates transfer drum only.
N pulses on PFI36 activates transfer drum only. [NOT EXPECTED]
N pulses on PFI32 activates transfer drum only. [EXPECTED]
Page 3-25 of the NI DAQ 6602 Manual shows a table of counter pairs:
CTR0
CTR2
CTR4
CTR6
<->
<->
<->
<->
CTR1
CTR3
CTR5
CTR7
"This pairing allows some counter signals to connect to signals on the other
counter."
The NI website
(http://digital.ni.com/public.nsf/allkb/485201B647950BF886257537006CEB89#case
3) explains:
"Generating a finite pulse train and another counter task on the same device
in LabVIEW with NI-DAQmx. For any device which uses the STCII chip
(CompactDAQ, E and M Series) a finite pulse train generation reserves both
counters.
When performing a finite pulse train generation, one counter generates the
pulse train, and the other counter generates a pulse that acts as a gate for
the first counter. If you change the pulse train to generate continuously or
only generate one pulse, you can run two counter tasks at the same time
without error."
In other words, generating finite pulses on CTR0 uses CTR1 as a gate which
also generates pulses, and vice-versa. This is why the transfer drum and
paper feed are both activated when either is controlled using N pulse
generation.
As a side note, the 6602 DAQ is only capable of operating two counters at a
time (whether for acquiring or generating signals, or both). Thus, if the DAQ
is instructed to perform N pulse generation that is all it can do because it
uses two counters.
SOLUTION:
Use non-paired counters or use continuous pulse generation on each counter in
a pair. Also look into purchasing another counter/timer DAQ card for access
to more counters (Jeff: “not necessary at this time”).
II) Use built-in i/o system (generally for safety, wiring, and determining nominal values)
On user interface, there is the ability to set pre-defined values for controllable variables in the
xerographic system such as velocities, bias, etc. These values can be stored in separate input .ini
files and the results of running the system under these settings can be saved in output files through
the user interface as well.
Sample of an input .ini file:
[Charging Station Parameters]
PC Velocity Across Coronode (mm/s)=110
Coronode Bias (v)=-650
Grid Bias (v)=-650
[Exposure Station Parameters]
Expose Time (s)=2
[Developer Station Parameters]
PC Velocity Across Developer (mm/s)=110
Toner Bias (v)=-525
[Pre-Transfer Station Parameters]
PC Velocity Across Pre-Transfer LEDs (mm/s)=110
[Transfer Station Parameters]
PC Velocity Across Transfer Drum (mm/s)=110
Number of Transfer Drum Rotations=3
Transfer Bias (v)=2000
Transfer Drum Velocity (mm/s)=110
Sample of an output .csv (excel) file: (Note: only a small portion of output shown here because it is
generally very large.
Time
(s)
PC Velocity
(mm/s)
0.1
34.272
0.2
84.481
0.3
110.772
0.4
110.772
0.5
110.772
0.6
110.772
0.7
110.772
0.8
110.772
0.9
110.772
1
110.772
1.1
110.772
1.2
110.772
1.3
110.772
1.4
110.772
1.5
110.772
1.6
110.772
1.7
110.772
1.8
110.772
1.9
110.772
2
110.772
2.1
110.772
2.2
110.772
2.3
110.772
2.4
110.772
2.5
110.772
2.6
110.772
2.7
110.772
2.8
110.772
2.9
110.772
3
110.772
3.1
110.772
3.2
110.772
3.3
110.772
3.4
110.772
3.5
110.772
3.6
0
3.7
0
Proposed Excel Macro Output:
120
PC Velocity (mm/s)
100
80
60
40
20
0
0
0.5
1
1.5
2
Time (sec)
2.5
3
3.5
4