Example Projects

Temperature Control Retrofit.

A revision to a standard test method meant that a client’s heated press needed better control of the temperature rate during the cooling process. CAMDAC added a new temperature controller and thermocouples to the existing equipment. The new controller was coordinated with the existing control system so that no extra effort was required of the operator but the temperature rate was kept within the tight-tolerance specification. The fast temperature rate over a broad range presented a real challenge for setting the PID tuning parameters of the controller, but the process is now running smoothly and meeting specifications.

Thermal Cycle Test Apparatus

Designed and constructed a PLC-controlled mechanism for moving pressurized tubing and fitting assemblies between high and low temperature water baths on a specified schedule per ASTM F877. The mechanism incorporated pneumatic cylinders, linear slides, and photoelectric sensors. Upgraded an existing control panel and three heated water baths to add a separate, precise temperature controller for each bath, improved the level and fill controls and the temperature sensors.

Medical Device Durability

A test machine was designed and assembled to test 15 prototype devices simultaneously. Each device was mechanically cycled to simulate thousands of normal uses by medical personnel. The cycle required rotational movement, application of a simulated resistance load, and activation of three different buttons in the correct sequence.

Temperature and Humidity Data Logger

A standard test laboratory atmosphere has tight tolerances for temperature and humidity. In addition, there are different conditioning durations for different types of samples. While there are off-the-shelf data logging applications available, none were found that provided all the desired real-time notifications and sample-specific records. LabVIEW software was used to develop a custom solution that was simple for technicians to use and recorded all the required data for the quality assurance department and accreditation auditors.

Compression Spring Fatigue Tester

An automotive component company needed to evaluate compression springs for resistance to fatigue failures. A variable speed motor with an elliptical cam was used to repeatedly compress each spring a precise distance. The machine could test 12 springs simultaneously at a rate of about 1000 cycles per minute and detect a failure in any one spring.

Automated Flexural Strength Test Span Fixture

For standard flexural strength tests (such as ASTM D790), technicians were manually resetting and measuring the span length of the support fixture for each new sample. An automated span fixture was created that set the span to the correct distance with an accuracy of a couple thousandths of an inch. The old manual procedure required a few minutes, but the automated fixture could perform the process in a few seconds and with better precision. The fixture utilized a linear slide, a dual-direction lead screw, and a stepper motor. Control was provided by a custom executable application that was developed with LabVIEW and installed on the test machine’s computer.

Temperature Mapping

Several laboratory freezers, refrigerators, stability chambers and rooms were mapped to demonstrate temperature uniformity over both time and space. The effects of disruptions such as door opening and power outage were also studied. The project included technical writing of test protocols and reports of results and recommendations, all within pharmaceutical GMP (Good Manufacturing Practices) quality requirements.