MIDDLE EAST TECHNICAL

UNIVERSITY

ELECTRICAL AND ELECTRONICS

ENGINEERING

EE 400

SUMMER PRACTICE REPORT

CEM RECAİ ÇIRAK

1674936

1

Student Name: Cem Recai ÇIRAK

Student ID: 1674936

Student e-mail address: cem.cirak@metu.edu.tr

Student phone contact number: +905052852872

Summer Practice EE 300 or EE 400: EE 400

Where did you do your previous (EE 300) SP: OKIDA Electronics

SP Specialization Area: Power Electronics and Computer

Name of Company: Arçelik A.Ş. (Dishwasher Plant)

SP Location:

Arçelik A.Ş. Bulaşık Makinesi İşletmesi, Sincan Organize Sanayi

Bölgesi, Altınordu Caddesi, No: 3, PK: 06935, Sincan/ANKARA

SP Company Telephone number and Fax number:

Phone: +903125892020

Fax: +903122670599

SP Beginning and Ending Date: 25 July 2016 to 19 August 2016

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TABLE OF CONTENTS

1. INTRODUCTION 4

2. DESCRIPTON OF THE COMPANY 5

2.1. General Description of the Company 5

2.1.1. Vision 5

2.1.2. History 6

2.1.3. TPM 7

2.1.4. Environmentalist Approach 8

2.1.5. Occupational Health and Safety 8

2.1.6. Brands 9

2.1.7. Product Range 10

2.1.8. Plants 10

2.1.9. Global Operation Network 12

2.2. General Description of the Dishwasher Plant 14

2.2.1. History of the Dishwasher Plant 16

2.2.2. History of the Products 16

3. QUALITY ASSURANCE MANAGEMENT 17

3.1. General Description of the Quality Assurance Management 17

3.1.1. Product Certifications 17

3.1.2. System Certifications 18

3.1.3 Terms and Definitions 19

3.1.4. Control of the Records 19

3.1.5. Control of the Documents 19

3.1.6. Engineering Specifications 20

3.2. Quality Control Steps 20

3.2.1. Incoming Inspection 21

3.2.2. Functional Test 22

3.2.3. Final Visual Control 22

3.2.4. Optical Control 23

3.2.5. Daily Product Audit 23

3.2.6. Functional Product Audit 24

3.2.7. Performance Test 24

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3.2.8. Product Life Test 25

3.2.9. Faulty Component Investigation 25

3.3. Examining Dishwasher 26

3.3.1. Inner Side of a Dishwasher 27

3.3.2. Control Mechanisms 27

3.3.3. Detergent 29

3.3.4. Components of a Dishwasher 29

4. GLOW WIRE TESTING 33

4.1. History of Glow Wire Testing 33

4.2. Glow Wire Testing Methodology 34

4.3. Safety of Household and Similar Appliances (IEC 60335-1) 35

4.4. Glow Wire Testing Device and Subject of the Project 37

5. PROJECT DEVELOPMENT PROCESS 38

5.1. Button Controlled Walking LED Light Circuit 38

5.2. Analog Input LED Display Circuit 39

5.3. Analog Input LCD Display Circuit 41

5.4. Analog Thermometer Reading 42

5.5. Button Controlled AC Dimmer Circuit 43

5.5.1. Photocoupler, Opto-isolator 44

5.5.2. Triac 44

5.6. Automatic AC Dimmer Circuit 47

5.7. Overall Circuit 48

5.8. Overall Circuit with Two Microcontrollers 50

5.9. Final Form of the Project 54

5.10. Project Prototype 56

6. CONCLUSION 57

7. REFERENCES 58

APPENDIX A: Glow Wire Testing Procedure Flow Chart 59

APPENDIX B: Microchip PIC 16F877A ADCON1 Register Selection Table 60

APPENDIX C: Project Prototype Components List 60

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1. INTRODUCTION

I have performed my second summer practice (EE 400) in Arçelik A.Ş. Dishwasher Plant in

which dishwashing machines are manufactured and assembled. My summer practice had lasted

for 4 weeks (20 workdays) between 25 July 2016 and 19 August 2016. I carried out my practice

under Quality Assurance Management of the Plant, mostly in Incoming Quality Control

Laboratory.

In Quality Assurance Management, 7 engineers and 13 technicians work mainly for decreasing

manufacturing defects and entrance of faulty materials which come from suppliers. Therefore,

I started to my summer practice with observing the work flow and collecting detailed

information about the whole quality assurance process. Then, I determined a deficiency of a

testing device which used in my department. Finally, I worked for developing a project to solve

this deficiency.

In this report, my all observations with the information that I collected during my summer

practice and my project works are included. At the beginning, there is a description of the

company which is involving necessary details about it. My observations about the quality

assurance and work flow are follows the part of description of the company. Details of my

summer practice work and project development process are placed after the part which

involving my observations. At the final, there are conclusion and comparison part and reference

part. Appendices are also attached at the end of this report.

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2. DESCRIPTON OF THE COMPANY

2.1. General Description of the Company

Arçelik A.Ş. was founded in 1955 in İstanbul, Turkey Having operations in durable consumer

goods industry with production, marketing and after-sales services, Arçelik A.Ş. offers products

and services around the world with its 27,000 employees, 15 different production facilities in 6

countries (Turkey, Romania, Russia, China, South Africa and Thailand), its international sales

and marketing organization in 27 countries and its 10 brands (Arçelik, Beko, Grundig,

Blomberg, Elektra Bregenz, Arctic, Leisure, Flavel, Defy and Altus) serving products and

services in more than 135 countries.

Arçelik A.Ş. has 14.166 billion TRY consolidated net sales turnover, in 2015. Arçelik A.Ş.

holds the market leader position in Turkey, in white goods, LCD TV and air conditioners. It

holds the position of strong leadership in Turkey and maintained its undisputed market

leadership with Arctic brand in Romania and Defy brand in South Africa.

Beko is the leader brand in European Freestanding White Goods Market. It is the white goods

brand with the largest growth in Europe. It is the leading brand in the United Kingdom and the

leader brand in Poland. Beko has the highest market share increase in Germany and Italy and

the highest market share growth in Western Europe.

2.1.1. Vision

Arçelik Group’s Vision targets to ensure profitable and long-term sustainable growth, to

increase market share acting on global target market approach, to reach more consumers with

innovative products and applications in rapidly changing world, to secure the future with the

consciousness of corporate responsibility, to integrate and optimize the components of global

organization to be a global group. The company motto is “Respects The Globe Respectful

Globally”.

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2.1.2. History

In 1955, Arçelik A.Ş. is established in Sütlüce, İstanbul.

In 1959, Arçelik A.Ş. produces the first washing machine in Turkey.

In 1960, Arçelik A.Ş. produces the first refrigerator in Turkey.

In 1975, Eskişehir Refrigerator Plant begins production.

In 1977, Ardem Cooking & Heating Appliances is founded and Eskişehir Compressor

Plant begins production.

In 1991, R&D Center is founded.

In 1993, Ankara Dishwasher Production Plant begins production.

In 1999, Arçelik A.Ş. acquires Ardem Cooking & Heating Appliances. Arçelik A.Ş.,

Türk Elektrik Endüstrisi A.Ş., Atılım A.Ş. and Gelişim A.Ş. merge to become a single

entity.

In 2002, Arçelik A.Ş. acquires Austrian white goods brand Elektra Bregenz and German

white goods brand Blomberg. British white goods brands Leisure and Flavel are

incorporated into Arçelik A.Ş., Romanian leading refrigerator brand Arctic is acquired.

In 2006, Refrigerator and Washing Machine Production Plant begin production in

Russia. Arçelik A.Ş. becomes the largest shareholder in Beko Elektronik A.Ş.

In 2007, Washing Machine Production Plant begins operations in China. Beko

Elektronik A.Ş. became the owner of the Grundig Multimedia Company and Grundig

brand.

In 2008, the first Tumble Dryer Production Plant begins operations in Çerkezköy. Legal

title of Beko Elektronik A.Ş. is changed to Grundig Elektronik A.Ş.

In 2009, the merger of Arçelik A.Ş. and Grundig Elektronik A.Ş. is completed.

In 2011, Arçelik A.Ş. acquires Defy Appliances Pty. Ltd., South Africa’s leading

household appliances.

In 2015, Arçelik A.Ş. lays the foundation of the Thailand Refrigerator Plant.

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2.1.3. TPM

TPM (Total Productive Maintenance) is a maintenance philosophy that requires the total

participation of the workforce. TPM incorporates the skills of all employees and focuses on

improving the overall effectiveness of the facility by eliminating the waste of time and

resources. Typically, total productive maintenance is a concept that is most easily applied to a

manufacturing facility.

Lean Production

Equipment and Labour Efficiency Improvement

Safe and Environmental Working Environment

Decrease in Stock/Scrap Ratio

Decrease in Maintenance Costs

Increase in Motivation of Employees

Figure 2.1: Arçelik A.Ş. TPM Excellence Awards

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2.1.4. Environmentalist Approach

Arçelik A.Ş. adopts “Sustainable Development” and principle of environmental protection

as a requirement of the Total Quality Management approach.

Within the context of this approach, Arçelik A.Ş. applies environment-friendly processes

and manufactures environment friendly products.

Arçelik A.Ş. evaluates and monitors its compliance with environment and health & safety

oriented national and international legal requirements.

In this context, Arçelik A.Ş. closely monitors the developments in the industry and complies

to the directives and regulations in Europe;

WEEE - Waste of Electrical and Electronic Equipment,

RoHS - Restriction of the Use of Certain Hazardous Substances,

EuP - Eco Design Requirements for Energy Using Products

REACH Regulation- Registration, Evaluation and Authorization of Chemicals.

In an effort to increase the awareness and sensitivity for environmental issues, trainings are

organized for employees.

2.1.5. Occupational Health and Safety

Arçelik A.Ş. performs its Occupational Health and Safety activities by

• Removing the hazards arising by the activities or minimizing the Occupational Health and

Safety related risks to the minimum level at source by using a proactive approach,

• Using the appropriate, safe and healthy technologies,

• Developing the awareness in Occupational Health and Safety issues among the employees

and helping them to adopt the appropriate behaviours in order to prevent work accidents and

work related diseases within the frame work of Arçelik A.Ş. Occupational Health and Safety

Management System.

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2.1.6. Brands

The leading brand in Turkish household appliances

industry.

One of the leader brands in Turkey and a global brand

preferred in more than 100 countries.

A brand of household appliances, combining aesthetic

design and technological with environment friendly

features.

A strong, prestigious brand of household appliances in

Austria.

The leading brand in the Romanian household appliances

market.

The traditional brand for solo cooking appliances in the

United Kingdom.

One of the strongest household appliances brand in the

United Kingdom and Ireland.

The household appliance and television brand of price

conscious consumers.

A well-known brand in Turkish and Western European

market with wide range of product portfolio of consumer

electronics and personal care appliances.

The leading home appliances brand in Southern Africa.

Figure 2.2.b: Beko brand logo

Figure 2.2.a: Arçelik brand logo

Figure 2.2.c: Blomberg brand logo

Figure 2.2.d: ElektraBregenz brand logo

Figure 2.2.e: Arctic brand logo

Figure 2.2.f: Leisure brand logo

Figure 2.2.g: Flavel brand logo

Figure 2.2.h: Altus brand logo

Figure 2.2.i: Grundig brand logo

Figure 2.2.j: Defy brand logo

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2.1.7. Product Range

Arçelik A.Ş.’s product range is classified under six main groups as built-in products, white

goods, consumer electronics, heating and cooling systems, small appliances and components.

Built-in products group involves refrigerators, freezers, washers, dishwashers, ovens,

cooktops, domino hobs, cooker hoods, chimney hoods and microwaves.

White goods group includes fridge freezers, freezers, washers, dryers, dishwashers,

cookers, water dispensers and water filtration systems.

Consumer electronics group contains televisions, home theatre systems, hi-fi sound

systems, portable audio systems, wireless telephones, cellular phones, notebooks, desktop

computers and POS cash registers.

Heating and cooling systems group comprises air conditioners, gas boilers, water heaters,

room heating devices, stoves and air conditioning systems.

Small appliances group involves kitchen line, irons, vacuum cleaners, personal care

products, steamy cleaners and cook wares.

Components group includes hermetic compressors, industrial motors and motor-pump

equipment.

2.1.8. Plants

Manufactured with superior technologies, Arçelik A.Ş.'s products and services originate from

15 manufacturing plants in Turkey, Romania, Russia, China and South Africa and meet millions

of consumers in over 135 countries.

Refrigerator Plant, Eskişehir, Turkey

Cooking Appliances Plant, Bolu, Turkey

Dishwasher Plant, Ankara, Turkey

Washing Machine Plant, İstanbul, Turkey

Electronics Plant, İstanbul, Turkey

Compressor Plant, Eskişehir, Turkey

Tumble Dryer Plant, Tekirdağ, Turkey

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Refrigerator Plant, East London, South Africa

Electric Motors Plant, Tekirdağ, Turkey

Arctic Cooling Appliances Plant, Gaeşti, Romania

Cooking Appliances and Tumble Dryer Plant, Jacobs, South Africa

Washing Machine Plant, Changzou, China

Refrigerator and Washing Machine Plant, Kirzhach, Russia

Cooling Appliances Plant, Ladysmith, South Africa

Beko Thai Co., Ltd. (Rayong, Thailand) founded as a production, sales and marketing

company in December 2014 and planned to start production by the beginning of 2017.

Having the goal of developing and offering environmentally friendly, efficient, innovative in

terms of technology and design, easy-use products in line with its sustainable development

approach, Arçelik A.Ş. carries out efforts to fulfil its responsibilities concerning solutions for

issues threatening the future such as global warming, decreasing natural resources and lack of

water. Resource saving is one of issues of top priority for Arçelik A.Ş. in its product

development processes. Controlling environmental effects of products during their life cycles

in Arçelik A.Ş. is approached as a process starting from designing step. For this purpose, units

carrying out research and development and industrial design activities also carry out efforts

concerning design of products, technology, product developing and product enhancement in

Arçelik A.Ş.

Realizing cost-decreasing, quality and process enhancement projects and increasing its

competitive superiority with its elastic manufacturing structure, Arçelik A.Ş. has a

manufacturing technology and quality in international standards in its plants. It manages its

processes managed on the basis of total quality philosophy in line with quality management,

environmental management system, energy management system, occupational health and

safety management systems. Arçelik A.Ş.'s all manufacturing plants operating in Turkey,

Romania, Russia and China have ISO 9001, ISO 14001 and ISO 50001 certificates. Greenhouse

gas inventory emitted from Company's headquarter and manufacturing campuses in Turkey is

calculated in accordance with ISO 14064-1 Greenhouse Gas Emission Standard and audited

and certified by an independent organization.

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As a result of the efforts made by Arçelik A.Ş. in energy efficiency field, 9 manufacturing plants

in total, were awarded with platinum certificate top level in energy efficient green factories.

Arçelik A.Ş.'s Plants continue to realize projects for decreasing water, energy consumption and

waste with efficiency in manufacturing.

2.1.9. Global Operation Network

Headquarters:

Turkey / İstanbul

Production Plants (Turkey):

Refrigerator Plant, Eskişehir

Washing Machine Plant, İstanbul

Electronics Plant, İstanbul

Cooking Appliances Plant, Bolu

Dishwasher Plant, Ankara

Electric Motors Plant, Tekirdağ

Compressor Plant, Eskişehir

Tumble Dryer Plant, Tekirdağ

Production Plants (International):

Refrigerator Plant, Romania / Gaeşti

Refrigerator and Washing Machine Plant, Russia / Kirzhach

Washing Machine Plant, China / Changzhou

Cooking Appliances and Tumble Dryer Plant, South Africa / Jacobs

Cooling Appliances Plant, South Africa / Ladysmith

Refrigerator Plant, South Africa / East London

Beko Thai Co., Ltd. (Thailand / Rayong) founded as a production, sales and marketing

company in December 2014 and planned to start production by the beginning of 2017.

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International Sales and Marketing, R&D Offices:

Ardutch B.V. Taiwan, Taiwan

Beko A and NZ Pty Ltd., Australia & New Zealand

Beko Deutschland GmbH, Germany

Beko Egypt Trading LLC., Egypt

Beko Electronics España S.L., Spain

Beko France S.A.S., France

Beko Italy SRL, Italy

Beko LLC., Russia

Beko Plc., United Kingdom & Ireland

Beko Slovakia S.R.O., Slovakia

Beko S.A., Poland & Czech Republic

Beko Shanghai Trading Company Ltd., China

Beko Ukraine LLC., Ukraine

Changzhou Beko Electrical Appliances Co. Ltd., China

Defy Appliances Limited, South Africa

Defy (Botswana) (Proprietary) Ltd., Botswana

Defy (Namibia) (Proprietary) Ltd., Namibia

Elektra Bregenz A.G., Austria

Grundig Multimedia A.G., Switzerland

Grundig Intermedia GmbH, Germany & Croatia

Grundig Nordic No A.S., Norway

Grundig Nordic A.B., Sweden

SC Arctic S.A., Romania

Beko Hong Kong Ltd., Hong Kong & China

Beko Balkans, Serbia

Beko R&D Office, Taiwan

Beko Plc. R&D Center, Cambridge Science Park, United Kingdom / Cambridge

METU Technopolis R&D Center, Turkey / Ankara

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2.2. General Description of the Dishwasher Plant

Arçelik A.Ş. Dishwasher Plant which is founded in 1993 in Ankara, is a large manufacturing

facility. Total number of employees in the Dishwasher Plant is 1251 (as 102 white collared and

1149 blue collared) employees.

The plant is settled on total 109000 m2 area, with 39000 m2 factory closed area and 11000 m2

warehouse closed area. The plant settlement can be seen below in Figure 2.3.

Figure 2.3: Arçelik A.Ş. Dishwasher Plant Settlement

Arçelik A.Ş. Dishwasher Plant’s total production is about 21 million and 9.4 percent of the

dishwasher market is produced in this plant.

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Work flow diagram of the Dishwasher Plant is shown below in Figure 2.4.

Figure 2.4: Arçelik A.Ş. Dishwasher Plant Work Flow Diagram

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2.2.1. History of the Dishwasher Plant

Actually in 1985, dishwasher production had begun with the assembling the main parts supplied

from abroad. In 1990, local production had begun and continued at the Çayırova Plant. The

dishwasher plant construction in Ankara project has its roots in year 1992. However, this plant

construction had planned to begin in the first quarter of 1993. Totally building up this plant

including the assembly of production lines and other machineries took 11 months and plant

construction completed in 1993 September. Tool try out and hard tooled functional built steps

just before the first proved product release had completed in 15 September 1993 and just after

completing these steps continuous built had started in 20 November 1993.

Official opening date for the plant is 3 December 1993. Additionally, total investment cost of

this plant is 52 million United States Dollars. The summarized chronology of the Ankara

Dishwasher Plant is as below.

Foundation in September, 1992

Trial Production in September, 1993

Serial Production in October, 1993

Start-up in December, 1993

2.2.2. History of the Products

BL 34 series, 1985 - 1996 (BSH type DW)

BM 4000 series, 1996 - 1999 (improved BSH type DW)

KO4 series, 1996 - 1999 (Whirlpool type DW)

Turkuaz series, 1999 - 2007

45 cm series 2005, continues

Tall Tub series 2006, continues

Turkuaz II (New Tub), 2007 - 2013

Angora Platform 2013, continues

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3. QUALITY ASSURANCE MANAGEMENT

3.1. General Description of the Quality Assurance Management

This standard is a technical specification for Arçelik A.Ş. suppliers in order to enhance the

performance. The intent of this technical specification is to achieve development of a basic

quality system management system which will ensure continual improvement by emphasizing

fault prevention and reduction of nonconformities and waste in the supply chain. It contains the

implementations, examples, illustrations, descriptions and conditions specific to Arçelik A.Ş.

This standard specifies the requirements for the suppliers of Arçelik A.Ş. in the following cases:

The supplier needs to demonstrate its ability to consistently supply the product that meets

customer and current regulatory requirements.

The supplier aims to the objectives of customer satisfaction enhancement through effective

implementation of the system including the processes for continual improvement of the

system and the assurance of conformity to customer and current regulatory requirements.

3.1.1. Product Certifications

Arçelik A.Ş. cooperates with different national and international standards institutes. TSE, TUV

Rheinland and Intertek-ETL inspects the plant periodically.

TSE (Türk Standardları Enstitüsü)

Intertek

IRAM (Instituto Argentino de Normalizacion y Certificacion)

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UL (Underwriters Laboratories)

NSF (National Sanitation Foundation)

TÜV SÜD

3.1.2. System Certifications

ISO 9001 ISO 9001:2008 Quality Management System,

First Certification: TSE (1994) – SGS YARSLEY (1994)

ISO 14001 ISO 14001:2004 Environmental Management

System, First Certification: SGS YARSLEY (1995)

ISO 50001 ISO 50001:2011 Energy Management System,

First Certification: BSI (2011)

ISO 14064-1 ISO 14064-1: Carbon Footprint Verification,

First Certification: BSI (2012)

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3.1.3 Terms and Definitions

The terms and definitions given in ISO 9000 standards are applied regarding the intention of

this standard. The terms used this edition of ISO 9001 standard for describing the supply chain

have been changed to reflect the current vocabulary as given below.

Supplier → Organization → Customer

The term ‘organization’ replaces the term ‘supplier’ in ISO 9000:1994 edition and indicates the

way this standard is implemented. In the same manner, the term ‘supplier’ replaces the term

‘sub-contractor’. Throughout the text of this standard, wherever the term ‘product’ takes place,

it can also mean ‘service’.

3.1.4. Control of the Records

The records should be established and maintained to demonstrate that the quality management

system conforms to the requirements and is implemented effectively. The records should

remain legible, readily identifiable and retrievable. A documented procedure should be

established to describe the controls needed to for the identification, storage, protection,

retention time and disposal. The control of the records should be at such a level that will fulfil

the requirements relevant to the laws and customers.

3.1.5. Control of the Documents

A documented procedure should be established for describing the following necessary controls:

Approval of the documents in terms of conformity and adequacy before they are issued.

Reviewing of the documents, updating if necessary and re-approval.

Ensuring that changes and the current revision status of documents are identified.

Ensuring the availability of the relevant versions of the applicable documents at points of

use

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Ensuring that the documents remain legible and readily identifiable.

Ensuring that the documents of external origin are identified and their distribution

controlled

Preventing the unintended use of obsolete documents and applying a suitable identification

to them if they are retained for any purpose.

3.1.6. Engineering Specifications

The organization should have processes for providing the timely reviewing, distribution and

implementation of any engineering standards, specifications and modifications of customer

depending on the delivery schedule specified by customer. The timely reviewing operation

should be realized promptly and should not exceed two weeks. The records showing the starting

dates of implementation of modifications should be maintained.

3.2. Quality Control Steps

In serial production process, following control steps are traced:

Incoming Material Quality Inspection

Q Point for Internal Production

Function Tests in Assembly Line (100 %)

Final Visual Control

Electrical Safety Tests (100 % at two operation steps)

Optical Inspection

Daily Audit (2,5%)

Performance Tests

Component and Dishwasher Life Tests

Faulty Component Investigation

RoHS Compliance Tests

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On new production platforms, following steps are traced:

Field Test

Life Tests for Specific Conditions

Packaging Test

EMC Tests

Standard Approval Tests

WEEE Compliance (Waste Electrical and Electronic Equipment Directive)

3.2.1. Incoming Inspection

Plastic, component and electronics incoming inspection and supplier development

50 times supplier process audit achieved in 2014 resulted with reduction of rejection ppm

Figure 3.1: Incoming Inspection Unit

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3.2.2. Functional Test

100% functional test during production

Figure 3.2: Functional Test Unit

3.2.3. Final Visual Control

100% final visual control of dishwashers before packaging

Figure 3.3: Final Visual Control Unit

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3.2.4. Optical Control

Specially designed optical control points on the assembly lines

Figure 3.4: Optical Control Unit

3.2.5. Daily Product Audit

2.5 percent sampling final product control that simulate customer usage

Figure 3.5: Daily Product Audit Unit

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3.2.6. Functional Product Audit

Product definition control for 100% of first production of every model

Figure 3.6: Functional Product Audit Unit

3.2.7. Performance Test

New platform and serial production performance confirmation

Figure 3.7: Performance Test Unit

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3.2.8. Product Life Test

12 and 30 cycles simulate first usage period (6 dishwashers per day)

900 cycles simulate domestic warranty

3000 cycles washing tests simulate for 10 years of usage

Figure 3.8: Product Life Test Unit

3.2.9. Faulty Component Investigation

Exchanged part investigations to take feedback

Figure 3.9: Faulty Component Investigation Unit

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3.3. Examining Dishwasher

Basically, a dishwasher is a machine that cleans and rinses dirty dishes. Humans have to load

the dishes, add detergent, set the proper washing cycles and turn it on, but the dishwasher

accomplishes a whole series of functions by itself. A dishwasher:

Adds water.

Heats the water to the appropriate temperature.

Automatically opens the detergent dispenser at the right time.

Shoots the water through jets to get the dishes clean.

Drains the dirty water.

Sprays more water on the dishes to rinse them.

Drains itself again.

Heats the air to dry the dishes off, if the user has selected that setting.

In addition, dishwashers monitor themselves to make sure everything is running properly. A

timer (or a small computer) regulates the length of each cycle. A sensor detects the water and

air temperature to prevent the dishwasher from overheating or damaging your dishes.

Figure 3.10: Water Intake and Discharge Lines of a Dishwasher

Another sensor can tell if the water level gets too high and activates the draining function to

keep the dishwasher from overflowing. Some dishwashers even have sensors that can detect

the dirtiness of the water coming off the dishes. When the water is clear enough, the dishwasher

knows the dishes are clean.

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3.3.1. Inner Side of a Dishwasher

Although dishwashers are watertight, they don't actually fill with water. Just a small basin at

the bottom fills up. There, heating elements heat the water to 130 to 140 degrees Fahrenheit.

Then a pump propels the water up to the water jets, where it is forced out and sprayed against

the dirty dishes. Think about a garden hose with no nozzle - if you put your thumb over the end

of the hose, decreasing the space for the water to come out, it sprays out more forcefully. The

dishwasher's jets work on the same principle. The force of the water also makes the arms that

hold the spray jets rotate, just like a lawn sprinkler.

Figure 3.11: Internal Structure of a Dishwasher

When the washing and rinsing is finished, the water drains down to the basin again, where the

pump propels the water out of the dishwasher. Depending on the type of dishwasher, the drain

water might go right into the pipes under your sink, or travel up a hose into your sink itself. The

final step in a wash cycle is optional - the dry cycle. The heating element at the bottom of the

dishwasher heats the air inside to help the dishes dry. Some people just let them dry without

heat to save energy.

3.3.2. Control Mechanisms

The control mechanism is located inside the door behind the control panel. Many units use a

simple electro-mechanical system: a timer determines how long each part of the cycle lasts and

activates the proper function at the proper time (such as the detergent dispenser, wash spray and

draining functions). Units that are more expensive might have a computerized control system.

Modern units also have a door latch that must be closed for the unit to run. Some also have

child safety locks.

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Intake Valve: This is where water from the home's water supply enters the dishwasher. The

unit's pump doesn't pump the water into the basin – when the intake valve opens, water

pressure drives the water into the unit.

Pump: An electric motor powers the pump. During the pump cycle, the pump forces water

up into the spray arms. During the drain cycle, the pump directs the water into the drain

hose. The motor-pump assembly is mounted beneath the basin, in the centre of the

dishwasher. There are two main types of pump:

For reversible pumps, switch between pumping water to the spray arms and pumping

water to the drain by reversing the direction of the motor. Reversible pumps are usually

vertically mounted.

For direct-drive pumps, the motor runs in one direction. So, the direction of flow is

switched from spray arms to drain by a solenoid that opens and closes the appropriate

valves or switches one hose connection to another. Non-reversible pumps are usually

horizontal mounted.

Dishwashers can be installed in either a portable or a permanent configuration. Portable units

have finished sides and top that can be used as a countertop when not in use, the machine sits

in place next to the wall. When it's time to run a cycle, the unit can be rolled on casters over to

the sink, where it connects to the faucet and plugs into a nearby outlet. In a permanent

installation, the dishwasher goes underneath the existing countertop and bolts into place. Hoses

underneath the kitchen sink connect directly to the hot water line and the drain line, and the unit

usually plugs in under the sink as well.

Figure 3.12: Inner View of a Dishwasher

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3.3.3. Detergent

Detergent is an important consideration when running a dishwasher. Detergents counteract

mineral deposits, or hardness, in the water. They contain solvents that help dissolve food, have

abrasives that scour away stuck-on gunk and help food slide off dishes more easily. You can't

use just any detergent in a dishwasher; only detergents specially formulated for dishwashing

machines will work. Other detergents could damage dishes or generate so many suds that the

dishwasher would overflow. Which detergent to choose tablet, powder, or gel is really based

on personal preference. One type hasn't been shown to clean better than another type.

The problem most people encounter with dishwashers is a simple inability to get the dishes

clean. There might be stuck-on food or residue from the detergent. A water pressure problem

may be the culprit. You may need to replace the water intake valve. Another common problem

is mineral build-up. If your house has hard water, the mineral build-up can clog the water jets.

Clear each jet with a wire or pin, and run an empty load with some vinegar in the detergent

dispenser about once a month. Sometimes, the dishwasher has problems draining properly.

There could be a clog in the drain hose, or a problem with the pump. It is also possible that the

dishwater is getting too sudsy, and sensors in the washer aren't detecting the soap foam as water.

This causes it to shut down the drain cycle too early. Just use less detergent.

3.3.4. Components of a Dishwasher

Parasite Capacitor: This absorbs the start effect of machine and protects other electronic

devices such as T.V., radio and collocate line voltage. When machine plugged in, voltage

across the output pin of capacitor is measured if there is no voltage that means capacitor is

out of order and need to be replaced.

Figure 3.13: Parasite Capacitor

30

Main Switch: It is the components that allow energy to pass through the machine so that it

works. When switch is on if there is no voltage on output pin that means it is out of order

and need to be replaced. When switch powered on 220 V flow in to the power board.

Figure 3.14: Main Switch

Door Security Switch: This component cuts the machine power if the door is open.

Figure 3.15: Door Security Switches

Electronic Program Device: This device is the brain of the machine. It controls every

component of the machine it is a microcontroller based device. In Arçelik components,

ATMega series microcontrollers are used. Microcontroller drives valves, motor, switches

and etc. by using triacs or relays.

Figure 3.16: Electronic Program Device

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Water Level Switch (Presostat): This is a pressure switch which works with pressure that

caused by the water contained in the water tank. It controls the water valves and controls

the water level. Presostat connects with small pipe to air tank and air tank connects with

water tank. Water that fills the water tank makes a pressure to air tank and that pressure also

goes to switch. When water level has come to the desired levels by the pressure switch

closes the water valve and no more water enters the tank.

Figure 3.17: Water Level Switch (Presostat)

Water Valve: It allows the water entry with the command of presostat. Water valve works

with 220V relays and 0.5 and 10 bar pressurized water. When relay inductors energized

valve opens and allows entry to machine. Even if relay energized water not enters the

machine that means filter chocked and it needs to be replaced.

Figure 3.18: Water Valves

Washing Motor: This device controlled by the microprocessor. Generally, it has an assistant

wrapping. It sends the water inside the machine to the up and down spouts. This is a 300 W

two-way motor. Assistant wrapping has a capacitor on it. Without this capacitor motor may

not start properly or never starts.

Figure 3.19: Washing Motor

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Pump Motor: This device used for getting water out of the machine at the end of the

programs. This device controlled by microcontroller at the end of the programs by applying

220 v to it conductors it throws out to dirty water out of machine.

Figure 3.20: Pump Motor

Thermostat: For keeping the washing water at the particular value this device senses the

water heat and control the heaters resistance.

Figure 3.21: Thermostat

Water Emasculation Container: Dishwasher water must be lime free. For making water lime

free water passes through a resin inside the machine. Calcium in the water holds by resin

and Emasculated water goes to machine. Resin puts to machine in the production sequences

and it never goes low. Salt in the machine cleans that resin.

Salt Container: When the resin in the emasculation container fully covered by calcium it

may not hold more and water with lime goes in to machine to prevent this we need sodium.

After end of the most of the program salt container opens and fills with water then water

goes to emasculation container and cleans the resin.

Resistance: It heats the washing water. After the dishes are cleaned it heats the machine so

that dishes get dry. It has approximately 2000 Watt power. With the power taken by

thermostat it heats the washing water to desired values. It is made by stainless steel and

works with 220 V.

33

4. GLOW WIRE TESTING

4.1. History of Glow Wire Testing

Safety is paramount in the home appliance industry. Due to the possibility of human

misapplication, over-current, or short circuit failures within an appliance wiring system, fire

protection requirements were created to evaluate and rate the flammability of material used

within an appliance. Glow wire testing is one such requirement used within the appliance

industry today.

Historically a number of methods have been developed to evaluate material flammability and

fire resistance. These include both direct flame and indirect flame testing methods. An example

of the direct flame method is defined in the UL 94 specification. This long accepted test method

involves applying a flame directly to a vertically or horizontally mounted specimen under

controlled conditions. On the other hand, the indirect flame method features a non-flaming heat

source applied to a sample. Glow wire testing is an example of the indirect flame method. Test

results from applying these methods provide a way to compare the materials’ tendency to resist

ignition, self-extinguish flames (should ignition occur), and to not propagate fire via dripping.

To better understand the differences between the direct method and the indirect method, refer

to Figure 4.1.

Figure 4.1: Direct Open Flame Method (UL94) and Indirect Method (IEC)

34

The International Electrical Commission (IEC) established the glow-wire testing method in

2001 because existing test methods did not cover all ignition sources. Specifically, the glow

wire test is used to simulate heating effects that may arise in malfunctioning electrical

equipment caused by an overloaded connection or component that is overheating.

4.2. Glow Wire Test Methodology

Glow wire requirements for home appliances are specified in IEC 60335-1. However, the actual

glow wire test methodology is covered in the IEC 60695-2 series of specifications.

Glow wire testing is performed by heating an element to a pre-determined temperature. The

heated element is referred to as the glow wire. See Figure 4.2 for an example of the heated

element used for glow wire testing. The sample to be tested is fixture in place and tissue paper

is positioned directly below the sample. After reaching the pre-determined temperature, the

element is then pressed into a sample material under a set force of 1N for 30 seconds. If ignition

occurs, recordings are made to note the duration, flame height, and if drips of the material ignite

the tissue paper.

Glow wire testing can be performed on both end products and raw material test plates. The

terminology used to define compliance in each case is slightly different.

GWT stands for Glow Wire Test (IEC 60695-2-11). GWT is used when glow wire testing

is performed on an end product. The results of this test will be either ‘pass’ or ‘fail’ at a

given temperature. Passing the test requires that the sample does not ignite or self-

extinguishes within 30 seconds after removal of the heated element. Also, the sample may

not ignite the tissue paper if drips occur.

GWFI stands for Glow Wire Flammability Index (IEC 60695-2-12). This is a property

associated with raw material used in the end product. This property is determined by

conducting the glow wire test on a test plate of a raw material of a given thickness. The

Glow Wire Flammability Index (GWFI) is the highest temperature at which the material

does not ignite or self-extinguishes within 30 seconds after removal of the heated element.

35

GWIT stands for Glow Wire Ignition Temperature (IEC 60695-2-13). This is a property

associated with raw material used in the end product. This property is determined by

conducting the glow wire test on a test plate of a raw material of a given thickness. The

Glow Wire Ignition Temperature (GWIT) is the lowest temperature at which the material

ignites and burns for longer than 5 seconds while the heated element is in contact with the

test plate.

Knowledge of the three terms is essential to understand how glow wire testing is applied under

the overall safety standard IEC 60335-1.

Figure 4.2: Typical Glow Wire Setup Showing Heated Element

4.3. Safety of Household and Similar Appliances (IEC 60335-1)

IEC 60335-1 is a general specification that governs the safety of household appliances. Within

the specification, glow wire testing is used to evaluate flammability of non-metallic materials

supporting current carrying connections used within the appliance. This international standard

deals with the safety of electrical appliances for household and similar purposes, their rated

voltage being not more than 250 V for single-phase appliances and 480 V for other appliances.

The glow wire test severity prescribed in IEC 60335-1 is determined by whether the appliance

is attended or unattended during use, and by the amount of current that is carried by the

connection. Attended appliances are basically any appliance that is operated by an attending

consumer such as vacuum cleaners, irons, and coffee pots. Unattended appliances are those that

are set in place and operated on their own. Such examples include refrigerators, cooking units,

dishwashers, washing machines, and dryers.

36

Connectors used in an application that is categorized as unattended with current greater than

0.2A are subject to the most severe evaluation. To comply with this specification, three levels

of flammability evaluation may be required:

In order to pass the first level of evaluation, the material must have a minimum GWFI 850

ºC or the end product must pass the glow wire test at 850 ºC. It is important to note that for

the end product to pass, the sample must self-extinguish within 30 seconds as identified in

the above passage. The test is subject to the procedure 60695-2-11.

In order to pass the second level of evaluation, the material must have a minimum of GWIT

775 ºC or the end product must pass the glow wire test at 750 ºC. It is important to note that

if the end product is tested, any ignition must self-extinguish within 2 seconds or the

surrounding components must pass a third level of evaluation.

The third level of evaluation (performed only if the connector exhibits a flame for longer

than 2 seconds) is not performed directly on the connector, but instead is performed on any

components within the appliance falling within a theoretical envelope above the connector.

Components within the envelope made from a material that has a minimum flammability

designation as UL 94 V1 are not subject to further evaluation. However, components within

the envelope that have less than UL 94 V1 are subject to a needle flame test.

Connectors used in Appliances that are categorized as unattended with a current less than 0.2A

or categorized as attended appliances are subjected to less severe testing methods. It is

important for the appliance manufacturer to understand the appropriate categorization of their

finished product, so as to apply the correct level of testing per IEC 60335-1 to the components.

The flow diagram is shown in Appendix A for an illustration of the testing required for materials

supporting connections carrying current greater than 0.2 A in unattended appliances.

37

4.4. Glow Wire Testing Device and Subject of the Project

Engineer Burak told me about a device that used to test components for electrical safety. This

device is the glow wire testing device and the main problem of it is the adjustment process of

setting the device to certain testing temperature values via an analog switch manually. See

Figure 4.3 for the glow wire testing device currently in use in the Dishwasher Plant.

Figure 4.3: Glow Wire Testing Device

This device is needed to be automated since current manual process is inefficient. Current test

process with manual temperature adjustment lasts about 5 minutes per piece tested. Manual

temperature adjustment process takes about 30 to 90 seconds. Daily tested materials vary

between 10 to 50 pieces with an average of 20. So, this automation project provides a gain of

average 20 minutes per day. In other words, it decreases the total process time about 20 percent.

As an engineering internship student who was practicing under quality assurance management,

I decided to take this testing device problem as subject of my summer practice project.

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5. PROJECT DEVELOPMENT PROCESS

Project development process lasts about two weeks. During this process, firstly a research about

typical voltage chopper circuits. Then a programming language and a simulation program was

learnt from scratch. To reach the final form of the project, a modular approach was followed.

Each part of the final project was developed as individual modules. Each module was designed

as an individual mini project and several simulations were made for each module. After

hundreds of simulations were conducted, as a final step, all individual modules modified and

combined into the final form of the project.

For this project, Microchip PIC 16F877A was chosen as microcontroller because of that it has

enough I/O pins, especially analog inputs. PIC Basic programming language was used to

program the microcontroller. All circuit designation processes and simulations were conducted

on Proteus ISIS simulator platform.

5.1. Button Controlled Walking LED Light Circuit

A basic circuit implementation was selected to start to work. It helped to familiarise with both

PIC Basic and Proteus ISIS. In this implementation, a simple circuit was constructed (refer to

Figure 5.1) with a microcontroller, a LED array and two buttons to shift the lit LED to the right

or to the left. Relevant PIC Basic codes is given on Table 5.1.

Figure 5.1: Button Controlled Walking LED Light Circuit Diagram

39

Table 5.1: Button Controlled Walking LED Light PIC Basic Codes

TRISD = 0 /port D sets as output or (TRISD=%00000000) TRISB = 6 /port B sets as input or (TRISB=%00000110) PORTB = 0 PORTD = 0 /initial value of port B and port D sets to zero RUN: /label WHILE PORTB.1 = 1 and PORTB.2 = 0 IF PORTD=%00000000 THEN PORTD=%00000001 PAUSE 100 /wait 100 microseconds ENDIF PORTD=PORTD<<1 PAUSE 100 WEND /end of while WHILE PORTB.1 = 0 and PORTB.2 = 1 IF PORTD=%00000000 THEN PORTD=%10000000 PAUSE 100 ENDIF PORTD=PORTD>>1 PAUSE 100 WEND GOTO RUN /for repetition of the loop /all of these loops means that are lit the LEDs in sequence

5.2. Analog Input LED Display Circuit

As next step, it was continued to learn about second level PIC Basic codes and microcontroller

applications. In this implementation, another simple circuit was constructed (refer to Figure

5.2) with a microcontroller, three LEDs and a potentiometer. Potentiometer sets analog input

and LEDs display digital (levelled) output. This implementation is a very basic ADC circuit.

Relevant PIC Basic codes is given on Table 5.2.

Figure 5.2: Analog Input LED Display Circuit Diagram

40

Table 5.2: Analog Input LED Display PIC Basic Codes

TRISA=1 TRISB=0 DEFINE ADC_BITS 10 /A/D conversion is how many bits in the result DEFINE ADC_CLOCK 3 /Clock source (RC=3) DEFINE ADC_SAMPLEUS 100 /The sampling time in micro seconds ADCON1 = %10000000 /details are given below VAL VAR WORD /VAL is a variable that is 16 bits (word means 16 bits=0 to 65535) BASLA: /Label ADCIN 0, VAL /Read the analog value from zero channel and transfer to the raw variable IF VAL <= 341 THEN /analog inputs reads only 0 to 5V but for transferring 3 LEDs PORTB.5 = 1 /apply division for 5V in 3 parts: 1,67 V-3,33V-5V then PORTB.6 = 0 /in order to find bit equivalent 341=1024/3, 683=1024*2/3, PORTB.7 = 0 /and 1023. If the value less than 341 third LED is active, ELSEIF VAL >341 AND VAL < 683 THEN /if the value between 341 and 683 second PORTB.5 = 1 /LED is active, if the value greater than 683 first LED is active PORTB.6 = 1 PORTB.7 = 0 ELSEIF VAL >= 683 THEN PORTB.5 = 1 PORTB.6 = 1 PORTB.7 = 1 ENDIF /end of if GOTO BASLA /Back to BASLA label *ADCON1 = %10000000 /ADCON1 REGISTER (ADDRESS 9Fh)

ADCON1 register and its bits are shown below on Table 5.3

Table 5.3: ADCON1 Register

Bit-7: The select bit of result format

If it is 1 the result is right-aligned 6. three bits of ADRESH is read as 0.

If it is 0 the result is left-aligned 6. three bits of ADRESL is read as 0.

6th to 4th bits are not used and read as between 0.

Between 0th and 3rd bits are PCFG3 – PCFG0 A/D ports tuning control bits. This is the

selection of the port by setting bits.

Selection table is shown in Appendix B.

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5.3. Analog Input LCD Display Circuit

In this step, it is learnt about dealing with LED display. Main difference between this and

previous implementation, LED display used in Analog Input LED Display Circuit was changed

with a LCD display. In this implementation circuit (refer to Figure 5.3) with a microcontroller,

a LCD display and a potentiometer. Potentiometer sets analog input and LCD display shows

digital output. This implementation is a complete ADC circuit. Relevant PIC Basic codes is

given on Table 5.4.

Table 5.4: Analog Input LCD Display PIC Basic Codes

TRISD = 0 TRISA = 1 DEFINE LCD_DREG PORTD /LCD data pins are connected port D DEFINE LCD_DBIT 4 /Starting from the LCD pins which bits DEFINE LCD_EREG PORTD /It shows LCD enable pin connected to which port DEFINE LCD_EBIT 3 /It shows LCD enable pin connected to which pin DEFINE LCD_RWREG PORTD /It shows LCD RW pin connect to port D DEFINE LCD_RWBIT 2 /It shows LCD RW pin connect to second bit DEFINE LCD_RSREG PORTD /It shows LCD RS pin connect to port D DEFINE LCD_RSBIT 1 /It shows LCD RS pin connect to first bit DEFINE LCD_BITS 4 /It shows LCD is 4 bit DEFINE LCD_LINES 2 /LCD can write 2 lines DEFINE ADC_BITS 10 DEFINE ADC_CLOCK 3 DEFINE ADC_SAMPLEUS 100 ADCON1 = %10000000 X VAR WORD Y VAR WORD TEMP VAR WORD D1 VAR WORD D2 VAR WORD D3 VAR WORD BASLA: ADCIN 0,X TEMP = X*49 Y=TEMP/10000 /Calculation of reading voltage value D1=TEMP//10000 D1=D1/1000 /Calculation of first digit after the comma D2=TEMP//1000 D2=D2/100 /Calculation of second digit after the comma D3=TEMP//100 D3=D3/10 /Calculation of third digit after the comma LCDOUT $FE,$80,"V:" ,#Y,",",#D1,#D2,#D3 /If LCDOUT is using with $FE it means a command to be sent to LCD GOTO BASLA

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Figure 5.3: Analog Input LCD Display Circuit Diagram

5.4. Analog Thermometer Reading

One step further, the circuit was constructed (refer to Figure 5.4) by aiming to control the

temperature. A heater which can go up to high temperatures (550 ℃, 650 ℃, 750 ℃ and 850

℃), considering glow wire test regulations. However, simulation platform library does not

contain a well modelled heater, therefore using it might be dangerous on reality. So, it is decided

to construct the simulation model by using LM35 heat sensor instead of the heater and an Op-

Amp amplifier circuit used to provide meaningful values for analog input. Again, a LCD display

is used to show digital output. This is also an ADC circuit implementation. Relevant PIC Basic

codes is given on Table 5.5.

Figure 5.4: Analog Thermometer Reading Circuit Diagram

43

Table 5.5: Analog Thermometer Reading PIC Basic Codes

TRISD = 0 TRISA = 1 DEFINE LCD_DREG PORTD DEFINE LCD_DBIT 4 DEFINE LCD_EREG PORTD DEFINE LCD_EBIT 3 DEFINE LCD_RWREG PORTD DEFINE LCD_RWBIT 2 DEFINE LCD_RSREG PORTD DEFINE LCD_RSBIT 1 DEFINE LCD_BITS 4 DEFINE LCD_LINES 2 DEFINE ADC_BITS 10 DEFINE ADC_CLOCK 3 DEFINE ADC_SAMPLEUS 100 ADCON1 = %10001000 X VAR WORD BASLA: ADCIN 0,X X = X/6 / we divided the reading value by 6 'IF X>1000 THEN /controlling the temperature ' LCDOUT $FE,$80,#X,"C" /it shows temperature on the LCD screen 'ENDIF IF X<1000 AND X>100 THEN /controlling the temperature LCDOUT $FE,$80," ",#X,"C" /it shows temperature on the LCD screen ENDIF IF X<100 AND X>10 THEN /controlling the temperature LCDOUT $FE,$80," ",#X,"C" /it shows temperature on the LCD screen ENDIF IF X<10 THEN /controlling the temperature LCDOUT $FE,$80," ",#X,"C" /it shows temperature on the LCD screen ENDIF GOTO BASLA

5.5. Button Controlled AC Dimmer Circuit

In this step, main purpose of the circuit (refer to Figure 5.5) was to control the current. For this

purpose, an AC voltage dimmer circuit is implemented. Firstly, 220 V AC input passes through

a full wave diode bridge rectifier. Then, zero-crosses of the rectified wave are detected via 4N25

photocoupler. For each zero-cross detection, an interrupt signal is sent to microcontroller to

synchronize all circuit at each cycle. Right after the interrupt signal, microcontroller provides a

certain amount of delay and then, it sends trigger signal to triac. Also, PC849 opto-isolator is

used to isolate the control and power parts of the circuit.

44

In this implementation, amount of the delay time is identified by two buttons (increment and

decrement) manually. Dimming percent of the circuit is directly proportional to the rate of the

delay time to half of the 220 V AC input wave period. According to dimming percentage, the

brightness of the lamp increases or decreases. To better understand the signal traffic on this

circuit, refer to Figure 5.6. Relevant PIC Basic codes is given on Table 5.6.

5.5.1. Photocoupler, Opto-isolator

An optical coupler, also called photocoupler, opto-isolator, optocoupler, opto-coupler or optical

isolator is a passive optical component that can combine or split transmission data (optical

power) from optical fibers. It is an electronic device which is designed to transfer electrical

signals by using light waves in order to provide coupling with electrical isolation between its

input and output. The main purpose of an optocoupler is to prevent rapidly changing voltages

or high voltages on one side of a circuit from distorting transmissions or damaging components

on the other side of the circuit. An optocoupler contains a light source often near an LED which

converts electrical input signal into light, a closed optical channel and a photo sensor, which

detects incoming light and either modulates electric current flowing from an external power

supply or generates electric energy directly. The sensor can either be a photo resistor, a silicon-

controlled rectifier, a photodiode, a phototransistor or a triac.

5.5.2. Photocoupler, Opto-isolator

The TRIAC is a three terminals semiconductor device for controlling current. It gains its name

from the term TRIODE for Alternating Current. It is effectively a development of the SCR or

thyristor, but unlike the thyristor which is only able to conduct in one direction, the TRIAC is

a bidirectional device. TRIACs are used in a number of applications. However, they tend not to

be used in high power switching applications, one of the reasons for this is the non-symmetrical

switching characteristics. For high power applications, this creates a number of difficulties,

especially with electromagnetic interference.

45

Figure 5.5: Button Controlled AC Dimmer Circuit Diagram

Figure 5.6: Button Controlled AC Dimmer Circuit Simulated Oscilloscope Result

46

Table 5.6: Button Controlled AC Dimmer PIC Basic Codes

X VAR WORD X=5000 PORTB=0 TRISB=1 TRISC=3 ON INTERRUPT GOTO TUS /where the program is going is determined. OPTION_REG=%00000000 /interrupt occurs on falling edge of RB0 INTCON=%10010000 /The cutting process in order to be active interrupt control register is used TRISB=1 BASLA: WHILE PORTC.0=1 IF X>8500 THEN /controlling temperature X=8500 GOTO BASLA ENDIF X=X+1 WEND WHILE PORTC.1=1 IF X<300 THEN /controlling temperature X=300 GOTO BASLA ENDIF X=X-1 WEND GOTO BASLA TUS: DISABLE /instantly interrupting and re-interrupting are prevented PAUSEUS X / pause this given value HIGH PORTB.1 /activate second pin of port B PAUSE 1 /pause 1 micro seconds LOW PORTB.1 /disabled second pin of port B INTCON.1=0 RESUME /is provided to return to its previous position. ENABLE /all interrupts are enabled END

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5.6. Automatic AC Dimmer Circuit

In this step, AC dimmer circuit was set again with a very small change, refer to Figure 5.7.

Oscilloscope results are the same as the previous result. The only change, buttons were removed

and microcontroller runs the AC dimmer automatically. Relevant PIC Basic codes is given on

Table 5.7.

Table 5.7: Automatic AC Dimmer PIC Basic Codes

X VAR WORD X=5000 /values are given in program PORTB=0 TRISB=1 TRISC=3 ON INTERRUPT GOTO TUS OPTION_REG=%00000000 INTCON=%10010000 TRISB=1 BASLA: WHILE PORTC.0=1 IF X>8500 THEN X=8500 /values are given in program GOTO BASLA ENDIF X=X+1 WEND WHILE PORTC.1=1 IF X<300 THEN X=300 /values are given in program GOTO BASLA ENDIF X=X-1 WEND GOTO BASLA TUS: DISABLE PAUSEUS X HIGH PORTB.1 PAUSE 1 LOW PORTB.1 INTCON.1=0 RESUME ENABLE END

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Figure 5.7: Automatic AC Dimmer Circuit Diagram

5.7. Overall Circuit

Where project process was coming to end, all of the partial works that was previously done

were aggregated under an overall circuit. AC dimmer circuit and analog thermometer reading

circuit were drawn together and combined into the overall circuit which is shown in Figure 5.8.

Relevant PIC Basic codes is given on Table 5.8.

Figure 5.8: Overall Circuit Diagram

49

Figure 5.8: Overall Circuit PIC Basic Codes

TRISA=1 TRISB=1 TRISD=0 ON INTERRUPT GOTO XINT OPTION_REG=%00000000 INTCON=%10010000 DEFINE LCD_DREG PORTD DEFINE LCD_DBIT 4 DEFINE LCD_EREG PORTD DEFINE LCD_EBIT 3 DEFINE LCD_RWREG PORTD DEFINE LCD_RWBIT 2 DEFINE LCD_RSREG PORTD DEFINE LCD_RSBIT 1 DEFINE LCD_BITS 4 DEFINE LCD_LINES 2 DEFINE ADC_BITS 10 DEFINE ADC_CLOCK 3 DEFINE ADC_SAMPLEUS 100 ADCON1 = %10000000 Y VAR WORD X VAR WORD D VAR WORD D=4000 BASLA: ADCIN 0,Y X=Y/4 WHILE X>75 PAUSEUS 10 D=4000+50*(X-75) ADCIN 0,Y X=Y/4 LCDOUT $FE,$80,#X,"C" WEND WHILE X<=75 PAUSEUS 10 D=4000-50*(75-X) ADCIN 0,Y X=Y/4 LCDOUT $FE,$80,#X,"C" WEND GOTO BASLA XINT: DISABLE PAUSEUS D HIGH PORTB.1 PAUSEUS 10 LOW PORTB.1 INTCON.1=0 RESUME ENABLE END

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5.8. Overall Circuit with Two Microcontrollers

One microcontroller was used in previous step; however, in this step another microcontroller

was added to overall circuit which is shown in Figure 5.9. The reason behind this change was

that while using only one microcontroller, simulations could not continue after it had worked

for a while and ended with runtime error due to the hardware limitations of the computer. Even

though this error was not meaningful in reality, to continue to the simulations healthfully, this

change was needed as a temporary solution.

A default set value was identified as 55 ℃. Then three buttons were put for changing set value

to 65 ℃, 75 ℃ and 85 ℃. If the measurement is more than the set value, dimming level is get

higher rapidly and average current level decreases. Vice versa, if the measurement is less than

the set value, dimming level is immediately get lower and average current level increases.

Relevant PIC Basic codes is given on Table 5.9.a and Table 5.9.b.

Figure 5.9: Overall Circuit Diagram with Two Microcontrollers

Table 5.9.a: Overall Circuit with Two Microcontrollers PIC Basic Codes of The First Microcontroller

TRISA=15 TRISB=0 TRISC=0 TRISD=0 PORTA=0 PORTB=0 PORTC=80 PORTD=0

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DEFINE LCD_DREG PORTD DEFINE LCD_DBIT 4 DEFINE LCD_EREG PORTD DEFINE LCD_EBIT 3 DEFINE LCD_RWREG PORTD DEFINE LCD_RWBIT 2 DEFINE LCD_RSREG PORTD DEFINE LCD_RSBIT 1 DEFINE LCD_BITS 4 DEFINE LCD_LINES 2 DEFINE ADC_BITS 10 DEFINE ADC_CLOCK 3 DEFINE ADC_SAMPLEUS 100 ADCON1 = %10001110 X VAR WORD L VAR BYTE l=55 BASLA: IF PORTA.1=1 THEN l=65 PORTB=1 ENDIF WHILE PORTA.1=1 WEND IF PORTA.2=1 THEN l=75 PORTB=2 ENDIF WHILE PORTA.2=1 WEND IF PORTA.3=1 THEN l=85 PORTB=4 ENDIF WHILE PORTA.3=1 WEND ADCIN 0,X X=X/4 WHILE X>L 'IF PORTA.1=1 THEN l=65 'IF PORTA.2=1 THEN l=75 'IF PORTA.3=1 THEN l=85 IF PORTA.1=1 THEN l=65 PORTB=1 ENDIF WHILE PORTA.1=1 WEND IF PORTA.2=1 THEN l=75 PORTB=2 ENDIF WHILE PORTA.2=1 WEND

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IF PORTA.3=1 THEN l=85 PORTB=4 ENDIF WHILE PORTA.3=1 WEND PORTC=PORTC+1 PAUSE 10 IF PORTC>=160 THEN PORTC=160 ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" WEND WHILE X<L 'IF PORTA.1=1 THEN l=65 'IF PORTA.2=1 THEN l=75 'IF PORTA.3=1 THEN l=85 IF PORTA.1=1 THEN l=65 PORTB=1 ENDIF WHILE PORTA.1=1 WEND IF PORTA.2=1 THEN l=75 PORTB=2 ENDIF WHILE PORTA.2=1 WEND IF PORTA.3=1 THEN l=85 PORTB=4 ENDIF WHILE PORTA.3=1 WEND PORTC=PORTC-1 PAUSE 10 IF PORTC<=10 THEN PORTC=10 ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" WEND WHILE X=L 'IF PORTA.1=1 THEN l=65 'IF PORTA.2=1 THEN l=75 'IF PORTA.3=1 THEN l=85 IF PORTA.1=1 THEN l=65 PORTB=1 ENDIF WHILE PORTA.1=1 WEND IF PORTA.2=1 THEN l=75

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PORTB=2 ENDIF WHILE PORTA.2=1 WEND IF PORTA.3=1 THEN l=85 PORTB=4 ENDIF WHILE PORTA.3=1 WEND WHILE PORTC!=80 IF PORTC<80 THEN PORTC=PORTC+1 IF PORTC>80 THEN PORTC=PORTC-1 PAUSE 10 WEND ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" WEND GOTO BASLA END

Table 5.9.b: Overall Circuit with Two Microcontrollers PIC Basic Codes of The Second Microcontroller

TRISB=1 TRISC=255 PORTB=0 PORTC=0 ON INTERRUPT GOTO XINT OPTION_REG=%00000000 INTCON=%10010000 X VAR WORD BASLA: X=50*PORTC GOTO BASLA XINT: DISABLE PAUSEUS x HIGH PORTB.1 PAUSEUS 10 LOW PORTB.1 INTCON.1=0 RESUME ENABLE END

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5.9. Final Form of the Project

In the final form of the project, some small changes were made for the sake of simplicity.

Buttons were removed from the circuit again, refer to Figure 5.10. Set value was fixed to 55 ℃

and this temperature value was stabilized by adjusting the current. Also, LCD display shows

the amount of delay in addition to measured temperature value. Relevant PIC Basic codes is

given on Table 5.10.a and Table 5.10.b.

Figure 5.10: Final Form of The Project Circuit Diagram

Table 5.10.a: Final Form of The Project PIC Basic Codes of The First Microcontroller

TRISA=1 TRISB=0 TRISC=0 TRISD=0 PORTA=0 PORTB=0 PORTC=80 PORTD=0 DEFINE LCD_DREG PORTD DEFINE LCD_DBIT 4 DEFINE LCD_EREG PORTD DEFINE LCD_EBIT 3 DEFINE LCD_RWREG PORTD DEFINE LCD_RWBIT 2 DEFINE LCD_RSREG PORTD DEFINE LCD_RSBIT 1

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DEFINE LCD_BITS 4 DEFINE LCD_LINES 2 DEFINE ADC_BITS 10 DEFINE ADC_CLOCK 3 DEFINE ADC_SAMPLEUS 100 ADCON1 = %10001110 X VAR WORD L VAR BYTE I=55 BASLA: ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" LCDOUT $FE,$C0,#PORTC WHILE X>L /If Measured Value Is Greater Than Reference PORTC=PORTC+1 PAUSE 10 IF PORTC>=160 THEN PORTC=160 ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" LCDOUT $FE,$C0,#PORTC WEND WHILE X<L /If Measured Value Is Less Than Reference PORTC=PORTC-1 PAUSE 10 IF PORTC<=10 THEN PORTC=10 ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" LCDOUT $FE,$C0,#PORTC WEND WHILE X=L /If Measured Value Is Equal To Reference WHILE PORTC!=80 IF PORTC<80 THEN PORTC=PORTC+1 IF PORTC>80 THEN PORTC=PORTC-1 PAUSE 10 ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" LCDOUT $FE,$C0,#PORTC WEND ADCIN 0,X X=X/4 LCDOUT $FE,$80,#X,"C" LCDOUT $FE,$C0,#PORTC WEND GOTO BASLA END

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Table 5.10.b: Final Form of The Project PIC Basic Codes of The Second Microcontroller

TRISB=1 TRISC=255 PORTB=0 PORTC=0 ON INTERRUPT GOTO XINT OPTION_REG=%00000000 INTCON=%10010000 X VAR WORD BASLA: X=50*PORTC GOTO BASLA XINT: DISABLE PAUSEUS x HIGH PORTB.1 PAUSEUS 10 LOW PORTB.1 INTCON.1=0 RESUME ENABLE END

5.10. Project Prototype

At the end of project development process, the project prototype circuit was implemented on a

breadboard. The prototype was run and it worked correctly. The project prototype is shown in

Figure 5.11 below and for the list of the components used in prototype, refer to Appendix C.

Figure 5.11: Project Prototype

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6. CONCLUSION

After these experiences, I made a presentation about our project. All of internship students

explained their projects to everyone. The availability of some projects was discussed. Then, I

also had a chance to meet experienced engineer and I had a chance to observe that. What is

professional? I think it is the most important think. In these institutional company, you have

lots of chances to see that. Their friendship with other workers and their bosses. It is so

instructive. I was so lucky from our Engineer Ali Burak Yolaşan. Because he answered all

question that I have asked. He helped me about my wonderings. They answer the all of

questions they could.

Last and most important thing about the production factories, working conditions are very safe,

everywhere of the factory are in security. In spite of I am happy to gone to Arçelik A.Ş, because

employees and managers are very friendly to me and they were very helpful and willing to learn

something to me. Production of high quality yarns with low cost is the main purpose of a

factory. Number of workers, energy and raw material consumption are the most important

outlays of a factory therefore managers are very careful with these factors. Production with

lower expense is very important in manufacturing processes. For instance, yarn is ready after

ring spinning frame but it is on bobbins high amount of yarn may not be wound on a bobbin

and a bobbin is more expensive than cones, accordingly, winding processes was added and yarn

on bobbins are wound on cones by winding process.

In conclusion, this summer practice is really beneficial and required for a complete education.

Anyway, preparing a detailed report is also a useful activity in addition to summer practice for

an engineering student. The last summer practice passed full-upped of valuable observations

and knowledge. I really enjoyed and it add lots of things to me.

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7. REFERENCES

1. UL (2011). Safety of Household and Similar Appliances (Ed. 5). Retrieved from

http://ulstandards.ul.com/standard/?id=60335-1_5 which is available on 31 October 2011.

2. TE Connectivity (2013). Glow Wire Testing for The Appliance Industry (Rev. A). Retrieved

from http://www.te.com/content/dam/te-com/documents/appliances/global/glow-wire-

testing-appliance-industry-white-paper.pdf which is available on 23 May 2013.

3. Arçelik A.Ş. (2015). Arçelik A.Ş. Kurumsal Tanıtım Sunumu 2015. Retrieved from

http://www.arcelikas.com/UserFiles/file/ArcelikAS_Kurumsal_Sunum_2015.pdf which is

available on January 2015.

4. Arçelik A.Ş. (2016). Arçelik A.Ş. Müşteri Sunumu 2016 Dishwasher Plant.

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APPENDIX A: Glow Wire Testing Procedure Flow Chart

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APPENDIX B: Microchip PIC 16F877A ADCON1 Register Selection Table

APPENDIX C: Project Prototype Components List

COMPONENTS QUANTITY TYPE

PIC16F877A 2 Microcontroller

4N25 1 Photocoupler

PC849 1 Opto-isolator

LM358N 1 Op-Amp

LM35 1 Thermometer

7805 1 Voltage Regulator

LM016L 1 LCD Display

Triac 1

Diode 4

Button 4

LED 5

Resistors -

Breadboard 1

Jumper cable -

Crystal 2 4Mhz

Capacitor 2