Internship – Summer/Fall 2015

Marcella Miller
Background

• University of Cincinnati
– 2nd year
– Major: Mechanical Engineering

• Verification Engineering
– Manager: Gregory Pasquesoone
– Mentor: Chad Rutherford
• ePump programs
– Ford 10R, GM BEV, Chrysler PHEV

12/3/2015 Disclosure or duplication without consent is prohibited 2

Agenda

• Tasks
– Design test fixtures
– Build test stands
– Write test cases
– Complete verification testing
• What I’ve Learned
• Challenges
• Final Thoughts

4/9/2018 Disclosure or duplication without consent is prohibited 3

Task - Design Test Fixtures

• Designed double medium brake fixture and dynamometer

bracket for 10R
• Created instrumentation box and fluid setup for EMC testing
for PHEV and BEV

4/9/2018 Disclosure or duplication without consent is prohibited 4

Task - Design Test Fixtures

• Researched parts to add to the setup

• Created the design using SolidWorks
• Held a peer design review
• Compiled a BOM and created a PR

4/9/2018 Disclosure or duplication without consent is prohibited 5

Task - Design Test Fixtures

• Use of SolidWorks
– Designed unique parts that needed to be manufactured
– Created a model assembly
– Prepared drawings of each machined part and created an ESR for the
machine shop

4/9/2018 Disclosure or duplication without consent is prohibited 6

Task – Build Test Stands

• Helped build and wire test stands for fluid setups

4/9/2018 Disclosure or duplication without consent is prohibited 7

Task – Build Test Stands
– Attached DIN rail, Phoenix contact terminal blocks, and other
components to the test stand frame
– Wired ZIF connector for MABx and wired other component/terminal
block interconnect wires

4/9/2018 Disclosure or duplication without consent is prohibited 8

Task – Write Test Cases

• Assisted with the creation of verification test cases for

Chrysler PHEV system functional and SRS test suites

4/9/2018 Disclosure or duplication without consent is prohibited 9

Task – Write Test Cases
– Read/analyzed PHEV system functional and SRS requirements
documents
– Helped write test cases (in Microsoft Excel format) and kept track of
requirements updates
– Used Excel document test cases to create test cases in PTC

4/9/2018 Disclosure or duplication without consent is prohibited 10

Task – Complete Verification Testing

• Completed system functional testing for GM BEV

– Included verifying pressure/flow set-points, testing for functionality after
maximum voltage and maximum reverse voltage application, and
testing for “normal operating behavior” at each specified temperature,
voltage and duty cycle combination

4/9/2018 Disclosure or duplication without consent is prohibited 11

Task – Complete Verification Testing

• Completed DoE testing for Chrysler PHEV

– Included modifying the existing DoE signal generator in ControlDesk,
running the automated test at each of four specified temperatures, and
creating an m-script to manipulate and extract the data from a Simulink
model

4/9/2018 Disclosure or duplication without consent is prohibited 12

Task – Complete Verification Testing

• Completed system functional testing for Chrysler PHEV

– Included testing for functionality after extreme voltage application, testing high
and low speed continuous run, and testing for full power operation

4/9/2018 Disclosure or duplication without consent is prohibited 13

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 14

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 15

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 16

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 17

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 18

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 19

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 20

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 21

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal Generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 22

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 23

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders with triggers and time limits
– Signal generator
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 24

What I’ve Learned
• SolidWorks
– Scroll zoom
– Move/rotate/scale entities
– 3D sketch
– Top-down part creation
– Material and appearance adjustment
– Part and assembly configurations
• PTC
– Searching and filtering
– Requirements
– Test cases and test suites
– Test sessions
– Defects
• MATLAB
– m-script interface with Simulink
• ControlDesk
– Locating variables
– Creating recorders
• Triggers and time limits
• CANape
– Scaling
– Splitting windows
– Saving configurations

4/9/2018 Disclosure or duplication without consent is prohibited 25

Challenges
• Timing
– Tight deadlines

• Problems with communication and documentation

– Test stand wiring
– Requirements updates

• Testing issues
– Pump misbehavior
– Equipment malfunction

• Internal Networking (to help solve problems)

– Knowledge acquired slowly
4/9/2018 Disclosure or duplication without consent is prohibited 26
Final Thoughts

• Magna Electronics
– Reorganization

• Personal Impressions
– Good progression of responsibility
– Exposure to broad scope of ePump verification

4/9/2018 Disclosure or duplication without consent is prohibited 27

 Questions?

4/9/2018 Disclosure or duplication without consent is prohibited 28