MTS Acumen™ Test System Operation 100-261-657 E be certain.
© 2014 MTS Systems Corporation. All rights reserved. Trademark Information MTS, FlexTest, RPC, and TestWare are registered trademarks and MTS Acumen, MTS TestSuite, Station Builder, and Station Manager are trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. All other trademarks are the property of their respective holders.
Table of Contents Table of Contents Preface Before You Begin.............................................................................................................................7 Documentation Conventions............................................................................................................7 Technical Support How to Get Technical Support.......................................................................................................11 Before You Contact MTS..............
Table of Contents Quick Access Toolbar..........................................................................................................47 Control Panels.....................................................................................................................47 System Panel...........................................................................................................47 Status Panel.................................................................................................
Table of Contents Best Practices for Other System Configurations and Tests Creating a Desktop Shortcut........................................................................................................144 Pre-Test Station Checkup............................................................................................................145 Setting Up the System.................................................................................................................
Table of Contents Clearing Interlocks............................................................................................................188 Applying Actuator Power...................................................................................................189 Editing Variables with the Express Editor..........................................................................190 Generating a Report in MP.............................................................................................
Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.
Preface Warning: Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage. Caution: Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury or equipment damage, or could endanger test integrity.
Preface Electronic manual conventions This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.
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 software, look for online help and README files that contain additional product information. Technical support methods MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact Technical Support in one of the following ways.
Technical Support When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order paperwork. Example system number: US1.
Technical Support — Messaging applications If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your: • Site number • Email address • Name • Company name • Company address • Phone number where you can be reached If your issue has a case number, please provide that number. A new issue will be assigned a unique case number.
Technical Support • Record the name of the person who helped you. • Write down any specific instructions. After you call MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you have questions about the status of your problem or have additional information to report, please contact Technical Support again and provide your original case number.
Safety Overview Topics: • • • • • • • • • • • Safety Considerations for MTS Acumen Systems............................................................................16 Safety Information Overview.............................................................................................................22 Site Precautions................................................................................................................................23 Personnel Qualifications................................
Safety Overview Safety Considerations for MTS Acumen Systems Restrictions for Using MTS Series 793 Controller Software Using MTS Series 793 Controller Software with MTS Acumen Systems Warning: Improper changes to the station configuration file can result in sudden and unexpected actuator motion. Unexpected actuator motion can damage equipment and injure personnel. Ensure the station configuration settings remain as set at the factory before operating the system.
Safety Overview Recommended: After you open your station configuration file with the Station Manager application, MTS recommends that you minimize the Station Manager window for the remainder of the session. Be aware that the Station Manager application hosts the station configuration and performs real-time control. Do not exit the Station Manager application while using your system.
Safety Overview Important: The C-Stop Interlock action configuration is set with MTS controller software and should not be changed for typical operations. For information about changing the C-Stop Interlock action configuration, contact MTS. C-Stop Action Versus Interlock Action The primary benefit of the C-Stop Interlock action is that when it is triggered, the controller performs a control mode switch to stable displacement and the actuator is held in place.
Safety Overview Warning: Actuators can produce dangerous forces. A moving actuator can injure anyone in its path. Always ensure that the system is in High-Power Prohibit mode when installing fixtures or specimens. Emergency Stop Button The frame-mounted control is equipped with an Emergency Stop button to be used for emergency purposes only. There is also an optional Remote Emergency Stop button. The Emergency Stop buttons will shut off power to the main actuator and crosshead lift system.
Safety Overview Optional Remote Emergency Stop Button Crush Zone A crush zone exists between the T-slot base and crosshead which is highlighted in red in the following figure. Keep clear of this area when the actuator is in motion. Press the Emergency Stop button on the frame-mounted control to shut off power to the motor and stop actuator motion.
Safety Overview Crush Zone of an MTS Acumen System Warning: Applying power can result in sudden actuator motion. A moving actuator can injure anyone in its path. Always clear the actuator area before applying power.
Safety Overview Safety Information Overview MTS systems are designed to generate single-axis or multi-axial motions and forces simultaneously in a controlled environment and impart these motions and forces into a specimen that is secured to the system.
Safety Overview Site Precautions Warning: The equipment is designed to operate in an environment where precautions have to be taken to minimize hazards to personnel and the equipment Ignoring hazards and failing to take necessary precautions can result in injury or death to personnel, and damage to equipment. Do not install or operate the system equipment in a hazardous environment. Warning: Hazardous situations or conditions can arise suddenly and without warning at all parts of the system.
Safety Overview Personnel Qualifications Caution: System installation, maintenance, setup, and operation require specialized training. Installation, maintenance, setup, and operation of the system by unqualified personnel can expose them, and others, to hazards that can cause death or personal injury and damage to equipment. Do not allow unqualified personnel to perform any of the system installation, maintenance, setup, or operating procedures.
Safety Overview Equipment Guards, Doors, and Covers Warning: Guards, doors, and covers are designed to protect personnel from moving parts, electrical shock, and pressurized fluid or gas. If guards, doors, and covers are not installed, potential hazards are exposed that can cause injury or death.
Safety Overview Warning: Guards, doors, and covers are designed to protect personnel from moving parts, electrical shock, and pressurized fluid or gas. If guards, doors, and covers are not installed, potential hazards are exposed that can cause injury or death.
Safety Overview 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.
Safety Overview Be aware of component movement with hydraulics off For hydraulic systems, be aware that mechanical assemblies can shift or drift due to changes within hydraulic hardware when hydraulics are turned off. This non-commanded movement is because oil can transfer between the pressure and return ports and across internal components of the hydraulic hardware. Be aware that this can happen and clear the area around the mechanical assemblies when hydraulics are turned off.
Safety Overview 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. When you bleed a gas or remove a fitting, hose, or component that contains a gas, remember that many gases cannot support life.
Safety Overview or move heavy objects over them. Route hoses and cables away from areas that expose them to possible damage. Provide proper hydraulic fluid filtration For hydraulic systems equipped with a non-MTS hydraulic power unit, make sure that hydraulic fluid filtration is established to maintain fluid cleanliness standards as stated in the Hydraulic Fluid Care Manual (see the System Documentation CD). Particles present in the hydraulic fluid can cause erratic or poor system response.
Safety Overview Provide means to access out-of-reach components Make sure you can access system components that might be out of reach while standing on the floor. For example, ladders or scaffolding might be required to reach load cell connectors on tall load units.
Safety Overview Test all limits for proper operation immediately before a test. Always use these limits and adjust them properly. Do not disturb sensors Do not bump, wiggle, adjust, disconnect, or otherwise disturb a sensor (such as an accelerometer or extensometer) or its connecting cable when pressure is applied.
System Introduction Topics: • • • About This Manual.............................................................................................................................34 System Overview...............................................................................................................................35 Parts of the Software Interface..........................................................................................................
System Introduction About This Manual Important: Read this entire manual before running a test. The MTS Acumen System Operator Guide provides an overview of the MTS Acumen electrodynamic load frame, and it provides basic guidelines for running tests using the MTS TestSuite Multipurpose (MP) software. All personnel that use the MTS Acumen frame and MP application to run tests must be trained in the safe use and setup of MTS equipment.
System Introduction System Overview System Components Item Name Description 1 MTS FlexTest (Series 793) controller software — Station Manager application MTS FlexTest controller software runs in the background underneath MTS TestSuite MP. While MTS FlexTest has a user interface, it is typically not used with Acumen load frame systems except to initially select a configuration and parameter set.
System Introduction Item Name Description interface for setting up and running tests with an Acumen load frame system. 3 Controller The controller provides the necessary interface between the PC and the load frame. The MTS Acumen system with standard configuration is supported by the MTS FlexTest Model 40 Controller, which can support two test stations, and the MTS FlexTest Model 60 Controller, which can support up to four test stations. Both controllers support one control channel per station.
System Introduction Two-Column Load Frame Item Description 1 Actuator and power electronics (behind hood). 2 Columns on which the crosshead moves up and down. 3 Actuator rod. 4 Manual crosshead locks. (Note: crosshead locks must be in a fully locked position to run a test.) 5 Frame-mounted control. 6 T-slot base plate. 7 Load cell mounted on table top (load cell can also be mounted on the actuator). 8 Crosshead lift.
System Introduction Item Description Red (Solid) Interlocked. Red or White (Blinking) System is in service mode. To move the system out of service mode, slide the Service Mode switch on the upper back of the system, and click Interlock Reset. If problems continue, contact MTS Technical Support. White (Solid) Interlock cleared, standby power is on. Blue (Blinking) Interlock cleared, low power. Blue (Solid) Interlock cleared, high power, not running.
System Introduction Frame-Mounted Control Frame-Mounted Control Description Section Controls Description A Display and display controls 1 Display. Shows four lines. There is a screen for Manual Command (MC), Auto Offset (AO), and a screen to change the power level. When the Interlock Reset/Override button is pressed, the screen shows the override countdown, and you can press the Enter button to cancel the override. 2, 3 Page forward or page back. Shows next or previous text in the display.
System Introduction Section Controls Description 4 Scroll. Scrolls down the text display. Selection cycles to the top when the bottom line is highlighted and you press the button. 5 Enter. Executes the highlighted command in the display (for example, selecting Low and pressing Enter would apply low power). B Indicators and controls related to actuator power and control 1 Controller interlock indicator. When illuminated, an interlock has occurred.
System Introduction Section Controls Description C Manual actuator control toggle button and rotary dial 1 Manual Actuator Control Indicator. When illuminated, manual control of the actuator is active, and you can adjust the actuator using the Actuator Control Dial (3). 2 Actuator Control Enable button. Press to enable actuator positioning using the rotary dial; press again to disable actuator positioning using the rotary dial.
System Introduction Section Controls Description G Crosshead manual lock indicators and crosshead positioning buttons 1 Left Crosshead Manual Lock icon. When illuminated, the left crosshead manual lock handle is in the fully locked position. When not illuminated, the handle is in the fully unlocked position. When blinking, the handle is in an intermediate position. 2 Right Crosshead Manual Lock icon. When illuminated, the right crosshead manual lock handle is in the fully locked position.
System Introduction Load Cell A load cell is a transducer that converts a mechanical force or load into an electrical output signal. The system load cell has an integrated accelerometer that allows MTS TestSuite MP software to measure acceleration and compensate for inertial errors. The MTS Acumen system table has a piloted interface that makes it easier to mount the load cell and fixtures. The load cell can be mounted on the actuator or the T-slot table top.
System Introduction There are eight bolts associated with the load cell. Four of the eight holes around the perimeter of the load cell (see the photo on the right) are used for mounting. The others are used to assemble the load cell and should not be manipulated by the user. The middle bolt hole is used to mount fixtures to the load cell. The following low-force load cells are optionally provided.
System Introduction Note: In case of emergency, power can also be removed from the frame or controller by removing the detachable power cord. Parts of the Software Interface Main Window When you initially start the MTS TestSuite MP application, the main window appears.
System Introduction Number Item Description more information about the menu options, see the MTS TestSuite Multipurpose Elite User Guide. 2 System panel Provides indicators for system status, crosshead locks, open enclosure door, and interlocks. For details, see System Panel (p. 47) and Status Panel (p. 49). 3 Actuator Power panel Allows you to turn off power to the actuator, turn on low power, and turn on high power. For details, see Actuator Power Panel (p. 53).
System Introduction Number Item Description generation date, and time. Right-click within the Application Log tab to open the existing log file, add a custom note to the log, clear all messages from the log, or export the contents to a Microsoft Excel file. Messages persist from one session to another. Quick Access Toolbar Use the Quick Access toolbar to open new tests, initiate test runs, set application preferences, adjust display settings, and perform other general MPE or MPX actions.
System Introduction System Panel Icon Number Icon 1 Description The system is ready. System warning. A system warning indicates that action may be required to achieve desired operating results, but most operations can still generally be performed when a system warning occurs. Hover your cursor over the icon to see the warning message. System error.
System Introduction Number Icon 5 Description Reset Interlock. Click to reset the interlock, or click the drop-down arrow to select Reset Interlock or Override Interlock. Override Interlock. Selecting this option overrides interlocks for 30 seconds. Use of this button is not recommended for Acumen systems.
System Introduction Note: The red indicators above are typical of a tripped E-Stop. Status Panel Item Status Indicator Error Corrective Action 1 Power Active items in this See individual status information. category cause power to be removed from the main actuator and lift system. 2 E-stop The Emergency-stop circuit is active. 3 Safety fault Active items in this See individual status information. category indicate that a safety-related fault has occurred.
System Introduction Item Status Indicator Error Corrective Action 5 Safety velocity monitoring status Velocity > 10 mm/s is detected while in High-Power Prohibit mode, which is active when the High-Power Prohibit button is active or the optional test area enclosure door is open. The system has shut down to protect the operator. Check that the control mode and tuning are appropriate for the current setup.
System Introduction Item Status Indicator Error Corrective Action The fans to cool the motor increase in speed with increasing temperature and will become louder. This is normal system operation, and it is not necessary to shut down the system. Reducing the frequency and/or force output of the system will allow the motor to cool down. Ambient air temperature may be too high. Check that air intake and exhaust vents on the MTS Acumen frame are clean and not obstructed.
System Introduction Item Status Indicator Error Corrective Action Restart the system controller software to clear this fault. 20 21 22 Watchdog timeout Indicate an interruption in communication Watchdog error between the controller Watchdog reset and the frame. See Watch Dog above. Actuator Power Panel Use the Actuator Power panel to control power to the actuator. You must apply low power (two of five bars) before you can apply high power (five bars) to the system.
System Introduction Manual Control Panel Icon Description Retracts the actuator and applies tension to the specimen. Extends the actuator and applies compression to the specimen. Moves the test station actuator to the predefined home position. Click to open the Manual Control window. Manual Control Window The Manual Control window allows you to modify the control settings. To open the Manual Control window, click the open window icon on the Manual Control panel.
System Introduction Item Name Description 3 Control Mode Select a control mode. 4 Command Applies the manual command to the actuator. If necessary, click the cog wheel icon to open the Slider Settings window, where you can change the slider-bar range. If you select a Master Command Group that has individual channels at different Command values, this control shows the highest and lowest Command values for the Group.
System Introduction Item Name Description 2 Display Unit Select the units of measurement shown on the slider control. 3 Range Minimum, Range Maximum Indicates the minimum and maximum range allowed on the slider according to the units of measurement in Display Unit. 4 Range Minimum Enter the minimum range for the slider control. 5 Range Maximum Enter the maximum range for the slider control.
System Introduction Test Run Status Panel Item Description Stop Stop the procedure. This button becomes active when a test is in the Initialized or Stopped status and a test run is selected. The button is inactive when the status is Running or Completed. The button is inactive when a test run is not selected. To make the button active when a test is running, click Stop or Stop At. When you click the Stop the Procedure button, the arrow changes color.
System Introduction Item Description Control Mode Shows the control mode between parentheses ( ) when connected to a station. Control modes are controller-dependent. Note: The active control mode is shown for one channel only if there is one channel with more than one mode. Situational Awareness Panel Caution: Although the actuator shown in the virtual diagram will move as you change settings, the crosshead shown in the diagram remains stationary.
System Introduction Situational Awareness Panel Showing Two Signals Situational Awareness Panel Controls and Icons On both sides of the frame diagram, there are small horizontal bars called thumb controls (see the following figure). The thumb controls on the left side of the diagram modify the settings for the fixture limits (for more information about setting fixture limits, see Setting Fixture Limits (p. 156)).
System Introduction Situational Awareness Panel Item 1 Icon Description Thumb control for setting a fixture protection limit. When you move the thumb control, the selected value appears. For more information, see Setting Fixture Limits (p. 156). Important: When setting limits, be sure to enable them! Blue indicates an enabled limit while gray indicates a disabled limit. Right click on the thumb control to change the status of a limit. 2 Indicates tension.
System Introduction Item Icon Description 5 Control icon, which opens the manual control panel allowing you to move the actuator using manual controls. For more information, see Moving the actuator using manual controls in this section. 6 Minus sign, which corresponds to the tension or compression symbol shown across the load frame. In this example it is shown across from the compression symbol indicating that compression is negative.
System Introduction Note: Limit detectors are sensors within the system that detect when the minimum and maximum limit values you select have been triggered. To enable or disable the limit detectors for a particular limit, right-click the thumb control and select the On or Off radio button. Axial Displacement Magnify Panel Moving the Actuator Using Manual Controls To move the actuator using manual controls, click the Control icon in the lower right corner of the diagram.
System Introduction Manual Command Control Settings Window Description Item Control Description 1 Manual Command Control Select the rotary dial or slider control. 2 Jog Increment Select how far the actuator will move when you press the Retract or Extend button on the Manual Control panel in the increments specified in the Resolution box. 3 Display Unit Select the units of measurement shown on the selected control interface in the Command box.
System Introduction Item Control Description 4 Range Minimum, Range Maximum Indicates the minimum and maximum range allowed on the manual control according to the selected units of measurement. 5 Range Minimum Select the minimum range for the manual control. 6 Range Maximum Select the maximum range for the manual control.
System Introduction Axial Force with Magnify Panel MTS Acumen™ | 65
System Introduction Axial Force with Control Panel Layer Control Panel The MTS Acumen system uses layers on the main window display of the frame so you can visualize the logical architecture of your system. It highlights the physical components of your system and associates them with the configuration changes you can make on the layered interface. The Layer Control panel has six toggle buttons and a button to open the Add/Reorder Signal Views window.
System Introduction Icon Hides or shows the... Fixture limit sliders. Specimen limit sliders. Fixture and specimen limit values. Offset reference. When you apply inertial compensation (Compensate for Fixturing on the Explorer tab), a secondary offset is applied for Axial Force to offset the force caused by gravity on the fixturing. You cannot clear this static offset, which shows up on the right side of the Axial Force diagram on the Situational Awareness panel.
Key Concepts Topics: • • • • • • • • • • • • • • • • About This Chapter............................................................................................................................70 Using the E-Stop Control...................................................................................................................70 Understanding Your MTS Software...................................................................................................
Key Concepts About This Chapter This chapter, as well as the information in the Safety chapter, contains information you should know before you attempt to run tests with your MTS Acumen system. This information applies to the typical system used throughout this manual and the test used in the Running the Example Spring Test chapter.
Key Concepts MTS FlexTest (Series 793) Controller Software Start Menu Directory and Desktop Icon It is important to understand that the only MTS FlexTest application you need to use to perform tests is the Station Manager application. You typically limit your use to launching the Station Manager application and selecting a Station Configuration and associated parameter set.
Key Concepts Note: The MTS MPE application can be configured for operators. In that configuration, it has the same capabilities as the MTS MPX application. • MPX operates in parallel with the Station Manager application. So while running tests, you must keep the Station Manager application operating at all times to maintain control of the system. (You typically minimize the Station Manager application after using it to set up your station.
Key Concepts File Type Description Station Configuration Files Define Physical Station Resources Parameter Sets A Parameter Set is a collection of information that optimizes how the components in your Station Configuration work together. You create Parameter Sets when use the Station Manager application to change settings in a Station Configuration. A Parameter Set is not a discrete file, it is information that is saved with the Station Configuration.
Key Concepts File Type Description by opening an existing Test Template file, which automatically copies the test definition information and adds a container for test data. MTS TestSuite Test Procedure Icon Reports When you run a test report, data is sent from MPX to an Excel spreadsheet. The spreadsheet can be viewed even if you do not have Excel on the interface PC using the Excel viewer.
Key Concepts Understanding the Control Loop MTS Acumen test systems use closed-loop control, and understanding it lays a foundation for many of the topics in this document. Closed-loop control is a basic servomechanism concept of controlling a test, in which a controlling element controls a controlled element. Closed-Loop Control Concept The controlling element is the computer, the digital controller, and the MTS MP application.
Key Concepts Basic Closed-Loop Control in MTS Acumen Systems 1. When you enter an increase tension manual command through the MPX software, a command is sent to the controller. This command instructs the digital controller to generate a signal that represents the direction and amount of force the actuator needs to apply to the specimen to accommodate your command. 2. The digital controller generates this command and sends it to the electrodynamic motor, which retracts the actuator. 3.
Key Concepts It is important to understand the following: • • • Load and displacement control modes are used primarily for testing. The stable displacement mode is used exclusively for setup and other circumstances in which stable system response is critical. It is best practice to select stable displacement as the active control mode when positioning the actuator to install the specimen.
Key Concepts Understanding the Low Power Actuator State Warning: When working in Power Low, there is still enough force to quickly move the actuator. If you do not expect the actuator to move quickly, the actuator can cause harm to the operator to damage to the specimen. Observe all safety measures when working in the Power Low state.
Key Concepts High-Power Prohibit Button and Indicator High-Power Prohibit can be started by: • • Pressing the High-Power Prohibit button on the frame-mounted control Opening the door on the optional test area enclosure Note: Starting High-Power Prohibit automatically sets an interlock that must be reset prior to applying high power. This is normal behavior and does not result in restarting tests already in progress.
Key Concepts Important: It is best practice to always have the crosshead high enough so that the actuator cannot contact the table if the actuator were to go to full extension. Retracting the Actuator This step accomplishes a couple things. First, it allows you to verify that the actuator moves in the direction that you expect when you invoke manual command. Second, it allows you to determine the retracted actuator endpoint.
Key Concepts Nested Limits Item Limit Set By Active Best Practice 1 Fixture Limits Set by operator on Active all the time. left side of virtual machine display. Set to protect the load cell, grips, and other fixturing. 2 Specimen Limits Set by operator on Active all the time. right side of virtual machine display. Set to protect the specimen. 3 Test Limits Set by test engineer Active only during in test design the test. program.
Key Concepts Note: The preceding illustration shows settings typical for a through-zero test. Note that these settings differ from the Example Test, which is a compression-compression test. Fixture Limits Fixture limits are generally the widest limits. There are fixture limits for both displacement and force. Each of these are set on the left side of the virtual machines found in the Situational Awareness panel.
Key Concepts Warning: Force and displacement limits must be turned on to be active. Failure to turn on limits after setting them can result in equipment damage or injury. Always ensure that the limit indicators are blue (indicating active) and not grey (indicating not active) after setting limits. Specimen Limits Specimen limits are generally lower than fixture limits. There are specimen limits for both displacement and force.
Key Concepts Warning: Force and displacement limits must be turned on to be active. Failure to turn on limits after setting them can result in equipment damage or injury. Always ensure that the limit indicators are blue (indicating active) and not grey (indicating not active) after setting limits. Test Limits Test limits are set by the test designer or test engineer. It is important to obtain these values before running a test to ensure that they do not conflict with your other limits.
Key Concepts Specimen Protection Important: Specimen Protection limits are only active during the Install Specimen node. This means that you do not need to manually turn them off at the conclusion of specimen installation. It also means that if you leave the Install Specimen node that you should stay clear of the crush zone unless you turn off actuator power. Note: Specimen Protection can be turned off for certain unusual tests that require it. Use extreme caution if you select this option.
Key Concepts • You set specimen limits on the right side of the virtual frame to protect the specimen. Example Fixture Limit Window Sensor Limits You set limit detectors for force and displacement sensor input signals for protecting fixturing and the specimen. Each sensor has a high and a low limit which you can enable separately. When a sensor exceeds (or trips) its upper or lower limit, the selected detector action occurs.
Key Concepts Important: When setting limits, be sure to enable them! Blue indicates an enabled limit while gray indicates a disabled limit. Right click on the thumb control to change the status of a limit. Setting Limits for Testing After the specimen is installed and you are ready to run the test, it is best practice to adjust the upper and lower force limit detectors to levels that will not interfere with forces that the test procedure is designed to apply to the specimen.
Key Concepts MTS Acumen System Interlocks Type of Interlock Description Frame Interlock The MTS Acumen frame contains safety features built into it that are independent of the controller and application software.
Key Concepts Type of Interlock Description Station Power Off This action is similar to the Power Interlock. It turns off all power on the station and must be reset before any power can be turned on again; however, it does not illuminate the Interlock indicator or assert the interlock line that is available on the back of the controller.
Key Concepts Understanding the Load Train It is important to understand the components in the load train. When installing and removing the specimen and performing test setup, you interact with elements of the load train. The load train consists of all the components between the actuator’s piston rod (the component that moves up and down) and the base of the T-Slot table. This typically includes the load cell, the upper grip, the specimen, the lower grip, and the load cell (force sensor), as shown.
Key Concepts Item Description 5 Specimen 6 Lower Grip Optimizing System Response Before Testing In MTS systems, optimizing system response involves inertial compensation and tuning. About Inertial Compensation Inertial error is a result of the unwanted feedback induced by the moving fixture mass mounted to the load cell. It is important to understand that the unwanted effects of this motion increase exponentially as the test frequency increases.
Key Concepts Item Name 4 Load 5 Time To prevent this unwanted feedback from affecting your test results, MTS MP includes a Compensate for Fixturing feature. This feature takes advantage of the accelerometer in the load cell and compensates for the inertial error induced by the moving mass. The Compensate for Fixturing routine is run with all fixturing in place, but without a specimen.
Key Concepts For more information, see Compensate for Fixturing (p. 158). To see how this feature is used when running the example test, see Create a Compensation Set . About Tuning Tuning refers to the process of adjusting your test system so that system performance matches specimen characteristics. When you tune, you are setting the response and stability of the servo control loop.
Key Concepts required. For quick reference, the Station Manager application includes a Message Pane, and the MPX application includes an Error List and Application Log that displays log file entries as they occur. MTS Echo Software MTS Echo Software allows you to monitor the status of your tests and lab operations from any computer or mobile device. You must have the latest version of MTS Series 793 Controller Software and access to the internet.
Running the Example Spring Test Topics: • • • • • • • • • • • Example Spring Test Procedure........................................................................................................96 Power Up the Station.........................................................................................................................96 Position the Crosshead and Actuator for Initial Setup.......................................................................98 Install Fixturing.........................
Running the Example Spring Test Example Spring Test Procedure Introduction Setting up and running the Example Spring Test is an excellent way to become familiar with the MTS Acumen system hardware and software. These instructions are based on the example MTS Acumen system shown in the Introduction chapter. If your system differs, see the Key Concepts and Best Practices for Other Tests and Configurations chapters for information on how to adapt the example test to your particular system configuration.
Running the Example Spring Test The controller power switch is located on the back of the controller. 2. Turn on the load frame. The switch is located on the back of the load frame. 3. Click the MPX station shortcut icon on your desktop. It should have a file name similar to Multipurpose Express (FT40_station1.cfg).
Running the Example Spring Test Note: If your desktop does not have an MPX icon that designates the station configuration (for example FT40_station1.cfg), see Creating a Desktop Shortcut (p. 144) for details regarding how to set one up. Position the Crosshead and Actuator for Initial Setup In this section, you will raise the crosshead high enough so that the actuator cannot contact anything even if it goes to full extension.
Running the Example Spring Test a) Calculate how high you need to raise the crosshead to prevent the actuator from contacting anything even if it goes to full extension. Your calculations should include the fixturing that will be used for the test. Note: The stroke for most MTS Acumen load frames is 70 mm (2.76 in). b) Move the left and right crosshead locks to the fully unlocked position. c) If necessary, turn Exclusive Control on.
Running the Example Spring Test If the load frame is not equipped with a test area enclosure, press the High-Power Prohibit button on the frame-mounted control until High-Power Prohibit is illuminated. This prevents high power from being applied to the actuator when working in the test space and places the system in High-Power Prohibit mode. Note: The MTS Acumen load frame shown in this manual does not have a test area enclosure for illustrative purposes.
Running the Example Spring Test b) Notice that as you move the actuator, the virtual actuator in the Situational Awareness Panel also moves. 6. Set your actuator to the initial position for the test.
Running the Example Spring Test Because this Example Spring Test is a compression test, you should set the actuator to 20% extension which, for this example, is -21 mm. For more information, see Positioning the Crosshead and Actuator for the Test (p. 79). Install Fixturing To mount the load cell and platens and set fixturing parameters: 1. Ensure that you have a complete Reference Specimen Kit.
Running the Example Spring Test The components you will need are: upper and lower platens, mounting bolts, and the 5 mm hex key. You will need the beige spring for the test. This beige spring, as well as the other components shown in the preceding photo were packaged with your Acumen at delivery. 2. Take safety precautions before putting your hands near the crush zone. a) Ensure that High-Power Prohibit is on and exclusive control is off.
Running the Example Spring Test Click the All Power Off button in the MPX main window. 3. If necessary, mount the load cell (force sensor). The load cell can be mounted to the actuator or the table. Either configuration will work. However, best practice is to mount the actuator to the table. For more information regarding mounting configurations, see Mounting a Load Cell on the Actuator (p. 184) or Mounting a Load Cell on the Table (p. 185). 4.
Running the Example Spring Test b) Repeat the procedure for the actuator mounted platen. 5. Make Install Fixturing selections.
Running the Example Spring Test a) Specify the location of the force sensor (load cell). In the Explorer panel of the MPX main window, select Set Up > New Specimen > Install Fixturing. Click the radio button to indicate where the load cell is mounted. If you receive a warning icon and a message that the system senses that this orientation is incorrect, ensure that the accelerometer in the load cell is connected to the frame. b) Ensure that Set the Signal Sense is set to Tension is Positive.
Running the Example Spring Test Set Limits You can use MPX limit detectors to protect you, your specimen, and the equipment. When a limit is tripped, an action is carried out (for example, Controlled-Stop Interlock). You can set both the limit values and the actions. In this section, you will set nested displacement and force limits. MTS highly recommends mastering the concepts presented in Understanding Nested Limits (p. 80) prior to performing the steps in this topic.
Running the Example Spring Test a) In the MPX Explorer panel, select Set Up > New Specimen > Install Fixturing. b) Under What signal sense do you want to use? select Tension is Positive. 2. Turn on all display information for the Situational Awareness panels. Click each button as necessary until they are all yellow. This will show: • • • • • • Fixture limit sliders Specimen limit sliders Fixture and specimen limit values Offset reference Range of the last peak and valley applied Help indicators 3.
Running the Example Spring Test b) Set the Fixture Force Limits to ±1000 N. 4. Set Specimen Force Limits. a) Calculate the Specimen Force Limits. For this example test, the beige spring has a capacity of 0 N and -4050 N. While you could use these values for a specimen limits, it makes more sense to set the specimen limits just outside our expected tuning and testing values in order to stop the test quickly if something unexpected happens.
Running the Example Spring Test 5. Set Fixture Displacement Limits. a) Calculate Fixture Displacement Limits. When the actuator is positioned to touch the uncompressed spring, the end of the actuator will be 90 mm above the table. Since full stroke is only 70 mm, no limit restriction is required. Fixture limits should be set at +35 mm and -35 mm. b) Set the Fixture Displacement Limits to ±35 mm.
Running the Example Spring Test 6. Set Specimen Displacement Limits. a) Determine Specimen Displacement Limits. For a compression test, like the MTS Acumen Spring Test, the initial actuator position should be set to 20% of full extension or 14 mm. That leaves 56 mm actuator travel remaining. Full compression of the spring is considered to be 45 mm which leaves 11 mm of over-travel if the actuator is allowed to go to full stroke.
Running the Example Spring Test 7. Right-click each of the eight values that you just set and set the Limit to On, and the Action to C-Stop Interlock.
Running the Example Spring Test Warning: You must turn limits on after setting limit values. Failure to turn limits on after setting the values could result in equipment damage or injury. After turning the limits on, always verify that the sliders are blue (active) and not grey (disabled). Set Up Meters and the Scope 1. If axial force and axial displacement meters are not shown at the bottom of the MPX main window, click the Expand button in the bottom center of the window. 2.
Running the Example Spring Test Note: Zeroing the Force signal is the same as applying an auto offset. 3. Right-click the Axial Force meter and select Add Meter > Axial Force. 4. Right-click the new Axial Force meter and select Meter Type > Peak Valley. 5. Using the preceding techniques, add a Timed Axial Displacement Meter.
Running the Example Spring Test 6. Using the preceding techniques, add a Peak/Valley Axial Displacement Meter. 7. Zero both Axial Displacement meters by right-clicking and selecting Zero Signal.
Running the Example Spring Test Note: Zeroing a signal is the same as applying an auto offset. As a precaution, always check to ensure that your limits are as expected after you zero a signal. 8. On the MPX menu bar, select Display > Scope. 9. Configure the Scope.
Running the Example Spring Test Use the parameters shown. Create a Compensation Set Compensating for fixturing is primarily done if the load cell is mounted to the actuator. With an actuator-mounted load cell, the accelerometer in the load cell helps create a compensation set that compensates for the moving mass. Actuator-mounted load cells usually require that a compensation set be created.
Running the Example Spring Test a) In the Explorer panel of the MPX main window, select Set Up > New Specimen > Compensate for Fixturing. b) Under What do you want to do? select Create a new compensation set. c) Under How would you like to create a new compensation set? select Have the system measure dynamically. Click Next. 2. Specify compensation parameters. • • Under Control Mode, Stable Displacement is automatically selected. Under Expected Test Frequency, select Low (0-20 Hz).
Running the Example Spring Test • • Under Target Setpoint, select 0.000 mm. Under Amplitude, select 1.000 mm. 3. Power up the load frame. a) Turn off High-Power Prohibit on the load frame-mounted control. b) Click the All Power Low and then the All Power High buttons on the Actuator Power panel so the “System ready to compensate.” message appears. If necessary, clear interlocks. 4. Create the compensation set.
Running the Example Spring Test Click the green arrow button to create the compensation set. The stages of verification are shown above the compensation progress bar. When verification is complete, the bar disappears. The mass of the fixturing and load cell is calculated, and the results are indicated by the arrow on the Correction Quality Indicator. Optimal results are achieved when the arrow appears in the green area.
Running the Example Spring Test With the values provided for this Spring Test, the arrow should be in the green area after verification. When you are satisfied with the results: a) Click Done. b) Enter a compensation set name. c) Click OK to save the compensation set. Install the Specimen To install the beige spring specimen: Note: The beige spring was included with your MTS Acumen load frame when it was delivered. 1. Take safety precautions before putting your hands near the crush zone.
Running the Example Spring Test Click the All Power Off button in the MPX main window. 2. Set specimen installation parameters. a) In the Explorer tab of the MPX main window, select Set Up > New Specimen > Install Specimen. b) Select Stable Displacement for the Active Control Mode. c) Set Specimen Protection limits. Because of the flexible nature of the spring, specimen protection limits are not really necessary.
Running the Example Spring Test Important: Specimen Protection Limits are active only while you are in the Install Specimen node. They are automatically disabled when you leave the Install Specimen node. You do not need to manually turn them off when you are done installing the specimen. 3. Place the spring on the bottom platen. 4. Position the crosshead so that there is 1-2 mm clearance between the upper platen and the spring.
Running the Example Spring Test Item Description 3 Exclusive Control a) If necessary, turn Exclusive Control on. b) Move the left and right crosshead locks to the fully unlocked position. c) Using the crosshead lift controls on the frame-mounted control, lower the crosshead so there is about 13 mm clearance between the spring and top platen. d) Move the left and right crosshead locks to the fully locked position. e) When you are done adjusting the crosshead, turn Exclusive Control off.
Running the Example Spring Test b) Right-click the offset value and select Auto Offset. This compensates for the weight of the fixture (and the specimen in tests where grips are used). c) In the Situational Awareness panel, show specimen limit sliders and the offset reference by making all buttons in the Layer Control panel yellow. 2. Turn actuator power off.
Running the Example Spring Test Actuator power must be off to select or change a tuning set. Click the All Power Off button in the Actuator Power panel of the MPX main window. 3. Select tuning parameters.
Running the Example Spring Test a) In the Explorer panel of the MPX main window, select Set Up > New Specimen > Tune for Specimen. b) If a tuning set is not shown in the Current Tuning Set box, select a tuning set from the drop-down menu. You will be creating a new tuning set, but you must start with an existing one. c) Under What would you like to do? select Auto tune – Have the system tune itself and click Next. d) Under How do you want to identify specimen characteristics? select System Identifies.
Running the Example Spring Test 6. Apply the tuning parameters. When the data has been acquired and the bar shows 100%, click Apply. This sends the specimen-based parameters to the controller. 7. Verify the tuning parameters for the displacement control mode.
Running the Example Spring Test Verify checks to see how the system reacts to the tuning parameters you just set. a) Click Verify. b) Under Select a Control Mode select Displacement. c) Do not change the Test Type, Minimum Compression, or Maximum Compression parameters that were used during tuning.
Running the Example Spring Test d) Click the green arrow button to begin verification. When the Verification Progress bar shows 100%, the control quality indicators will show whether the tuning is optimal (in the green area), is running cold or slow (in the blue area), or is running hot or fast (in the red area). e) If you want to make the system run hotter or cooler, you can click and move the white dot on the Displacement and Velocity Control Quality indicators.
Running the Example Spring Test a) Click Done. b) Give the tuning set a name. c) Click OK to save the set. 10. Review the Pretest Configuration. In the Explorer panel, select Pretest Configuration. Check to ensure that all values are as expected. 11. Turn off Actuator Power. Run the Test The example MTS Acumen Spring Test ramps from 0 to 150 N, and then cycles the spring between 100 and 200 N compression. 1. Create a new test.
Running the Example Spring Test In the MPX main window, select File> New > Test from Template. The New Test from Template window opens. 2. Select the test template. Double-click the MTS Acumen folder, and then double-click the MTS Acumen Spring Test file. You may be prompted to save the file. If so, click Yes to save the test with a new name, and open the test. The test name appears in the Explorer tab. 3. If desired, rename the test.
Running the Example Spring Test You can do so by right-clicking on the test name in the Explorer tab and selecting Rename. 4. Create a new test run. a) Right-click the test name or Test Runs in the Explorer tab and select New Test Run. The Specimen Selection window opens. b) In the Specimen Selection window, click the “+” button, and then click OK.
Running the Example Spring Test The Edit Variable Values window appears. c) In the drop-down list, select Beige Spring, and click OK. The Edit Variable Values window reappears. d) Accept the default value of 90.541 for Nominal Stiffness and click OK. e) On the Monitor tab, do not change any values.
Running the Example Spring Test 5. If necessary, power up the load frame. Click the All Power Low button and then the All Power High button on the Actuator Power panel in the MPX main window. 6. Run the test. In the Program Control panel, click the green Run the Test (green arrow) button. 7. Complete the test.
Running the Example Spring Test When the test run has completed, you are prompted to Retract actuator? Click Yes. 8. Review the results. a) Notice the following data on the Monitor tab: • • • • • • • • Peak Displacement Valley Displacement Peak Force Valley Force Geometry Type Nominal Stiffness Cycle Count Measured Stiffness b) Notice that the chart shows a line that plots the Spring Rate. 9. Run a report.
Running the Example Spring Test MTS Acumen™ | 137
Running the Example Spring Test Click the Run Report button in the Monitor tab to generate a report of the test run. You must have Microsoft Excel or a Microsoft Excel viewer installed to view the report. 10. Turn off actuator power. Click the All Power Off button. Remove the Specimen 1. Take safety precautions before putting your hands near the crush zone. a) Ensure that High-Power Prohibit is on.
Running the Example Spring Test If High-Power Prohibit is not illuminated, press the High-Power Prohibit button. b) Ensure that actuator power is off. Click the All Power Off button in the MPX main window. 2. Position the crosshead to provide clearance. a) Press the Exclusive Control button on the frame-mounted control.
Running the Example Spring Test b) Move the left and right crosshead locks to the fully unlocked position. c) Using the crosshead buttons on the frame-mounted control, raise the crosshead to provide adequate clearance. d) Move the left and right crosshead locks to the fully locked position. e) When you are done adjusting the crosshead, turn Exclusive Control off. 3. Remove the specimen.
Running the Example Spring Test MTS Acumen™ | 141
Best Practices for Other System Configurations and Tests Topics: • • • • • Creating a Desktop Shortcut...........................................................................................................144 Pre-Test Station Checkup................................................................................................................145 Setting Up the System.....................................................................................................................
Best Practices for Other System Configurations and Tests Creating a Desktop Shortcut If an MPX shortcut does not already exist on your desktop for your station configuration, create a station shortcut. A station shortcut is a desktop icon that, when clicked, automatically opens the proper controller and the desired Station Configuration. MTS recommends you create a new station shortcut whenever you change Station Configurations.
Best Practices for Other System Configurations and Tests Pre-Test Station Checkup This procedure is recommended anytime you select a new station, change parameter sets or sensor calibration files with the existing station, or question whether the station is ready to collect valid data. It describes how to: • • • • Select a controller, configuration, and parameter set. Verify that the proper calibration file is in use. Ensure that Station Manager detectors are properly set.
Best Practices for Other System Configurations and Tests b) If necessary, select a project. Note: A project may have already been selected, so you may not need to perform this step. It is common practice to keep all files in Project1. If you find this acceptable, in the Select Project window, select Project1. Otherwise, enter your own project name for the project. Note: This window will not appear if you selected Project1 as the default project when you installed the MTS TestSuite application.
Best Practices for Other System Configurations and Tests At the controller selection window, select the controller for the station that you are using (for example, MTS FlexTest 40). Note: This window may not appear in all cases. d) Select a parameter set and configuration. 1. Select a configuration. Select the configuration file recommended by your lab experts (e.g. FT40_station1.cfg) but do not click Open yet. 2. Select a parameter set.
Best Practices for Other System Configurations and Tests Your system is equipped with identical detectors in both the controller (set with the Station Manager application) and in MPX. To ensure detectors do not conflict with each other and cause unwanted shutdowns, MTS configures MTS Acumen Station Configurations to enable detectors in MPX and disable detectors in the controller (with the exception of the Axial Acceleration Limit). This step ensures all controller settings are set properly.
Best Practices for Other System Configurations and Tests 3. Verify that the correct calibration file for the force sensor (load cell) is in use. Select Station Manager > Display > Station Setup > Channels > Axial (or other depending on configuration) > Force > Sensor. Match the serial number in the software to the serial number on the load cell. 4. Close MPX and the Station Manager application.
Best Practices for Other System Configurations and Tests Setting Up the System Generally, whenever you change your system configuration (specimen, load cell, fixturing), you should re-perform each task on the Explorer tab using the new system configuration.
Best Practices for Other System Configurations and Tests Important: When you apply a program command manually (by applying the command via the manual command controls or the function generator in the Generate Command element of the Set Up node), and stop the command using the Stop button on the control panel, the actuator may move unexpectedly. The occurrence depends on the relationship between program command and specimen characteristics.
Best Practices for Other System Configurations and Tests Load Cell Mounted on Actuator If you have mounted your load cell to the table top, click the bottom radio button. Note that the Axial Displacement diagram now shows the load cell positioned on the bottom (see the following figure below). Load Cell Mounted on Table Top Setting Signal Polarity Quick access: Explorer tab > Set Up > New Specimen > Install Fixturing Note: Stop all tests before changing signal polarity.
Best Practices for Other System Configurations and Tests Changing polarity does not change the actual (electrical) polarity of the sensor or calibration; it simply changes how data is shown. For example, consider a situation where tension is positive and the home position is 0. If you retract the actuator 5 mm, the meters on the bottom of the screen will show +5 mm axial displacement.
Best Practices for Other System Configurations and Tests When creating a custom test, the test designer can optionally configure the test to check that the polarity of the system corresponds correctly to the template. However, if you are running a custom test that was not supplied by MTS, it is important to verify which polarity mode (tension positive or compression positive) that the test designer intended because the test designer may not have added a polarity validation step to the test.
Best Practices for Other System Configurations and Tests Edit Polarity Window Balance Fixturing Quick access: Explorer tab > Set Up > New Specimen > Install Fixturing Important: Before clicking the Balance Fixturing button, ensure the following: • • • • The power is on. The upper fixturing is in place. The specimen is not in contact with the upper fixture (that is, the only force on the motor is the weight of the upper fixturing). The actuator is not moving.
Best Practices for Other System Configurations and Tests • If a yellow caution symbol appears next to the button, the system is unbalanced, and you should click the Balance Fixturing button. Note: If the Balance Fixturing button is disabled (appears gray), the fixturing cannot be balanced because of one or more of the following: • • • The station power is off. The actuator is moving. a command is being applied.
Best Practices for Other System Configurations and Tests 4. To set the Minimum Limit, repeat steps 1 through 3 using the Minimum Limit thumb control. 5. After you have set the physical limits, install the fixtures or grips required to hold your specimen. Fixture Limit Window About Detector Actions The following actions can be taken when setting fixture and specimen limits in the Situational Awareness panel.
Best Practices for Other System Configurations and Tests Action Description Reset the interlock to resume testing. Program Hold Interlock Places a hold on any program command, writes a message to the Application Log, and forces a program interlock. Reset the interlock to resume testing. The Function Generator does not recognize Program Hold Interlock but instead goes to Stop.
Best Practices for Other System Configurations and Tests When you apply inertial compensation, a secondary offset is applied for Axial Force to offset the inertial force caused by gravity on the fixturing. You cannot clear this static offset, which shows up on the right side of the Axial Force diagram on the Situational Awareness panel. If you do not apply inertial compensation, this offset is not shown. You can hover your cursor over this offset and see a tooltip explanation.
Best Practices for Other System Configurations and Tests Explorer Tab 2. In the Compensate for Fixturing panel, select Create a new compensation set in the drop-down menu for What do you want to do?, and click the Have the system measure dynamically radio button. Compensate for Fixturing Panel 3. Click Next. 4. Below Define Command, enter the values to create a modeling program that will generate load feedback from which the application will model compensation values.
Best Practices for Other System Configurations and Tests 9. Adjust the values under Define Command for creating a program that will generate load feedback to which the application will apply compensation (based on the values the application generated while running the modeling program). 10. When the system is ready, click the green run button to apply the modeling program. Click the Scope tab and observe the results (load feedback in response to the command). 11.
Best Practices for Other System Configurations and Tests 3. Click Next. 4. In the Mass box, enter the unit of measurement and fixture mass for which you want to compensate the effects of acceleration. In the Fine Adjustment box, enter the unit of time and value for the delay between the acceleration (compensating) signal and force feedback. In the Polarity box, select Normal or Invert.
Best Practices for Other System Configurations and Tests 3. Click the Install Specimen element in the Explorer tab. Use Existing Compensation Set In this procedure, you will use a compensation set that has already been created. 1. Click Compensate for Fixturing on the Explorer tab. 2. Select Use existing compensation set. 3. Select the existing compensation set you want to use in the drop-down menu for Compensation Set. 4.
Best Practices for Other System Configurations and Tests frame diagram on the Situational Awareness panel. You typically set specimen limits to 50% of the desired test forces prior to tuning. Note: To show all fixture and specimen limits on the virtual frame diagram, click the Show the fixture and specimen limit values button on the layer controls. 1. To adjust the Maximum Limit, click and hold the Maximum Limit thumb control, and slide it to the desired limit. The limit value appears.
Best Practices for Other System Configurations and Tests Install Specimen Quick access: Explorer tab > Set Up > New Specimen > Install Specimen Specimen Protection Specimen Protection mode limits the current to the motor, which limits the force available from the actuator. You can specify the maximum tension and compression force values.
Best Practices for Other System Configurations and Tests • If the handset wheel control is active, you may not be able to turn specimen protection off until you press the exclusive control toggle button on the frame-mounted control to release control to the software.
Best Practices for Other System Configurations and Tests 5. On the frame-mounted control, press the exclusive control toggle button. 6. If the load frame is not equipped with an enclosure, press the High-Power Prohibit button on the frame-mounted control. This prevents high power from being applied to the actuator when working in the test space. 7. Open the lower grip. If applicable, use the lower pneumatic grip control toggle button to open the lower grip.
Best Practices for Other System Configurations and Tests Tune for Specimen Quick access: Explorer tab > Set Up > New Specimen > Tune for Specimen About Tuning Tuning refers to the process of adjusting your test system so that system performance matches specimen characteristics. When you tune, you are setting the response and stability of the servo control loop. While precise tuning is not usually necessary, inaccurate tuning increases the error and phase lag between command and feedback.
Best Practices for Other System Configurations and Tests Tip: For experts only: To access the expert level of manual adjustment of tuning parameters, right-click the Tune for Specimen element on the Explorer panel. This shows the Tuning panel with individual P Gain, I Gain, D Gain, F Gain, F2 Gain, and FL Filter controls.
Best Practices for Other System Configurations and Tests Tune for Specimen Element When you choose an existing tuning set or select the auto tune feature, you typically do so in the stable displacement control mode (best practice). The tuning set you select or generate (with the auto tune feature) determines tuning values for control modes used for testing, such as force and displacement.
Best Practices for Other System Configurations and Tests over-perform and become unstable (also referred to as “tuned hot”), the pointer will be positioned to the right in the red zone. Best Practices for Auto Tuning Before auto tuning, read and understand the following: • • • Tuning electrodynamic systems is fundamentally different than tuning servohydraulic systems. Therefore, any best practices observed for tuning servohydraulic systems are likely not applicable when tuning electrodynamic systems.
Best Practices for Other System Configurations and Tests Tuning Procedures The following procedures provide step-by-step information about how to select an existing tuning set, create a new tuning set, use auto tuning capabilities, verify your tuning set, or manually adjust your tuning set: • • • • • • • Using the selected tuning set as is (p. 172) Auto Tune - Generate Specimen Characteristics (p. 172) Auto Tune - Enter Specimen Characteristics (p. 173) Verifying the Tuning Set (p.
Best Practices for Other System Configurations and Tests Tuning Progress Bar Note: At this point, the system has generated specimen characteristic values, but has not applied auto tune values appropriate for the specimen to the controller. 9. Click Apply to save the new auto tune values over the current auto tune values.
Best Practices for Other System Configurations and Tests Note: This window allows you to enter master gain multipliers for force and displacement in the outer loop, and for velocity in the inner loop. The default is 100%. You can adjust the default multiplier value for each master gain to increase or decrease the default gain values the system generates in response to the Stiffness, Mass, and Damping values you enter. 5. Click Apply to save the new auto tune values over the current auto tune values.
Best Practices for Other System Configurations and Tests Verification Complete There is no slider position that is optimal for all specimens, so do not assume that it is best to move the slider to the green zone regardless of the auto-tuning results. Optimal tuning depends on the specimen characteristics. Some specimens may perform better if the slider is to the left of the green zone, and some specimens may perform better if the slider is to the right.
Best Practices for Other System Configurations and Tests If the loop is over-tuned, that is, responds in an over-responsive or unstable manner (also referred to as “tuned hot”), the indicator will be positioned to the right in the red zone. In the scope graph, the feedback line (red) will over-respond to the command line (blue): Over-Tuned Loop Note: The indicator in the tuning quality graph becomes a slider control when verification is complete.
Best Practices for Other System Configurations and Tests to adjust only the tuning values of the control mode you intend to use (active control mode). For dual-mode use, adjust and verify the tuning values of both modes iteratively until you obtain satisfactory results. 1. 2. 3. 4. 5. 6. 7. 8. 9. Select Adjust - Adjust the selected tuning set. Click Next. In the What control mode would you like to optimize? list box, select Force or Displacement.
Best Practices for Other System Configurations and Tests 9. Repeat for displacement and force control modes. Adjust Tuning (Expert) In this procedure, you will adjust individual tuning controls in the controller while applying program command and observing the system response. Important: This workflow is intended for advanced users only. Improper tuning may result in unstable system performance and equipment damage. Important: There is an interrelation between control modes when tuning.
Best Practices for Other System Configurations and Tests new specimen, such as turn on Specimen Protection. Typically, after you have the new specimen installed, you do not have to adjust tuning because the properties of the specimen will not have changed. If additional acceleration compensation or tuning is required, return to those elements in the Explorer tab to make the necessary adjustments before creating a new test run.
Best Practices for Other System Configurations and Tests Generate Command Panel Generate Command Element Descriptions Item Description Channel Select the control channel. By default, the first channel is selected. Control Mode Select the control mode used when the Generate Command element starts. Options include the control modes of the selected channel.
Best Practices for Other System Configurations and Tests Item Description Active Mode Shows the current control mode. Command Type Select the type of command: • • • Target Setpoint Cyclic—The function cycles at the specified amplitude and frequency. Sweep—The function sweeps the command signal between the specified frequency limits at the rate specified. Random—The function sweeps randomly according to the amplitude and frequency limits you specify.
Best Practices for Other System Configurations and Tests Manage Limits Quick access: Explorer tab > Set Up > Tools > Manage Limits The Manage Limits element allows you to view or modify fixture and specimen limits and offset values using either the virtual frame diagrams on the Situational Awareness panel (see Situational Awareness Panel (p. 58)) or by using a table format on the Summary tab. The Summary tab contains the Float Limits tab and the Error Limits tab.
Best Practices for Other System Configurations and Tests Common Hardware Tasks Mounting a Load Cell Mounting a load cell involves securing the load cell to the actuator or table top using four threaded bolts. Depending on your specific testing needs, you may have additional adaptive hardware.
Best Practices for Other System Configurations and Tests Low Force Load Cells When you need to use a low force load cell, you can mount it onto a system load cell, called mounting in tandem. You must attach the low force load cell cable to the load frame. Because the low force load cell (see figure on right) uses the accelerometer on the system load cell to send information to the conditioner in the controller, it is not necessary to connect another accelerometer to the low force load cell.
Best Practices for Other System Configurations and Tests 5. Place the load cell up to the actuator, orienting the accelerometer and load cell cable connectors to the rear of the load unit, so that when connected to the frame, the cables do not wind around the load cell and become disconnected. 6. Align the four holes, and using the hex key, turn the bolts clockwise to tighten. If necessary, raise the crosshead so you have enough space to work between the crosshead and table. 7.
Best Practices for Other System Configurations and Tests Mounting a System Load Cell on the Table 7. Torque the load cell bolts to specifications. 8. Using a small flathead screwdriver, attach the accelerometer cable from the load cell to the back of the load unit in the slot labeled “Accelerometer.” 9. Using a small flathead screwdriver, attach the load cell cable to the back of the load unit in the slot labeled “Force Transducer.
Best Practices for Other System Configurations and Tests Tandem Mounted Load Cells Installing Grips and Fixtures MTS offers a wide variety of optional fixtures used to mount your specimen in the load frame, such as tension grips, bend fixtures, pneumatic wedge grips, compression platens, and many other types. Adapter kits are available for fixtures used with the MTS Acumen load frame. For information about ordering and using the optional items specific to your testing needs, see the accessories manual.
Best Practices for Other System Configurations and Tests 3. Browse to the Station Configuration file you will be using, or type the file name in the Station Configuration box. Ensure that this configuration file contains the parameter and tuning sets that you want the operator to use for the tests. 4. If the Controller Name box is not already populated, type the name of the controller you will be using. 5. Click OK. The configuration message that states that the shortcut was created on the desktop appears.
Best Practices for Other System Configurations and Tests Interlock Info Tip on System Panel Caution: Clearing interlocks overrides all interlocks and may result in unexpected actuator motion. Unexpected actuator motion may result injury or damage to equipment. Always make sure the actuator area is clear and double check your work before clearing interlocks.
Best Practices for Other System Configurations and Tests Important: Verify that you are either in Stable Displacement or a control mode that is tuned to your specimen or situation. Otherwise, uncontrolled actuator movement may occur. Actuator Power Panel 1. On the Actuator Power panel, click the Power Low button (two of five bars highlighted). 2. On the Actuator Power panel, click the Power High button (five of five bars highlighted).
Best Practices for Other System Configurations and Tests shown below the test run name in the Explorer tab. You can click Preferences > Configuration and select a different location for generated reports on the Project tab. Generating a Report Using the Excel Reporter Add-In Note: To generate a report using the Excel Reporter Add-In, you must have purchased a separate license for the Reporter Add-In product.
Best Practices for Other System Configurations and Tests • • • • • Select a template as the default. Edit the template. You must have the required software application. Select the report format of Excel Workbook, comma-separated values, or tab delimited text. Select whether the report is new, overwrites an existing report, is appended to an existing worksheet, or added as a new worksheet.
Maintenance Topics: • • • • Routine Maintenance Overview Checklist.......................................................................................194 General Cleaning ............................................................................................................................196 Monthly Maintenance......................................................................................................................196 Other Service ......................................................
Maintenance Routine Maintenance Overview Checklist Important: There are no customer-serviceable components on the MTS Acumen frames. Maintenance consists of keeping the frame and work area clean, general inspection, checking interlocks, and scheduled frame calibration. Recommended Service Calendar Time Using 8 Hours Running Daily Time Rate per Day Monthly Annually Running Time-Hours 8 160 2000 Clean work area / machine surfaces. X Check frame-mounted control Emergency Stop.
Maintenance Calendar Time Using 8 Hours Running Daily Time Rate per Day Monthly Annually Clean exposed cooling surfaces. MTS Ensure actuator movement is smooth. MTS Check actuator guidance mechanism. MTS Check brake operation. MTS Check anti-rotate mechanism. MTS Check for excessive contamination. MTS Electrical Ensure displacement transducer is clean. MTS Verify displacement transducer is aligned. MTS Confirm reference transducer is aligned.
Maintenance Calendar Time Using 8 Hours Running Daily Time Rate per Day Monthly Annually Check frame mounted control—high power prohibit functions. MTS Verify that unlocked crosshead generates an interlock. MTS Check system cable bundle connectors. MTS Check system cable bundle for abrasions. MTS Check supplemental ground attached. MTS Verify tuning parameters are correct for stable control modes. MTS Verify load frame protection limits are correct and enabled.
Maintenance Other Service Regular inspection and service of the drive motor system and crosshead positioning components are needed to prolong the life of your frame and keep it performing optimally. This type of service is performed by MTS field service engineers or an MTS authorized service representative. Contact your MTS authorized representative for additional information. Note: MTS offers annual maintenance and calibration plans. Contact your sales representative for more information.
Decommissioning Topics: • Decommissioning............................................................................................................................
Decommissioning Decommissioning 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. To decommission the system: 1. Remove the specimen and fixtures. Large grips should be removed if the load frame could be tipped over. 2. Isolate the system from electrical power. 3. When the system electronics, control software, and the system PC are powered down, turn off the system’s main electrical supply.
Index Index 793 software, See MTS FlexTest (Series 793) controller software A acceleration compensation 158 actions setting 109–111 active control mode 122 actuator crosshead mounted 37 High-Power Prohibit button 53 power high button 53 power low button 53 power off button 53 power panel 189 retracting 136 actuator speed velocity limiting 18 application MTS Multipurpose (MP) Express 35 Station Manager 35 Application Log MTS Multipurpose (MP) Express application 93 auto offset 124–125 auto tune 127 auto tu
Index E E-Stop control 70 edit variables window 134 emergency stop 70 Emergency Stop button 19 enclosure test area 25 error conditions 93 detectors 148 list MTS Multipurpose (MP) Express application 94 exclusive control 98, 103, 124, 139 F feedback 75, 91, 158 file calibration 149 file extensions .cfg 72 .
Index L layer control panel 124 lights system status 37 limit detector axial acceleration 148 limit detectors 62, 148 limits hiding 124 learning more 87 overview 107 setting 86 setting fixture displacement 110 setting fixture force 109 setting specimen displacement 111 setting specimen force 109 showing 125 specimen protection 122 load cell mounting 183, 185–186 set location 151 load cell (force sensor) mounting 104 specifying location 106 load frame description 36 powering up 119, 127, 135 turning on 97 l
Index project selecting 146 protection 31 Q quick access toolbar 47 R remap resources 188 renaming a test 132 report generate in Microsoft Excel 191 generate in MP 190 running 136 templates 191 reports 74 resource validation errors 188 resources in configuration files 72 mapping 188 results test 136 running a report 136 S safety c-stop interlock 17 crush zone 20 general practices 26 hazard placards 24 hazard zones 24 operating practices 31 overview 22 personnel qualifications 24 pre-operation practices 2
Index system overview 35 system panel c-stop interlock 17 indications 49 overview 47 system status light 37 T technical support 11 template selecting 132 test creating new 131 hold button 56 New Test from Template 47 open new 47 renaming 132 results 136 run button 56 running 131 save as template 47 save changes 47 stop button 56 stop procedure button 56 test area enclosure 25 test execution raw data export task 192 test procedure files 73 test run creating 133 export 191–192 generate report in Microsoft Ex
Index 206
MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within U.S. or Canada) Phone:952-937-4000 (outside the U.S. or Canada) Fax 952-937-4515 E-mail: info@mts.com Internet: www.mts.
