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Copyright information Trademark information © 2012 MTS Systems Corporation. All rights reserved. MTS, TestStar, and TestWare are a registered trademarks of MTS Systems Corporation within the United States. Station Manager and MTS Landmark are trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. Microsoft is a registered trademarks of Microsoft Corporation. All other trademarks or service marks are property of their respective owners.
Contents Technical Support 5 How to Get Technical Support Before You Contact MTS 5 5 If You Contact MTS by Phone 6 Problem Submittal Form in MTS Manuals 7 Preface 9 Before You Begin Conventions 9 9 Documentation Conventions 9 Introduction 11 Other MTS Manuals 12 Typical Test System Configuration Test Controller 13 14 Servohydraulic and Mechanical Components Interlocks 15 16 Safety 17 General Safety Practices 17 Safety Practices Before Operating the System 19 Safety Practices While th
Run the Test 34 793 Controller Operation Overview 35 About Running Tests 35 Understanding Files Used for Testing 35 Test Desktop 35 Monitoring Test Information Perform a Practice Test 36 39 About Setting Up a Practice Test Steps to Run a Test 39 40 Routine Maintenance 45 Decommission 51 4 Damper System Operation
Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes MTS software, look for online help and README files that contain additional product information. If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance. Technical support methods MTS web site www.mts.
Know information from prior technical assistance Identify the problem Know relevant computer information Know relevant software information If you have contacted MTS about this problem before, we can recall your file.
Identify system type Be prepared to troubleshoot Write down relevant information After you call To assist the Call Center agent with connecting you to the most qualified technical support specialist available, identify your system as one of the following types: • Electromechanical materials test system • Hydromechanical materials test system • Vehicle test system • Vehicle component test system • Aero test system Prepare yourself for troubleshooting while on the phone: • Call from a telephone
Technical Support Damper System Operation
Conventions Preface Before You Begin Safety first! Before you attempt to use your MTS product or system, read and understand the safety information provided with your system. Like an automobile, your test system is very useful—but if misused, it is capable of deadly force. You should always maintain a healthy respect for it.
Conventions Notes Notes provide additional information about operating your system or highlight easily overlooked items. For example: Note Special terms Illustrations 10 Resources that are put back on the hardware lists show up at the end of the list. The first occurrence of special terms is shown in italics. Illustrations appear in this manual to clarify text.
Introduction This manual provides operating procedures and safety practices for operation of an MTS Damper test system configured with an MTS test controller, an MTS load frame, and an MTS Hydraulic Power Unit. It also contains a general description of the typical system components. An MTS test system can be designed for a wide variety of testing applications.
Other MTS Manuals Other MTS Manuals Because MTS systems can be configured with a variety of similar products, this operation manual covers general operation. Operation specific for a given product will be covered in its product manual. For example, you might be instructed to position the crosshead to accommodate the specimen height and grips or fixtures. For detailed information about how to position the crosshead, you would refer to your load unit or load frame product manual.
Typical Test System Configuration Typical Test System Configuration The following illustration shows the common MTS 85X Damper System components.
Typical Test System Configuration Test Controller The test controller can be either a FlexTest SE Basic, FlexTest SE Plus, FlexTest GT, or FlexTest 40/60/100/200. Note Because the FlexTest 40 is the most common test controller used on the MTS Landmark System, this manual will primarily focus on that controller. The FlexTest 40, FlexTest SE Plus, and FlexTest SE 2-Channel are single station PC-based digital controllers. The FlexTest 60/100/200 controllers are PC-based multi-station digital controllers.
Typical Test System Configuration Servohydraulic and Mechanical Components The following paragraphs briefly describe the servohydraulic and mechanical components that are typical supplied with the MTS Landmark System. Load frame There are a variety of load frames that can be supplied with the system. The load frame is the mechanical foundation of the test system in which the load cell transducer, specimen fixturing or grips, and hydraulic actuator are mounted.
Interlocks Interlocks The test controller incorporates interlock circuitry that can automatically stop a test when a system problem, specimen failure, or an operator error could result in unwanted or unexpected actuator movement. The test controller interlock circuitry will cause one of two interlocks to occur in response to specific conditions encountered during testing. These interlocks are: • Hydraulic Interlock – stops the program and removes hydraulic pressure from the system.
Safety General Safety Practices This section provides information about safety issues that pertain to servohydraulic systems in general. These issues include statements to the intended use and foreseeable misuse of the system, the hazard zone, definition for the graphical hazard labeling that is affixed to your product, and other (more general) safety information that relates to the high-pressure and highperformance characteristics of MTS servohydraulic systems.
• Do not use the system in a test area where uncontrolled access to the test system is allowed when the system is in operation • Do not operate the system unless an interlock is installed to monitor supply pressure into the HSM and initiate a system interlock if a low or no pressure event occurs.
information manuals for a description of hazard placards associated with the various products that comprise the MTS Landmark System. Safety Practices Before Operating the System Before you apply power to the test system, review and complete all of the safety practices that are applicable to your system. The goal, by doing this, is to improve the safety awareness of all personnel involved with the system and to maintain, through visual inspections, the integrity of specific system components.
Remember, when hydraulic power is interrupted on a servohydraulic system, it is likely that stored accumulator pressure will persist for some time within the system. In addition, it is likely that as stored energy dissipates, gravity will cause portions of the system to move. Be aware of component movement with hydraulics off A load frame crosshead can slowly drift down the columns if the locks are turned off and when hydraulic pressure is turned off.
• Use only dry-pumped nitrogen to precharge nitrogen-charged accumulators. (Dry-pumped nitrogen can also be labeled “oil pumped” or “dry water pumped.”) Do not use compressed air or oxygen for precharging: the temperature increase caused by rapid gas compression can result in highly explosive conditions when hydraulic fluid is in the presence of oxygen or compressed air. • Always follow the recommended bleeding procedures before you remove or disassemble components that contain pressurized gas.
Protect hoses and cables Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause the cables to harden and eventually fail. Ensure that all cables have appropriate strain relief devices installed at the cable and near the connector plug. Do not use the connector plug as a strain relief. Protect all system hoses and cables from sharp or abrasive objects that can cause the hose or cable to fail.
Wear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. Some systems can create sound pressure levels that exceed 70 dbA during operation. Wear appropriate personal protection equipment (gloves, boots, suits, respirators) whenever you work with fluids, chemicals, or powders that can irritate or harm the skin, respiratory system, or eyes.
Contain small leaks Do not use your fingers or hands to stop small leaks in hydraulic or pneumatic hoses. Substantial pressures can build up, especially if the hole is small. These high pressures can cause the oil or gas to penetrate your skin, causing painful and dangerously infected wounds. Turn off the hydraulic supply and allow the hydraulic pressure to dissipate before you remove and replace the hose or any pressurized component.
System Startup Getting Started System Startup Before system startup, you should be familiar with the test fixtures, test controller or electrical console, PC workstation, hydraulic power unit, and other system components. This includes reading all of the sections in this Operation Manual and the various additional documents supplied with the system. If applicable, also read the vendor manuals supplied with the system. Observe all safety practices and operating procedures to ensure proper use of the system.
System Startup A. Press the Hydraulic Pressure Low switch to start the HPU and apply low hydraulic pressure to the actuator (the Off indicator will extinguish and the Low indicator will light). B. Observe the actuator for any movement caused by hydraulic fluid pressurizing the system. Ensure that the actuator stabilizes before proceeding. C. Press the Hydraulic Pressure High switch to apply high hydraulic pressure to the actuator (the Low indicator will extinguish and the High indicator will light).
Test Setup Test Setup Before setting up or operating the test system, the hardware component configuration must be defined, control settings (or test parameters) should be calculated, and test setup decisions must be made. This section describes some of the factors to consider when completing these pre-operation procedures.
Test Setup 28 Getting Started Damper System Operation
Operation This section covers hardware operation for an MTS 85X Damper system. Hardware operation consists of load frame setup and specimen installation. All other system operation is performed on the computer through the system controller software. Refer to the controller documentation for information on test definition, system tuning for the test to be performed, and hydraulic pressure operation.
Initial Setup Initial Setup The initial setup tasks include the following: • Determine what types of fixtures/grips will be needed to secure the specimen into the load frame. • Determine the position of the load frame crosshead. • Prepare the fixtures/grips, specimen, and data acquisition transducers. • Ensure that the load cell is properly rated for the test and that it is aligned with the actuator. • Ensure the appropriate servovalve configuration is set up properly.
Install the Specimen Install the Specimen The procedure to install a specimen varies due to the variety of test fixtures, grips, and the type of specimen being installed. This section should be considered a guideline. You need to modify this procedure to suit your equipment. For first time operation, it is recommended to install a dummy specimen and use it for the initial test settings. This minimizes the chance of unintentional damage to the actual test specimen.
Install the Specimen 5. Turn on low hydraulic pressure; turn on high hydraulic pressure if low pressure is not available. 6. If there is a specimen in the load unit, remove it. Note The actuator starting position depends on the type of test being set up. 7. Ensure the control panel Set Point control is enabled by the controller software. Adjust the Set Point control to move the actuator to its start position (usually mid-displacement). 8. This step pressurizes the lift actuators.
Install the Specimen You can use the Set Point control to fine tune the alignment of the specimen and actuator positions. 15. Use the Lock Control to clamp the crosshead to its current position. The clamped symbol is shown at the right. Wait 30 seconds for the locks to fully clamp the columns. 16. Install the specimen into the lower grip or fixture. 17. You may need to reposition the crosshead to accommodate the starting position of the specimen. A. Use the Lock Control to unclamp the crosshead. B.
Run the Test Run the Test Note Before you can start a test, the test must be set up by a specialist. This would include: • The system software is started and the appropriate configuration file and HWI file loaded. • The test control mode is selected. • The test program is defined. • The forces and/or displacements to be achieved during the test are calculated and limits defined and set. • The signals that should be monitored during the test are defined.
About Running Tests 793 Controller Operation Overview This section is intended to give you information on how to run 793 Software and help you learn how to use your system. It is not intended to provide a step-bystep procedure to perform a specific test. Specific tests are usually performed by special application software programs such as the MTS Damper Software for testing elastomers and shock absorbers (refer to MTS manual part number 015194-700).
About Running Tests • Manage the execution of the Basic TestWare and MultiPurpose TestWare applications • Monitor signals on the built-in scopes and meters Windows typically open while running a test. The windows shown here all display some element of status while a test is in progress, and can be displayed on the desktop until the test is complete. This example shows an MPT test in progress. Meters display the numeric value of selected signals.
About Running Tests MPT Counters Run time counter The Run Time counter displays the elapsed time of the current test since the last time it was reset. Channel counters Channel Counters display a cumulative count of segments or cycles that have been applied to a specific channel since the start of the test. Sequence counters Sequence Counters display the progress of individual processes within the test.
About Running Tests • Mean/amplitude data • Maximum/minimum values Meters can be aligned on the desktop vertically, horizontally, or in a grid. Meter displays can be sized to your preference. Scope display The Scope window in the Station Manager application is an oscilloscope. You can use it to plot signals against time, frequency, and against each other. You can create up to four scopes per station, and add up to four signal pairs per scope.
Perform a Practice Test Perform a Practice Test About Setting Up a Practice Test This section includes step-by-step instructions for performing a practice test. The purpose of this procedure is simply to help you learn how to use your system. While performing this test you will: • Select a Project at the beginning of the test, and review test data stored in the Project at the end of the test. • Set limits and manually position the actuator to install the specimen.
Perform a Practice Test • Tune the system To perform the Series 793 Software installation, see the Installation Instructions readme file on the Series 793 System Software CD, and follow the installation wizard. To perform the remaining tasks, see the MTS Series 793 Tuning and Calibration manual. You may also find it necessary to see the following manuals: • MTS Series 793 Utility Software manual—To setup or edit the hardware interface file to reflect any hardware changes to your system.
Perform a Practice Test C. If HSM controls are present, click the (Low) and then (High) buttons. 4. Adjust force tuning. A. From the toolbar, select an access level of Tuning (or higher). You will have to enter the password created at installation. B. From the Application control bar, select the Function Generator. C. Select the following settings in the Function Generator.
Perform a Practice Test • Adjust the Manual Command slider to position the actuator while installing the specimen. • Switch to the Force control mode. F. Adjust the P Gain and D Gain tuning controls. • Start the Function Generator by clicking the Program Run control and observe the resulting waveform on the Scope. • From the Display menu, select Station Setup. • From the tree view, expand Channels, then select Channel 1.
Perform a Practice Test • Adjust Manual Command to position the actuator as required. C. Switch to the force control mode. 6. Set test limits and actions. From the Station Controls panel, click the Detectors icon. Set upper and lower limits and associated actions to accommodate your test as desired. For instance, you may want to adjust displacement limit detectors to limit piston rod travel. This stops the test when the specimen is on the threshold of complete failure.
Perform a Practice Test Control Setting Type Timed Signals Included Channel 1 Output Time Between Points default Buffer Size 2048 Buffer Type Linear D. In the Data File tab, set the following: Control Setting Destination File Test Default Data Header Enter “First Test” Data File Mode Append Data File Format Plain E. Close the Test Setup window. 9. Start the test. A.
Routine Maintenance WARNING High pressure fluids can be present in the test system. High-pressure hydraulic fluid can cause cuts and burns. Ensure that you establish and follow standard lock out/tag out safety procedures and the test system is hydraulically isolated before you perform routine maintenance procedures on the test system.
As a guideline, for a test system that operates eight hours per day, one week will equal 40 hours, and one month will equal 160 hours. For a test system that operates up to 24 hours per day, one week will equal 160 hours and one month will equal 720 hours. When to perform visual checks Routine maintenance procedures that are scheduled on a daily or weekly basis usually involve visual checks only, and should not interfere with the operation of your test system.
. Calendar time Daily 1 week 1 2 month months 3 6 1 months months year 2 year 5+ years Running time - Hours 8 40 160 500 4,000 10,000 320 1000 2,000 Hazard labels Inspect for legibility X Replace as required - Hydraulic Hoses Inspect for leaks and wear X Replace MTS Hydraulic Fluid Sensory Check X Particle count MTS Analyze for contamination MTS Load Frame Set initial accumulator check interval X Check accumulator N2 precharge X Clean actuator rod and columns Inspect actua
Calendar time Daily 1 week 1 2 month months 3 6 1 months months year 2 year 5+ years Running time - Hours 8 40 160 500 4,000 10,000 320 Maintain airmount pressures When the load frame sits unevenly.
Calendar time Daily 1 week 1 2 month months 3 6 1 months months year 2 year 5+ years Running time - Hours 8 40 160 500 4,000 10,000 320 1000 2,000 Controller Check cooling Perform shunt calibration X X Verify controller calibration MTS Verify Safety Circuits Check E-Stops X Check limits X Check test area guard interlocks X Check actuator speed control (if applicable) X Damper System Operation Routine Maintenance 49
Routine Maintenance Damper System Operation
Decommission The decommissioning process is performed when the system is going to be moved or taken out of service. Disassembly is required when performing either of these tasks. 1. Remove specimen(s) and fixtures. Large grips should be removed if the load frame is going to be tipped over. 2. Move the actuator piston rod down to its lowest position, fully into that cushion. 3. If the unit has hydraulic lifts move the crosshead to its lowest position and torque the manual crosshead locking bolts.
10. Isolate the system from electrical power. When the system electronics, control software, and the system PC are powered down, turn off the system’s main electrical supply and disconnect all cables. Residual hydraulic pressure can produce a high pressure spray. You could be cut by this spray or hydraulic fluid could be forced into your skin. Do not start this procedure unless the system has been isolated from hydraulic pressure for at least 20 minutes.
Electrical components and parts can contain hazardous chemicals and compounds. Improper disposal of hazardous chemicals and compounds can cause injury and death to people, animals, and plants. In addition, it can cause contamination of the soil, air, and water. Always refer to local codes that govern the disposal of potentially hazardous materials and follow these codes for the proper handling and disposal of these materials.
Decommission Damper System Operation
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