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Colorado Op Manual (Orig)

1. Safety Practices 2 1 Review Operation Procedure Read Safety Placards Locate Emergency Stop Buttons Use Eye Protection Stay Clear of System When Running Clean Work Area Know Effects of all Adjustments Ensure Interlocks Work Avoid Moving Cables and Hoses 2 2 Safety Practices Before operating the system for the first time make a trial run through all operating procedures to locate and become familiar with all of the appropriate controls If any operating adjustment seems unclear review the operation and adjustment procedures listed in the associated product manual If you need additional information you can contact MTS for technical assistance Special points to consider when reading the manuals include e Locate all caution and warning notices for the known hazard characteristics of your system These notices are located in the standard hardware product manuals provided in the system Reference Manual e Refer to the Operation Manual for step by step system operating procedures If the operating procedures for your system change due to component modifications or other reasons mark the changes in this manual to reflect the proper procedure Locate read and follow all instructions on equipment safety placards Locate all system Emergency Stop or E STOP buttons on the system so you can quickly stop system operation in an emergency situation Use adequate eye protection when working with system fluids o
2. Check actuator and attachment hardware Check the actuator and attachment hardware for any sign of damage Correct any problem that exists Clean exposed areas Clean all exposed areas of the test sysstem including transducers and servovalves Check E Stop safety devices It is important to check the E Stops to ensure operator safety The E Stops should be tested for proper operation Run a dummy test hit the E Stop and ensure that the system operation stops Inspect all bolts Inspect bolts for obvious signs of looseness or structural failure Correct any problem that exists Check hoses Check hoses for wear or damage Every 3 Months Every 6 Months Check accumulator precharge levels Check precharge of all accumulators If the accumulator pressures are outside of the accepted levels charge or discharge the accumulators Reference Manual Accumulator 111 Product Manual Run the system Start the system and allow it to reach operating temperature on a monthly basis This action drives moisture out of the system and lubricates components that may have drained while inactive Check calibration Check calibration of the feedback devices re tune if necessary Operation Manual Calibration Check accessible cap screws Check the torque of all accessible cap screws of size M16 or larger Tighten if necessary Reference torque tables or appropriate drawings Reference Manual Actuator Assemblies for the 244 xxx
3. When checked the software will differentiate the output signal to remove any integrator between the input and output Use to select the desired sample rate of the spectrum analyzer Use to select the FFT size The FFT size determines the frequency resolution of the analyzer Resolution 1K Hz FFT size Use to adjust the decay time constant which determines how long the analyzer keeps data before discounting it A lower average will allow the analyzer to track better but the signals will be noisier Displays how many averages have been taken by the analyzer Can be reset to zero using the Reset button Resets the Averages taken to zero Control Panel Reference 5 57 Testpoint Units 3 Testpoint Units lol x Act 1 DP Force fbk Select Next Previous Maximum 220 0 kip 220 0 kip Panel Description Access When to Use the Panel Control Descriptions Control Allows you to set engineering units for testpoints in the software NOTE If the testpoint is a feedback signal the units of the associated converter will not change Open the Testpoint Units panel by selecting the Testpoint Units option from the Configuration menu on the main panel Use this panel when viewing signals in analog form allowing the conversion to digital units Maximum value corresponds to 10 Volts and Minimum value corresponds to 10 Volts E O Deon Channel text box Select button Next button Previous
4. NOTE not available in RMS mean capture mode Sensitivity slide bar and For peak valley detection sets the sensitivity of detection to a text box percentage of full scale band You can use the slide bar to set a value or you can enter it in the text box Averaging interval slide For RMS Mean capture mode sets the averaging interval You can bar and text box use the slide bar to set a value or you can enter it in the text box 5 18 Control Panel Reference Digital Readouts Digital Readouts Of xj Panel Description The Digital Readouts panel allows you to select multiple signals to view their values Access Open the Digital Readouts panel by selecting the Digital Readout from the View menu on the main panel When to Use the Panel Use this panel to simultaneously view the values of selected signals in engineering units Refer to Appendix for a list of the available signals Control Descriptions E O Deon Numerical text box Click near any display box to open a pulldown channel selection box Select a channel The selected channel and its value in engineering units is displayed Control Panel Reference 5 19 Encoder Conditioners ixi 170771 User ENC 1 Select Next Previous Encoder type Temposonics Ill 25 bit Interlocks Baud rate 100 kHz Y Disabled Reset Sensitivity 838861 counts volt O Watchdog timer Excitation fail Zero 0 counts 9 Limit Glitch width 0 samples
5. The spool LVDT provides a signal that is proportional to the position of the spool and that is therefore approximately proportional to the output flow of the servovalve MTS Model 252 Servovalve Pilot Supply LVDT i Slave Stage Hydraulic Actuator Figure 3 2 Multi Stage Servovalve Understanding Control Principles 3 3 3 4 Figure 3 3 schematically illustrates the inner and outer closed loop control concept As shown the outer loop is similar to the basic closed loop control concept discussed in the previous subsection The de error generated in the outer loop is the same as the dc error signal of the basic closed loop illustrated in Figure 3 1 This dc error signal is then applied to the inner loop as a valve command signal Inner Loop Gain Gain Summing Junction Summ
6. Upper limit 10 0 Le ea Nel TA Lower limit 10 0 Clear count SC A C Engineering Units 10 volts 10 0 inches 10 volts 10 0 Raw output 0 counts Final output fo D Y 0 0 volts Panel Description The Encoder Conditioners panel allows you to perform the following tasks e Select a specific encoder conditioner e Calibrate the conditioner to its associated transducer e Select polarity of output e Select filtering option baud rate and sensitivity e Set hardware limits for the conditioner output feedback e Identify whether an interlock has occurred e Disable and or reset interlocks Access Open the Encoder Conditioners panel by selecting the Encoder Conditioners option from the Calibration menu on the main panel When to Use the Panel Use the Encoder Conditioners panel to calibrate a conditioner with its associated transducer and to identify and reset hardware interlocks Whenever a transducer is replaced or moved the associated conditioner should be calibrated Hardware limits should be checked and reset before starting a test In addition MTS recommends verifying calibration values periodically 5 20 Control Panel Reference Encoder Conditioners continued Control Descriptions Control E essipo Cond text box Select button Next button Previous button Encoder Type pop up Baud rate button Sensitivity text box Zero text box Glitch width text box Shows the name of the cur
7. and left center Click to save plotted values to a text file A dialog box will appear to ask for a file name Control Panel Reference 5 25 Function Generators Cyclic Source Phased Source CJ Function Generators i Of x C Function Generators O xj Act 1 Displ Act 1 Displ Select Next Previous Select Next Previous Program Phased Program Cyclic z Master Act 2 Shape Square Shape Square Triangle Triangle Sine Sine Peak amplitude 0 051429 in Peak amplitude 0 0 in Neill Nel e Frequency 5 0 Hz Phase 0 0 deg Neji _ p SKJ Z Random Source Scramnet CJ Function Generators Oj xj ct 1 Dispi PEE Select Next Previous act 1 Displ Select Next Previ m _Select Next Previous Shape Flat Program Scramnet RMS Amplitude 0 0 in sei e Minimum freq 0 0 Hz Ne Cd Maximum freq 40 0 Hz ha SKJ u 5 26 Control Panel Reference Function Generators continued Remote Application Data Player File Function Generators EE ici x Function Generators EE ici xi Act 1 Displ Act 1 Displ Pod Slaving Function Generators Function Generators Act 1 Displ Act 1 Displ Control Panel Reference 5 27 Function Generators continued Panel Description Access When to Use the Panel Important Information The Function Generators panel allows you to select the p
8. run Pause or Abort a test Refer to the Main Panel in Section 5 Control Panel Reference for more detailed information on how to use the main panel controls and indicators Introduction to Control Software 4 5 Main Panel Menus The following figures illustrate the pulldown menus and corresponding option panels and commands available from the main panel Option panels are used to set up a test Each option panel contains a panel label a close box and controls and displays specific to the option panel Each main panel menu and corresponding commands and control panels are defined below Refer to the following section Control Panel Reference for more detailed explanations on how to use each panel File Structural Test System Settings set 3 E ai Calibration Configuration Operation View Service About STS Change access gt Change password Translate gt Enabled Reset 0 Function Generator Restore settings Save settings Enable simulation Pod ready Scramnet OK Quit Master gain 100 Ne A E Desired span 100 0 Ne A E Current span 0 0 Stop Run Pause apor Use the commands on this menu to perform the following tasks tasks marked with an asterisk are available only to users with extended or service access privileges About STS displays current software version and copy rights e Change Access change access
9. 3 Stage Valve DIV di tl 5 61 Section 6 Operation Pre Test Adjustments tii dc eee 6 2 Hydraulic Turn On Procedure ies sirsiran E E E AE O eias 6 4 O RN 6 7 Test Ex cution Procedure necia eso E eiii 6 8 Remote Control Pod Operational 6 10 Using the Low Flow High Flow Shutoff System ssse ssssssessssessssesresresessiesesnenrentsnenrisnesnenrenenneeness 6 13 Hydraulic Shutdown Procedure issie ni eieiei nN iei ea E s S nennano 6 15 Emergency Shutdown Procedure ss iiviisscissccstesasisssvess caninas stds eves E ia EE EE EE erratas 6 16 Section 7 Maintenance General Inspect ons oirir ina aan aE EERE EN EEE E EE E TOE RE EOR ERER Rh 7 1 System Operating Inspections A ARNAR 7 2 System Maintenange LOD g mirerien eranen tl e ER ARRERA 7 7 ii Table of Contents Section 8 Calibration and Tuning A D Converters Calibrations ccs os iececasies a coke ices thedhes Pia dash ova Adak snetesh vais a EOE AE antes 8 1 D A Converters Calibrations s senn ree E Aula EEE Caretta bv ates eee 8 2 AC Conditioner Calibrators cisecsez cosdcsaccescessecendesccoszessctscesebivanlessssonceekgeuseess basvtesgete vecssteceteastuesesatteeeieds 8 3 DE Conditioner Calibratie eeii a e diese a teste din 8 6 Linear Encoder Calibration ccccccccccesccesccssecssecssecssecssesssesscesscesscesscssecssecssecssecsseeseeestecesessessescenscnase 8 11 256 Inner Loop Valve Tuning siscsscscicssscccssussessstessecsevcsssessseiessssvsdie ntvcosssvaenessssiesesesboseschasobce
10. Check HSM pilot operated pressure reducing valves Check the setting of the pressure reducing valves and adjust if necessary Adjust as follows e Reduce pressure on both valves by loosening lock nut and turning counter clockwise e Turn one valve clockwise to raise pressure to desired output Then adjust second valve with clockwise motion to a pressure greater than the desired output e Reduce pressure of second valve until setting of each valve is equal e Lock valves in place with lock nuts Analyze hydraulic fluid sample Take a sample of the hydraulic fluid and have it analyzed Replace the fluid if necessary Oil condition is critical for servovalve and internal cylinder component life Reference Manual Hydraulic Fluid Care Guide Maintenance 7 5 Yearly Every 5 Years 7 6 Maintenance Replace actuator seals low pressure Replace the low pressure actuator seals whenever leakage occurs or whenever the actuator has been disassembled A decrease in system performance can also be an indication of seal wear Reference Manual Actuator Product Manual Replace hoses Replace any hoses that show signs of wear or damage immediately Even with no apparent flaws the hoses should be replaced every 5 years due to natural aging of the hose material System Maintenance Log The system maintenance log is a tool to use for recording and tracking maintenance The maintenance interval date of maintenance entries should be made
11. Hydraulic Turn On Procedure Complete the following adjustments to ensure a safe start up of the test system Final Safety Checks e Read the operating safety practices detailed in Section 2 of this manual e Verify the Pre test adjustments made in the preceding subsection Adjustments e Reset any interlocks generated during test setup procedures Click on the Interlocks Reset button on the Main Panel to clear interlock and limit detection indicators If the Interlock indicator does not clear a hardware interlock or a software limit remains uncleared in the system There are two ways to approach the disabling of Interlocks 1 Disable interlocks on the main panel This disables all interlocks It is used only to move the system out of a limit state under hydraulic power This method creates a global change 2 Disable the offending limit detector either by expanding its limit thresholds or by changing its limit action This method creates an individual change If you disable limits you must re enable the interlock on the main panel once the system has been moved to a non limit condition If you suspect a hardware interlock A Check the Conditioners panel to see if a red fault indicator has been set If a conditioner channel is interlocked move the limits outside of the current signal value press the Conditioners Reset button and then return the limit setting to its original value B Click on main panel Interlo
12. Next Previous Offset 0 0 Volts Nel f Gain f1 o YW Ne tC l i B Engineering Units 10 volts 10 0 volts 10 volts 10 0 Current value 0 0 Volts Panel Description The Analog Inputs panel allows you to perform the following tasks e Select a specific analog to digital A D converter e Adjust the offset and gain for the selected converter e Define engineering units for the selected converter e View the current voltage output value at the selected converter Access Open the Analog Inputs panel by selecting the Analog Inputs option from the Calibration menu on the main panel When to Use the Panel Use the Analog Inputs panel to periodically calibrate the A D converters or ADCs in the system to ensure that the input and output voltages are balanced NOTE Both offset and gain are saved in the Settings set file 5 6 Control Panel Reference Analog Inputs continued Control Descriptions E O Dopin O Conv text box Shows the name of the currently selected channel The adjacent channel ID box shows the number of the selected channel Select a channel using the Select Next or Previous buttons Select button Opens the converter selection panel from which you can select a converter Next button Selects the next converter in the selection panel list Previous button Selects the preceding converter in the selection panel list Offset slide bar and text Adjusts the offset of the sign
13. Post gain amplifier out 5 Volt reference Spool zero output Spool position Demodulator filter input When checked disables hardware interlocks for the selected channel When pressed resets the hardware interlocks for the selected channel Indicates the status of the watchdog timer Shows whether excitation has failed This detector is always enabled both in hardware and software Excitation failure causes a system interlock because it may indicate a broken defective or missing conditioner cable Control Panel Reference 3 Stage Valve Drivers continued Control Descriptions continued Control Inner Loop Tuning Proportional gain slide bar and text box Rate gain slide bar and text box Rate input radio buttons Spool Conditioner Calibration Excitation amplitude slide bar and text box Demode phase slide bar and text box Spool zero slide bar and text box Conditioner gain slide bar and text box Invert polarity check box Valve driver input display box Spool position display box These adjustments are for three stage valves only Adjusts the proportional gain for the selected valve driver You can use the slide bar to set a value or enter it in the text box Adjusts the derivative rate gain for the selected valve driver You can use the slide bar to set a value or enter it in the text box Sets the signal source for rate input as spool position or spool error Sets the level of the excitati
14. and Sets the time in seconds that an upper or lower out of limit text box condition can persist without causing an interlock Control Panel Reference 5 35 Main Panel Structural Test System Settings set File Calibration Configuration Operation Yiew Service HPSOn Y HSM A HSM Lo O HSM Hi Interlocks Program Source Enable simulation 2 Pod ready Scramnet OK Stop Run Pause Aor Enabled Reset Master gain 100 Nel Jl Function Generator Desired span 100 0 Nel Jl Current span 0 0 Panel Description The main panel allows access to all other parts of the Structural Test System application It includes both menus and system controls The following menus are provided File allows you to add comments to the message log change passwords for access privileges close windows restore or save settings convert files from binary to text format or visa versa and quit the application Calibration allows you to calibrate A D and D A converters AC and DC conditioners and valve drivers Configuration allows you to configure testpoint units slaving matrix and ramp rates Operation allows you to setup PID controllers function generators data players data recorders limit detectors setpoints and spectrum analyzers Display allows you to use analog and digital readouts digital meters FRF plotters the digital oscilloscope and read the message
15. checked disables hardware interlocks for this channel Reset button When pressed resets the hardware interlocks for this channel Watchdog timer Indicates the state of the watchdog timer indicator Excitation fail indicator Shows whether excitation has failed This detector is always enabled both in hardware and software Excitation failure causes a system interlock because it may indicate a broken defective or missing conditioner cable Limit indicator Indicates whether the conditioner output has gone outside of the limits set using the Upper and Lower Limits slide bars Upper Limit slide bar and Sets the upper limit of the conditioner output You can use the slide text box bar to set a value or you can enter it in the text box If the conditioner output feedback has exceeded this limit the Limit indicator is lit Lower Limit slide bar and Sets the lower limit of the conditioner output You can use the slide bar text box to set a value or you can enter it in the text box If the conditioner output feedback has exceeded this limit the Limit indicator is lit Engineering Units display Sets the engineering value that equates to 10 volts box Conditioner output text Shows the value of the signal output by the selected conditioner The box upper box gives the voltage the lower value is in engineering units Not editable Control Panel Reference 5 5 Analog Inputs analog inputs TST 017 User A D 1 Select
16. clicking once on the mouse button Then click on the appropriate arrow to move the channel to the other box Press the Reset button to clear the Selected box of all channels Make sure the number of channels selected and the order of these selected channels matches the number and order in the selected playout file Control Panel Reference Data Recorder Hax Sample rate 64 0 Hz Available Starting delay 0 0 sec Displ Recording period 30 0 sec ae I Enable AA filters eee adds delay of fo 321777 sec Y Synchronize with Run I Loop forever Slave Valve Valve File SuperSin dll Displ Displ Comment Disp Selected cmd fbk err cad gt gt gt fbk err Extern cmd lt lt lt cnd DF Force fbk cnd spool pos cnd fbk err Reset E ua Panel Description Access When to Use the Panel The Data Recorder panel allows you to e Record data from selected channels and store in a user selected file e Set the sample rate starting delay and recording period e Choose whether to start recording data when the START button is pushed or to synchronize the data recording with the RUN button on the main panel Open the Data Recorder panel by selecting the Data Recorder option from the Operation menu on the main panel Use the Data Recorder panel to record data from selected channels and store the data ina file The data in the file will be in MTS binary format This da
17. data channels and choose a file to be played out as the program source when the Data Player selection is enabled for the program source on the Main panel First choose the desired channels and then select the file Itis very important that the number of channels and order of channels selected match the number and order in the selected file Tip Always keep the natural order of channels as they are listed by the software in the Available list When using a file for the playout source the file must be in MTS binary format The Translate text to binary option under the File menu on the Main panel will translate an ASCII text file to MTS binary format The text file to be translated must be in the following format The first value in the text file must be the time period between samples followed by the data in engineering units arranged in a single column The translator will prompt you for the ASCII text file The converted file will be given the same name as the text filename but will have a bin extension Control Panel Reference 5 11 Data Player continued Playout File Information con t Control Descriptions Control File button and text box File Sample Period text window Play Sample Period text box File Length text window Elapsed Time text window Pass _ of _ text boxes Reset button Channel Selection text boxes 5 12 Note that when a file is played out the system does not automatically ram
18. level Basic Extended or Service e Change Password create or change the password for access privileges Translate text to binary translates data files from text to MTS binary format This can be used to translate a playout file Refer to the Function Generator panel in Section 5 of this manual e Translate binary to text translates data files from MTS binary to text format This can be used to translate data acquisition files Refer to the Data Recorder panel in Section 5 of this manual Restore settings restore Structural settings from an existing disk file Save settings save Structural Controller settings to a disk file e Quit quit from Structural Controller application 4 6 Introduction to Control Software Calibration Structural Test System Settings set File My Configuration Operation View Service Analog Inputs neS Analog Outputs Enabled Reset ie Function Generator HSM AC DC Conditioners Encoder Conditioners 2 Stg Valve Drivers Hs 3 Stg Valve Drivers HSM e simulation Y Pod ready Scramnet OK Master gain 100 Nel hR Desired span 100 0 K CL foo Stop Run Pause Avot Current span Use the commands on this menu to calibrate the following devices e Analog Inputs e Analog Outputs AC DC Conditioners Encoder Conditioners e 2 Stage Valve Drivers e 3 Stage Valve Drivers Configuration Structural Test System
19. limit the Pause button can be used to resume the signal from where it left off the indicator remains lit until the Reset button is used The out of limit condition will be recorded in the message log Program abort This selection causes the system to trigger an abort if the signal goes outside the limit The Reset button is required to reset the system The out of limit condition will be recorded in the message log e Abort amp switch to displ This selection causes the system to trigger an Abort if the signal goes outside the limit If the system is in force control it will switch to displacement control The Reset button is required to reset the system The out of limit condition will be recorded in the message log Interlock This selection causes the system to trigger an Emergency Stop if the signal goes outside the limit The Reset button is required to reset the system The out of limit condition will be recorded in the message log Refer to Section 5 Control Panel Reference and Section 6 Operation for additional information about setting the limit detectors After setting limit parameters you enable the limit detectors and choose an action before running a test Understanding Control Principles 3 9 Error Detector Setting Error Detectors Error detectors are limit detectors that monitor the error signal that is the difference between the command and feedback as shown in the following figure An error detector c
20. log Note that you can click on an underlined icon on the main panel to open the associated panel for that item 5 36 Control Panel Reference Main Panel continued System controls on the main panel allow you to perform the following tasks e Monitor the current settings file Monitor hydraulics Enable or disable limits e Reset limit interlock conditions e Select the program source Set the master gain e Setthe desired span and monitor current span e Stop run pause or abort a program Indicate if the pod is ready e Indicate if scramnet is OK Access The main panel opens when you start the application It cannot be closed except by quitting the application When to Use the Panel Use this panel to set system controls and to access all other panels Control Descriptions O O Dopa O Hydraulics HPS On status The status indicator will turn green when the pumps reach the system indicator operating pressure HSM 1 2 3 buttons Selects the hydraulic service manifolds that will turn on when the HSM Lo button is enabled HSM Lo button and Puts the HSM into low pressure mode The status indicator will turn status indicator yellow when low pressure is achieved HSM Hi button and Puts the HSM into high pressure mode The status indicator will turn status indicator green when the system is in high pressure mode Control Panel Reference 5 37 Main Panel continued Control Descriptions continued Interlo
21. reduces the error between command and feedback by integrating out offsets in the dc portion of the Integral feedback ee de Offset _ Limited _ Increased Overshoot Overshoot Reduced Offset No Offset Increasing Integral Gain _ gt Because the integrator can integrate to large or even infinite values a limit is placed on how much correction the integrator can apply This limit is called Integrator Authority 5 46 Control Panel Reference PID Controllers continued Feedforward Derivative Bandwidth Delta P Feedforward effectively alters loop response by introducing a derivative of the command signal The feedforward component is used to minimize following errors or phase lag It is especially useful because it does not affect the control loop stability As illustrated higher settings reduce following error during a ramp command ultimately producing a leading error Reduced Leading Following Error Error Following Error Increasing Feedforward _2 Derivative adjustments affect the servo control loop dynamic stability You can use derivative to reduce overshoot at higher proportional gain settings In addition it can reduce the system bandwidth closing the servovalve in anticipation of achieving the commanded position through the rate of change in feedback The following figure shows the effect of adding deriv
22. selected channel When pressed resets the hardware interlocks for the selected channel Indicates the status of the watchdog timer Shows current value input to the valve driver by the servocontroller Not editable Control Panel Reference 3 Stage Valve Drivers Prete 170572 fact 1 Inner Loop Tuning Select Next Previous Proportional gain 1 0 YN Nell e Y Enabled Rate gain 1 0 msec Balance fo o V Nelli e Nel TCs Rate input Spool position Dither amplitude 0 0 Y Nel II TB Spool Conditioner Calibration Mi Excitation ampl 0 0 Vpp Ne sd Readout Demod phase 0 0 deg Spool position Nel dS Interlocks Spool zero 0 0 Y Y Disabled Reset Nel E PA Watchdog timer Conditioner gain 1 0 YN Nell e f H O Excitation fail Invert polarity Valve driver input 0 0 Spool position 0 0 Y Panel Description For three stage valves the Valve Drivers panel allows you to perform the following tasks e Select a specific valve driver channels e Adjust the dither amplitude and balance for the selected valve driver channel e View the value input to the valve driver by the servocontroller e Insert the valve phase e Disable and or reset interlocks e Monitor interlocks e Tune the inner loop e Make spool conditioner adjustments Access Open the Valve Drivers panel by selecting the 3 Stg Valve Drivers option from the Calibration menu on the main panel When to Use the Panel U
23. the method of adjustment The operating procedures detailed here are e Pre Test Adjustments e Hydraulic Turn On e Warm Up e Test Execution e Remote Control Pod Operation e Using the Low Flow High Flow Shutoff System e Hydraulic Shutdown e Emergency Shutdown As familiarity with the system is gained these procedures can be altered to suit specific test requirements The test system is capable of causing personal injury and damage to the test specimen and or test facility Injury or damage can result from attempting to operate the system and disregarding system safety precautions warnings and cautions Operation 6 1 Pre Test Adjustments Before applying hydraulic pressure complete the following adjustments Specimen Preparation e Ensure that the actuators are securely mounted or positioned e Securely mount the test specimen e Attach the specimen transducers and cables if applicable e Calibrate the specimen transducers if required Activate the Control System Turn on electrical power to the PC computer After the PC has completed booting turn on the controller and then wait one minute before double clicking on the sts exe icon located on your PC desktop The Calibration parameters and default Settings file Settings set will be loaded and the main panel will appear If Settings set does not exist you will be prompted for a settings file Note When quitting the application you must wait one minute before
24. the span controls during test setup to scale the command signal You can also make minor adjustments to the span control during the test Understanding Control Principles 3 7 Setpoint Adjustment Determining Setpoint Position Setting the Setpoint Controls Application for Structural Testing The maximum and minimum amplitudes of a waveform output by a programmer are 10 volts which represent 100 of the peak amplitude operating range The local setpoint control changes the mean level offset of that program 100 Setpoint Affects Program Mean Level y Mean Level Offset Amplitude 100 The setpoint position is the position about which the actuators will move during testing For seismic testing setpoint is typically the actuator midstroke position If a different position is desired you must ensure that the position does not limit the program capability For example if you adjust a channel setpoint to 75 of the full scale operating range then any command that exceeds 25 of the full scale range will shut down the test system when a full scale system limit is encountered You set Setpoint control during test setup Refer to Section 6 Operation for procedures used to adjust the setpoint controls In this structural system setpoints can be used to load the structure being tested In these cases the setpoint adjustment attemps to change the actuator position although if there is insufficient available
25. to the slot that the DC conditioner daughter card is plugged into and connect that BNC cable into channel 2 of the oscilloscope Adjust the zero value on the DC Conditioner panel until the conditioner output equals OV Adjust the exciter so that a known amount of acceleration is being delivered to the accelerometers Verify this by viewing the peak to peak voltage on channel 1 of the oscilloscope Adjust the gain level on the DC Conditioner board until the peak to peak output voltage of the DC Conditioner channel 2 corresponds to the acceleration shown on channel 1 Since the output voltage scaling of the reference accelerometer and the system accelerometer may be different you have to calculate the actual p p voltage that will be output by the DC Conditioner When the DC Conditioner calibration procedure is complete select Save settings from the File menu on the main panel to save the new calibration settings Remove the calibration equipment and restore system to its normal configuration Linear Encoder Calibration Encoder Conditioners 1 07 1 User ENC 1 838861 oo Qo Calibration of the Linear Encoder means adjusting the sensitivity in counts per volt to correspond to a known displacement The Encoder Conditioner uses a count volts to measure bidirectional displacement from a zero reference position To calibrate an Encoder Conditioner stroke channel complete the following steps Cal
26. when the maintenance is actually performed An example maintenance log is illustrated in the Figure below MAINTENANCE INTERVAL DATE OF MAINTENANCE ANA precharg arge pi Pom A Cuan actuator rods As reg NNN LA FM029 Example System Maintenance Log It may be helpful to maintain separate logs for maintenance procedures that are required weekly monthly yearly etc Maintenance 7 7 7 8 Maintenance Section 8 Calibration and Tuning Overview The Calibration section explains how to calibrate devices using the following panels e Analog Inputs e AC DC Conditioners e Encoder Conditioners The Tuning section explains how to tune the 256 Valve Inner Loop A D Converter Calibration lx 017 User A D 1 Select Next Previous Offset 0 0 Volts VTi TA Gain 1 0 YN Ne A E Engineering Units 10 volts 10 0 volts 10 volts 10 0 Current value 0 0 Volts A D Converter Calibration Procedure To calibrate an A D converter take the following steps 1 Select the desired A D channel 2 Ground the input signal 3 Adjust the Gain control to 1 00 Calibration and Tuning 8 1 D A Converter Procedure 8 2 Adjust the Offset control until the current value reads 0 00V Input a DC signal between OV and 10V from a calibrated voltage source such as a D A or a power supply Adjust the Gain control until the current value displayed matches the value of the signal input fr
27. ID box shows the number of the selected channel Select a channel using the Select Next or Previous buttons Select button Opens the channel selection panel from which you can select a channel Next button Selects the next channel in the selection panel list Previous button Selects the preceding channel in the selection panel list Program pop up menu Selects the programming source for the channel The choices are Cyclic Slaving Phased Scramnet Random Remote Application Pod Data Player File These options are available only to users with extended access NOTE If the main panel buttons for Remote Application Data Player Scramnet or Pod are selected all function generators are set to that same source This menu is then grayed out and cannot be changed Control Panel Reference 5 29 Function Generators continued Control Descriptions for Cyclic Program Controls for Cyclic source Shape radio buttons Square Triangle Sine Peak amplitude slide bar and text box Frequency slide bar and text box Control Descriptions for Random Program Control Controls for Random source Shape pop up menu RMS Amplitude slide bar and text box Minimum freq slide bar and text box Maximum freq slide bar and text box 5 30 Selects the shape of the function to be generated for the selected channel by the cyclic function generator Sets the peak amplitude of the function to be generated for
28. MTS p Operation Manual Fast Hybrid Test System for University of Colorado MTS Job No US1 20454 CUS Feb 2003 Rev A 2003 by MTS Systems Corporation All rights reserved Table of Contents Section 1 System Overview FAY drauilie System aesa e a a editadas 1 1 Hydraul A Ctu ators netrn osni a ar NEEE EEES I ANE EEES e ETETE 1 2 DELVOVAIVES tarot ae E a E E E E A E E 1 3 C ntrol Systeri NN 1 3 Section 2 Operator s Safety Practices Geheral G idelihi Svn iiair ien raa e NEE TEETAN RARE EN EEOAE 2 1 Hazards Related to Unexpected Actuator Reactions e sessesessessersrsesesteserreresrsstsrerrerserersesrestet 2 5 Section 3 Understanding Control Principles Actuator Control Concepts ssn n R E A E A N aa 3 2 Basie Closed Loop Contro lisses ieiet pili ahii neate aa hree siS 3 2 Inner and Outer Closed Loop Control sessesseseeseeesseesrsrssserrrisesrsrrsrereetsesrsntsrererrsesrenterereee 3 3 Differential Pressure Stabilization misstir ia cada 3 5 Test Adjustments tddi is 3 6 Master Gainers a E EE EE S E RAE E EEE 3 6 SPA p jew eal aida daha EEA RR ETEA EE AR 3 7 SEPO rai ea e A A EPES N EAERI EON RESA ONES E 3 8 Limit Detecci n E AEEA A E ia s 3 9 Section 4 Introduction to Control Software Setting Up Your Hard Disk vicsic scesccscocusies cotendtesosovenssesoncvednebaiacchsnasescesutuaace cutsnososbasesdbsonsussastuveccnsnacods 4 1 Using the Structural Test System Software oo cece ccs cecsescscscseseseseseee
29. Settings set File Calibration QAAN Operation View Service Ramp Rates HPSOn 9 Slaving Matrix pbled Reset 0 HSM I Testpoint Units ction Generator Source maa Y Enable simulation HSM Lo 9 HSM Hil Pod ready Scramnet OK Master gain 100 Sel A E77 Desired span 100 0 Sel E foo Stop Run Pause apor Current span Use the commands on this menu to configure the following Ramp Rates e Slaving Matirx e Testpoint Units Introduction to Control Software 4 7 Operation CU Boulder Structures Lab Settings set 3 4 8 File Calibration Configuration Operation view Service HPSOn Y HSM BIE HSM Lo O HSM O Controllers Interlocks E Data Player Data Recorder Prog ae F Function Generators Limit Detectors IV Enable simu Setpoints Bypass cont Spectrum Analyzer Y Pod ready Scramnet OK Master gain 100 S A E77 100 0 Desired span Current span 0 0 Stop Run Pause Abort Use the commands on this menu to perform the following tasks e Controllers set parameters for PID Controllers e Data Player select a time history file as the program source Data Recorder set up data acquisition to a file e Function Generators set parameters for function generators Limit Detectors setup limit detectors e Setpoints setup setpoints e Spectrum Analyzer set parameters for spectrum analyzer Introdu
30. actions automatically Open the Message Log panel by selecting the Message Log option from the View menu on the main panel In this view the message log can be read but not changed To add data to the message log use the Add comment option on the File menu Use this panel to read the message log Only messages from the current session are displayed The file message txt however keeps a running list of all messages from all sessions The file message txt continues to grow recording events from session to session It may grow too large and unwieldy You can quit the application and rename it The application will then create a new message txt file next time you start up NOTE This file must periodically be cleaned up to prevent it from growing large and affecting performance Use the scroll bar to scroll through messages in the message log 5 40 Control Panel Reference Oscilloscope EJ Digital Oscilloscope Cha act 1 Force cmd Select Next Previous Ch B act 1 Force fbk Select Next Previous Sweep Period 0 999023 sec Nel Tf l B kip 0 0 Time Autoscale Display mode Same scale Y 8 Time Freq XY Sweep Single Auto Panel Description Access The Oscilloscope panel shows oscilloscope traces for one or two signals This panel allows you to perform the following tasks Select one or two signals to be monitored Set the sweep period and delay for th
31. ain 10 0 V V Conditioner Polarity Inverted f Select Spool Position in the Rate input readout pop up menu Monitor this signal using the User A D input selected earlier g Set the Inner Loop Tuning Proportional gain to zero This will allow the third stage pilot spool to float into one of the end caps h Adjust the Demodulator phase to maximize the Spool Position feedback value i Adjust the Conditioner gain so that the amplitude of the spool position feedback is 10 volts The spool position feedback may be 10 volts depending on the mechanical bias of the servo valve 8 14 Calibration and Tuning j Use the valve Balance to drive the servo valve into the other end cap change the sign of the spool position feedback If the amplitude of the spool position feedback exceeds 10 volts lower the conditioner gain setting until spool position feedback reads 10 volts Servo Gain Tuning The digital controller has programmable proportional and derivative gain terms that are set using the valve driver panel a Open the 3 Stage Valve Drivers panel b Attach the service cable to the I O Carrier card housing the 493 15 valve driver card The position of the valve driver card in the carrier card determines which channel to use on the service cable see the Valve Drivers Panel to determine the chassis and slot number of the 493 15 c Attach the appropriate service cable channel output to an unused User A D input on the con
32. al controller that provides PID closed loop control with a delta p feedback signal It also provides an operator interface to the real time hardware from a PC over an Ethernet link The control hardware architecture is based on Digital Signal Processing technology which optimizes the performance of the embedded control system and allows for the implementation of advanced control and data filtering operations The controller consists of a MTS console assembly associated cabling and control software The MTS console assembly has an imbedded processor real time hardware The control software consists of the real time control software and the control panel software The real time control software drives the processors to generate command and error signals The control panel software runs on a PC and has a graphical user interface consisting of interactive modeless dialogs that are used to enter system parameters and execute a test System Overview 1 3 1 2 System Overview Overview Section 2 Operator s Safety Practices This section contains general operating safety techniques and precautions for operators of MTS testing systems Your testing system operates within a unique environment that includes e Facility utilities including mechanical and electrical equipment and atmosphere e Test specimens e Operator experience and specializations Equipment modifications you make to perform specific tasks Because of these variables t
33. al output by the converter Use the box Offset slide bar to set the A D Converter for a current value of 0 00V You can use the slide bar to set a value or you can enter it in the text box Gain slide bar and text Adjusts the gain of the signal output by the converter Use the Gain box adjustment to set the full scale range of the A D Converter You can use the slide bar to set a value or you can enter it in the text box Engineering Units text Shows the 10 voltage values that equate to the inputted engineering boxes value Current value text boxes Shows the current value output by the selected converter Not editable Control Panel Reference 5 7 Analog Output Scaling la Analog Readout 2 Select Next Previous Offset 0 0 Volts Nel CT TY Gain 1 0 YN Panel Description The Analog Output Scaling panel allows you to perform the following tasks e Select a specific digital to analog D A converter e Adjust the offset and gain for the selected converter e View the current voltage output value at the selected converter Access Open the Analog Output Scaling panel by selecting the Analog Outputs option from the Calibration menu on the main panel When to Use the Panel Use the Analog Output Scaling panel to ensure that the input and output voltages are balanced Normally you do not need to calibrate D A converters or DACs Any D A converter calibration should be completed only by experienced MTS ser
34. als Replace accumulator seals whenever leakage occurs Reference Manual Accumulator Product Manual Check Servovalves The servovalves should have a periodic checkup and possible reconditioning MTS has a valve exchange program to facilitate this The actual running time of the system will determine the replacement interval for the servovalves Reference Manual Servovalves 252 amp 256 Series Product Manual Maintenance 7 3 Each Shift Weekly Monthly 7 4 Maintenance Check hydraulic fluid level color and odor Check the fluid level to ensure that it is within the correct operating range A below normal level would indicate a loss of hydraulic fluid If below normal inspect the system for leakage correct the problem and refill it to the proper level Check the fluid color and compare it to the first test sample taken after initial system installation Check the smell of the hydraulic fluid If necessary replace the hydraulic fluid Inspect all safety devices It is important to inspect all safety devices to ensure operator safety e Refer to Product Manuals for specific safety precautions and features Inspect hydraulic components Inspect the hoses hard line pressure sensors gages and hose connections for signs of damage wear or leakage Correct any problem that exists Clean actuator piston rod Clean the exposed area of the hydraulic actuator piston rods Reference Manual Actuator Product Manual
35. alues display box to open a signal selection box Select a signal Displays the selected signal value Input value to be subtracted from the Values textbox This result for a given feedback signal will be multiplied by the value in the corresponding Coefficient textboxes If you click on the gt button the tare offsets value will set to the current feedback value This allows a given feedback signal to have no effect on the outputs You can edit the Tare Offset values by manual text entry Inputs coefficients for the slaving matrix The slaving matrix multiplies a vector the difference between feedback values and tare offsets The result of this product becomes the actuator commands The ij element multiplies the itt feedback signal to sum towards the jt actuators command as shown in the formula below Slave Command gt Coefficient jX Input Tare Offset i l Displays the command signal for the appropriate actuator Control Panel Reference 5 55 Spectrum Analyzer ox Input Act 1 Displ cmd Select Next Previous Output Act 1 Displ cmd Select Next Previous Sample rate Y Remove mean Difference output i021 Hz FFT size 1024 Decay time const 100 avgs Nel f B Averages taken 0 avgs Reset Panel Description Access When to Use the Panel The Spectrum Analyzer panel allows you to set up the spectrum analyzer to measure the
36. an stop the test if an error in excess of the preset level is detected Program Command eee The level of acceptable error depends directly on the accuracy requirements of each testing situation You set the operating band and persistence for the error limit detector For static and low frequency testing the initial error detector levels can be determined before beginning test setup The level selected should reflect the response requirements of the specific test For example if the test can tolerate up to 25 deviation from the program signal the error detector level can be set to 25 The error detector level can also be adjusted during testing if desired Operator experience is the best guide for adjusting the error detectors for high frequency testing 3 10 Understanding Control Principles Feedback Limit Detectors Feedback limit detectors monitor the feedback signals As shown in the following figure when a feedback signal exceeds its preset upper limit or falls below its preset lower limit the corresponding limit detector can if set to hold a program or trip the system interlock stop the test 100 Upper Limit Detected Upper Limit Detect Level 0 Full Scale Amplitude Lower Limit ae Detect Level Lower Limit Detected 100 Determining Limit Detector The limit detectors should be set to minimize the chances of accidental Levels damage to test specimens and test equipment They are typically set t
37. ance of the equipment read the Safety Practices section of this manual Maintenance 7 1 In order to maintain a safe system it is very important to contact the MTS Service Department immediately if any of the following conditions are noted e Excessive nitrogen leakage Any bolt or nut fastener failure or any sign of loss of bolt preload even if the bolt appears to be defective or if the system has been operated with insufficient torquing through oversight e Any operation or maintenance procedure that may have accidentally overloaded any structural component e Any loss of system control or unexplained tripping of the limit detector interlocks Any unexplained loss of hydraulic fluid from the system reservoir System Operating Inspections Check for normal system operation whenever the system is run In addition to the maintenance safety checks listed in Section 1 routine operation inspections should consist of checks for the following e Fluid level in the hydraulic power supply reservoir is normal as indicated on the reservoir fluid level gage e Nitrogen precharge in the accumulators is within 20 of posted pressure Preventive Maintenance Checklist 7 2 Maintenance Most system maintenance is limited to routine inspections for signs of obvious component damage or failure and maintenance of the correct nitrogen precharge for the accumulators The following subsections briefly describe specific maintenance t
38. anel Control Descriptions Control or Display Description Check Boxes Check boxes are used when you can select any option in a set of options A selected check box Autoscale Y shows a check mark Same scale Y Click on a check box to select or deselect its option Function Buttons Click a function button to complete the function associated with the button Some of the most common function buttons are Stop Preview Run illustrated at the left The Stop Preview and Run buttons are used to system The Select Next and Previous buttons are used to select a channel Select Next Previous or signal for which you want to enter information Any function button that has an ellipsis following its label accesses a secondary panel For example the Select button shown at the left accesses a selection panel from which you select a channel or signal Indicators An Indicator is a small circle that identifies a specific condition in the test system The condition identified by the label associated with the indicator exists if the indicator is filled like the Tracking indicator shown on the left Tracking The indicators in the control panels are set by the control electronics Refer to the appropriate description in Section 5 Control Panel Reference for more information about a specific indicator and if applicable for instructions on clearing an indicator Introduction to Cont
39. ar to set a value or enter it in the text box Current span display Shows the current value of the span The master span may take time to ramp up to its set value This shows the actual value at any moment 5 38 Control Panel Reference Main Panel continued Control Descriptions continued Stop Run Pause A bort Controls the program buttons Stop stops the test program Span will ramp to zero System returns to setpoint levels Run enables and runs the program Pause allows user to pause the program while hydraulic service manifold is open Motion is temporarily halted Clicking on the Pause button again will resume motion The program runs without commands being sent to the servo controller Abort aborts the test program Motion is halted setpoints are updated to current feedback levels and span is zeroed Control Panel Reference 5 39 Message Log lol 15 15 30 Tue 04 Feb 03 Settings file C Documents and Set 15 15 34 Tue 04 Feb 03 Function generators enabled 15 15 34 Tue 04 Feb 03 Service access privilege 15 15 34 Tue 04 Feb 03 Program stop D4 Feb 03 Interlocks reset 04 Feb 03 Panel Description Access When to Use the Panel Editing the Log Control Descriptions Control Scroll bar Function generators enabled The Message Log panel allows you to read messages generated by system events Messages are saved to a file called message txt This file records many system
40. asks Refer to the appropriate Product Manuals for detailed maintenance procedures PAWNS The hydraulic pump must be turned off before any maintenance procedure is begun Follow established company safety procedures to assure that the unit cannot be operated while maintenance is being performed Before Starting a Test The time between maintenance intervals may require re evaluation and may change from the specified interval due to experience gained after the system has been in operation General inspection before starting a test Inspect the test area for damage or obstruction e g forgotten tools etc Check oil temperature Ensure that the hydraulic system is at its normal operating temperature at or above 40 C before proceeding with a test After Completing a Test As Required General inspection after completing a test Inspect the system for obvious signs of cracking buckling loose bolts leaks or other conditions requiring maintenance or repair If any of these conditions are found contact MTS Systems Corporation Replace HSM filter Replace HSM filter whenever its indicator pops out Reference Manual Hydraulic Service Manifold Product Manual Replace actuator seals Replace the piston rod seals whenever leakage occurs or whenever the actuator has been disassembled A decrease in system performance can also be an indication of seal wear Reference Manual Actuator Product Manual Replace accumulator se
41. ative to a transducer feedback signal that has already been adjusted for proportional gain Increased Freq Decreased Amp Decreasing Slope sluggishness Increasing Derivative i The bandwidth adjustment is used to filter the drive signal to the servovalve and can be used to remove frequency content that can make the system become unstable Used to provide damping of the oil column spring Control Panel Reference 5 47 PID Controllers continued Control Descriptions Control E O Deon Channel text box Select button Next button Previous button Apply button Current gains and Reference gains Proportional slide bar and text box Integral slide bar and text box Integ Authority slide bar and text box 5 48 Shows the name of the current selected signal Select a signal using the Select Next or Previous buttons Opens the signal selection panel from which you can select a signal Selects the next signal in the selection panel list Selects the preceding signal in the selection panel list Pressing this button will apply the controller settings on this panel to selected modules A gain parameter can be entered as Current gains which go into effect immediately Current gains can be copied to Reference gains which are kept in memory but not used The lt lt Copy lt lt lt lt Switch gt gt and gt gt Copy gt gt buttons are used to move the complete set of gain parameters bet
42. available commands are setpoint and control mode Refer to Section 6 Remote Control Pendant Operation NOTE While Pod is the program source dynamic commands can not be run This option indicates that the program command is generated from Scramnet Control Panel Reference 5 31 Limit Detectors lala act 1 Displ err A Select Next Previous Reset Action Indicate g g l Upper 10 1 u Lower 10 Nei Persistence 0 0 Nell A WN i BY sec Panel Description Access When to Use the Panel 5 32 The Limit Detector panel allows you to e Select a specific software signal for which a limit can be set e Choose the action to be taken if a limit is exceeded e Set an allowable operating range and persistence value for the signal e Identify if an upper or lower out of limit has occurred e Reset the software limit detector circuit Open the Limit Detector panel by selecting the Limit Detectors option from the Operation menu on the main panel You can also open this panel by clicking on the Interlocks icon on the Main panel specification Use the panel to set safety limits for the test system during test This panel can be used to set software limits for the following signals Actuator displacement feedback Actuator displacement error Actuator force feedback Actuator force error User A D User DUCs User Encoders Each of the above signals have 2
43. before attempting to operate the system Failure to do so could lead to serious safety problems The primary components of the hydraulic system are the Hydraulic Power Supply HPS the Hydraulic Service Manifolds HSM and the flow averaging accumulator manifold assemblies Hydraulic fluid from the HPS system is distributed to and from the servovalves that control movement of the actuators Hydraulic power for the fast hybrid test system is controlled by the control system via the HSM on off low high controls System Overview 1 1 The flow averaging accumulator manifold assemblies qty 4 total are free standing assemblies that can be connected either upstream or downstream of the HSM With the use of some supplied tees they can also be connected in tandem to be used in a single actuator setup Each HSM assembly also includes a pressure and return accumulator so as to reduce pressure fluctuation in the hydraulic system Hydraulic Actuators 1 2 System Overview The actuators used in the test system are specially designed low friction hydraulic actuators One 244 515 220 kip actuator and two 244 415 110 kip actuators are provided for this system The actuators are attached to the specimen or reaction mounting fixturing by robust MTS 249 series swivel assemblies lt 4 Swivel Rod End Force Transducer 4 Swivel Base 244 Actuator Actuator operation is accomplished by porting high pressure hydraulic fluid
44. button Maximum display box Minimum display box Shows the name of the current selected channel Select a channel using the Select Next or Previous buttons Opens the channel selection panel from which you can select a channel Selects the next channel in the selection panel list Selects the preceding channel in the selection panel list Displays the maximum engineering value of the selected analog signal as viewed as a testpoint Displays the minimum engineering value of the selected analog signal as viewed as a testpoint 5 58 Control Panel Reference 2 Stage Valve Drivers lola 170571 Act 1 Select Next Previous IY Enabled Balance 0 0 Y Nel CL TCS Dither amplitude 0 0 eee IY Invert polarity Max current 25mA e 50 mA Readout Valve A current Interlocks M Disabled Reset O Watchdog timer Valve driver input 0 000153 Y Panel Description For two stage valves the Valve Drivers panel allows you to perform the following tasks e Select a specific valve driver channels e Adjust the dither amplitude and balance for the selected valve driver channel e View the value input to the valve driver by the servocontroller e Insert the valve phase e Disable and or reset interlocks e Monitor interlocks Access Open the Valve Drivers panel by selecting the 2 StgValve Drivers option from the Calibration menu on the main panel When to Use the Panel Use the Valve Driver
45. ccordingly When hydraulic pressure is not applied to the system the actuator can drift down to its endcap unless restrained in some manner If hydraulic pressure is applied again and the system is operating in static control the actuator will quickly return to its previous position The setting of the active Setpoint control is the determining factor in most cases Always adjust the active Setpoint control to zero the servovalve command before applying hydraulic pressure Do not use any interlock reset to bypass the interlock chain and attempt to apply hydraulic pressure Doing so will apply hydraulic pressure to the system regardless of the interlock condition Turning off electrical power or an electrical power failure when hydraulic pressure is applied to the system can cause considerable and unpredictable actuator reactions Loss of electrical power generally causes the actuator to stroke at maximum velocity in either direction Unexpected actuator movement or excessive actuator force can result from operator error when adjusting a Setpoint or Span control The composite command to the servo control loop is the algebraic sum of the signals produced by these controls Either Setpoint or Span can program 100 of the system force producing capability For example in most systems a 10 volt signal produces full scale response If the program input to the control electronics is a 10 volt sine wave and Span is adjusted to 100 any mean level
46. cks Reset button to clear the hardware interlock indicators If you suspect a software limit detector is set A Open the Message Log panel from the View to see if a software limit detector remains uncleared The message will identify the limit detector 6 4 Operation B Open the Limit Detectors panel from the Operation menu and select the associated signal Make a note of the limit value Then move the limits outside of the current signal value and press the main panel Interlock Reset button to clear the software interlock indicators C Open the Limit Detectors panel from the Operation menu and set the limit detector you adjusted in Step D back to its original value Make sure system is in Stop mode by clicking on the Stop button on the main panel Operation 6 5 Hydraulic Start up A OOOO Actuator movement may occur when the HSM Lo button is pressed Actuator movement can result in injury to personnel or damage to the specimen Ensure that all personnel are clear of the actuator s or fixturing before pressing the HSM Lo button Click on the HSM 1 2 or 3 buttons to select the desired HSMs e Verify the gain settings for stable system control Decrease the Master Gain control on the main panel if necessary e Apply low pressure at the hydraulic service manifold by clicking on the HSM LO button The Low Pressure indicator on the Main panel will turn yellow when the system reaches low pressure e Apply
47. cks pop up menu Enables disables the software and hardware limit detectors The hardware limit detectors are only enabled if the hardware limits disable control is not checked on the AC DC Conditioner panels Interlocks indicator and Indicates whether a system interlock condition exits Use the Reset Reset button button to clear the hardware and software limit status indicators located on the AC DC Conditioner Encoder Conditioner and Limit Detector panels and the E STOP chain Program Source radio Select the desired program source buttons Function Generator setup function using Function Generator panel Data Player File select file using Data Player panel Remote Application select to enable a program source from a remote application via TCP IP Scramnet input external digital signal from Scramnet Pod input external analog signal Enable simulation check When checked allows the user to rehearse or simulate how the box system will perform Hydraulics will not be enabled but real time controller will function as if the system is real Pod Ready indicator Indicates if the remote control pod is ready Scramnet OK indicator Indicates that Scramnet is connected and functioning properly Master Gain slide bar and Adjusts the master gain You can use the slide bar to set a value or text box enter it in the text box Desired span slide bar Adjusts the desired span of the command signal You can use the and text box slide b
48. cted if the master channel has a cyclic source The master channel determines the frequency The shape amplitude and phase lag between the master slave channels is selectable Selects the master actuator Selects the shape of the function to be generated for the slave channel Sets the peak amplitude of the function to be generated for the slave channel You can use the slide bar to set a value or enter it in the text box Sets the phase lag between the master channel and the slave channel You can use the slide bar to set a value or enter it in the text box Controls for Slaving source Controls for Remote Application source Controls for Data Player File source Controls for Pod source Controls for Scramnet source NOTE The following controls are not selectable via the Function Generator panel They are for display purposes only and are selected via the Main panel This option indicates that the program command to the selected actuator is the command at the bottom of the Slaving Matrix panel Refer to the Slaving Matrix panel information This option indicates that the program command to the selected actuator is generated by a remote source to be determined by the user This option indicates that the program command to the selected actuator comes from playing an external data file Refer to Data Player panel information This option indicates that the program command is set by the remote control pod The only
49. ction to Control Software View Structural Test System Settings set File Calibration Configuration Operation MAGTE Service HPSOn Y HSM maoa HSM Lo HSM fil e Analog Readouts Interlocks Enabled Re Digital Meter A Digital Meter B_ e TPE Program n gt pace FRF Plott Ee A Message Log Y Enable simulation ERE 0 0 Oscilloscope Stop Run Pause apor Pod ready Scramnet OK Use the commands on this menu to display data on the following types of panels e Analog Readouts to route a digital signal to a D A converter for monitoring by external analog equipment e Digital Meters A and B to read the present value of a signal and to monitor the maximum minimum values or the peak valley values over time e Digital Readouts to display the present value of one or more signals FRF Plotter to plot the FRF frequency response function to show frequency responses computed by the Spectrum Analyzer e Message Log display current messages in the message log e Oscilloscope display oscilloscope traces of various signals Introduction to Control Software 4 9 Selecting an Option To access a control panel from a main panel menu complete the from a Main Panel following steps Menu 1 Click on the menu title associated with the option you want to access 2 Move the mouse to highlight the option you want to access 3 When the option is highlighted cl
50. d Move the Setpoint to full scale positive displacement Reduce the GAIN if required so that the actuator rod is in the end cap Record the displacement reading when fully extended Half of the difference between the fully retracted and fully extended displacement readings will be the zero point of actuator displacement Move the Setpoint to zero displacement Adjust the ZERO until the displacement measurement device is reading half the difference between the fully retracted and fully extended displacement readings Move the Setpoint to full scale negative displacement 21 22 23 24 25 Adjust conditioner Gain until the displacment measurement device reads the correct full scale displacement Repeat steps 17 21 until zero and full scale are within desired tolerance Adjust Setpoint to full scale positive displacement Adjust Delta K on the AC Conditioners panel until the displacement measurement device reads the correct positive full scale displacement Plot the actuator linearity by recording the conditioner output values from the displacement conditioner for 20 40 60 80 and 100 of full scale a For example adjust Setpoint for a dial indicator readout of 15 mm 20 Record the conditioner output values on your transducer calibration sheet Repeat this step for 20 40 60 80 and 100 of full scale displacement NOTE The accuracy tolerance linearity should be 1 of f
51. de is Peak valley and Display Mode is Extrema Displays the Mean value for the signal when Capture Mode is RMS Mean display Mode is grayed out Displays the Base value of the signal when Capture Mode is Max Min or Peak valley and Display Mode is Amplitude Base Current value text box Displays the current value of the selected signal Reset button Clears the Minimum and Maximum text boxes gt arrow Toggle the gt arrow to open close the right side of the display panel which contains the options described below Control Panel Reference 5 17 Digital Meter A or B continued Control Descriptions Capture Mode pop up Selects a monitoring mode The choices are menu Max min display the maximum and minimum values of the signal in the Maximum and Minimum boxes Peak valley banded display the peak and valley values of a signal determined by reversal outside a specified sensitivity band Peak valley timed display the peak and valley values of a signal determined by reversal within an amount of time determined by the signal frequency RMS Mean display the RMS and mean values of a signal averaged over a specified sliding time interval Display pop up menu Selects a display mode The choices are Extrema Displays min max or peak valley values See Capture mode above Amplitude Base Alternative form of displaying extrema where max min max min Amplitude _ and Base
52. detectors designated A and B Control Panel Reference Limit Detectors continued Important Information Background Information Control Descriptions Control Det text box Select button Next button Previous button Reset button The limit detectors are designed to protect equipment from damage They are not designed and should not be used to protect personnel from injury The limit detectors are enabled and disabled from the main panel If not enabled they will not set an indicator or interlock A limit event for a particular signal indicates that the signal has exceeded its upper or lower limit The upper and lower limits establish a range of values that represent a desired system operating range This band also represents the range where valid test data can be ensured The persistence value is a time in seconds that an upper or lower out of limit condition can persist without causing an interlock When an out of limit condition occurs the Message Log panel identifies the specific out of limit condition Shows the name of the current selected signal Select a signal using the Select Next or Previous buttons Opens the signal selection panel from which you can select a signal Selects the next signal in the selection panel list Selects the preceding signal in the selection panel list When pressed clears the Upper and Lower indicators and any software interlocks generated by the out of limit condi
53. e changed by using the Up and Down arrows to highlight the Displ or Force text box Press Enter to finalize the change Use the Left and Right arrow buttons or enable the encoder wheel to change the setpoint The Enter button must be pressed to finalize the change 6 12 Operation Using the Low Flow High Flow Shutoff System MTS has provided a servovalve bypass option to allow you to run the actuators more slowly Low Flow Low Speed Actuator Operation 1 Press and turn the red bypass button clockwise to activate the 3 stage servovalve shut off poppets This will place the button in the fully depressed position In this position oil flow from the 3 stage servovalve to the actuator control port is blocked Bypass Button 2 Using a1 wrench turn the 2 stage servovalve shut off spool until the indicator pin points to OPEN This allows flow from the 2 stage servovalve to control actuator movement Indicator Pin Shut Off Spool Side View Bottom View Operation 6 13 High Flow High Speed Actuator Operation 1 Press and turn the red bypass button counter clockwise the to deactivate the 3 stage servovalve shut off poppets This will release the button allowing the 3 stage servovalve to control actuator movement Bypass Button 2 Using a 1 wrench turn the 2 stage servovalve shut off spool until the indicator pin points to CLOSE This blocks oil from the 2 stage servovalve to the actuator contro
54. e default Settings file NOTE After you use the control software to set up the system for a test you can save the system settings in a new file During system startup the system automatically opens the default Settings file You can select and use a different settings file after system startup The Structural Test System main panel is the control center of this application You can use the menus of this panel to access all options for calibrating configuring setting up tests and displaying data You can also use the controls and displays of this panel to set or check functions and to run a test When you set up your system for a test you will complete a number of procedures defining the system test settings These settings include servo control loop adjustments limit detector settings and function generator settings These settings will be stored in Settings set or a settings file of your choice The hardware dependant parameters for the system are also stored in Settings set which is automatically loaded when the application is opened This file contains calibration data for the A D and D A Converters DC Conditioners AC Conditioners and Valve Drivers Hardware is calibrated using the panels found under the Calibration menu and new parameters are saved using the Save Settings option If needed you can restore the parameters stored in the calibration file by selecting the Restore Settings option This is useful if you change parame
55. e display of the selected signals Select the scaling mode of the selected signals Select the display mode for the monitor Select the sweep mode for the monitor Open the Oscilloscope panel by selecting the Oscilloscope option from the View menu on the main panel When to Use the Panel Use this panel at any time to monitor system signals Refer to Appendix A for a list of available signals Control Panel Reference 5 41 Oscilloscope continued Control Descriptions O ee Channels select controls Ch A or Ch B text box Select button Next button Previous button Sweep Period slide bar and text box A B Delay slide bar and text box Autoscale check box Same scale check box Display mode radio buttons 5 42 Shows the name of the currently selected signal Select a signal using the Select Next or Previous buttons You can select NONE from the Select list or a blank from Next or Previous to remove a channel from the display Opens the signal selection list from which you can select a signal Selects the next signal in the list Selects the preceding signal in the list Sets the sweep period in seconds for a trace on the oscilloscope display You can use the slide bar to set a value or enter it in the text box Sets the time by which the Channel B trace follows the Channel A trace If the value is negative B precedes A You can use the slide bar to set a value or enter it in the te
56. e pendant to be used in emergency situations Enter i Manual Contro The pendant has several control buttons that are used for entering in commands These buttons are described in more detail in the table below 6 10 Operation Remote Control Pendant Control Descriptions BUTTON DESCRIPTION Up and down buttons Moves the highlight cursor from one field to another Left and Right arrow Changes the value of the currently selected field buttons If the field is a number control field the change is a function of the step size button The Left arrow decreases the value and the right arrow increases the value The command change is executed as soon as the button is pressed If the field is a combo box field pressing the left or right button changes the display to the next available selection in the combo box The Enter button needs to be pressed to make the selection final Panel gt Setpoints Shows the Setpoints panel Used for manually selecting force or displacement mode and setting an actuator setpoint Note that all the controls in this panel are disabled when a program is executing F1 F2 F3 F4 buttons Currently not used Enter Button Acknowledges changes in Combo Box control fields This also hides the highlight cursor when pressed Station Stop Button Initiates an Abort HSMs will shut down Coarse Sets a coarse step size for any number control field in the panel Medium Sets a medium step size for an
57. e spool zero adjustment and adjusting the spool LVDT position a Open the Digital Meter panel and select the valve drive signal Turn the hydraulic power and HSM to High Adjust the Spool zero value in the valve driver panel to zero Loosen the locknut on the spool LVDT and slowly move the LVDT in or out until the valve drive signal displayed by the digital meter is zero Tighten the locknut on the LVDT such that the valve drive signal remains as close to zero as possible Adjust the spool zero value in the valve driver panel to a value that results in zero valve drive Overview Signal List Appendix A Signal Name Lists This appendix contains a list of signals that can be monitored at one or more of the display panels such as oscilloscope digital meter and data recorder The following signals are available for each actuator Displacement Command Displacement Feedback Displacement Error Force Command Force Feedback Force Error Scramnet command Slave Command DP Force Feedback Valve Command Valve Spool Position User A D 1 6 User DUC 1 39 User Encoder 1 3 Signal Name Lists A 1
58. e top and bottom text boxes on the right and left sides show the minimum and maximum values of the A and B traces respectively the right and left text boxes on the bottom of the monitor show frequency If in X Y display mode values of A and B are shown on the left and bottom respectively and nothing is displayed in the text boxes on the right If you click on a specific point in the scope display area a dot appears and the corresponding X and Y values will be shown in the text boxes in the right center bottom center and left center Control Panel Reference 5 43 PID Controllers PID Controllers Act 1 Displ Select Next Previous Current Gains Reference Gains Proportional s 285714 WN o o 1 m a Integral fo 1 sec foo Ne Cd Integ authority 3 FS gt gt Copy gt gt fo o aa O o Derivative foo sec lt lt Switch gt gt fo o Feedforward 0 0 sec lt lt Copy lt lt 0 0 Panel Description Access When to Use the Panel The PID Controllers panel allows you to set up and tune the PID servo control loops Open the PID Controllers panel by selecting the Controllers option from the Operation menu on the main panel You can use the PID Controllers panel to set up or adjust parameters for a PIDF controller including the following e Gain P e Reset I e Rate D Integ Authority Bandwidth e Delta p 5 44 Control Panel Reference PID Contro
59. ect control variable is selected a Immediate and unexpected actuator response is possible when a Run command is applied to the system Unexpected actuator response can result in personal injury or equipment damage Clear all personnel from the test system before running a test 6 8 Operation Adjustments During a Test Stopping a Test Press the Run button on the main panel to begin the test Make adjustments to the readout devices as desired Minor adjustments to the Desired Span control can be made at this time While constantly checking for system stability slowly adjust the main panel Desired Span control towards 100 If the system becomes unstable immediately remove hydraulic pressure by pressing the EMERGENCY STOP button Identify the cause s of the instability before attempting the test again Click on the Stop button on the main panel to stop the test Span will ramp to zero System returns to setpoint levels Click on the Abort button on the main panel to abort the test Motion is halted setpoints are updated to current feedback levels and span is zeroed Click on the Pause button on the main panel to pause the test Motion is temporarily halted Clicking on the Pause button again will resume motion Operation 6 9 The Remote Control Pod can be used to manually set the system setpoints and mode An Abort button is also available to initiate an abort if necessary An E stop button is located on th
60. ection panel list Selects the preceding conditioner in the selection panel list Displays the type of conditioner selected AC or DC Sets the amplitude of the excitation signal sent to the transducer You can use the slide bar to set a value or you can enter it in the text box Available for AC excitation mode only Selects the frequency of the excitation signal sent to the transducer Available for AC excitation mode only Sets the demodulator phase of the AC conditioner output You can use the slide bar to set a value or you can enter it in the text box Sets the dc offset of the conditioner output You can use the slide bar to set a value or you can enter it in the text box Sets the total gain of the conditioner You can use the slide bar to set a value or you can enter it in the text box Sets the delta K value for the conditioner You can use the slide bar to set a value or you can enter it in the text box Control Panel Reference AC DC Conditioners continued Control Descriptions Filter cutoff pop up menu Select the desired output filter cutoff frequency Invert Polarity check box Selects the polarity of the output signal The choices are Inverted or noninverted Shunt cal button Available for DC excitation mode only Closes the shunt calibration relay to complete a shunt calibration of the conditioner and displays the value in the Conditioner Output value display Interlocks Disabled check box When
61. eecesesesecscscsesesesesaeneeenens 4 2 The Structural Test System Main Panel ccceeeccescscsescscscscsesesessssssesesescanseseseseseseseseseseseseceesenens 4 5 Main Panel Mens iii 4 6 Using the Software Control Sraten cannes eso eee aae ae dass aphesta a asa a ea Siaa aaas 4 11 Table of Contents i Section 5 Control Panel Reference AC DC Conditioners ss tit e di A erate eos 5 3 Analog INP UtS vrai tas ir EEEE ESEE Esas 5 6 Analog Outputs Scaling meant int i 5 8 Analog Outputs escindida anio aa a ici 5 8 Analog Re d ts enai e atiaeina ea e E Aa ae anaE E AE ENESTE aeaii 5 10 Data Playera E ENAA A E aN 5 11 Data Recorder tisscssciss cisssessaicsiescesshotacatet ines aiie ia eia aiaia eiiis 5 13 Digital Meter A Or Borreroa na k en T ERONEN O RANAR R 5 15 Digital Reado tss tii e hina labia AA u E aia iaa 5 19 Encoder Conditioners minita id AA dd A dica 5 20 FRE PO Her ao pedi dd tail 5 23 F ticton O A cseeucotaucocavessies wteeussePrapeuneeancoets 5 26 Limit Detector id da di ii dais 5 32 Mairi Palin A EE RE EERE A 5 36 Message LoS vada bad EE E EE da ali laa 5 40 OSCUIOSCOPE Fiestas colton a a daddies datas hance Shia het T 5 41 PID Controllers ainia is dais a dieta 5 44 OO 5 50 SODOM ti A ie 5 52 Slaving Matrix seies sess iss teasabas tesa dian a A maria dario A a a iinis 5 54 Spectrum Analyzer nenian aia Daiana 5 56 Testpoint Units isis id osiiiih ocn cabo lan tania hdd iaa qa iba 5 58 2 Stage Valve DAVET iii aaa 5 59
62. en the two sides of the differential pressure cell P1 and P2 by readjusting the gain appropriately If desired repeat the measurements for 20 40 60 80 and 100 of fullscale Record the conditioner output values on your transducer calibration sheet When the DC Conditioner calibration proceduisare completed select Save settings from the File menu on the main panel to save the new calibration settings When the calibration is complete disconnect the pressure source from the differential pressure cell and reconnect the differential pressure cell to the actuator according to its original orientation Calibration and Tuning 8 9 Acceleration Feedback Calibration 8 10 To calibrate the DC Conditioner for use with an accelerometer NOTE Turn on the console and allow the modules to warm up properly 10 Calibration and Tuning approximately 5 minutes before you make any electrical adjustments Select the AC DC Conditioners option from the Calibration menu on the main panel Select the DC Conditioner channel for the acceleration feedback Mount the accelerometer to be calibrated onto a portable accelerometer calibration stand with a built in exciter Connect the output of the exciter to Channel 1 of a dual trace oscilloscope Connect the Calibration Service cable to the RJ45 connector at the top of the 493 I O carrier that has the DC conditioner daughter card installed Select the BNC cable that corresponds
63. ent inside the system control consoles Avoid exposure to these areas when electrical power is applied Avoid touching any exposed wiring or contacts anywhere in the system Systems that use pneumatic devices such as accumulators and static supports contain high pressure gas that is very hazardous if improperly handled or poorly maintained Read all gas cylinder labels to properly identify the type of accumulator and the type of gas to use Follow all charging instructions given in the appropriate manuals When charging accumulators use only dry nitrogen Dry nitrogen can be labeled oil pumped or dry water pumped Do not use oxygen in place of nitrogen If oxygen comes in contact with pressurized hydraulic fluid a highly explosive condition will exist Contact your MTS representative if in doubt about any charging procedure Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause cable hardening and eventual cable failure Clean spilled hydraulic fluid from electrical cables as soon as possible Inspect cables for cuts exposed wires or other types of damage prior to system operation Ensure that cable connectors are securely plugged into their respective receptacles Remove system electrical power before replacing a defective cable Ensure that all cables have appropriate strain relief devices installed Protect all system cables and hoses from sharp or abrasive objects Never walk o
64. ets the averaging process of the spectrum analyzer The Update button for each signal updates the display to the most current frequency response function Selects independent autoscaling In this mode the two signals are scaled to fill the entire display area regardless of their relation to each other Even if Auto scale is selected you can change the frequency range of interest using the text boxes on the X axis If this box is checked the same scaling is applied to both signals If checked plots on a logarithmic scale Unchecked plots on a linear scale Control Panel Reference FRF Plotter continued Control Descriptions continued Points text box Selects and shows the number of points displayed at the selected scale You can enter a number of points in this box range 32 to 384 Update both button The Update both button updates the display to the most current frequency response function for both signals Display area text boxes The text boxes surrounding the display area show the values of the upper and lower ranges currently displayed The top and bottom text boxes on the right and left sides show the minimum and maximum values of the A and B traces respectively the right and left text boxes on the bottom of the monitor show frequency If you click on a specific point in the display area a dot appears and the corresponding X and Y values will be shown in the text boxes in the right center bottom center
65. ext box you have to use functions buttons associated with the field for example a Select button The name of the entry can be changed by selecting the text in the box typing the desired name over it and then pressing the return key Double clicking on the text will select all of it A display text box is not editable but is updated whenever you change the associated selection An example of this type of text box is the Chan text box shown on the left An alphanumeric text box is used to enter data into the system Examples of this type of text box are the text boxes shown on the left To change the data in a text box select the existing text type the desired information over it and then press the Phase rate 45 0 deg s return key 4 14 Introduction to Control Software Section 5 Control Panel Reference Overview This section contains alphabetically arranged descriptions for each control panel in the Structural Test System software NC For most options a control panel is automatically opened when you select the option These control panels display current settings Before you change a displayed setting know the effect the change will have on the system Refer to Section 6 Operation before adjusting any value or attempting to operate the system Control Panel Reference 5 1 The following table identifies each panel described in this section as well as its corresponding option name and menu location Re
66. f recommended preventive maintenance schedules for the system components supplied by MTS and a system maintenance log For corrective maintenance information refer to the Maintenance Procedures section or contact MTS Systems Corporation A thorough understanding of the system s nature should be achieved by reading the system manuals and studying the equipment before any maintenance procedure is begun Some repair or maintenance procedures may require the use of heavy machine rigging techniques This manual is not intended to be a primer in this area and assumes knowledge of such techniques and the use of personnel skilled in rigging General Inspection Criteria Before performing any maintenance routine read the safety practices in Section 2 of this manual and the maintenance procedures in the applicable product manuals Any system component not specifically discussed in this section or in other sections should not be adjusted or tampered with Consult MTS Systems Corporation about any problems concerning adjustment of such components CC The Safety Practices section of this manual contains information that can help maintenance personnel minimize hazards which can be encountered during system maintenance Failure to observe the Safety Practices described in this manual prior to attempting the following maintenance procedures can result in injury to personnel and or damage to equipment Ensure that all persons involved in the mainten
67. fer to Section 4 Introduction to Control Software for information on how to select these menu options Panel Name Menu Menu Option AC DC Conditioners AC DC Conditioners Analog Inputs Analog Inputs Analog Output Scaling Analog Outputs Analog Outputs Analog Readouts Data Player Data Player Data Recorder Digital Meter B Digital Readouts Encoder Conditioners Frequency Response Function Plotter Function Generators Main Panel Limit Detectors Limit Detectors E E Message Log Oscilloscope PID Controllers Ramp Rates Setpoints Slaving Matrix Spectrum Analyzer Testpoint Units 2 Stage Valve Drivers 3 Stage Valve Drivers 5 2 Control Panel Reference AC DC Conditioners AC DC Conditioners mj m xj 170271 Act 1 Displ fbk Select Next Previous Excitation mode Ac Interlocks Excitation amp 0 0 Vpp_ M Disabled Reset Nel Cd O Watchdog timer Excitation freq 9830 Hz y Excitation fail Demod phase 0 0 deg O Limit Ne tt B Zero foo W Upper limit 9 999664 Y Nel ff Nei l B Gain 0 999561 WY Lower limit 10 0 Nel ti eC Delta K 1 0 VN Sel TTC Filter cutoff None Invert polarity Engineering Units 10 volts 6 0 in 10 volts 6 0 a Conditioner output 0 0 0 0 in Panel Description The Conditioners panel allows you to perform the following tasks e Select a specific AC or DC conditioner e Calibrate the condit
68. forward transfer function between two channels Use the FRF Plotter panel to display the transfer functions Open the Spectrum Analyzer panel by selecting the Spectrum Analyzer option from the Operation menu on the main panel Use the Spectrum Analyzer when tuning the system to monitor signals for frequency content and to check for system resonances The Spectrum Analyzer produces a true FFT transfer function with input and output PSDs and coherence functions It uses Hanning windows 50 frame overlaps and exponential averaging to minimize leakage effects and to smooth spectral estimates 5 56 Control Panel Reference Spectrum Analyzer continued Control Descriptions Control E O Deon Input and Output text boxes Select button Next button Previous button Enable button Remove mean check box Difference output check box Sample rate selection box FFT size selection box Decay time constant slide bar and text box Averages taken display box Reset button Shows the name of the selected input channel Select a channel using the Select Next or Previous buttons Opens the channel list box from which you can select a channel Selects the next channel in the list Selects the preceding channel in the list Use to enable disable the spectrum analyzer When checked removes the dc content of the signal by adding a hi pass filter with an extremely low cut in frequency to the input of the analyzer
69. gnal s current frequency Thus changes in signal peaks and valleys can be continuously monitored Can be used only for cyclic waveforms RMS mean Monitors the RMS and mean of a signal since the display session began or the reset button was last selected The amount of signal averaging can be adjusted via the Averaging Interval slidebar textbox Can be used for cyclic and non cyclic waveforms Shows the name of the current selected signal Select a signal using the Select Next or Previous buttons Opens the signal selection panel from which you can select a signal Selects the next signal in the selection panel list Selects the preceding signal in the selection panel list Control Panel Reference Digital Meter A or B continued Control Descriptions Maximum or Peak or Displays the Maximum value for the signal when Capture Mode is RMS or Amplitude text Max Min and Display Mode is Extrema box Displays the Peak value for the signal when Capture Mode is Peak valley and Display Mode is Extrema Displays the RMS value for the signal when Capture Mode is RMS Mean Display Mode is grayed out Displays the Amplitude of the signal when Capture Mode is Max Min or Peak valley and Display Mode is Amplitude Base Minimum or Valley or Displays the Minimum value for the signal when Capture Mode is Mean or Base text box Max Min and Display mode is Extrema Displays the Valley value for the signal when Capture Mo
70. he system could operate under unforeseen circumstances resulting in an operating environment with unknown hazards Common sense and a thorough knowledge of the system s operating capabilities usually suggest the appropriate approach to system operation In addition to reading these guidelines you should also read all supplied manuals Anyone who operates an MTS system should also have had prior schooling and training on similar systems MTS has training facilities for system operators and maintenance personnel to provide experience and training on MTS products General Guidelines Read all Provided Manuals The following operating safety considerations are applicable to most systems As you read each item consider your system to ensure that your operating environment and procedures do not result in hazardous situations Although complete elimination of hazards may not be possible in a laboratory environment the following guidelines can help identify hazards so appropriate training operating procedures and safety equipment can be implemented Contact an MTS representative if you have any questions System operators should gain an understanding of the system functions by studying the various drawings and product manuals in the system reference manual set The reference manual set includes Assembly Drawings and Product Information These drawings and manuals provide a good background for the structure and operating principles of the system
71. high pressure at the hydraulic service manifold by clicking on the HSM Hi button The High Pressure indicator on the Main panel will turn green when the system is in high pressure mode e Slowly restore the Master Gain control to 100 while verifying control stability 6 6 Operation Warmup Procedure e Runa low frequency low amplitude sine wave until oil temperature is at or above 32 C Operation 6 7 Test Execution Procedure After applying hydraulic pressure to the actuators complete the following procedure to execute a test Verification and Safety Checks Note Optimum system response is achieved when the hydraulic fluid is at its normal operating temperature e Ensure that the hydraulic system is at its normal operating temperature at or above 32 C before proceeding with testing Refer to previous Warmup Procedures section e Check the program input and pre test adjustments completed in the preceding subsections e Clear all personnel from the test area Starting the Program CAUTION When adjusting the SPAN and SETPOINT controls ensure that the test program does not exceed 100 of the full scale limits The SPAN and SETPOINT controls can cause the program to exceed 100 of the system full scale limits e Verify that the Desired Span control program amplitude on the main panel is set to a known safe operating level or 0 e Verify the program source selection and parameters e Verify the corr
72. ibration and Tuning 8 11 NOTE Turn on the console and allow the modules to warm up properly approximately 5 minutes before you make any electrical adjustments 1 Select the Encoders option from the Calibration menu on the main panel 2 Select the Encoder channel 3 Ensure that the Encoder Type is set to Incremental 24 Bit 4 Set the sensitivity to the number of counts the encoder outputs in one inch if you want 1 inch to equal 1 volt NOTE The accuracy tolerance should be 10 um 0004 in 5 When the Encoder Calibration procedure is complete select Save settings from the File menu on the main panel to save the new calibration settings 8 12 Calibration and Tuning 256 Valve Inner Loop Tuning 170572 act 1 Pele Inner Loop Tuning Select Next Previous Proportional gain 3 5 YM Sep o P IY Enabled Rate gain 1 0 msec Balance 0 09766 Y Nel f B Ne CT TY Rate input Spool position Dither amplitude 0 0 Y Nel e Invert polarity NWN Readout Spool position Interlocks IY Disabled O Watchdog timer O Excitation fail Reset Spool Conditioner Calibration Excitation ampl 10 0 pp Nei l B Demod phase 20 736 deg Nel l B Spool zero 0 0 Y ye f f e Conditioner gain 10 YM Y Invert polarity Valve driver input 0 0 0 Y Spool position 0 A programmable digital controller controls the position of the third stage pilot valve spool which
73. ick the mouse button again When you release the mouse button the panel associated with the option will open automatically and become the active panel Making a Control Panel Although more than one control panel can be open at the same time Active only one panel can be active at a time You can enter information and use the controls only on the active panel Inactive Panel Active Panel E Digital Meter A Reference Maximum foo _ ea E gt i ese Minimum Jo o g Current Current 0 0 g When you first open a panel it automatically becomes the active panel and you can use the panel s controls To make a different panel active click anywhere on that panel When you do this the panel will be redrawn on the top of the other panel s and become active NOTE When switching from one panel to another the first mouse click only activates the panel The first click is not directed at a control regardless of the pointer position Closing a Control Panel Each control panel has a close box in its upper right hand corner To close a control panel click on the close box when the panel is active 4 10 Introduction to Control Software Using the Software Panel Controls The control panels contain a variety of controls that you use to make selections and enter test parameters You use the controls by moving and clicking the mouse The panel controls are illustrated and described in the following table Table 1 1 Software P
74. iles must be installed on your PC NOTE The application and support files listed below have already been installed on the computer system by MTS during installation The following procedure for installing the programs should only be done in the event of a hard disk failure or other event that corrupts the disk or software files The files named sts exe and Settings set and the folder bin must be installed on your hard drive in the folder c sts These files contain the Structural Test System application software default setting parameters calibration parameters and system specific data for your system MTS recommends that you make backup copies of the Structural Test System application and support files Keep this backup copy in a safe place to ensure that if a file is corrupted during operation you can restore the file and operate your system Introduction to Control Software 4 1 Using the Structural Test System Software Starting the Control Software Saving and Restoring System Settings Files Calibration File This section describes how to start the control software load calibration parameters save and restore system settings files and quit the control software The Structural Test System application contains the control software calibration data and the default setting parameters for your system Opening this application will load the calibration parameters and open the Structural Test System Main Panel and th
75. in turn controls the flow of hydraulic fluid to the actuator Valve spool position is measured using a LVDT linear variable differential transformer Inner loop tuning consists of setting the LVDT conditioner settings and tuning the analog controller servo loop gains Equipment The following equipment is required for inner loop tuning 493 I O Carrier service cables P N s 100 026 162 and 100 026 163 Calibration and Tuning 8 13 Spool Conditioner Gain An LVDT is used to measure the position of the third stage pilot spool in a 3 stage servo valve The 3 stage valve driver card provides excitation and conditioning for this transducer The first step in inner loop tuning is setting the spool conditioner adjustments a Open the 3 Stage Valve Drivers panel b Attach the service cable to the I O Carrier card housing the 493 15 valve driver card The position of the valve driver card in the carrier card determines which channel to use on the service cable see the Valve Drivers Panel to determine the chassis and slot number of the 493 15 c Attach the appropriate service cable channel output to an unused User A D input on the controller d Turn hydraulic power ON This provides pilot pressure to the 3 stage servo valves while preventing the actuator from moving e Set the Spool Conditioner adjustments to the following initial values Excitation 10 Vpp Demodulator Phase 22 5 deg Spool Zero Offset OV Conditioner G
76. ing Junction Command from Programmer Servovalve LVDT Transducer Conditioner Feedback Transducer Conditioner Figure 3 3 Inner and Outer Loop Control The inner loop controls the position of the slave stage spool in the same manner that the basic closed loop concept controls the actuator The inner loop summing junction produces a dc error signal that drives the slave stage spool in the desired direction This second loop enhances closed loop performance to meet the hydraulic flow and frequency response requirements of the testing Understanding Control Principles Differential Pressure Stabilization Differential pressure stabilization is commonly used in MTS test systems to improve the fidelity of system performance This function stabilizes the extremely high frequencies encountered during testing to provide more stable acceleration Differential pressure AP stabilization is applied to all electronically controlled axes The functional diagram in the following figure illustrates the application of AP stabilization in a single degree of freedom Average AP Actuator Force High Pass Stabilization AP Transducer Feedback Filter Feedback Compensation Signals Reference Signal Proportional Error gt SS Feedback Signal Derivative of Error didt _ Composite Error Integral of Error Servo Stability Function Understanding Control Principles 3 5 Test Adj
77. into the actuator cylinders through the servovalve As fluid is ported into the cylinder pressure is applied to one side of the piston the other side is opened to the return line and the piston moves If the piston rod is connected to some external reaction point a force is applied that is equal to the effective piston area times the actuating pressure As the actuator drives the specimen mass inertial forces are developed in direct proportion to displacement and frequency Servovalves Control System A linear variable differential transformer LVDT is mounted inside each actuator to provide an electrical feedback signal that indicates the actuator piston rod position An MTS high capacity 661 force transducer is equipped on each actuator to provide an electrical feedback signal that indicates the force exerted by the actuator The actuators are equipped with servovalves which control the direction and amount of fluid flow to the actuators 252 Se rovalve For the Fast Hybrid Test System both two staged and three staged valves are used The 244 51S actuator uses a three staged 256 25 servovalve providing 250 gpm with a 252 22 pilot valve providing 2 5 gpm The 244 415 actuators each use a three stage 256 18 servovalve providing 180 gpm and 252 22 pilot valve providing 2 5 gpm All actuators include a low flow high flow shutoff system that utilize a 252 25 servovalve providing 15 gpm The 493 Controller is a real time digit
78. ioner to its associated transducer e Select polarity of output e Select filtering option e Set hardware limits for the conditioner output feedback e Identify whether an interlock has occurred e Disable and or reset interlocks Control Panel Reference 5 3 AC DC Conditioners continued Access When to Use the Panel Control Descriptions Open the Conditioners panel by selecting the Conditioners option from the Calibration menu on the main panel Use the Conditioners panel to calibrate a conditioner with its associated transducer and to identify and reset hardware interlocks Whenever a transducer is replaced or moved the associated conditioner should be calibrated Hardware limits should be checked and reset before starting a test In addition MTS recommends verifying calibration values periodically Cond text box Select button Next button Previous button Excitation mode pop up Excitation ampl slide bar and text box Excitation freq pop up menu Demod phase slide bar and text box Zero slide bar and text box Gain slide bar and text box Delta K slide bar and text box 5 4 Shows the name of the currently selected conditioner The adjacent conditioner ID box shows the slot number of the selected conditioner Select a conditioner using the Select Next or Previous buttons Opens the conditioner selection panel from which you can select a conditioner Selects the next conditioner in the sel
79. ithout entering a new range value click on the striped rectangle again One mouse click on the slide bar moves the current value of the adjustment by 1 of the full range Slide Bars continued on next page Introduction to Control Software 4 13 Table 1 1 con t Software Panel Control Descriptions Control or Display Description Slide Bars continued This also affects scrolling resolution To increase the scrolling resolution reduce the range If the range is large small movements of the slide bar can cause large changes in the control loop Unexpected actuator action could result Unexpected actuator action can cause injury to personnel or damage to equipment To avoid injury or damage use a small enough range to ensure that no major control system motions occur Status Buttons with indicator HPS On e A status button is a function button that is linked to an indicator The function is selected by the button and the status of the function is identified by the indicator For example the HPS On status button changes the state of the hydraulic power supplies Text boxes 1 01 4 x1 Displacement fbk 25 0 F Sis 100 0 FSIs 2 l 2 0 Hz s Setpoint rate Setpoint accel Frequency rate A text box contains current selections selection information or alphanumeric data Some text boxes are editable and some are not editable To change the entry in a selection t
80. ks Disabled check box When checked disables hardware interlocks for this channel Reset button When pressed resets the hardware interlocks for this channel Watchdog timer Indicates the state of the watchdog timer indicator Excitation fail indicator Shows whether excitation has failed This detector is always enabled both in hardware and software Excitation failure causes a system interlock because it may indicate a broken defective or missing conditioner cable Limit indicator Indicates whether the conditioner output has gone outside of the limits set using the Upper and Lower Limits slide bars Upper Limit slide bar and Sets the upper limit of the conditioner output You can use the slide text box bar to set a value or you can enter it in the text box If the conditioner output feedback has exceeded this limit the Limit indicator is lit Lower Limit slide bar and Sets the lower limit of the conditioner output You can use the slide bar text box to set a value or you can enter it in the text box If the conditioner output feedback has exceeded this limit the Limit indicator is lit Engineering Units display Displays the engineering units that equate to 10 volt boxes Raw output value text Shows the value of the signal output in counts by the selected button conditioner Not editable Final output value text Shows the value of the signal output by the selected conditioner The button upper value is in volts the lowe
81. l ports Indicator Pin Shut Off Spool Side View Bottom View 6 14 Operation Hydraulic Shutdown Procedure After the completion of a test the following procedure should be completed to ensure safe shutdown of the test system Note Do not use the EMERGENCY STOP or E STOP buttons during routine system shutdown An emergency shutdown bypasses normal shutdown control sequences and if used for routine shutdown will place unnecessary mechanical strain on the system System Shutdown e If necessary press the Stop button on the main panel to stop the test e Toggle the HSM Hi button to put the system in low pressure mode e Toggle the HSM Lo button to close the HSMs Operation 6 15 Emergency Shutdown Procedure The following actions should be taken if an emergency arises during operation of the test system Note If the system electronics senses an exceeded limit or open interlock condition a system shutdown will be activated automatically e If an emergency situation occurs activate an emergency shutdown by pressing one of the large red EMERGENCY STOP or E STOP buttons These buttons are located on the control console desk e Correct the condition that caused the emergency shutdown e Execute the Hydraulic Turn On Procedure 6 16 Operation Section 7 Maintenance The Fast Hybrid Test system demands periodic routine maintenance to continue to provide optimum performance This section contains lists o
82. ll start as soon as the Start button is pressed If checked data recorder will record over and over again Input the filename where the recorded data is to be stored Use this text box to input a comment to be stored with the data This comment box can be used to input information to identify the particular acquisition such as a Serial ID number etc Select the signals to be recorded The Available box shows the available signals The Selected box shows the selected signals To move a signal between boxes first highlight the signal by placing the cursor on it and clicking once on the mouse button Then click on the appropriate arrow to move the signal to the other box Pressing this button will clear the Selected box of all signals Starts data recording If acquisition is synchronized the button will read Arm and will gray out after you click on it Acquisition is then queued to start with the appropriate event After data acquisition starts the progress bar grows from left to right showing how much data has been recorded 0 to 100 Stops data recording 5 14 Control Panel Reference Digital Meter A or B Act 1 Displ err Select Next Previous g Maximum 0 0 e Reset Minimum 0 0 in fo o in Current Panel Description Access The Digital Meter A or B panel allows you to monitor a signal Open the Digital Meter A or B panel by selecting the Digital Meter A or Digital Meter B optio
83. llers continued Background Information Servo Controller Error Proportional Gain Before making any adjustments you may wish to use the gt gt Copy gt gt command to copy the current stable settings to the reference gains If the system then becomes unstable you can immediately click on the lt lt COPY button and restore the stable setting to current gains You can also switch between reference and current gains via the lt lt Switch gt gt button for quick comparisons Each of the controls on the PID Controllers panel affects the system in a distinct way It is important to understand these effects before attempting to tune the system The servo control process sums feedback and command signals to generate an error signal which is sent to the valve driver to generate the servovalve control signal The command and conditioned feedback signals are summed to create an initial error signal That signal is gain adjusted and summed with integral and derivative factors before a bandwidth adjustment is made to the signal The resulting error signal is sent to the valve driver or valve controller The servo loop adjustments establish the response and stability of the servo control loop Servo loop adjustments are experimental and you should become familiar with the effects of these adjustments while using dummy specimens during both dynamic and static system operation Because each adjustment can have some effect on the other adj
84. n from the View menu on the main panel Toggle the arrow gt to display the right side of the display panel as shown below Digital metera as Act 1 Displ err Select Next Previous a Capture mode Max min Display mode Extrema Ne CY Maximum 0 0 in Sensitivity Reset Minimum 0 0 in Averaging interval sec Current 0 0 in Y When to Use This Panel Use either panel to read the present voltage value of the selected signal Refer to Appendix A for a list of available signals Control Panel Reference 5 15 Digital Meter A or B continued Background Information Control Descriptions Signal text box Select button Next button Previous button 5 16 The digital meters provide the following signal monitoring modes Max min Monitors the maximum and minimum signal values since the display session began or the reset button was last selected Signal values are displayed in the Maximum and Minimum text boxes Peak valley banded Similar to Max min mode except the Reset button is automatically pressed after the signal reverses by an amount determined by the sensitivity adjustment Thus changes in signal peaks and valleys can be continuously monitored Can be used for cyclic and non cyclic waveforms Peak valley timed Similar to Max min mode except the Reset button is automatically pressed after the signal reverses a quarter of a cycle as determined by the si
85. n hoses or cables or move heavy objects over them Route hoses and cables away from areas that expose them to possible damage Thoroughly inspect hoses for blisters cuts or other damage prior to system operation Replace damaged hoses or cables While the system is operating inspect all hoses and cables to ensure that there is no excessive thrashing bending or chafing that could cause cable or hose damage Because of servovalve silting an actuator can develop random instability or erratic operation at unusually low hydraulic pressure levels such as bypass This is even more common if the system uses large servovalves or the hydraulic fluid is dirty Contact MTS for information on hydraulic fluid maintenance procedures Flush the hydraulic system immediately after any of the system s hydraulic components have been replaced or the system configuration has been changed Contact MTS for information on hydraulic fluid maintenance procedures Safety Practices 2 3 Use Caution When Special safety considerations are necessary when operating a system that Handling Fire Resistant contains any type of fire resistant hydraulic fluid These fluids are toxic Hydraulic Fluids and present a lethal situation if the fluid is accidentally swallowed or if a sufficient amount of fluid is absorbed through the skin Avoid contacting fire resistant fluid Do not mix fire resistant fluid with petroleum based fluids Also do not add fire resistant fluids to s
86. nd hydromechanical parts of the testing equipment the transducers and the test specimen The response collected shows all the changes in phase and amplitude that the system produces in the signal These changes are calculated and used to compensate for the effects of the system on the signal If any system component is significantly changed for example if a test specimen accelerometer is replaced a new FRF should be measured for the system Control Panel Reference 5 23 FRF Plotter continued Control Descriptions Control An FRF is measured by exciting the test system with a shaped random drive signal whose frequency content is similar to the desired drive signal and collecting responses to the excitation comet fF essrptom Channels select controls FRF A or FRF B text box Select button Next button Previous button Magnitude Phase Delay pop up menu Reset button Update button Scale checkboxes Auto 5 24 Shows the name of the selected channel Select a channel using the Select Next or Previous buttons Opens the channel list box from which you can select a channel You can also select a channel by clicking in the appropriate box in the cross coupling configuration diagram Selects the next channel in the list Selects the preceding channel in the list Selects the type of Y axis data to be displayed The choices are Magnitude in V V Phase in degrees Delay in seconds Res
87. nverter Access Open the Analog Outputs panel by selecting the Analog Readout from the View menu on the main panel When to Use the Panel Use this panel to select a signal to be written to an auxiliary D A converter Refer to Appendix A for a list of the available signals Control Descriptions Signal Name text box Click near any number to open a pulldown channel selection box Select a channel The name of the selected channel is displayed NOTE The engineering units associated with 10 volts output of the D A converters can be read from the Testpoint Units panel Additional scaling and offsetting of the D A converter outputs can be done via the Analog Output Scaling panel 5 10 Control Panel Reference Data Player File Available Selected File sample period z Play sample period File length fl Elapsed time Po gt Pass gt of fi Reset Panel Description Access When to Use the Panel Playout File Information Act 1 Force Act 1 Displ sec Act 2 Displ Act 2 Force Act 3 sec Act 3 Force h m s h im s The Data Player panel allows you to list the data channels and select a time history file for the program source Open the Data Player panel by selecting the Data Player option from the Operation menu on the main panel You can also open this panel by clicking on the Program Source icon on the Main panel when Data Player File is selected Use the Data Player panel to list the
88. o shut down the system upon specimen failure in order to prevent fixturing or equipment damage Under no circumstances should the limit detectors be relied on to protect personnel Setting Limit Detectors You set the operating band and persistence for each feedback limit detector A limit event for a particular signal indicates that the signal has exceeded its upper or lower limit The selected band establishes a range of values that represent a desired system operating range This band also represents the range where valid test data can be ensured The persistence value is a time in seconds that an upper or lower out of limit condition can persist without causing an interlock Understanding Control Principles 3 11 Overview Section 4 Introduction to Control Software This section contains information on the following topics e Setting up your hard disk e Using the Structural Test System software e Using the software control panels This manual does not describe standard PC procedures Before using the system you should be familiar with your PC operating system Of particular importance are the procedures relating to selecting and moving files opening and closing files moving windows and using file folders For information about the PC refer to the PC documentation provided with your system Setting Up Your Hard Disk Required Files Backup Copies To run the Structural Test System software the application and support f
89. offset introduced by the Setpoint control causes the command to exceed the capabilities of the system Section 3 Understanding Control Principles Overview This section contains information on the control principles used in the Structural Test System The following topics are discussed e Actuator Control Concepts Basic Closed Loop Control Inner and Outer Closed Loop Control e Differential Pressure Stabilization e Test Adjustments Master Gain Span Setpoint e Limit Detection Before setting up the test system or executing a test it is important that you fully understand these control elements Understanding Control Principles 3 1 Actuator Control Concepts System motion is governed by movement of its actuators Each actuator is controlled through basic closed loop inner and outer closed loop These basic servohydraulic control concepts are discussed in the following subsections Basic Closed Loop Control 3 2 Summing Junction In general closed loop control consists of comparing a command signal with a feedback signal Consider the system schematically illustrated in Figure 3 1 In this system a displacement command signal is generated by a program source that is outside of the control loop Feedback is generated by a linear variable differential transformer LVDT Feedback Transducer Conditioner Figure 3 1 Basic Closed Loop Control The polarity and magnitude of the dc error signal derived b
90. om the calibrated voltage source Remove the calibrated voltage source When the calibration procedures are completed select Save settings from the File menu on the main panel to save the new calibration settings No D A calibration procedures should be necessary Consult MTS Systems Corporation if calibration concerns arise Calibration and Tuning AC Conditioner Calibration EJ AC DC Conditioners J ol xj 170271 Act 1 Displ fbk Select Next Previous Excitation mode AC Interlocks Excitation ampl 10 00015 pp Y Disabled Reset Sel CL e O Watchdog timer Excitation freq 9830 Hz 8 Excitation fail Demod phase 47 19036 deg O Limit Nel B Zero 0 01068 Y Upper limit 9 999664 Y Yel Yel E C Gain 2 361118 YN Lower limit 9 99966 Nel CC Cd Nel ti Cd Delta K 0 994 VN Nel CUT TC Filter cutoff None VY Invert polarity Engineering Units 10 volts 6 0 in 10 volts 6 0 Conditioner output 0 0 0 0 in Calibration for a displacement channel means adjusting displacement to correspond to a pre defined maximum and minimum voltage The AC Conditioner uses a reactive type transducer such as a linear variable differential transformer LVDT This transducer measures bidirectional displacement from a zero reference position To calibrate an AC Conditioner displacement channel complete the following steps NOTE Turn on the console and allow
91. ommand signal You can use the slide bar to set a value or enter it in the text box Control Panel Reference 5 49 Ramp Rates lx Act 1 Displ Select Next Previous Setpoint rate 10 0 FS s Run span rate 25 0 s Stop span rate 50 0 s Frequency rate 2 0 Hz s Phase rate 45 0 deg s Panel Description The Ramp Rates panel allows you to set maximum values for the setpoint generator velocity and acceleration the span run stop frequency and phase rates Access Open the Ramp Rates panel by selecting the Ramp Rates option from the Configuration menu on the main panel When to Use the Panel Use this panel to set limits on how fast the system can reach the displacement or force setpoint and how fast it can ramp up or down Note that these values are of full scale not engineering units Control Descriptions Signal text box Shows the name of the current selected signal Select a signal using the Select Next or Previous buttons Select button Opens the signal selection panel from which you can select a signal Next button Selects the next signal in the selection panel list Previous button Selects the preceding signal in the selection panel list Setpoint rate input Input the maximum velocity that the system is allowed to achieve while trying to reach the displacement or force setpoint value set on the Setpoints panel 5 50 Control Panel Reference Ramp Rates continued Con
92. on signal sent to the transducer You can use the slide bar to set a value or enter it in the text box Sets the demodulator phase of the conditioner output You can use the slide bar to set a value or enter it in the text box Sets the spool position zero offset You can use the slide bar to set a value or enter it in the text box Adjusts the conditioner gain for the selected valve driver You can use the slide bar to set a value or enter it in the text box Selects inverted or non inverted spool conditioner polarity Shows current value input to the valve driver by the servocontroller Not editable Displays the current spool position Control Panel Reference 5 63 5 64 Control Panel Reference Section 6 Operation The complex nature of the test system requires that the operator be familiar with all aspects of the mechanical and electrical components of the system prior to performing any of the following operating procedures MTS recommends that the mechanical and electrical component descriptions in the Operation Manual and the component Product Manuals be studied and thoroughly understood prior to operating the system This section contains the most commonly used operating procedures These procedures should serve as a guideline and reminder of the critical adjustments and checks to be made for each operation Execution of these procedures requires that the operator be familiar with the reason for the adjustment as well as
93. p 6 two more times Calibration and Tuning 10 11 12 13 14 Apply a known exact pressure at 80 capacity of the system Calculate the ideal DC conditioner output value for this pressure and compare it with the actual DC Conditioner output value The actual value should be within the permissible variation of the ideal calculated value Refer to the original calibration sheet for the permissible variation If the actual value is not within the permissible variation adjust the Gain setting on the DC Conditioner panel until it is Apply pressures equal to 20 40 60 and 100 capacity of the system Monitor the conditioner output values to make sure these values are within specification Refer to the original calibration sheet for the permissible variations Readjust the 80 gain if any values are out of specification by going back to step 7 Disconnect the pressure source from the differential pressure cell input labeled P1 and connect it to the differential pressure cell input labeled P2 Apply a known exact pressure at 80 capacity of the system Calculate the ideal DC conditioner output value for this pressure and compare it with the actual DC Conditioner output value The actual value should be within the permissible variation of the ideal calculated value Refer to the original calibration sheet for the permissible variation If the actual value is not within the permissible variation balance the error betwe
94. p up at the beginning of the file It is assumed the file will contain this ramping data if it is required The span will jump to 100 at the beginning of the file The only exception to this is in the middle of the file if the program is put into Stop mode then the system will ramp down to 0 and ramp back up to 100 when it starts up again Run mode enabled You can scale the playout file by playing it out at a different sample rate than the recorded rate The Play Sample Period input allows the user to input a playout sample period different from the recorded sample period Description Selects the file which contains the playout data The file must be in MTS binary format The Translate text to binary option under the File menu on the Main panel can be used to convert an ascii text file to MTS Binary format Displays the sample period of the recorded file Input the desired sample period for playing out the recorded file This value will default to the File Sample Period Displays the playout file length Displays the amount of time that the file has been played out Input the number of times to play the selected file The current pass will be displayed When pressed resets the playout file to the beginning Select the channels to be played out The Available box shows the available channels The Selected box shows the selected channels To move a channel between boxes first highlight the channel by placing the cursor on it and
95. r near an operating system Never enter the test area while the test is in progress Do not approach or touch the test specimen when the system is running Ensure that hydraulic pressure is removed from the system before entering the test area Always keep work area floors clean Spilled hydraulic fluid on any type of floor surface is dangerously slippery Do not make any mechanical or electrical adjustments to system components unless you know exactly how the adjustment will affect system operation Consult your MTS representative if in doubt about any adjustment procedure System interlock devices should always be used and properly adjusted Test all interlock devices for proper operation before starting a test Due to the possibility of operator error misadjustments or component failure interlock devices must not be relied on to protect personnel These devices are primarily designed to minimize the chance of accidental damage to test specimens and test equipment Stay clear of cables and hoses that move along with the test specimen or equipment Objects may get tangled or dragged along with such cables and hoses Serious injury can be inflicted by a fast moving cable or hose Avoid High Voltage Areas Use Care When Charging Accumulators Maintain Electrical Cables in Good Condition Use Care When Routing Cables and Hoses Check Hoses and Cables Be Aware of Servovalve Silting Flush Hydraulics High voltage is pres
96. r value in engineering units Not editable 5 22 Control Panel Reference FRF Plotter FRF Spec Analyzer xfer func Select Next Previous Magnitude Reset Update FRF B Spec Analyzer inp PSD Select Next Previous Magnitude Reset Update Scale Auto Y Same I Log Points 100 Update both Panel Description Access When to Use the Panel Background Information The FRF frequency response function Plotter panel allows you to display the frequency response characteristics of the selected channels This panel is also used to display the forward FRF determined by the spectrum analyzer The display plots magnitude or phase vs frequency Open the FRF Plotter panel by selecting the FRF Plotter option from the View menu on the main panel Use this panel to display the FRF for one or two channels It allows you to identify cross coupling between channels Before using this panel use the Function Generator panel to set a random drive signal for the channel s The frequency response function or FRF is a mathematical model that accounts for the effects of a system on a signal It provides a linear approximation of the changes in phase and amplitude that occur in the frequencies making up a signal as that signal passes through a system Itis used within a component test to compensate for those changes The system that the signal is played through contains the electronic a
97. rently selected conditioner The adjacent conditioner ID box shows the slot number of the selected conditioner Select a conditioner using the Select Next or Previous buttons Opens the conditioner selection panel from which you can select a conditioner Selects the next conditioner in the selection panel list Selects the preceding conditioner in the selection panel list Displays the type of encoder selected The choices are Temposonics Ill 25 bit Incremental 24 bit Temposonics Ill 24 bit Temposonics III 25 bit Teledyne absolute 17 bit Generic SSI Incremental timer mode Sets the baud rate of the excitation signal sent to the encoder You can use the slide bar to set a value or you can enter it in the text box Sets the counts volts Sets the home position for the encoder Sets the of samples of dropout expected NOTE Output deglitcher Because this conditioner is often used for conditioning Temposonics transducers which are prone to dropouts and glitches the output is run through a deglitching filter in the form of a median filter Set glitch width to the number of samples of dropout expected Setting glitch width to zero turns the filter off default Control Panel Reference 5 21 Encoder Conditioners continued Control Descriptions Invert Polarity check box Selects the polarity of the output signal The choices are Inverted or noninverted Clear count button Clears the count Interloc
98. restarting the application Initial Test Parameter Adjustments If you wish to use a settings file that you have saved earlier use the Restore Settings option under the File menu The hydraulics must be off before you can you save settings restore settings or quit the application This option restores all settings except the following e Parameters that appear in any panel under the View menu e Hydraulic button states always Off e Run Stop button states always Stop Select the Program Source e Select the Program source on the main panel If Function Generator is selected use the Function Generators panel under the Operation menu to set up the parameters If Data Player is selected use the Data Player panel under the Operation menu to choose the playout file If Remote Application is selected make sure an ethernet connection exists to the Remote Application 6 2 Operation If Scramnet is selected use Scramnet as the program source If Pod is selected use the remote control pod to set the setpoint and mode Readout Adjustments e Setup and enable the desired readout devices using the View menu System Limit Adjustments e Adjust limit detector levels Use the Limit Detectors panel under the Operation menu to set limit detector levels that ensure the safety of the system components e Enable the limit detectors Enable the limit detectors on the main panel via the Interlocks Enabled popup menu Operation 6 3
99. rogram source and set the appropriate parameters The Function Generators panel allows you to perform the following tasks e Selecta specific channel e Select the program source for the channel Enter the appropriate parameters to define the program output depending upon the program source selected Open the Function Generator panel by selecting the Function Generators option from the Operation menu on the main panel You can also open this panel by clicking on the Program Source icon on the Main panel when Function Generator is selected You can use this panel to generate and apply a program to any channel of the test system Typically you will want to use the function generator when you are tuning the servo control loops during test setup but it can also be used for testing PAWNS Whenever hydraulic pressure is applied adjustment of the controls on the Function Generators panel can cause actuator movement Unexpected actuator movement can result in personal injury or equipment damage Ensure that all personnel are clear of the actuators fixturing and specimen before adjusting any Function Generators control In addition make sure that all operators know the effect of control adjustments before they make any adjustments 5 28 Control Panel Reference Function Generators continued Control Descriptions Controls for all sources Chan text box Shows the name of the currently selected channel The adjacent channel
100. rol Software 4 11 Table 1 1 con t Software Panel Control Descriptions Control or Display Description Pulldown Menus Observers Ramp Rates Units A pulldown menu is used to select one option from a list of options To display the selections on a pulldown menu click and hold on the pulldown menu field until the menu appears Move the mouse to highlight the option you want to select and then release the mouse button Radio Buttons Display mode Time Freq XY Radio buttons are used when you can select only one option in a set of options The selected radio button is the one with the darkened center Click on a radio button to select an option When you select one of the radio buttons in the set the other button s in that set are automatically deselected Scroll Bars Long Reference Vert Reference Pitch Reference Long Feedback Vert Feedback Pitch Feedback Roll Feedback Varp Feedback Cancel A scroll bar can be used to view all available selections in a selection box or all available messages in the Message Log To view selections or messages use the scroll bar in one of the following ways e Click and hold or click repeatedly on the scroll bar arrows to scroll through the selection message list e Click and then drag the box in the scroll bar to move through the selection message list Click on the bar outside of the box to jump through the a
101. rol electronics through a transducer cable This cable must be protected from damage to minimize the chance of unexpected actuator reaction If the cable is routed around corners or through wall openings ensure that all sharp edges are padded Ensure that this cable has appropriate strain relief devices installed e The error detectors in the control electronics minimize the potential for equipment damage caused by loss of feedback or larger than normal dc errors Do not rely on these circuits to protect personnel An open control loop results if the cable from the control electronics to the servovalve is broken or disconnected while hydraulic pressure is applied to the system The response of the actuator will depend on several different factors piston rod position the servovalve in use etc In any case actuator reaction can be violent The same precautions that apply to transducer cables must be observed for servovalve cables Safety Practices 2 5 Program Interruption and Step Functions Applying Hydraulic Pressure with a Command Present Electrical Power Failure or Shutoff Over Programming 2 6 Safety Practices The composite command signal for the servo control loop usually consists of several program inputs such as program command setpoint span and master span If one of these inputs is inadvertently removed or suddenly changed the servo loop will detect a large instantaneous dc error and the actuator will respond a
102. s panel when adjusting the valve balance and dither amplitude during test setup Control Panel Reference 5 59 2 Stage Valve Drivers continued Control Descriptions Control E O Deon Driver text box Select button Next button Previous button Enabled check box Balance slide bar and text box Dither amplitude slide bar and text box Invert polarity check box Max current radio buttons Readout pop up menu Interlocks Disabled check box Reset button Watchdog Timer indicator Valve driver input display box 5 60 Shows the name of the selected valve driver The adjacent driver ID box shows the chassis location slot location and channel of the selected driver Select a channel using the Select Next or Previous buttons Opens the valve driver list box from which you can select a channel Selects the next valve driver in the list Selects the preceding valve driver in the list When checked sets input of valve driver to zero For tuning purposes only Adjusts the electrical balance of the servovalve Adjusts the dither applied to the servovalve You can use the slide bar to set a value or enter it in the text box Selects inverted or non inverted valve phasing Sets the maximum current to be sent to the valve driver The choices are e 25mA e 50mA Selects a function for direct readout The choices are e Valve A current e Valve B current When checked disables hardware interlocks for the
103. s required to reset the system The out of limit condition will be recorded in the message log Interlock This selection causes the system to trigger an Emergency Stop if the signal goes outside the limit The Reset button is required to reset the system The out of limit condition will be recorded in the message log NOTE the following definitions Pause allows user to pause the program while hydraulic service manifold is open Motion is temporarily halted Clicking on the Pause button again will resume motion The program runs without commands being sent to the servo controller Abort aborts the test program Motion is halted setpoints are updated to current feedback levels and span is zeroed 5 34 Control Panel Reference Limit Detectors continued Control Descriptions continued Upper slide bar and text Sets the upper limit of the selected signal Note that when you set the box upper limit value the lower limit is automatically set to the negative of the upper limit value If you desire a different lower limit value you should change it using the lower slide bar after setting the upper limit Upper indicator Lights when an out of limit condition occurs for the upper limit Lower slide bar and text Sets the lower limit of the selected signal Setting this value does not box affect the upper limit value Lower indicator Lights when an out of limit condition occurs for the lower limit Persistence slide bar
104. se the Valve Drivers panel when adjusting the valve balance and dither amplitude during test setup If three stage valves are being used the Valve Drivers panel also allows you to tune the inner loop and make spool conditioner adjustments Control Panel Reference 5 61 3 Stage Valve Drivers continued Control Descriptions Control E O Deon Driver text box Select button Next button Previous button Enabled check box Balance slide bar and text box Dither amplitude slide bar and text box Invert polarity check box Readout pop up menu Interlocks Disabled check box Reset button Watchdog Timer indicator Excitation fail indicator 5 62 Shows the name of the selected valve driver The adjacent driver ID box shows the chassis location slot location and channel of the selected driver Select a channel using the Select Next or Previous buttons Opens the valve driver list box from which you can select a channel Selects the next valve driver in the list Selects the preceding valve driver in the list When checked sets input of valve driver to zero For tuning purposes only Adjusts the electrical balance of the servovalve Adjusts the dither applied to the servovalve You can use the slide bar to set a value or enter it in the text box Selects inverted or non inverted valve phasing Selects a function for direct readout The choices are Valve current Peamplifier output Spool command
105. sired displacement boxes If you change from force mode to displacement mode displays current position feedback The software reads the current displacement feedback and automatically sets the displacement setpoint to that value and transfers authority to the force feedback control loop Act 1 2 3 Force text In force mode inputs desired force boxes If you change from displacement mode to force mode displays current force feedback The software reads the current force feedback and automatically sets the force setpoint to that value and transfers authority to the force feedback control loop Control Panel Reference 5 53 Slaving Matrix Slaying Matrix O x El B E La gt E B z a Panel Description The Slaving Matrix panel allows you to create a command to an actuator that is a linear combination of other system feedbacks This allows slaving the motion of an actuator to the motion of another Access Open the Slaving Matrix panel by selecting the Slaving Matrix option from the Configuration menu on the main panel When to Use the Panel Use this panel to use any linear combination of feedback signals to create an actuator command 5 54 Control Panel Reference Slaving Matrix continued Control Descriptions O OO Dopa O Values display boxes Tare Offsets text boxes gt Coefficients textboxes Outputs display boxes Click on near any V
106. sponse are operator error and equipment failure broken cables damaged hoses damaged electrical components etc An actuator piston rod that reacts unexpectedly can strike an operator or cause expensive equipment damage Anyone who must be close to the system while hydraulic pressure is applied should acquire a thorough knowledge of the system s operating characteristics The following examples are some of the most probable causes of an unexpected actuator reaction If the control mode feedback signal is interrupted during operation the active Controller senses a de error The actuator will then attempt to correct the error by stroking at maximum velocity until it reaches an internal or external mechanical limit The external limit may be anything in its path tools specimens or hands Be aware that the full force of the actuator will be applied to that external limit or obstruction Also be aware of the following special points regarding the force producing characteristics of hydraulic actuators e A selectable operating range does not reduce the static force capability of a hydraulic actuator It only increases or decreases the sensitivity of the electronic control and readout components e The only way to effectively minimize the static force capability of a hydraulic system is to reduce the system hydraulic pressure e The control mode feedback originates from a transducer located in the system and is transported to the cont
107. ssevastesbenteces 8 13 Appendix A Signal Name List Table of Contents iii Hydraulic System Section 1 System Overview This section of the User s Manual provides a brief description of the Fast Hybrid Test System designed by MTS Systems Corporation for the University of Colorado It also identifies the function of the major components used in this system The Fast Hybrid test system contains the following hardware e The 3 actuators apply the forces necessary for specimen testing The Hydraulic Service Manifolds and Hydraulic Distribution System HDS distribute hydraulic power to the system actuators The control system conditions monitors and generates program command and feedback signals for control of the test system e The digital system provides computerized program management through the conversion of program command signals from digital to analog forms and the conversion of feedback signals from analog to digital forms It also provides data acquisition processing and storage functions for data acquired during testing All of these major system components are discussed in the following subsections It is important to note that these descriptions are generic in nature More detailed information about each component including engineering drawings is included in appropriate sections of the system Reference Manual The system operator should obtain a good functional understanding of all major system components
108. static force the actuators will reach some steady state load controlled by the gains see PID This allows a mode switching between setting a desired position setpoint versus a desired force setpoint See Setpoints panel 3 8 Understanding Control Principles Limit Detection Limit Detector Settings Limit Detector Actions Enabling Limits Limit detectors can be set to monitor any of the following signals e reference signals e feedback signals e error signals e auxiliary signals You set the following parameters for each limit detector the operating band and a persistence value The operating band defines the allowable range for the signal The persistence value is a time in seconds that the signal can remain outside of the operating range before setting an indicator or interlock You can set an action to be taken when a limit or error is detected The action can be any of the following e Indicate signal is outside of the limit When the signal returns inside the limit the indicator goes out e Alert This selection causes the indicator to light and latch When the signal returns inside the limit the indicator remains lit until the Reset button is used The out of limit condition will be recorded in the message log e Pause This selection causes the indicator to light and latch and the system will hold the current controller commands as they were when the signal violated the limit When the signal returns inside the
109. t Quit the system will open the following window a a x Do you really want to quit 2 Select OK to quit or Cancel to return to the control software without quitting NOTE After you have selected Okay to Quit you must wait 45 seconds before restarting the software This allows the software to properly prepare for startup 4 4 Introduction to Control Software The Structural Test System Main Panel Structural Test System Settings set File Calibration Configuration Operation View Service HPS On interlocks Enabled Reset HSM Hoe Eregram Function Generator Y Enable simulation HSM Lo e HSM fil O Y Pod ready Scramnet OK Master gain f1i0o Ne A E7 Desired span 100 0 Ne A E7 Current span 0 0 Stop Run Pause Abort As previously described the Main Panel contains a menu bar system controls and indicators It is opened automatically when you start the control software You use the menus on the Structural Test System Main Panel to access option panels used to set up the system The following menus are included on the main panel File 7 Calibration Configuration Operation 7 View The main panel also has system controls and indicators which allow the user to do the following Enable and Monitor hydraulics e Reset Interlocks Enable disable limits 7 Select program source Set master gain and span values Monitor current span Stop
110. t the displacement engineering units for this conditioner to volts for example 10 000 V 10 000 V and 10 000 V 10 000 V If necessary adjust the Excitation Gain and Delta K controls to the respective values listed on the original calibration sheet Couple the actuator to the load and calibration cells Set the control mode for the control channel to FORCE via the Setpoint panel Adjust the Setpoint control on the Setpoint panel to zero force Apply LOW Hydraulic pressure via the HSM Adjust the ZERO control until zero force is indicated on the calibration cell readout Adjust the Setpoint control on the Setpoint panel to zero force Apply HIGH Hydraulic pressure via the HSM Adjust the ZERO control until zero force is indicated on the calibration cell readout Move the Setpoint to 80 full scale force Adjust the GAIN until the calibration cell reads out 80 force Repeat steps 11 15 until zero and 80 are within desired tolerance Adjust Setpoint to 80 positive force Adjust Delta K on the AC DC Conditioners panel until the calibration cell reads 80 force Calibration and Tuning 8 7 19 Plot the force load cell linearity by recording the conditioner output values from the force conditioner for 20 40 60 80 and 100 of full scale by setting the SETPOINT value in the Setpoint window and reading the actual force on the calibration load cell readout The accuracy tolerance lineari
111. ta file can be converted to an ascii text format file by choosing the Translate binary to text option under the File menu on the Main panel Refer to Appendix A for a list of the available signals Control Panel Reference 5 13 Data Recorder continued Control Descriptions Control Sample Rate pulldown menu Starting delay text box Recording period text box Enable AA Filters check box Synchronize with Run check box Loop Forever check box File button Comment text box Signal Selection text boxes Reset button Start Arm button Progress bar Stop button Description Select the recording sample rate The available sample rates are 50 100 125 200 250 500 and 1000 Hz Input the time delay between when the Start or Run button is pressed and data recording begins Input the period of time that the data recorder should run When checked a digital anti aliasing filter is added to each selected signal The software will select an appropriate filter type dependant on the sample rate The frequency response of this AA filter can be viewed using the FRF panel The AA filter will add a delay which is displayed for your reference You may need to adjust the starting delay and or extend the recording period accordingly If checked data recorder will start when the Run button on the main panel is pressed the Start button on the Data Recorder panel must also be on If not checked the data recorder wi
112. ters on any of the calibration panels and wish to return to the original values NOTE When you save a system settings file use the Save Settings option from the File menu on the Structural Test System Main Panel 4 2 Introduction to Control Software Changing Access Modes You can save these settings files and use them when running different types of tests In this way you can eliminate the need for re defining the system parameters when running a different type of test You can choose to save system settings for a test in the same file you are currently using to run the software or in a new file When saving a settings file you should name the file in a way that makes it easily identifiable To save system settings 1 Select Save Settings from the main panel File menu When you select Save Settings the system will open a PC Save window 2 To save system settings in the same file you are currently using Using standard PC file procedures select the folder containing the existing settings file Do not change the file name To save system settings in a new file Using standard PC file procedures select the folder that you want to save the new settings file in and change the file name 3 Click the OK button to save the file in the selected folder or click Cancel to cancel the procedure close the save window and return to the Structural Test System Main Panel To restore a system settings file that has been sa
113. the modules to warm up properly approximately 5 minutes before you make any electrical adjustments Calibration and Tuning 8 3 8 4 10 11 12 13 14 15 16 17 18 19 20 Calibration and Tuning Select the AC DC Conditioners option from the Calibration menu on the main panel Select the desired AC Conditioner displacement channel Adjust the Gain Excitation and Delta K controls to the respective values listed on the original calibration sheets or set Gain to approximately 3 V V Excitation to 10 000 Vpp and Delta K to 1 000 V V these are the approximate midpoint values for each control Set the displacement engineering units for this conditioner for example 10 000 V 6 000 in and 10 000 V 6 000 in Set the control mode for the control channel to DISPLacement via the Setpoint panel Select HSM Lo on the main panel Adjust the Setpoint control to fully retract the actuator without positioning it in the end cap Remove the Hydraulics Adjust GAIN so the conditioner output is less than 10 000 V Adjust the Demod phase to maximize the output of the conditioner Apply the Hydraulics Adjust Setpoint to obtain a reading of zero from the conditioner Connect a displacement measurement device to the actuator rod Move the Setpoint to full scale negative displacement Reduce the GAIN if required so that the actuator rod is in the end cap Record the displacement reading when fully retracte
114. the selected channel by the cyclic function generator You can use the slide bar to set a value or enter it in the text box Sets the frequency of the function to be generated for the selected channel by the cyclic function generator You can use the slide bar to set a value or enter it in the text box Selects the shape of the function to be generated for the selected channel by the random function generator The choices are 1 F 2 1 F Flat F F 2 Selects the root mean square amplitude for the function to be generated for the selected channel by the random function generator You can use the slide bar to set a value or enter it in the text box Selects the minimum frequency content for the signal to be generated for the selected channel by the random function generator You can use the slide bar to set a value or enter it in the text box Selects the maximum frequency content for the signal to be generated for the selected channel by the random function generator You can use the slide bar to set a value or enter it in the text box Control Panel Reference Function Generators continued Control Descriptions for Phased Program Control Controls for Phased channel source Master pop up menu Shape radio buttons Sine Peak amplitude slide bar and text box Phase slide bar and text box Control Descriptions for Others This can be considered a master slave channel relationship This source can only be sele
115. tion if the channel is within limits Control Panel Reference 5 33 Limit Detectors continued Control Descriptions continued Action pop up menu Select the result of an out of limit condition Selections are Indicate This selection causes the indicator to light only while the signal is outside of the limit When the signal returns inside the limit the indicator goes out Alert This selection causes the indicator to light and latch When the signal returns inside the limit the indicator remains lit until the Reset button is used The out of limit condition will be recorded in the message log Pause This selection causes the indicator to light and latch and the system will hold the current controller commands as they were when the signal violated the limit When the signal returns inside the limit the Pause button can be used to resume the signal from where it left off the indicator remains lit until the Reset button is used The out of limit condition will be recorded in the message log Program abort This selection causes the system to trigger an abort if the signal goes outside the limit The Reset button is required to reset the system The out of limit condition will be recorded in the message log Abort amp switch to displ This selection causes the system to trigger an Abort if the signal goes outside the limit If the system is in force control it will switch to displacement control The Reset button i
116. trol Descriptions O O Depa O Run span rate input Stop span rate input Frequency rate input Phase rate input Input the maximum rate that the span function generator is allowed to ramp up when starting a program Input the maximum rate that the span function generator is allowed to ramp down when stopping a program Input the maximum rate that the program will ramp to a new frequency when the program cyclic generator frequency is abruptly changed Input the rate that the phase lag between a master and slave channel can be changed Control Panel Reference 5 51 Setpoints lala ott Dispi fo o in Act 2 Force oo M A a E Act 3 Displ come in TP Act 3 Force Fom G Panel Description The Setpoints panel allows you to define a desired position or force setpoint for each actuator Access Open the Setpoints panel by selecting the Setpoints option from the Operation menu on the main panel When to Use the Panel Use this panel to define a desired position or force setpoint for each actuator The software will move the actuator to this position or load the structure to the desired force when power is applied to the actuator and the Run button is pressed on the Main panel 5 52 Control Panel Reference Setpoints continued Control Descriptions E O O Dopa O Act 1 2 3 radio buttons Selects the control mode for a specific actuator Act 1 2 3 Displ text In displacement mode inputs de
117. troller d Use the Oscilloscope to monitor the selected User A D input e Turn hydraulic power ON This provides pilot pressure to the 3 stage servo valves while preventing main pressure from reaching the machine f Select Spool position in the Rate input readout pop up menu of the valve driver panel g Set the Inner Loop Tuning Proportional gain to 0 0 and the Rate gain to 0 0 h Open the Function Generator panel set up square wave to 1 Hz and start with small amplitude such as 5 to 10 i Use the oscilloscope to view the spool position feedback signal On the Valve Driver panel raise the proportional gain until the spool begins to overshoot Calibration and Tuning 8 15 8 16 Calibration and Tuning Adjust the valve Balance until the overshoot is the same in the positive and negative directions Raise the Rate gain to dampen out the overshoot Raise the Proportional gain to achieve overshoot then dampening out the overshoot using rate gain Continue this iterative cycle until the feedback begins showing some sawtooth waveform or instability occurs Back off proportional and derivative rate terms for clean rise and corner move to horizontal Spool Zero Adjustment Ideally setting the valve drive signal to zero should result in no motion in the system and minimum oil flow Realistically all three stage valves have a little mechanical electrical bias that must be adjusted out This is done using th
118. ty should be 1 of full scale Therefore in the example above 15 mm should indicate a range between 1 90 to 2 10 Vdc on the conditioner output If not return to step 1 20 When the DC Calibration procedure is completed Save settings from the File menu on the main panel to save the new calibration settings Differential Pressure Transducer Delta P Calibration 8 8 To calibrate a DC Conditioner for use with a differential pressure cell NOTE Turn on the console and allow the modules to warm up properly approximately 5 minutes before you make any electrical adjustments Select the AC DC Conditioners option from the Conditioners menu on the main panel Select the DC Conditioner channel for the delta P feedback Disconnect the differential pressure cell from the actuator being careful to note its orientation Attach an appropriate calibrated pressure source to the differential pressure cell input labeled P1 The pressure source must meet the capacity of the differential pressure cell and have a higher accuracy than the differential pressure cell MTS recommends using a dead weight pressure tester If necessary adjust the Excitation and Gain controls to the respective values listed on the original calibration sheet Apply a pressure as close to 100 capacity of the system as possible Then apply zero pressure and adjust the ZERO value on the DC Conditioner panel until the Conditioner Output equals OV Repeat ste
119. ull 26 scale Therefore in the example above 15 mm should indicate a range between 1 90 to 2 10 Vdc on the conditioner output If not return to step 1 When the AC Calibration procedures are completed Save settings from the File menu on the main panel to save the new calibration settings Calibration and Tuning 8 5 DC Conditioner Calibration AC DC Conditioners 170373 act 2 Force tik 9 999664 gt 10 0 ES The DC Conditioners are used for different types of feedback force pressure and acceleration Force is measured using a load cell pressure is measured using a differential pressure cell and acceleration is measured using an accelerometer Each has its own calibration procedure 8 6 Calibration and Tuning Force Transducer Calibration To calibrate a DC Conditioner for use with a load cell NOTE Turn on the console and allow the modules to warm up properly 10 11 12 13 14 15 16 17 18 approximately 5 minutes before you make any electrical adjustments Select the AC DC Conditioners option from the Conditioners menu on the main panel Select the DC Conditioner channel for the force feedback Install a calibration reference load cell in series with the system load cell to verify accurate force feedback settings Connect the reference cell to it s corresponding electronics so you can monitor the output readings from the reference load cell Se
120. ustments Master Gain Adjustment Master gain is a multiplier applied to the error signal It determines how quickly the controller responds to error The greater the gain the more the servovalve opens for a given error As master gain is increased the error decreases indicating closer tracking of the feedback to the command The following figure shows a step command and resulting transducer feedback signal with a small gain lt Response Time Command Feedback 0 Increasing the master gain decreases the stability margin of the system increases the frequency of oscillation and decreases response time The following figure shows the effect on the transducer feedback of increasing the master gain adjustment Command Feedback 0 Setting the master gain too high can result in unstable system operation causing specimen damage Master gain should be set high enough to achieve an appropriate response time while maintaining stable system operation 3 6 Understanding Control Principles Span Adjustment The maximum and minimum amplitude of a waveform output by a programmer is 10 volts which represents 100 of the full scale operating range The master span control determines the amplitude of the command signal that is sent to the servo control process 100 Span Level 2 1 202 T Span Affects n S P Zms 0 rogram a8 E Amplitude FRE a 100 Setting the Span Controls You set
121. ustments adjustments to the servo loop should be made iteratively The following paragraphs explain how the servo loop controls affect the error signal Proportional gain adjustments affect how well the error signal will follow the program The greater the proportional gain the more the servovalve opens for a given error As proportional gain is increased the error decreases indicating closer tracking of the feedback to the command The following figure illustrates the program and resulting transducer feedback signal with a small proportional gain Response Time gt Program Transducer Feedback 0 Control Panel Reference 5 45 PID Controllers continued Increasing the gain decreases the stability margin of the system increases the frequency of oscillation and decreases response time The following figure illustrates the effect that increasing the proportional gain has on the transducer feedback Response Time Overshoot to Program Transducer Feedback 0 If the proportional gain is set too high unstable system operation and ringing can result This instability may cause specimen damage Consequently proportional gain should be set as high as possible while maintaining stable system operation Integral adjustments affect system accuracy during static or low frequency operation when the actuator cannot keep the commanded position Increasing the Integral adjustment
122. vailable selections messages 4 12 Introduction to Control Software Table 1 1 con t Software Panel Control Descriptions Control or Display Description Slide Bars Master gain Ne Cd E A slide bar is used to enter numeric values in the system Each slide bar is associated with a specific signal or value which is identified by the label on the slide bar The current value is shown in a text box above the bar The units associated with the signal or value are also identified on the slide bar Change the value identified on a slide bar in one of the following ways e Click and hold or click repeatedly on the slide bar arrows to scroll through the range of values e Click and hold and then drag the box in the slide bar to change the value e Click on the arrow on either side of the box to Sump through the range of values Highlight the text box type in the desired value and then press the return key on the keyboard A quick double click highlights existing text in the entire box Typing then replaces the box contents Each slide bar has a defined range For example the range of the Master gain slide bar is O to 100 You can change the range associated with a slide bar by clicking on one of the small striped rectangles at the end of the bar After clicking on the rectangle type the value desired and press the return key to enter the new range value in the system To cancel w
123. ved 1 Select Restore Settings from the Structural Test System Main Panel File menu The system will open a PC Find window 2 Using standard PC file procedures select the file that contains the system settings that you want to use 3 Click the OK button to restore the selected file or click Cancel to cancel the procedure close the find window and return to the Structural Test System Main Panel To change the access mode select Change Access from the main panel File menu and select the desired access level The current access level will have an The available access modes are Basic The basic user can adjust variables on the main panel and run a test along with setting up the function generators and the data recorder and using all the display panels The basic user can only observe the calibration and configuration panels the controller panels and the limit detector panel Extended The extended user is responsible for setting up or designing a test and has access to all the parameters on all the panels Service For MTS service personnel only Introduction to Control Software 4 3 Quitting the Control To ensure you do not accidentally close the control software application Software the close box on the Structural Test System Main Panel is not functional To quit the control software complete the following steps 1 Select Quit from the File menu on the Structural Test System Main Panel When you selec
124. vice personnel NOTE Both offset and gain are saved in the Settings set file 5 8 Control Panel Reference Analog Output Scaling continued Control Descriptions O OO Dopa O Conv text box Shows the name of the currently selected channel The adjacent channel ID box shows the number of the selected channel Select a channel using the Select Next or Previous buttons Select button Opens the converter selection panel from which you can select a converter Next button Selects the next converter in the selection panel list Previous button Selects the preceding converter in the selection panel list Offset slide bar and text Adjusts the offset of the signal output by the converter Use the box Offset slide bar to set the D A Converter for a current value of 0 00V You can use the slide bar to set a value or you can enter it in the text box Gain slide bar and text Adjusts the gain of the signal output by the converter Use the Gain box adjustment to set the full scale range of the D A Converter You can use the slide bar to set a value or you can enter it in the text box Current value text box Shows the current value output by the selected converter Not editable Control Panel Reference 5 9 Analog Outputs ixi 1 Act 1 Displ cmd 3 Act 1 Displ err 5 Act 2 Force cmd 2 Act 1 Displ fbk 4 Act 1 Force fbk 6 Panel Description The Analog Outputs panel allows you to select a signal to be outputted to a D A co
125. ween Current and Reference gt gt Copy gt gt Copies all current gain parameters to their corresponding reference gains lt lt Switch gt gt Swaps all current gain parameters with their corresponding reference gains lt lt Copy lt lt Copies all reference gain parameters to their corresponding current gains Adjusts the gain value You can use the slide bar to set a value or enter it in the text box Adjusts the reset value You can use the slide bar to set a value or enter it in the text box Adjusts the limit for the reset integrator control authority Input the value in of full scale output You can use the slide bar to set a value or enter it in the text box Control Panel Reference PID Controllers continued Control Descriptions Control Derivative slide bar and text box Feedforward slide bar and text box Bandwidth slide bar and text box Delta P slide bar and text box Adjusts the rate value You can use the slide bar to set a value or enter it in the text box Adjusts the amount of the differentiated program signal summed with gain reset and rate to create the valve command signal for the selected channel You can use the slide bar to set a value or enter it in the text box Adjusts the bandwidth of the low pass filter You can use the slide bar to set a value or enter it in the text box Adjusts the amount of delta pressure that is summed with gain reset and rate to create the c
126. xt box Selects independent autoscaling In this mode the two signals are scaled to fill the entire scope display area regardless of their relation to each other If this box is checked the same scaling is applied to both signals Select a relation for the A and B traces Time time is displayed along the X axis amplitude along the Y axis Freq frequency is displayed along the X axis amplitude along the Y axis X Y signal A amplitude is displayed along the X axis signal B amplitude along the Y axis Control Panel Reference Oscilloscope continued Control Descriptions continued Control Sweep Single and Auto buttons Scope display area text boxes Select single sweep or automatically updated sweeps for display e Ifin Single mode only one sweep will be displayed To update the display use the Single button again If in Auto mode the display will be updated when one sweep period as set on the Sweep Period slide bar of new data is available To return to the single mode from the automatic mode use either the Single or Auto button The text boxes surrounding the scope display area show the values of the upper and lower limits currently displayed e Ifin Time display mode the top and bottom text boxes on the right and left sides show the minimum and maximum values of the A and B traces respectively the right and left text boxes on the bottom of the monitor show time If in Freq display mode th
127. y number control field in the panel Fine Sets a fine step size for any number control field in the panel Enable Disable Button and Enables or disables the Encoder wheel used for changing number control fields Indicator in the panel Encoder wheel is enabled when indicator is lit Encoder Wheel If enabled changes the value of the currently highlighted number control field Clockwise rotation increments the value Counter clockwise decrements the value The step size is determined by the Step size buttons course medium and fine Operation 6 11 Changing Mode and Setpoints with the Remote Control Pod Complete the following procedure to change the mode and setpoints using the Pod Verification and Safety Checks e Ensure that there are no obstructions Change Settings 1 Turn on hydraulics from the Main Panel 2 Select Pod as the program source on the Main Panel The Pod will show the screen below Remote Station Con 3 Select an actuator by using the Up and Down arrows to tab through screen selections until you get to the Channel textbox Use the Left and Right arrow buttons to select the desired actuator Press Enter to finalize the change 4 The control modes of the actuators can be changed by using the Up and Down arrows to highlight the Mode text box Use the Left and Right arrow buttons to change the desired mode The Enter button must be pressed to finalize the change 5 The setpoint of the actuator can b
128. y the command feedback comparison causes the servovalve spool to open in a direction and by an amount necessary to cause the desired actuator response As the actuator responds feedback approaches command As the program input changes the command feedback comparison continuously generates dc error signals that drive the servovalve to create the desired actuator displacement When command and feedback are equal the dc error is reduced to zero the servovalve spool closes and the actuator does not move This control method is referred to as closed loop control In addition to gaining the proportional error described above the system also gains the rate of the proportional error derivative gain and the duration of the proportional error integral gain This is the PID controller Understanding Control Principles Inner and Outer Closed Loop Control The simplest form of closed loop control as described in the preceding subsection is used in systems containing a standard one stage servovalve However the large flow and frequency response requirements of seismic testing require the use of a multi stage servovalve The multi stage servovalve Figure 3 2 contains a spool LVDT that introduces a second loop into the basic closed loop control system the basic closed loop described above becomes an outer loop and the second loop becomes an inner loop The MTS Model 252 servovalve is used solely to drive the slave stage spool
129. ystems that are not compatible with these types of fluids Avoid System Crush Stay away from any potential crush points especially when the system is Points running The system is capable of producing very high forces within a fraction of a second Never assume that human reaction time is fast enough to escape injury Know where the crush points are on your system and protect yourself and others with appropriate safety devices Use Care When Test specimen installation is potentially the most hazardous part of Installing Test system operation You are very close to or in contact with the system Specimen force train during installation Exercise great caution to avoid crush points Be sure to follow all provided installation instructions along with the following e Clear the work area especially near crush points e Balance the servo control loop reduce dc error to zero use low hydraulic pressure and ensure that the servo control system is stable Be particularly alert for phase or control reversal if the system setup has been modified since the last time the system was operated e Do not bump wiggle adjust or otherwise disturb a transducer that provides a feedback signal to the control system 2 4 Safety Practices Hazards Related to Unexpected Actuator Reactions Loss of Control Mode Feedback Loss of Servovalve Control Signal Destructive forces can be generated from unexpected actuator response Likely causes of such re

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