Researcher`s Resource Guide - MAST Laboratory, University of
Contents
1. 22 75 21 25 Minimum distance from bottom of gt 19 75 crosshead to strong floor lt _ 8 25 Strong floor D12 Figure 12 Standard crosshead positions The insertion of combinations of spacers in vertical actuators enable the crosshead to attain the standard positions Spacers totaling up to 126 inches can be inserted At the maximum clearance the maximum number of spacers are used At the minimum distance no spacers are used At each standard position the vertical actuators are at mid height to provide flexibility for actuator extension For taller specimens less tension may be applied For smaller specimens less compression may be applied It is possible to temporarily remove vertical actuator Z3 to admit a large or odd shaped specimen into the test floor space below the crosshead MAST Resource Guide Ver 2 0 9 27 2011 Page 37 of 48 Researcher s Resource Guide Strong walls reaction system The MAST Laboratory has North and West reaction walls in the Test Bay The strong walls are L shaped in plan and are post tensioned horizontally and vertically Each leg is 35 feet high 35 feet wide and seven feet thick The overall load capacities at the base of the wall are e out of plane horizontal shear equal to 1760 kips 7800 kN e out of plane moment equal to 43 600 kip ft 59 100 kN m e vertical torsion equal to 38 000 kip ft 52 600 kN m The walls maximum horizontal deflection design limit is 0 52. NI l1 I K E SL l I Pitch i Y Positive Y l I Actuator Z2 Figure 1 Isometric of crosshead positioned in strong walls Using ancillary actuators The four 220kips ancillary actuators have strokes of 10 inches Ancillary actuators offer options to customize a testing protocol Each of the ancillary actuators has the option of being independently controlled by user specified targets or of being in a master slave combination Controlling one or more ancillary actuators to apply simulated gravity loading to test structures is an example using independently controlled ancillary actuators When an ancillary actuator is slaved to one or more DOFs it is controlled by scaled master control signals from the six DOF controller MAST Resource Guide Ver 2 0 9 27 2011 Page 9 of 48 Researcher s Resource Guide An example of slaving one or more ancillary actuators to a set of scaled master actuator drive signals is to use the ancillary actuators to apply lateral displacements or loads to intermediate stories of multi story subassemblages that are proportional to those applied at the crosshead Another example of this control combination is the case of employing the ancillary actuators to control the beam end boundary conditions at assumed inflection points For more information The HCC User Guide has related information that you will need to know Refer to that Guide for topics
3. ccssssssccceeeeeeeeees 40 Figure 15 Pattern of attachment holes on strong floor oe ecccceeeeseesnteeeeeeeeeeeeees 41 Figure 16 Srongfloor Strong Wall Attachment Plate ecccseessssetteeeeeeeeeeeees 42 Figure 17 Pattern of attachment holes on crosshead bottom flange and stiffening plate44 MAST Resource Guide Ver 2 0 9 27 2011 Page 5 of 48 Researcher s Resource Guide How this Guide is organized How this guide is organized The Researcher s Resource Guide has several purposes The first 1s to provide basic information about the MAST Laboratory environment that may help a researcher prepare an NSF proposal The major purpose however is to support the design and planning of your MAST project its all important work plan and testing protocol The Resource Guide describes resources it is anticipated a visiting researcher will need Therefore the Guide includes specific information such as the contents of a work plan actuator dimensions attaching a specimen in the MAST Test Bay tools and instrumentation available for loan and placement of the light camera towers Some information is best kept available on up to date Web sites rather than on a printed page The Resource Guide contains a number of URLs for useful Web pages The necessities of brief visits and longer term stays at the MAST Lab require attention to practical matters as well The Guide also contains information regarding places to stay transportation and local re
4. and research Training the project team As stated in the MAST Laboratory Safety Plan The MAST Laboratory requires that all students employees and others who will be working for some length of time at the Lab review the contents of the Safety Memo MAST Resource Guide Ver 2 0 9 27 2011 Page 27 of 48 Researcher s Resource Guide and sign the Agreement Statement The Agreement statement affirms that the person has read the Safety Memo and agrees to abide by its contents The PDF version of this document is available on the MAST Web site under the safety tab Available tools Power tools can be checked out of the Storage Room on a daily basis Please request a list of available tools from MAST Staff Electric welder and cutting torch The electric welder and cutting torch may be used by qualified subcontractors however prior approval from the Operations Manager is needed The subcontractor is required to verify professional qualifications and prior experience Hand tools Hand tools can be checked out daily from the store room NEES researchers are responsible for returning all tools to the Storage Room in operable condition Practice good housekeeping Keeping the Lab as clean and orderly as possible is part of good safety practice e Use the Lab s mobile workstations for operations in and near the Test Bay e During construction ensure regular clean up so debris does not accumulate Page 28 of 48 9 27 2011 University o
5. available to apply to the test specimen Force balance compensation corrects for this by trying to control the shear and warp to zero This ensures that the force is distributed equally among all driving actuators Compensation for geometric cross coupling Geometric cross coupling between degrees of freedom can limit or cause unintended crosshead motion For example if you want the vertical actuators to achieve a purely vertical extension or retraction the longitudinal actuators must also extend a distance D If they did not the vertical actuators could not keep strictly vertical there would be an unwanted horizontal component Figure 7 Figure lillustrates the behavior Amount actuator kK must extend xX 2 x 4 WW 2L Longitudinal D06 Figure 7 Diagram showing the effect of geometric cross coupling The MTS controller eliminates the effect by introducing a cross coupling compensation into the displacement control loop of each affected axis The Geometric Limits of MAST Crosshead 1s a spreadsheet based application that a researcher can use to determine whether a desired translation or rotational movement of the crosshead is within the capabilities of the crosshead actuators This application also performs the same compensation as does the MTS controller To maximize MAST Resource Guide Ver 2 0 9 27 2011 Page 19 of 48 Researcher s Resource Guide horizontal stroke the specimen height should be designed to
6. commercial area It has food pizza drug store and other necessities http www dinkytownminneapolis com Stadium Village Web site Stadium Village is located on the eastern side of the East Bank Campus and is a small hence name commercial area It has food pizza Hotels and other necessities http www stadiumvillage com Public transportation site The University is the destination for many bus lines http www metrocouncil org transit Parking at the MAST Lab Two meter spaces 2 hour limit metered 6 10 daily except Sunday One Disability space 3 hour limit 7 4 30 Three blocks east of the Lab is a 2 day lot Weather in Minneapolis The table below contains average weather statistics for Minneapolis These temperatures are F Maximum Minimum Average Rain Snow temperature temperature temperature inches inches Page 48 of 48 9 27 2011 University of Minnesota
7. degree of flexibility for configuring various test programs MAST Resource Guide Ver 2 0 9 27 2011 Page 7 of 48 Researcher s Resource Guide Performance specifications The goal of the MAST facility is to test components subassemblages or substructures in a reliable and predictable manner that simulates three dimensional conditions present in the response of a particular structural system To support the use of full scale or near full scale specimens the MAST system has the non concurrent force and displacement capabilities shown in Table 1 Table 1 Maximum non concurrent capacities of MAST DOFs DOF ean Stroke Max Specimen Degree of Freedom Rotation Dimension Translation 880 kips 16 inches 20 feet Rotation 8910 kip ft 7 degrees Translation 880 kips 16 inches 20 feet Rotation 8910 kip ft 7 degrees i 1320 kips 20 inches Z Translation Rotation 13 200 kip feet 10 degrees 28 feet 9 inches inboard inboard Note that these capacities assume the horizontal actuators are connected to the crosshead at the inboard position The horizontal clear distance between the vertical actuators can accommodate specimens up to 20 feet in length in the two primary orthogonal directions Specimens up to about 40 feet in length may be oriented along the diagonal directions but the width is limited to approximately 10 feet in width To support flexibility in loading users can specify target inputs in terms o
8. inches A regular grid of non threaded through holes with a nominal 18 inch spacing center to center are incorporated into each strong wall As built measurements are available on the MAST Web page You will need these as built measurements if you want to have an attachment plate drilled to fit the hole pattern in a specific area of the wall This would be the case for example if you plan to attach a specimen to the strong wall Fixtures with extremely tight tolerances should be discussed with the Operations Manager prior to detailing and fabrication Each through hole has a nominal capacity of 125 kip axial and shear loading together Page 38 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide North strong wall Figure 13 shows the grid of holes in the North wall This is the view of the wall A A as you face it from the office area A A Staging Test bay GG LLL Control room North gt strong wall BACK OF WALL 324 Y END OF WALL 180 Y WALL 240 Y A 207 Y B 189 Y C 171 Y D 153 Y E 135 Y F 117 Y G 99 Y H 81 Y 1 63 Y J 45 Y K 27 Y L 9Y M 9 Y 2 O 45 Y P 63 Y Q 81 Y R 99 Y S 117 Y T 135 Y U 153 Y V 171 Y TOP OF WALL 420 Z 22 396 Z 21 378 Z 20 360 Z 19 342 Z 18 324 Z 17 306 Z 16 288 Z 15 270 Z 14 252 Z 13 234 Z 12 216 Z 11 198 Z 10 180 Z 9 16
9. safe manner The MAST Lab provides four robotic towers that are 24 feet in height adjustable in heights of 12 feet and 18 feet The towers have two shelves on each shelf is a digital video camera a digital still camera a microphone and a light source The shelves themselves move vertically by remote control units from the safety of the Control room and through a Web interface across Internet2 Researchers can direct and focus the cameras using the Telepresence console in the Control room and through a Web interface across Internet2 MAST personnel install the towers and bolt them into the strong floor or staging area floor Towers install into the floor before during or after construction depending upon the type of specimen and the requirements of its construction To minimize the potential for damage to the telepresence equipment it is desirable to install the towers just prior to testing After a test completes MAST Staff remove the cameras and lights and the towers as demolition permits The floor plan below shows one arrangement of towers about the crosshead oo G PSH ca is pia RHEE SCR O08 0 eo 6 7 Pees ecan Le Figure 11 Test Bay floor plan with camera towers installed at corners Page 34 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Features of the video cameras and microphones There are eight digital video cameras assigned to specimen detail with a separate
10. strain gage sensor circuits Formula channels You should plan the calculated formula channels These are mathematical combinations of a specified set of strain or voltage sensors and are archived and displayed along with the physical sensor data channels Graph plots DAQ provides a graph function in which you can create four 2 dimensional graphs of sensor data or formula results There are no limitations in that you can plot sensor versus sensor or formula or analog output you do not have to plot against time You can plot multiple variables on the Y axis against a single variable on the X axis Data Policy NEES data curation and responsibilities To comply with the NEES data curation process data collected for each NEES project is uploaded to the NEEShub Project Warehouse Data transferred to the Warehouse consists of unprocessed formats produced by the following systems data acquisition DAQ Krypton HCC still images from the telepresence towers and video frames and MP4 encoded files All files are linked to the appropriate project experiment and trial once on the NEEShub MAST Resource Guide Ver 2 0 9 27 2011 Page 23 of 48 Researcher s Resource Guide In addition to the unprocessed data NEES also requires other metadata and documentation Key documents include but are not limited to the following test specimen material properties sensor locations technical drawings experimental setup report site equipment us
11. to set up and configure data collection It will be helpful for you to become familiar with its contents and you will gain some understanding of how best to use DAQ for your project The DAQ User Guide is available at the MAST Web site www nees umn on the training tab Sensor information to bring to the lab Sensor leads connect to the DAQ hardware channels Each channel has a unique number and those numbers organize the DAQ setup windows As your sensors are connected MAST Staff will be able to tell you these channel numbers You need to create a unique name for each sensor and you will enter this name in the DAQ setup window The name can have up to 32 characters BUT no spaces Range and precision Range and precision are related quantities In the DAQ system the user can specify the range over which valid measurements can be taken The DAQ system displays the precision associated with the selected range to give the user an indication of the smallest possible measurement increment You need to use an appropriate instrument and appropriate resolution to capture the desired output Precision values reflect the 16 bit analog to digital conversion capabilities of DAQ analog to digital hardware If the range is in volts then the precision 1s 1n volts If you select a range of 5 0 to 5 0 volts the precision of the A D equipment is at 0 000153 volts As an example if a 40 inch string pot is calibrated to produce 0 5 volts per inch of move
12. 011 Page 41 of 48 Researcher s Resource Guide The strong floor is post tensioned to minimize deflection The maximum vertical deflection design limit is 0 10 inches Deflection will vary For example deflection has been measured at vertical actuator Z3 to be 0 006 inches In this case a steel column specimen was at the center of the crosshead under maximum crosshead load of 1 300 000 pounds As the crosshead applies force through the vertical actuators the floor carries the reactions with the specimen The holes that appear darker are the same as all the others Not shown on this drawing are non threaded holes used for rods that placed the panels into the concrete foundation The strong floor has a regular grid of holes at 18 inches center to center This is the nominal measurement As built measurements are available on the MAST Web page Each threaded hole has a capacity of approximately 125 kips tension or compression and 125 kips shear The floor holes are 3inches in diameter and 4 inches deep 4UNC 2B threads A limited number of threaded inserts are available to reduce hole diameters to 1 SUNC 2B threads or 1 5 6 UNC 2B threads to accommodate smaller bolts or rods As you look at the diagram note the hole patterns for each of the vertical actuators Z1 Z4 The vertical actuators must remain as currently positioned in the strong floor All the holes shown in the drawing are available for project use Strong tloor
13. 2 Z 8 144 Z 7 126 Z 6 108 Z 5 90 Z 4 72 Z 3 54 Z 2 36 Z 1 18 Z BOTTOM OF WALL 0 Z View A A Figure 13 Pattern of attachment holes in North strong wall The vertical columns of three hole sets are for attachment of the horizontal actuators X1 and X2 they can only be attached along these columns As numbered at the top of the wall the three hole sets are E F G H Q R and S T MAST Resource Guide Ver 2 0 9 27 2011 Page 39 of 48 Researcher s Resource Guide West strong wall View B B Figure 14 shows the grid of holes in the West strong wall This is the view of the West wall B B as you face it from the Control room Staging Test A West strong wall BACK OF WALL x Q a z u O a zZ w V 171 X U 153 X T 135 X S 117 X R 99 X Q 81 X P 63 X O 45 X N 27 X M 9 X L 9 X K 27 X J 45 X 63 X H 81 X G 99 X F 117 X E 135 X D 153 X C 171 X B 189 X A 207 X WALL 240 X TOP OF WALL 420 Z 22 396 Z 21 378 Z 20 360 Z 19 342 Z 18 324 Z 17 306 Z 16 288 Z 15 270 Z 14 252 Z 13 234 Z 12 216 Z 11 198 Z 10 180 Z 9 162 Z 8 144 Z 7 126 Z 6 108 Z 5 90 Z 4 72 Z 3 54 Z 2 36 Z 1 18 Z BOTTOM OF WALL X 0 Z View B B Figure 14 Pattern of attachment holes on the West strong wall Page 40 of 48 9 27 2011 Univ
14. C windows for monitoring and control of the testing apparatus as you and the MAST Staff run your experiments MAST Laboratory Safety Plan This is the official Safety Plan for the Lab It has several sections of interest to the researcher because the project work plan must demonstrate the incorporation of good safety practice Safety Training Memorandum This manual is the basis for the MAST Lab safety and awareness training session In this session the person reviews the contents of the Safety Training Memorandum directly with MAST staff and then signs the Agreement Statement The Agreement statement affirms that the person has read the Safety Memo and agrees to abide by its contents MAST Laboratory Site Access and Policy This manual informs and supports researchers as to expectations resources and boundaries at the MAST Lab MAST Resource Guide Ver 2 0 9 27 2011 Page 25 of 48 Researcher s Resource Guide Construction Depending upon the type of project scheduling constraints and the specimen being investigated construction or assembly may take place in either the Staging area or the Test Bay area When possible construction in the Staging area is preferred Because construction location has a direct impact on the MAST schedule specimen construction location should be discussed in the work plan MAST personnel will work with researchers to suggest possible construction rigging plans associated with specimen fabrication in t
15. Guide http nees umn edu training HCC pdf 2011 Regents of the University of Minnesota All rights reserved The University of Minnesota is committed to the policy that all persons shall have equal access to its programs facilities and employment without regard to race color creed religion national origin sex age marital status disability public assistance status veteran status or sexual orientation Page 2 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Contents and Figures Contents How this guide is organiZed sseecsceccosecsecccccccececceceecccccessccccccccceseecooseosescccccccceseccossosssseee 6 Capabilities of the MAST Systeim cssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssess 7 Performance specications nsina a a a a 8 Usine Ancillary ac tudtoiS unose a dinesaute eee cvesectoalamdiaees 9 For morcinlormanoii senne a a a a a 10 MAS T SV Stein ACIU ALONS acti td2ecec ste reecccte da tedcictennectelatictenascctedsteteistndeteletielenaseiedetiten 11 Primary vertical ACWlatOrs ssh Saher cate nie aa Ga ben ante AATA A 11 Primary horizontal actuators soiin cin eas 12 Ancillary acato S onsena A n eda acess atte 13 Hydraulic power supply and service manifolds ccc ccccccccceceeceeeeeeeeeeeeeeeeeeeees 13 MAS ECEOSSICAG assoc ss cstssatecstceunecebieesecansadesevanessenudecsucebeeensdeasvasesubedsactessssshasvedebaseeseunsess 15 TOSSING AG GE lechones en e a E seta
16. OF and each actuator drive signal is determined by summing together all individual DOF error signals that are effected by that actuator In addition to the six DOFs the control system monitors and manages force imbalances among the horizontal actuators shear controller and vertical actuators warp controller Eight controllers Eight actuators X DOF X1 longitudinal Y DOF X2 longitudinal Z DOF Y3 lateral RX DOF Y4 lateral RY DOF Z1 vertical RZ DOF Z2 vertical Shear Z3 vertical Warp Z4 vertical MAST Resource Guide Ver 2 0 9 27 2011 Page 17 of 48 Researcher s Resource Guide In MAST DOF space shear and warp reflect how efficiently the controller system is applying the loads you request Shear is the unbalanced portion of horizontal actuator forces Warp is the unbalanced portion of vertical actuator forces Shear in the crosshead aresult of V4 actintorteadbacke X2 actuator feedbacks Y3 actuator feedbacks Y4 actuator feedbacks Shear value D11 Z1 actuator feedbacks Z2 actuator feedbacks Z3 actuator feedbacks Z4 actuator feedbacks 71 Warp value L ON Z4 Ce D10 Figure 6 Shear and warp acting on the MAST crosshead The HCC MAST Controller window displays real time values for DOF shear and warp During testing the DAQ system records DOF shear and warp data through the analog outputs which are hard wired to the DAQ A D hardware Closed loop control The control l
17. ONM OR and chanus e SESE ETENEE EESE 46 P rsonal LOGS OCS oeri esaeen e EAEE 47 Hsin the oriee arei n aetna Dace cue ede gars acerca peeauncueees 47 NOTE SUL ON ea a nett seeuites naneu E EE 47 ISSR WEDS ES trees dete detract cclnavadialene a dncuadadead ina cdudthadeltaenctedanseds 47 POT IVE WC DIA OS sac e a ada tan saddled seid naltate usenet adbaseutitenes 47 Dink ytow i Web Sie lt 5 fa tase iactunthcivndiaedintecaemeaatanleesddnd anaes 48 Stadiu Village WV CD SIUC Gers sacertiorscedeassnseyOicdenasnedtnner Gaerne E EA 48 Public transportation Sitesi eremie e a ERORE 48 Patkine at he MAST LaDonna a E E 48 Weather IMAC AP ONS aeien a a a a e eiior 48 Figures and tables Table 1 Maximum non concurrent capacities of MAST DOFS c ccc ccccccceceeeeeeeeees 8 Figure 1 Isometric of crosshead positioned in strong walls cccccceessssseeseesseeeeees 9 Figure 2 Diagram of a vertical actuator from the MAST system cc ssssseeeeeeeeees 11 Table 2 Characteristics of MAST vertical actuators 00ssneeeeeeeesesssssssssesesresssssssssssseo 12 Table 3 Characteristics of MAST horizontal actuators ccccseesssseeceeeeeeeeeeseeeeens 12 Table 4 Characteristics of MAST ancillary actuators cccccccccccccccccceceeeeeeeeeeeeeeeeeees 13 Figure 3 Diagram showing basic flow of actuator hydraulics cccceeesesseeeeeeeeeeees 14 Figure 4 Partial side view of MAST crosshead cccccccccc
18. Page 30 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Currently six units Applied Geomechanics 716 2B are available 12 tilt measurements Additional load cell equipment The following load cell equipment is available at the Lab e two 1000 kip clevis load cells e four 600 kip clevis load cells e related signal conditioners amplifiers Load cell specifications include e biaxial load cells 2 force outputs oriented 90 degrees apart on the pin e full bridge 350 ohm e 12 volt excitation maximum e output signal 2 mV V e non repeatability 0 15 FS or better e non linearity 0 5 FS or better on primary axes e hysteresis 0 5 FS or better e temperature effects no greater than 0 008 load F on output e zero balance 2 FS or better e 17 4 stainless steel e 5 step loading calibration on primary X and Y axes Strain gage simulator The Lab has a decade resistor designed to simulate the behavior of strain This is a precision strain gage simulator model V E 40 from Vishay It can be used to verify the DAQ hardware setup Specifications include e resistance range of 30 0 to 1111 10 ohms in 0 01 ohm steps e accuracy 0 02 of setting e maximum current 120 ohms 65mA 350 ohms 55mA 1000 ohms 25mA Connection boxes for the test bay Data acquisition sensor connection boxes are provided for easy connection of sensor signals into the DAQ data acquisition system Eight channel 16 channel and 24 channel b
19. SO 8601 standard except for omitting the T that separates dates from times This omission 1s to ensure compatibility with spreadsheet programs File headers do include the T that separates the date and time Units of measurement The MAST system and MTS controller can be programmed to operate in metric or customary U S units By default customary U S units are used However you can choose the units in the DAQ program so that the units your sensor data is archived and displayed in can be metric or any other type Page 24 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide MAST user documentation This Resource Guide refers you to several other manuals All the manuals listed here are available in pdf format on the MAST NEES Web page at http nees umn edu training Here is a list of the current MAST user documentation DAQ User Guide This manual introduces you to data collection in the MAST research environment It is a resource to help you plan your project s data collection activities before you come to the MAST laboratory When you are at the Lab the manual provides a step by step guide to using the DAQ software as you run your experiments HCC User Guide This manual introduces you to the HCC software and its role in the MAST system It describes the MAST coordinate systems DOF space and other concepts of use as you plan your project During testing the manual is a step by step guide to using the HC
20. Strong Wall Attachment Plates MAST has four 48 x48 x4 steel aii transfer plates that can be used for i ia don specimen attachment to the strongfloor or strongwalls and have a nominal capacity of 1000 kips normal to the plate and a shear capacity of 1000 kips The plates are attached to the strongfloor or strongwall and the specimens connect to the plates via the 1 diameter threaded holes Figure 10 details the plate layout and dimensions 932 O O 1 8 threaded A through thickness a a p 0000 0 0 a 00000000 0 90 Q ooc0 qc GO O DO O 000000000000 0 0 0 og 0000090 0 0 O O O O O O O O O O O O O O O O O O O O O O O Figure 16 Srongfloor Strong Wall Attachment Plate Page 42 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Crosshead attachment Load demands on the MAST crosshead due to specimen attachments are determined for each experiment In general the following guidelines will reduce potential problems with crosshead connections When possible specimens attached to the underside of the crosshead should span the 4 5 ft by 4 5 ft central box of the crosshead For specimens that cannot span this distance MAST provides a stiffening plate to reduce the localized effects of the point load on the crosshead Specimens put into compression will have fewer crosshead attachment issues than those put into pure shear or shear tension forces S
21. UNIVERSITY OF MINNESOTA Department of Civil Engineering College of Science amp Engineering Multiaxial Subassemblage Testing System Researcher s Resource Guide Project Planning for the MAST Lab MAST Laboratory Updated September 27 2011 Ver 2 0 Researcher s Resource Guide The MAST testing facility is supported in part by the George E Brown Jr Network for Earthquake Engineering Simulation NEES Program of the National Science Foundation under Award Number CMMI 0927178 The MAST Laboratory building was funded in part by the University of Minnesota Office of the Vice President for Research the College of Science and Engineering the Department of Civil Engineering and individual donors The MAST Computer Infrastructure was jointly developed by the Department of Civil Engineering the Department of Computer Science amp Engineering and the Department of Electrical and Computer Engineering This publication is also available electronically in PDF format at the MAST Laboratory Web site http nees umn edu training RES pdf Other MAST manuals are available at this site including MAST Laboratory Site Access and Policy http nees umn edu training MAST Access Policy pdf e MAST Laboratory Safety Plan http nees umn edu safety Splan pdf e Safety Training Memo http nees umn edu safety Smemo pdf MAST user manuals are also available e DAQ User Guide http nees umn edu training DAQ pdf e HCC User
22. ach at the same level Page 16 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide MAST control system The embedded control system conditions monitors and generates program command and feedback signals that control the MAST system Digital controller MTS Controller The MTS Controller orchestrates the movements for each actuator Using geometric information and actuator load and displacement feedback signals the Controller generates the appropriate servo valve command Degree of Freedom DOF control The movement of the MAST crosshead is governed by the collective movement of the primary actuators To create a desired crosshead movement actuators are time synchronized using a proprietary DOF control concept This concept allows the user to control system motion in a coordinate domain most natural to the test With multiple actuators positioning the crosshead it is impractical to control the system by individually controlling each actuator The required combination of actuator commands needed to position the crosshead in space is complex Because the position and orientation of the crosshead can be defined in terms of its six degrees of freedom it is possible to program the desired motion in DOF terms The MTS Controller provides simultaneous DOF control in all six degrees of freedom In DOF control the feedbacks for each loop are determined by summing together all individual feedbacks that contribute to that D
23. ain in a specially marked off area of the staging floor while the MAST system is active and actuators are moving Interested observers are urged to take advantage of the Lab s Telepresence capabilities for Internet access MAST Resource Guide Ver 2 0 9 27 2011 Page 45 of 48 Researcher s Resource Guide Demolition and clean up After the test completes and demolition of the specimen is at hand the MAST Staff and trained student assistants will remove the sensors and wiring The researcher is responsible for demolition and removal of the specimen after the sensors and wiring are removed There are options for demolition and removal of the specimen e experienced contractors e team of U of MN undergraduates Also the Principal Investigator can supply a team of graduate and undergraduate students The work must be done with MAST Staff on hand who are qualified to operate the crane and other needed Lab equipment Page 46 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Personal logistics Scheduled visits to the MAST Laboratory prior to the approval of work plans are welcome and encouraged Please contact the Operations Manager to set up a visit Your access to the MAST Lab is for the project period defined in the work plan During your project you will have physical access through card keys Using the office area Cubicles in the office area include regular office furniture desk chair and lockable storage ca
24. be one of the standard dimensions between the crosshead and the strong floor given in the section titled Standard Crosshead Positions Interactive limits checker To develop an understanding of how to maneuver and balance limits you need to experiment with the interactive limits checker available on the MAST NEES Web site GeometricLimitsCrosshead Geometric_ Limits of Crosshead zip The Limits Checker tool determines if a desired translation rotation movement of the crosshead is within the capabilities of the crosshead actuators The results obtained using the Limits Checker are accurate only if all DOFs are in displacement control Page 20 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Workplan and responsibilities Each researcher with a successfully funded project must submit a work plan MAST Staff will provide sample workplans for their reference Workplans will contain the following the loading protocol for the specimen slaving requirements anticipated peak loads and displacements and computational needs connection details to the MAST system components including the strongwalls strongfloor and crosshead A finite element model of the crosshead is available to determine crosshead stresses specimen details detailed instrumentation plan which includes the sensor locations DAQ data acquisition setup Krypton system use and LED locations and the telepresence camera and video requirements loca
25. binets Each cubicle has a communications port for the MAST LAN You are behind the U of MN firewall and have Internet access Shared phones are available in the office area IT support The MAST Lab does not provide any computing equipment or digital imaging equipment other than the video and digital still cameras in the MAST Test Bay After training is completed the MAST Lab System Administrator will establish accounts on the following computers for NEES researchers on an as needed basis e data acquisition servers e client machines e local data repository e video teleconferencing equipment Access to all other MAST Lab computers is restricted to MAST personnel Access to the NEEShub including curation services is administered by NEESComm MAST Staff will upload all raw sensor video and stillimage data but researchers are responsible for the data upload of all processed data and metadata Useful Web sites U of MN web pages Campus maps are at http onestop umn edu Maps Short term possibly furnished rentals 3 6 months are at the U of MN housing site especially during summer http www housing umn edu other index html The University newspaper has a classifieds section and rental listings The Daily is online at http www mndaily com MAST Resource Guide Ver 2 0 9 27 2011 Page 47 of 48 Researcher s Resource Guide Dinkytown Web site Dinkytown is a located just north of the East Bank Campus and is a small
26. ccccccceesssseeesssssnteeeeeeeeeeeeees 15 Figure 5 Location of inboard and outboard attachment plates ceeesssseeeeeeeeeeees 16 Figure 6 Shear and warp acting on the MAST crosshead ccccsseesssseceeeeeeeeeeeeees 18 Figure 7 Diagram showing the effect of geometric cross coupling scceeeeeeeees 19 Figure 8 Floor plan of MAST Lab showing areas Of access ccceseessereeeeeeeeeeeeees 26 Table 5 Quantity and types of LVDTs available at the MAST Lab eee 29 Table 6 Quantities of Unimeasure stringpots at MAST Lab ccccceeeeeeeeeees 30 Peur 2 Coordina 4 actectanci cece antatubae a aa EA 32 Figure 9 Coordinate Measuring Machine cccssssssccccceeeeeeeeeeseseeeesssnneeeeeeeeeeeeeees 32 Page 4 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Contents and Figures SAR Uae san ae OMe Sua A sO Eo he aca seh ae NER Ea hansen aie anase Naess 33 Figure 10 CCM System Accuracy Zones from User Manual ccsssssseeseeeeeees 33 Table 7CMM Accuracy from User Manual ccccccccccccccccceceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeees 33 Figure 11 Test Bay floor plan with camera towers installed at corners ceeeee 34 Figure 12 Standard crosshead positions oisinnean aae ea niea 37 Figure 13 Pattern of attachment holes in North strong wall ccccsssccccscceceeeeeeeeees 39 Figure 14 Pattern of attachment holes on the West strong wall
27. ctuator in the MAST system Fluid flow operates very similarly in the system s horizontal and ancillary actuators Fluid pumped into the chamber below the piston causes the actuator rod to extend and generate a displacement in the vertical or positive Z direction To move the actuator in a negative Z direction or to generate a negative force fluid is pumped into the chamber above the piston Upon loss of pressure the manifold due to a pump failure power failure or other cause the actuators lock up keeping the same amount of hydraulic fluid in each chamber This lock up keeps the system from rapidly unloading and keeps the MAST Resource Guide Ver 2 0 9 27 2011 Page 13 of 48 Researcher s Resource Guide crosshead weight off the specimen upon loss of pressure at the manifold In the event of extended loss of hydraulic power the MAST Lab has props that can be installed to support the weight of the crosshead to protect any installed specimen Rod Return Return Hydraulic connections and flow Fluid pumped into the chamber above the piston causes the actuator to contract and generate a tension force Fluid pumped into the chamber below the piston causes the actuator rod to extend and generate a positive displacement Piston gt m Temposonic cable gt es z Servo valve Manifold and hose connections Hydraulic cables Return Servo valve drain D Power 3000 psi Strong floor for vertica
28. directional microphone per camera Four other digital video cameras are positioned to perform sweeps of the Laboratory The cameras provide 470 line resolution and are equipped with a composite video interface From the Telepresence console MAST Staff can position the cameras using on screen controls to pan tilt and zoom the video cameras A robotic motion control system provides vertical movement of these cameras from the Control room Capturing and archiving video and audio data Video data is handled three ways in the Lab First video data is time stamped by Data Turbine and is sent to local network buffers at 1 frame second Periodically a Data Turbine client synchronizes the video data with DAQ sensor data and archives this version The synchronized data is moved onto the Lab s Visualization and Archiving Server system VAS Second the video and audio data 1s converted into Apple MPEG4 format at 30 frames per second When requested video data is also streamed through the Data Turbine to the Real Time DataViewer RDV for Internet2 access Features of the digital still image cameras There are eight digital still image cameras assigned to capture specimen detail They are 9 8 mega pixel devices and output JPEG files From the Telepresence console MAST Staff can manipulate on screen controls to pan tilt zoom set shutter speed and focus the still image cameras Also these controls enable users to capture images specify whi
29. ed and start and end date MAST staff is available to help with data curation however since much of the information required is research focused the responsibility rests primarily with the researcher For more information on the NEES data curation process please consult the official policy online https nees org topics NEESCuration MAST file naming system To the NEES name the DAQ HCC and Telepresence programs automatically add this file naming structure YYYYMMDD_MAST_project_experiment_trial_content_sequence_extension As a result the filenames are long This is the full name of a DAQ data file file nees Twall Zloading Test_1 20040501_MAST_Twall_Zloading_Test_1_data_01 dat Sequence numbers If you change a data or offsets file on the same day the sequence number increases by one Log files are an exception one per Trial name As an example this is the first DAQ data file for May 1 NEES directory omitted 20040501_MAST_Twall_Zloading_Test_1_data_01 dat This is the second data file for May 1 20040501_MAST_Twall_Zloading_Test_1_data_02 dat If you run the test the next day this is the first DAQ data file for May 2 20040502_ MAST _Twall_Zloading_Test_1_data_01 dat Internal time stamps Within the MAST files time stamps use the 24 hour system Time of day is in the range from 00 00 00 to 23 59 59 Dates and times reflect Central Standard Time CST the local MAST time zone MAST programs follow the I
30. er and can cause unexpected actuator reactions and compromise the safety of yourself and others Checks to make during testing During testing the researcher must periodically look for instruments that are subject to damage if a portion of the specimen fails or that can become out of range Check 1f slip has occurred at any of the keel marked interfaces Look for leaks in hydraulic components For safety reasons only MAST Staff are allowed to operate the MTS Controller and local HCC computer The researcher is required to assist MAST Staff by verifying target values entered in the HCC NEES researchers have full access to e the Remote Client HCC program e the Data Acquisition DAQ program and its data and graphing displays e the video controls and video display wall in the Control room Where can researchers and the team be when actuators are moving This is a difficult issue The MAST Lab is built to apply large forces and the reactions to these forces cannot always be safely anticipated Much effort has been expended to build and install computer controlled cameras and lighting equipment to give researchers visual feedback on their specimen and to minimize the amount of time that people are in close proximity to structural elements carrying large forces applied with high pressure hydraulic lines Unless otherwise decided by the Lab s Operations Manager one project personnel will remain in the Control room and all others will rem
31. ersity of Minnesota 324 X Researcher s Resource Guide The vertical columns of three hole sets are for attachment of the horizontal actuators Y3 and Y4 they can only be attached along these columns As numbered at the top of the wall the three hole sets are T S R Q H G and F E Strong floor reaction system The MAST strong floor is a seven foot thick solid concrete slab on piles It is covered with a 5 5 inch thick steel plate forming the tie down surface The steel plate is tied into a 7 5 foot deep foundation that is 35 feet square Plan view Figure 15 shows the placement of the steel panels on the floor and the grid of threaded tie down holes BACK OF WALL 324 X D 153 X L 9 X a WALL 240 X A 207 X B 189 X C 171 X V 171 Y U 153 Y olo T 135 Y olo o o S 117 Y olo o o R 99 Y o o ojo Q 81 Y 0 O o o P 63 Y o o o o O 45 Y z Q O o o N 27 Y NORTH 19 ota a o oo M 9Y 0 STRONG 4 ob o o L 9Y i ojo U o o K 27 Y WALL o lo gt o o J 45 Y olo oO o o 1 63 Y gt o o os o o H 81 Y me Aeon ojo G 99 Y ES ojo F 117 Y ay EE A olo E 135 Y A omes t wo D 153 Y Zi i Oust _ _ 20 C 171 Y B 189 Y A 207 Y HYDRAULIC LINE TRENCH WALL 240 Y WEST STRONG WALL BACK OF WALL 324 Y Plan view Figure 15 Pattern of attachment holes on strong floor MAST Resource Guide Ver 2 0 9 27 2
32. et eat aac atau tan ed 15 Standard crosshead POsSIIONS sonaa aea aa eei Atari EOE ie es 16 Attachment of vertical actMalorS 25 cesetasct iier a E aa Ea A al ad caleuss 16 Attachment of horizontal acttatots scsssirrengisiirei nes 16 MAS L control Sysilia eaer a aaaea 17 Digit l controller MTS Conmtronler i ccsdes sex vvncduce cases vex dunce ed cade aa 17 Destee o1 Freedom WOE Contro lracerairireecenai na a 17 CTOSEC OOM Coniro kreskan e a a a ate antes 18 Torce balance compensano ranee a a baled medesetneetaad ies 19 Compensation for geometric cross COUPLING ccccccceceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 19 Interachiye Hints ehee Ker 3 05 sian test Gove ain trian aaa nciesomasaas Sasi ao Ee 20 Workplan and responsibilities ccccccccccsssssssssssssssssssccscccccccccsscccccsssssssssscsssssssscoooes 21 Planning your project s data COllection ssscssccsssccsssssssscssssssssssssssscscsccccccscsssseeees 22 Initiate the documentation of the project Metadata cc ccccccccccecceeeeeseeeeeeeeees 22 Preparation for Data Acquisition cccccccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees ey 22 Sensor information to bring to the lab ooo cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeess 22 Dua 0 es peers eee ee ee ie Rc restr ae re rece ree eee ee ee ee ere me eee ee 23 NEES data curation and responsibilities ccccccccccceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeees 23 MAS Fflenaming systemi 23 isons seat dhe
33. f Minnesota Researcher s Resource Guide Specimen instrumentation Depending upon the type of project instruments are attached to the specimen in either the staging area or the Test Bay area Instrumentation available at the MAST Lab LVDTs The instruments purchased through NEES are available for use by NEES researchers Sensor and applicable cabling may be checked out for the project period identified in the work plan Project specific calibration of any of this equipment is the responsibility of the NEES researchers Non MAST sensors may also be used on the project but must be identified in the workplan and calibration of these sensors is the responsibility of the NEES researcher At the end of all testing on your project MAST Staff will remove all instruments All non MAST reusable sensors will be returned to the researcher The LVDTs and conditioner units available at the MAST Lab meet these specifications e AC operated e null voltage lt 0 5 full scale or better e shock survival 1000g for 11msec or better e vibration tolerance 20g up to 2 kHz or better e 1 16 inch radial core to bore clearance e frequency range 400Hz to 5 kHz e linearity at 100 of specified range less than or equal to 0 25 of full range e output of 10 volts at full scale can be calibrated Additional specifications for LVDTs with ranges between 0 5 and 2 e screw terminal connection to LVDT body e no exposed wires The MAST Lab uses Schaevit
34. f either global position or global load and these can be different for different degrees of freedom For example in one set of targets a user can specify forces in X and Z stroke in Y moments about Y and Z axes and rotation about the X axis The control system supports the ability to control degrees of freedom in a master and slave relationship The user can specify target inputs for certain degrees of freedom as simple arithmetic operations of the inputs or feedbacks for other degrees of freedom For example if the input in the global X is a stroke then the input for moment in the global Y can be proportional to the force in X Input can also be provided in the form of pre programmed loading histories MAST can also accommodate hybrid testing continuous and ramp and hold MAST has successfully demonstrated a distributed test using the SimCore system Page 8 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide There are six degrees of freedom vertical lateral longitudinal yaw pitch and roll Actuators X1 and X2 form the longitudinal X DOF Actuators Y3 and Y4 form the lateral Y DOF Actuators Z1 Z2 Z3 and Z4 form the vertical Z DOF Figure 1 shows the direction of rotational DOFs as well as the positive directions for forces X Y and Z Positive Z i _ Actuator Xi __ Actuator YY es 4 oe Acfuator Agtuator Ct Zi 7 7 YA Vertical Bo ertica Longitudinal 5 Actuator Actuator _ ose tee ene Iz4
35. find an approved contractor Also if you wish to hire contractors new to the Lab please provide the Operations Manager with the information needed to contact and qualify them Deliveries to the MAST site Space within the MAST Lab is limited Please do not schedule any equipment materials or supplies for delivery to the MAST Lab without discussing the delivery with the Operations Manage or Project Manager No deliveries can be made prior to receiving approval of your work plan and completion of the ESUF An outline of proposed deliveries is a useful element in researcher work plans Project labor Options for project labor include e the principal investigators provide graduate students and undergraduate students from their home institution e the principal investigators hire contractors e Uof MN undergraduates supervised by project personnel and or graduate student paid for by the research project The U of MN Department of Civil Engineering has a number of students who have experience at the MAST Laboratory or the Department s Structural Engineering Laboratory SEL housed within the Civil Engineering building These students are allowed sufficient autonomy to develop their skills in design construction instrumentation and testing of structural specimens Their laboratory work is prefaced with introductory training followed by continued consultation with the faculty and full time laboratory staff who are committed to teaching
36. he Staging area Also the locations of the camera and lighting towers are planned in advance MAST Staff will consult with the researcher about where to install the cameras and lighting Only MAST Staff can install the towers Some specimen design may require that a tower be installed during construction rather than after Although MAST assumes no responsibility for making technical decisions on specimen fabrication some decisions may benefit with input from MAST personnel Dimensions of staging area and test bay The Staging area is about 45ft by 45ft as shown in the floor plan below The Test Bay is the steel strong floor shown within dotted lines It 1s 35ft by 35ft Areas of 7 ZZA Visitor viewing Kept open for deliveries area Exit Storage cS Room Office Area gt Conference Room Electrical Control Room Mechanical Pump Room Room Room 107 110 111 112 Front 4 Entry lt Parking gt Figure 8 Floor plan of MAST Lab showing areas of access Researchers have access to the shaded areas shown in Figure 8 Page 26 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide The following areas non shaded are not available for project use or storage e pump room e storage room e mechanical room e electrical room e crane catwalk e space behind the reaction walls Recommendations for approved contractors Please contact the Operations Manager to help you
37. ide Ver 2 0 9 27 2011 Page 15 of 48 Researcher s Resource Guide Standard crosshead positions Standard dimensions between the crosshead and strong floor using different combinations of actuator spacers are 18 3 19 9 z Ble 229 24 3 25 9 27 3 28 9 Attachment of vertical actuators The vertical actuators are attached at the ends of the crosshead where the actuator connection plates are located The hole positions are shown in Figure 17 Attachment of horizontal actuators The crosshead has attachment fixtures for attaching the horizontal actuator in two positions inboard and outboard The diagram shows the location of each position Outboard plate lt 126 gt Inboard plate lt 90 gt Plate for vertical Two upper plates are Two lower plates are used actuator used by Y3 Y4 by X1 X2 plates are only on the plates are only on the D09 West face of crosshead North face of crosshead Figure 5 Location of inboard and outboard attachment plates For a testing situation that needs to apply a large twisting force the actuators attach to the outboard plates For testing that needs to achieve the most twist displacement the actuators attach at the inboard locations MAST Staff will work with researchers to determine the optimal placement of the horizontal actuators when developing the workplan Notice that the lateral and longitudinal actuators do not att
38. it walking the Lab staging and test areas while patched into VTC via audio NEEShub Account Remote access to data from the MAST Lab requires access to the NEEShub To obtain information about NEEShub accounts see the NEES website http www nees org Page 36 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Attaching a specimen to crosshead strong floor or strong wall Attachment of a test specimen to the crosshead or ancillary actuators must be performed under the direct supervision of the Operations Manager The clear horizontal distance between the vertical actuators can accommodate specimens up to 20 feet in length in the two primary orthogonal directions To increase the horizontal clearance limitations by several feet it is possible to orient a test specimen along a diagonal The vertical clearance is set by the height of the L shaped reaction walls to which the lateral and longitudinal actuators attach Repositioning the horizontal actuator attachments and inserting spacers into the vertical actuators obtains a maximum vertical clearance of 28 9 Standard dimensions between the strong floor and the bottom of the crosshead start at 18 3 and go to 28 9 in 18 increments This diagram illustrates the standard crosshead positions Standard crosshead Maximum clearance from strong jel positions floor to bottom of crosshead gt 28 75 27 25 25 75 24 25
39. l actuators strong wall for D02 horizontal Figure 3 Diagram showing basic flow of actuator hydraulics Page 14 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide MAST crosshead The MAST crosshead weighs 94 000 pounds and is supported by the four vertical actuators 1 5 top plate Cross section of arm lt 56 gt 2 bottom plate Plate for vertical actuator E 147 8 e a 14 65 feet __________ r feet _______________ ___ _ p08 Figure 4 Partial side view of MAST crosshead The MAST crosshead is symmetrical Its length is 29 3 ft tip to tip In section a crosshead arm is 56 inches wide and 65 inches deep Plates of 1 5 inch steel form most of the panels the bottom plate is 2 inches thick Crosshead deflection The design of the crosshead specifies a tip deflection limit of lt 0 1 inches under full load The MAST system will deflect and does so according to the stiffness of the specimen The crosshead itself will not soften but the specimen type and its orientation along the arms of the crosshead may result in deflection that is not negligible When using the controller displacements to determine specimen movement the deflection of the crosshead may need to be considered A more accurate measurement of specimen movement may be made using external displacement measurement instrumentation MAST Staff can help you plan for this MAST Resource Gu
40. ment and the range on DAQ is chosen as 20 inches then the minimum possible displacement that can be resolved is 0 000306 inches Achievement of this resolution is also dependent upon the noise in the test setup Page 22 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide When you select a Range you in effect select a level of precision Try to match the range with the capability of your instrumentation and the anticipated reading range to get the best possible 16 bit precision for your application During a test it is often necessary to balance the need for measurement over a large range of values with being able to resolve small changes in the measurement DAQ lets you choose from the discrete sets of ranges and associated level of precision available with the National Instruments system Voltage sensors As you prepare to come to the Lab collect the conversion factor information for the voltage sensors you plan to use Strain sensors You must use 120Q 3 wire strain gages in the MAST Lab Before you come to the Lab you must have the following information for your strain sensors e gage factors The gage factor expresses how change in resistance relates to the change in strain for that device The gage factor you specify determines which range and precision options DAQ presents for that device e filter options 10 Hz 100 Hz 1 kHz and 10 kHz e calibration information DAQ can perform shunt calibration of
41. nection boxes for the test Day ccececeeceeeeeeeeeecceeeeeeceeeeeceeeeeeeeeeees 31 Nikon Metrology Coordinate Measuring Machine cccccceeeeeeeeeeeeeeeeeeees 32 Video still image and lighting options sssssccccssssccccccsssssssssssssssccsccsccccccssssssseees 34 Camerrand OMIM TOW el Saoi ec aseshe vieen cessed EAE eee 34 Features of the video cameras and MIcrophones ccccccceeeeeeeeeeeeeeeeeeeeeeees 35 Features of the digital still image Cameras ccccccceeeeeeeeseeeeeeeeeeeeeeeeeees 35 Cameras available fOr loane A ENE w ea eels 35 Portable communications VTC laptop wireless headsets ccccccccccseeeeeeeeeees 35 INE SHU ACC OUING eiie a E N E O E 36 Attaching a specimen to crosshead strong floor or strong wall esseeeeeecesscssssssssee 37 Strone walls reaction Syste ni pereina a a a ai 38 Nortisitrone Walea a a A 39 West stono Wall ziana a a a Meena eawtaaelcs 40 Sone FOOL TEACIONES SLC aroi a a A 4 Strong floor Strong Wall Attachment Plates cccccsesssesseseeeeessssssseessssseeeas 42 Crosshead attachment siea a N 43 D rine COS LING soes cae ceicava cos coscacsccuspacessusvenscevasecsecsstctasauapeusesacssdsecencatasceaseabaseusstasseusseeseesieues 45 Pre test equipment INSPECHON sssrin e dea tevin dena secoatieaeels 45 Checks to make urine Stine 93 6 nie ee 45 Where can researchers and the team be when actuators are mMOving 6 45 DGM
42. oop has several feedback components on each actuator One is from a load cell connected to controller electronics by a load cell cable The load cell sends force feedback signals to the controller The other is a displacement feedback from a Temposonic sensor located within the rod chamber near the servo valve and connected to controller electronics by a transducer cable Closed loop control consists of comparing a DOF load or displacement command signal with a DOF load or displacement feedback signal The controller defines the difference between the two as error and generates individual actuator drive signals to minimize the error The Page 18 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide drive signal for individual actuators 1s based on the errors associated with multiple degrees of freedom Force balance compensation When a system has more actuators operating in a single degree of freedom than are theoretically required to define its plane the system is said to be over constrained The MAST six DOF structural testing system is over constrained 1n all six directions Because the crosshead is designed to have a very high stiffness tiny offsets in actuator position can generate large distortion forces The force imbalances can seriously limit the performance of the system when applying large forces to the specimen Force wasted in distorting the crosshead with actuators working against each other 1s force not
43. ormations and loading in a straightforward and reproducible manner The six DOF control software employs synchronized control technology to locate the position of the crosshead through real time simultaneous control of the eight crosshead actuators The MAST system not only enables control of the position in a point of space it enables control of a plane in space This makes it possible to apply biaxial control of structures such as multi bay subassemblages or walls It also enables application of planar translations as well as the possibility of applying gradients to simulate overturning that is axial load gradient in the columns of a multi bay frame or wall rocking With the MAST system full six DOF loading conditions can be imposed at one point on the test structure Additionally it 1s possible to control the crosshead in mixed mode setting some of the degrees of freedom in load control and others in displacement control An example might be controlling vertical force to simulate gravity while applying displacement drifts in the X and Y directions A DOF or ancillary actuator can be configured in a slaving relationship to the command or feedback signals of an independent DOF As an example the moment on the test structure can be controlled as a function of the applied shear of the test specimen which might be used to control moment to shear ratios on wall elements Because of the nature of its design the MAST system enables a high
44. oxes are available Each group of eight signals must be of the same type all voltage or all strain Connection of wires to the MAST Resource Guide Ver 2 0 9 27 2011 Page 31 of 48 Researcher s Resource Guide sensor connection boxes is done by use of lever type connectors no tools are necessary Strain relief for the wires 1s provided by the top of the connection box once the box is closed An eight channel box has one card a 16 channel box has two cards and a 24 channel box has three cards Each card is numbered 0 7 The cables that attach to the boxes will have labels that indicate their physical channel number Each box also has 15 volts DC available for powering tiltmeters string potentiometers etc Full time MAST personnel will connect cables between the sensor connection boxes and the DAQ system Researchers are responsible for the connections between the sensors and the connector boxes Nikon Metrology Coordinate Measuring Machine The MAST Laboratory has one Nikon Metrology Coordinate Measuring Machine CMM system The system consists of a camera infrared Light Emitting Diodes LEDs and control hardware and software Through triangulation the system can calculate the 3D positions of up to 128 LEDs in the camera s 13 1 m field of view Data sampling and archiving of the CMM system are synchronized with the DAQ system using TTL signals The CMM system can be used to perform Figure 9 Coordinate as built verifica
45. pecimens that are placed diagonally to the crosshead may require large spreader systems provided by the researcher to be attached between the crosshead arms The specimen then attaches to these diagonal spreader frames Masonry specimens generally require concrete footers and headers with reinforcing to provide shear capacity at the crosshead interface Non threaded 5 8 holes are drilled into the bottom plate of the crosshead Access is provided to the inside of the crosshead for tightening bolts The nominal hole pattern on the underside of the crosshead is shown in Figure 9 The four hole tabs at the side of the vertical actuator attachment sites are not intended for specimen use MAST Resource Guide Ver 2 0 9 27 2011 Page 43 of 48 Researcher s Resource Guide 69 x 69 x 2 Thick Crosshead Stiffening Plate Mounted Externally Crosshead Attachment Hole Layout Crosshead Stiffening Plate Details Reflective plan view Figure 17 Pattern of attachment holes on crosshead bottom flange and stiffening plate Page 44 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide During testing Pre test equipment inspection Prior to testing the researcher should inspect instrument cable connections and hydraulic lines and must protect any that are subject to damage during testing Do not run equipment over or into any cables Compromising a cable can affect hydraulic performance a load cell or transduc
46. rtical actuators accommodates specimens up to approximately 20 feet in length in the two primary orthogonal directions The table below summarizes vertical actuator characteristics Table 2 Characteristics of MAST vertical actuators Vertical actuator Static load capacity 330 kips tension and compression Displacement transducer Temposonic with 40 inch range Swivels at actuator ends Low friction hydraulic swivel angle 30 Load cell Linear in the full range 330 kips 50 overload capacity Primary horizontal actuators The MAST system has four horizontal actuators one pair in the lateral Y direction and one pair in the longitudinal X direction The horizontal actuators have the same basic components as the vertical actuators except the actuator swivels are a u joint style The 440 kip horizontal actuators attach to the L shaped strong wall with universal swivels and each pair provide lateral loads up to 880 kips in the orthogonal directions with strokes of 16 inches Table 3 summarizes horizontal actuator characteristics Table 3 Characteristics of MAST horizontal actuators Horizontal actuator Static load capacity 440 kips tension and compression Displacement transducer Temposonic with 32 inch range Swivels at actuator ends Low friction mechanical swivel angle 25 Load cell Linear in the full range 440 kips 50 overload capacity Page 12 of 48 9 27 2011 University of Minnesota Researcher s Re
47. source Guide Ancillary actuators The MAST system has four ancillary actuators They mount to the specimen and to either the strong floor or a strong wall The 220 kip ancillary actuators can apply either lateral loads or displacements at intermediate story levels gravity loads or simulated specimen boundary conditions with strokes of 10 inches Another use of ancillary actuators 1s to simulate inflection points in beams Table 4 summarizes ancillary actuator characteristics Table 4 Characteristics of MAST ancillary actuators Ancillary actuator Static load capacity 220 kips tension and compression Displacement transducer Temposonic with 20 inch range Swivels at actuator ends Low friction tilt angle at lower swivel 16 at upper 90 Load cell Linear in the full range 220 kips 50 overload capacity Hydraulic power supply and service manifolds The MAST system has one Hydraulic Power Supply HPS with a 190 gallon per minute pumping capability There are five Hydraulic Service Manifolds HSM located in the Test Bay Four that serve the primary actuators have a capacity of 50 gpm The model that serves the four ancillary actuators has a capacity of 100 gpm One supports longitudinal actuators X1 and X2 One supports lateral actuators Y3 and Y4 Two support vertical actuators Z1 Z2 Z3 and Z4 One supports the ancillary actuators Al A2 A3 and A4 Figure 3 shows the flow of hydraulic fluid to a vertical a
48. staurants Page 6 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide Capabilities of the MAST system There are two key features of the MAST system The first is the implementation of a sophisticated six degree of freedom control system to enable application of complex multi directional deformation or loading schemes to structural subassemblages The second 1s the ability to apply large loads and deformations to enable testing of large scale structural subassemblages including portions of beam column frame systems walls tanks and bridge piers Large scale testing of structures or components of structures can deliver engineering insight into structural behavior that cannot be realized by any other means Often the loading and boundary effects where the specimen couples to the reaction structure are reduced to simple uniaxial loading configurations not necessarily representing the physical boundary conditions or loading experienced in practice Furthermore the difficulty of imposing multiple degree of freedom states of deformation and load using conventional structural testing means can be expensive time consuming and difficult to achieve The MAST system employs an MTS six degree of freedom controller to position a crosshead using eight actuators Four actuators are normally vertical and two pairs are normally oriented horizontally orthogonal to each other Together these components can apply realistic states of def
49. such as e crosshead control and movement e coordinate domains e types of control modes e slaving of DOFs and actuators e limit detection with error reporting system interlocks and aborts e using analog inputs e analog output readings from actuators and the DOF system Page 10 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide MAST system actuators Primary vertical actuators The MAST system has four vertical actuators The 330 kip vertical actuators connect the crosshead and the strong floor and have a stroke of 20 inches Diagram of MAST vertical actuator EEE EEE Top swivel The swivel nearest the crosshead is the top swivel Load cell Example Z1 Force fbk Electrical cables to actuator Ground Servo valve Load cell Temposonic Piston Temposonics Example Z1 Displ fbk Servo valve Temposonics cable i Manifold and hose i connections Spacers insert here Add up to 126 only on vertical actuators Bottom swivel Strong floor Figure 2 Diagram of a vertical actuator from the MAST system MAST Resource Guide Ver 2 0 9 27 2011 Page 11 of 48 Researcher s Resource Guide Vertical spacers mount between the swivel bearings and the lower actuator end cap to vary the height of the crosshead The lateral and longitudinal actuators rear swivel is attached to the reaction walls and are repositioned when the crosshead 1s raised Horizontal clear distance between the ve
50. taseisasl e EE 24 De GUCMGe NANDE ei e a E E EAA E E EENE 24 lntemaltime stamps aesan a a A 24 Umts or Measure MENT r pano a a dg a a ical eie 24 MAST user doc mentation 4 csscssscescissecestisdeccucccsnceviscdsvesdcesecessieti aia a e isea aaia 25 Construcoes onina an a a a a a a aa 26 Dimensions of staging area and test bay ccccccesssesssessessseessssseeseeeseeeens 26 Recommendations for approved CONtrACtOLS ccccccccecccecccceeeeeeeeeeeeeeeeeeeeees Zi Deliveries to the MAST SUE ee sisting cates tee cere en ee 27 Project NAD OF oi so Sesech ides Gs cesta E E A 2 Tianna ANS 1 O SCE TS AUN ashes ahead eo alec anal cease dees 2l PRAM ANG TOONS ois giave eas Ree ara aa igs E e anes Ei EE AE A 28 Hnd toO Soissa ioe eed dee ee 28 Practice pood NOUSEKCe ING sa i55 5 5 nies sae aie aa 28 Specimen instrumentation ssssscsscecceeccccccsesccccccecceecccesosesccccccecceecccosooscossecececcecceeecossesss 29 Instrumentation available at the MAST Lab cc ccccccccccccccccceeeeeeeeeeeeeeeeeeeeeees 29 LVD ieee eee ee sere tee now Seeenn re ne eer ee a e eee 29 String potentiometer displacement measuring devices cceeeecceeeeeeeeeeeeeees 30 TICE CTS rona acti nti T caterer tide een 30 Additional load Cellequipiment wc s s0 ttederiscests Hades ee dee 31 MAST Resource Guide Ver 2 0 9 27 2011 Page 3 of 48 Researcher s Resource Guide Contents and Figures San gase SIMAN eeii tater meter E T teeter eta sects 31 Con
51. te balance set ISO speed set the flash and do light metering Pan and tilt capabilities are available A robotic motion control system permits vertical movement of these cameras from the Control room and through a Web interface across Internet2 Capturing and archiving still image data Still image data is time stamped and archived by the Data Turbine locally and on VAS When desired still images are streamed through the Data Turbine to a remote telepresence GUI for Internet2 access Cameras available for loan The Lab has a hand held 18 mega pixel digital SLR camera that can be checked out on a daily basis during operating hours for short term use Portable communications VTC laptop wireless headsets The four site MCU video teleconferencing system VTC is portable to almost anywhere in the Lab During a test it can be set up in the Control room to share the process with remote audiences Usually the VTC system is in the Conference room MAST Resource Guide Ver 2 0 9 27 2011 Page 35 of 48 Researcher s Resource Guide Because it 1s portable it can be used on the Lab floor during test preparations This system is also available with a wide angle camera and monitor The Lab has a portable laptop equipped with Via Video This is particularly helpful during test setup for example a graduate student can use it to communicate with a remote project leader or consultant while pointing to necessary details Wireless headsets perm
52. tions specimen construction plan specimen installation plan including rigging and moving requirements specimen demolition plan a schedule for the project lists of required resources staffing and equipment After MAST review and approval of the work plan and schedule MAST will initiate an Equipment Site User Form once this form has been executed the project can be scheduled by the NEESComm Site Scheduling Committee Additional information about the contents of a work plan are in the MAST Laboratory Site Access and Policy Manual available at nees umn edu on the training tab MAST Resource Guide Ver 2 0 9 27 2011 Page 21 of 48 Researcher s Resource Guide Planning your project s data collection Initiate the documentation of the project metadata Metadata represents the information that provides the greater context for the project A sample of such tasks include e collect the dimensions composition and material properties of the as constructed specimen e determine the needed height of the MAST crosshead and horizontal actuators use and placement of ancillary actuators and any other testing apparatus e determine descriptions of all boundary conditions e create a target loading history outline crosshead degrees of freedom or actuator loads and displacements over time e plan a list of sensors and an associated coordinate system Preparation for Data Acquisition The DAQ User Guide describes the steps you need to take
53. tions of specimens generating metadata Measuring Machine associated with sensor locations and measuring 3D displacements of the structural surface The Metris system is not very robust hence MAST staff recommends that the researcher take redundant data using a different type of sensor for important data Also MAST has the ability to stream the data from the CCM camera to the Data Turbine CMM Manufacturer Specifications units are shown in metric e Noise 10 0 01 mm e Field of view 13 1 m distributed into three accuracy zones as shown in Figure 10 Page 32 of 48 9 27 2011 University of Minnesota Researcher s Resource Guide 3000mm 1600mm 800 x 480mm 3000 x 2180mm CMM Camera Figure 10 CCM System Accuracy Zones from User Manual Table 7CMM Accuracy from User Manual Zone Volumetric Accuracy Single Point Accuracy 20 20 190um 25um m 130um 17um m The CCM camera equipment available at MAST include e K600 Camera 1 e K600 Controller 1 e Space Probe 1 e LED s 100 e Sync Cables1 e Twenty Port Strober 5 e Three Port Strober 13 e 8m Strober Extension Cables 6 e Camera Tripod 1 e K Reference Bar 1 e Calibration Stand 1 MAST Resource Guide Ver 2 0 9 27 2011 Page 33 of 48 Researcher s Resource Guide Video still image and lighting options Camera and lighting towers The large scale of MAST projects requires that capturing video still images and audio data be done effectively and in a
54. z ATA 2001 LVDT conditioner units for all of its LVDTs This table shows sets of these instruments available at the Lab Table 5 Quantity and types of LVDTs available at the MAST Lab Quantity LVDT and te Range Macrosensor model signal conditioning 27 1 inch 1000MP SQ 1250 1000 MAST Resource Guide Ver 2 0 9 27 2011 Page 29 of 48 Researcher s Resource Guide 32 0 5 inches 500MP SQ 1250 500 20 0 1 inches 1OOHR PRH 812 100 String potentiometer displacement measuring devices The string potentiometer units available at the MAST Lab meet these specifications e able to be powered by 15VDC output at full range 10VDC adjustable to 5VDC e zero adjustment range 10 to 90 of full range e span adjustment range 50 to 100 of longest possible travel from zero position e repeatability 0 015 full scale or better e wire rope tension 24 34 oz e shock survival 50g for 0 1msec or better e vibration tolerance of 15g or better e wire rope exit at top e dust wiper installed Table 6 Quantities of Unimeasure stringpots at MAST Lab Quantity Range Unimeasure model 38 2 inches P1010 2 DS L7M Tiltmeters The tiltmeter units available at the MAST Lab meet these specifications e biaxial tilt measurement about two orthogonal horizontal axes when mounted on a wall e switchable gain between 8 degrees and 0 8 degrees at full scale e 1 micro radian resolution or better e able to be powered by 15 VDC
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