Defence Research & Development Organization

Defence Laboratory, Jodhpur (Rajasthan)

A
TRAINING REPORT
On
STUDY OF CLIMATIC TEST CHAMBER
Submitted for Partial Fulfilment of the Requirement for the award of
Degree of
BACHELOR OF TECHNOLOGY
In
ELECTRICAL ENGINEERING










Submitted To:
MR. DEEPAK GUPTA
Scientist D
Defence Laboratory Jodhpur
(Raj.)

Submitted By:
Praveen Parihar
4
th
B.tech 2011-15
Electrical Engineering
JIET Jodhpur
CERTIFICATE
This is to certify that PRAVEEN PARIHAR student of B.Tech IV
th
year VII
th
semester of Electrical
Engineering of Jodhpur Institute of Engineering and Technology, Jodhpur, has successfully
completed his Summer Training under the project Study of Climatic Test Chamber under my
supervision Mr. DEEPAK GUPTA at Defense Research and Development Organization, Defense
Laboratory, Jodhpur.
He has fulfilled the tenure successfully from 2
nd
June to 30
th
June 2014 with sincerity and
regularity. He was good at understanding the concepts and shown efficient mutual understanding
during his training.



Mr. Deepak Gupta Date
Scientist D 30 June 2014
Defense Laboratory
Jodhpur (Raj.)



ACKNOWLEDGEMENT

It gives me immense pleasure in presenting my training report. I would like to take this opportunity
to express my deepest gratitude to the people, who has contributed their valuable time for helping me
to successfully complete this training.

With great pleasure and acknowledgement I extend my deep gratitude to Dr. S. R. Vadera, Director
Defense Laboratory, Jodhpur for providing me an opportunity to accomplish training at this
esteemed organization.

I am thankful to Mr. Deepak Gupta, Scientist D Diploma in Electronics, Post Diploma in
computer applications, Engineering in Electrical and in Electronics, M.E. in Electrical Control
Systems, also having experience of more than 18 years in the industry. He has provided me
necessary guidance about instruments and gave me directions to proceed my training and helped me
lot in enhancing my skills.

I would also like to thank my college and my colleagues who directly or indirectly helped me for
providing this opportunity to nurture my professional skills at Defense Laboratory, Jodhpur.


Praveen Parihar
4
th
B.Tech 2011-15
JIET, JODHPUR

ABSTRACT
CONTENTS

S.No. Chapter No. Chapter Name Page No.
1 Certificate
2 Acknowledgement
3 Abstract
4 1 About defence research & development organization
(DRDO)

5 2 Training Location
6 3 Introduction
7 4 Specifications
8 5 Types of Chambers and Parameters
5.1 Types of Chambers
5.2 Parameters
5.3 Types & Parameters Under Study

9 6 Bench- Top Climatic Test Chamber
6.1 Introduction
6.2 Constructional Details
6.3 Mechanical Diagram
6.4 Various Parts of a Bench- Top CTC
6.5 Types of Available Temperature Sensors
6.6 List of Components Used in the CTC
6.7 Operation and Controlling

10 7 Walk- In Chamber
7.1 Introduction
7.2 Specifications

11 8 Testing of a Product and Analyzing its Parameters
12 9 Other Types of Chambers
13 10 Conclusion
14 11 Bibliography


CHAPTER- 1

ABOUT DEFENCE RESEARCH & DEVELOPMENT
ORGANIZATION (DRDO)

The Defence Research and Development Organisation (DRDO) is an agency of the Republic of India,
responsible for the development of technology for use by the military, headquartered in New Delhi, India. It
was formed in 1958 by the merger of the Technical Development Establishment and the Directorate of
Technical Development and Production with the Defence Science Organisation. It is under the administrative
control of the Ministry of Defence, Government of India.
With a network of 52 laboratories, which are engaged in developing defence technologies covering various
fields, like aeronautics, armaments, electronics, land combat engineering, life sciences, materials, missiles,
and naval systems, DRDO is India's largest and most diverse research organisation.

Vision
Make India prosperous by establishing world class science and technology base and provide our Defence
services decisive edge by equipping them with internationally competitive systems and solutions.

Mission
Design, develop and lead to production state-of-the-art sensors, weapon systems, platforms and allied
equipment for our Defence Services.
Provide technological solutions to the Services to optimise combat effectiveness and to promote well-
being of the troops.
Develop infrastructure and committed quality manpower and build strong indigenous technology
base.

CHAPTER- 2
TRAINING LOCATION
Defence Laboratory, Jodhpur (DLJ)

Defence Laboratory, Jodhpur was established on 16th May, 1959. DLJ is located at the gateway of Thar
Desert of Rajasthan. It enhances the operational efficiency of troops in desert warfare and logistics support.
The aim of the lab is to undertaken research studies in the following areas:
1. Camouflage & Low Observable Devices
2. Nuclear Radiation Management & Applications
3. Desert Environmental Science & Technologies

In addition to R&D activities in the above field, the lab conducts several training programs to the benefit of
Services and Civil population, e.g. industrial radiography, NBC, radiation safety aspects, water desalination,
quality, monitoring and desert meteorology. The lab has also been identified as a material development lab.
The objective of DEST or HMG (Heat Management Group) is the removal of unwanted heat from man and
machine, such as soldiers, electronic devices, systems and semiconductors without negatively affecting the
performance or reliability of adjacent components. Thermal management addresses heat removal by
considering the ambient temperature (and temperature gradients) throughout the entire product from an overall
system perspective. Thermal removal solutions cover a wide range of options.

CHAPTER-3
INTRODUCTION
Climatic Test Chamber (CTCs) are used for various types of testing procedures such as Prototype Evaluation,
R&D Testing, Production testing, Accelerated Stress Testing, Reliability Testing, Failure Analysis, and other
applications where environmental simulation is needed.
It is used to stimulate temperature over a range of -30c to 120

C humidity from 10% to 90% as well as solar

radiation.
A CTC is used to generate virtual environmental conditions for any product to be tested, so that its behaviour,
operation, and reliability could be checked and analysed at extreme conditions.
Manufactured samples, specimens, or components are placed inside the chamber and subjected to one or more
of these environmental parameters such as extremely high or low temperature, various humidity levels, and
solar radiations, to determine reliability or measure after-effects such as corrosion. In the case of machinery
such as internal combustion engines, by products such as emissions are monitored.
Test chambers are available from 1.2 cubic foot of interior workspace and up with temperature range
capabilities of -184c (-300f) for cold chambers all the way to 350c (662f) for the extreme high
temperature conditions.

CHAPTER- 4

SPECIFICATIONS

S.No. PART RATING/SPECIFICATION
1. CLIMATIC TEST CHAMBER

Model Number
Sl. No.


CMEI-SPL
CMEI/653/2004-05

2. WORK SPACE 560X750X750 mm

3. INNER MATERIAL Stainless Steel AISI 304

4. TEMPERATURE RANGE
Accuracy & Resolution
-30
o
C to +120
o
C
1
o
C / 0.1
o
C

5. HUMIDITY RANGE
Accuracy
75% to 90% RH
3% RH

6. TEMPERATURE CONTROL By Eurotherm Make Model 2604 With
ITOOLS Software

7. COMPRESSOR
Make
SR. No.
CR42 (1 nos.)
Kirlosker
CBA-13434

8. REFRIGERATION R-404a

9. HEATER 2KW with safety Thermostat

10. POWER REQUIREMENT 380V- 440V AC, 50Hz, 4- Wire, 3- Phase
with Neutral + Earth



CHAPTER-5

TYPES OF TEST CHAMBERS & PARAMETERS

5.1 TYPES OF CHAMBERS

Highly Accelerated Life Test (HALT) involves a combination of temperature, shock and vibration to
locate a product weakness and assess the life of a product.

Highly Accelerated Stress Screening (HASS) involves fast temperature cycling and is performed on
production units.

Thermal Cycling involves subjecting an object to extreme changes in temperature within an
environmental chamber while ramping up and down in temperature.

Temperature Chambers simulate temperature and tests the effects on a product over a range of
temperature conditions. Temperature cycling may be performed while combining environments such as
humidity, altitude, and vibration.

Humidity Chambers simulate humidity and tests the effects on a product over range of humidity
conditions. Humidity tests may be performed with or without temperature.

Bench top test chambers are used when testing small items and take up minimal floor space.

Thermal Shock chambers thermally shock and stress a product as a result of rapid temperature changes
from extreme cold to hot environments.

Liquid-To-Liquid Thermal Shock chambers immerse a part/assembly in hot and cold fluids. Product is
transferred between hot and cold baths without contamination.

Air-To-Air Thermal Shock chambers typically involve transferring the product from a hot chamber to a
cold chamber. Configurations include two zone, three zone, and double duty.

AGREE Vibration Chambers can produce fast temperature changes. These chambers have removable
floors and integrate with a variety of electrodynamic shakers for vertical and/or horizontal vibration.
Temperature and/or humidity environments are also simulated in conjunction with vibration.

Altitude chambers simulate the effects of low pressure and are capable of altitudes of up to 200,000 feet
above sea level.

Environmental Stress Screening (ESS) chambers are designed to test products for highly accelerated
stress testing and fast ramp rates.

Walk-in chambers are environmentally conditioned rooms that may be configured to almost any size or
footprint. Types of walk-in chambers include modular and welded (unitized) construction. Welded types
are ideal for high temperature testing.

Drive-in chambers are similar to walk-in chambers and are designed for vehicle testing. Temperature,
humidity, vibration, and solar may be simulated.


5.2 TEST PARAMETERS
The parameters of performance testing for accurate environmental chambers are:
Temperature range
Accuracy of temperature control
Humidity span and its Control Accuracy
Vibrations
Capacity of the chamber.
Corrosion (Salt Fog/ Immersion)

5.3 TYPES OF CTC AND TEST PARAMETERS UNDER STUDY
The following types of Climatic Test Chambers have been studied:
Bench- Top Test Chamber
Walk- In Test Chamber

The following parameters for product testing have been observed:
Effect of Temperature
Effect of Humidity
Effect of Solar Radiations


CHAPTER-6
BENCH- TOP CLIMATIC TEST CHAMBER
6.1 INTRODUCTION
This type of CTC is a smaller version of the conventional CTCs, which is mainly used to test
products which are smaller in size, and within a specified limit of parameter changes.
Its operating parameters and operating range is limited to a few values.

6.2 CONSTRUCTIONAL DETAILS
A Bench- Top Climatic test Chamber has double wall construction of 6 thick fiber glass wool
between the inner and the outer walls.
Inner of the chamber is fabricated with mirror finished stainless steel and outer is CRCS with
Electrostatic powder coating. A double lined silicon gasket is provided one on the door and other on
the flange of the chamber. It has been provided with a glass window and a light for checking state of
experiment being performed inside the chamber.



The above figure shows the Bench- Top Climatic Test Chamber.
It consists of a main cabinet where the product to be tested is placed. On the right side, the control
panel of the chamber is located which is both manual and software controllable.
The left part of the chamber shows the cooling system, which consists of a fan having 1/5HP motor
installed in it.

6.3 MECHANICAL DIAGRAM


6.4 VARIOUS PARTS OF A BENCH- TOP CTC

1. Temperature Controlling
For gentle and uniform temperature in workspace, one 1/5 HP fan motor with a 94.5
width SS impeller is used.


2. Heaters
This chamber provided with wet and dry heaters to control humidity inside the chamber so
that the specimen could be tested in same environmental condition as that of field.

3. Solar Radiation Lamp
The Metal Halogen lamp is used having radiation intensity of 100W/m
2
with a range of 280 to
3000 mm from a distance of 60 cms to stimulate solar radiation. This lamps radiation is very
much figurative to suns radiation in field.

Fig.: A Solar Lamp


4. Refrigeration System
The refrigeration system is a single stage eco-friendly system with air cooled condensing unit.

5. Temperature Sensors
The temperature sensor used in this type of CTC is a class Pt-100 RTD (Resistance
Thermometer Detector).


6.5 TYPES OF AVAILABLE TEMPERATURE SENSORS

1. Thermistor
Thermistors are the Thermal Resistors and used fir precision temperature measurement,
control and compensation.
Their working principle is based on the change in the resistance of semiconductor materials
with change in temperature. A thermistor is made up of semiconductor material and has a
negative co-efficient of resistance, i.e., their resistance decreases with the increase in
temperature. This negative temperature co-efficient of the resistance can be as large as
several percent per degree Celsius, thus allowing the thermistor circuit to detect very small
changes in the temperature.


2. Thermocouple
A thermocouple is temperature transducer that s used for measurement of high temperatures.
It works on the principle of Thermo- Electric Effect, which says that when two dissimilar
metals are joined together so as to form a closed circuit, there will be two junctions where
they meet each other. If one of these junctions is heated and other one is kept at fixed lower
temperature, then a current flows in the circuit which can be detected by a galvanometer. The
amount of current produced depends on the difference in the temperature between the two
junctions and on the characteristics of the two metals.


3. Resistance Temperature Detector (RTD)
This type of temperature transducer is use for the measurement of small temperature
difference as well as for wide range of temperature.
It works on the principle of the utilization of the change in resistance property of certain
metals (conductors). With the increase of the temperature, the electrical resistance of the
certain metals increases in direct proportion to the rise of temperature.
Thus, if the resistance of a wire of known and calibrated material is measured, the
temperature of the wire can be determined.











6.6 LIST OF COMPONENTS USED IN THE CHAMBER

S.No. PART RATING/SPECIFICATION Number
1. Chamber Fan
Motor
1/5 HP, single phase 230V AC, 0.8
Amps

1 nos
2. Air Heater 0.5 KW Heater

4 nos
3. Controller Microprocessor based
Eurotherm, make 2604 Dual Loop
Programmable With iTools Software


1 nos
4. Blower 9 X 4.5 diameter SS Impeller

1 nos
5. Compressor

Model
SR No

Make


CR42
CBA13434
3-phase, 440V AC
Copeland



1 nos
6. Condenser Fan
Motor
Make
FHP, 1400 RPM 230 V
AC, 1 Phase,
EBM NARDI


1 nos
7. Evaporator 20 X 14 X 17rows

1 nos
8. Refrigerant Gas R-404a

5 gm
9. Solenoid Valves

Make
3/8 Flair
Flair
Danfoss

2 nos
1 nos
10. Auto Oil Return
Make
OUB-1
Danfoss

1 nos
11. Accumulator 2 ton

1 nos
12. Liquid Drier
Make
3/8 Flair
Danfoss

1 nos







6.7 OPERATION AND CONTROLLING

Entire chamber is controlled using a State Of Art Eurotherm controller. Indicator cum controller is a
programmable profile dual loop controller. This means that controller can be manually operated or
can be interfaced with a system. Its interfacing facilitates automatic temperature control as preset by
user and moreover readings can be automatically got stored; thus eliminating need of an attendant.

CHAPTER- 7
WALK- IN CLIMATIC TEST CHAMBER
7.1 INTRODUCTION
Walk-In Environmental Test Chambers are Capable of testing large components, assemblies, and finished
products. They simulate a wide range of temperature and humidity environments. These chambers can be used
for testing and controlled storage as well as a versatile laboratory environment for conducting test procedures
in the telecommunications, defence, aerospace, pharmaceutical, automotive, and electronics industries.
Walk-in chambers consist of a self-contained conditioning module and a room constructed from interlocking
panels or welded, insulated solid walls.








7.2 SPECIFICATIONS

S.No. PART RATING/SPECIFICATION
1. CHAMBER SIZE

8m x 5m x 5m (L x W x H)
2. MAX. TEST OBJECT SIZE 3m x 2.5m x 2.5m

3. TEMPERATURE RANGE

-10
o
C to +80
o
C

4. HUMIDITY RANGE

10% to 90% RH

5. SOLAR INTENSITY 300 to 1120 W/m
2

6. IRRADIATED AREA 3.2m x 2.4m

7. TEST PROFILES Desert Diurnal Cycle, Accelerated Cycle, and
Tailor Made Cycle


CHAPTER- 8
TESTING OF PRODUCT AND ANALYZING ITS PARAMETERS

CHAPTER- 9
OTHER TYPES OF CHAMBERS

CONCLUSION

BIBLIOGRAPHY

1. Internet Sources
a. http://en.wikipedia.org/Resistance_thermometer
b. http://en.wikipedia.org/Thermistor
c. http://en.wikipedia.org/Thermocouple
d. http://cmeipl.com/products.html

2. Reference Books
a. Power System Instrumentation- Ramnath (Genius Publications)
b. Electrical and Electronics Measurements and Instrumentations- A. K. Sawhney