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Contents Technical Support 5 How to Get Technical Support 5 Before You Contact MTS 5 If You Contact MTS by Phone 6 Problem Submittal Form in MTS Manuals 7 Preface 9 Before You Begin 9 Conventions 10 Documentation Conventions 10 Introduction 13 Functional Description 13 Optional Equipment 13 Closed-Loop Rotary Actuator Systems 15 Actuator Specifications 16 Options Specifications 19 Reaction Brackets 22 Reaction Bases 23 Diaphragm Flexures 24 Flange Adapters 25 Safety Information 27 Hazard Placard Placemen
Installation 31 Actuator Installation 32 Reaction Bracket and Torque Cell Installation 32 Diaphragm Flexure Installation 34 Aligning Force Train Components 34 Component Alignment on an MTS Base Plate 35 Component Centerline Alignment 35 Adjusting Actuator and Torque Cell Centerline Height 35 Adjusting Actuator and Torque Cell Concentricity 36 Adjusting Actuator and Torque Cell Centerline Angularity 37 Operation 39 Thrust and Side Load Characteristics 39 Definition of Useful Mathematical Terms 40 Test Setup
How to Get Technical Support 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.
If You Contact MTS by Phone 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.
Problem Submittal Form in MTS Manuals If you are calling about an issue that has already been assigned a notification number, please provide that number. You will be assigned a unique notification number about any new issue.
Problem Submittal Form in MTS Manuals 8 Technical Support Series 215 Rotary Actuator Product Manual
Before You Begin Preface Before You Begin Safety first! Before you attempt to use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices contain safety information that is specific to the task to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow the directions that are given.
Documentation Conventions 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.
Documentation Conventions 12 Preface Series 215 Rotary Actuator Product Manual
Functional Description Introduction Functional Description MTS Series 215 Rotary Actuators are heavy-duty, torque-generating actuators that operate under precision servovalve control. When coupled with an appropriate MTS servovalve and transducer, Series 215 Actuators provide the rotational motion and torque required to torsion test materials and components. These actuators receive drive power from a hydraulic power unit via a servovalve which is manifold-mounted to the top of the actuator.
Optional Equipment Rotary Actuator Test System with Optional Equipment Optional Equipment for Series 215 Rotary Actuators OPTION FUNCTION Reaction base plate or T-slot table A reaction base plate or T-slot table is used with the rotary actuator for two purposes; (1) it provides a mounting surface for the actuator and drive train components; (2) it provides a structure which can react the large forces generated by the rotary actuator.
Closed-Loop Rotary Actuator Systems Optional Equipment for Series 215 Rotary Actuators (Continued) Torque cell A torque cell provides a precise electrical feedback signal that is proportional to the torque applied to the specimen. For more information on MTS torque cells, refer to the appropriate MTS product specification. ADT An angular displacement transducer (ADT) connected to the rear shaft of the actuator produces a DC electrical signal that is proportional to the angular position of the actuator.
Actuator Specifications As the block diagram shows, a program command signal is input to the controller. The command signal is compared to the feedback signal from one of the actuator transducers. If the command signal equals the feedback signal from the transducer conditioner, no DC error is present and the valve driver circuit produces little or no servovalve control signal. If the command signal does not equal the feedback signal, a DC error signal is sent to the valve driver circuit.
Actuator Specifications Series 215 Rotary Actuator Ratings by Model MODEL MAX VELOCITY CUSHION LIMITATION‡ ROTARY ACTUATOR ROTATIONAL INERTIA¶ U.S. Customary rad/sec SI Metric rad/sec lbm-in.2 J kg-m2 I 215.32 260 w = --------J 4.4 w = ------I 11.67 0.00342 215.35 305 w = --------J 5.2 w = ------I 18.54 0.00544 215.41 385 w = --------J 6.6 w = ------I 20.23 0.00594 215.42 840 w = --------J 14.4 w = ---------I 29.04 0.00852 215.45 w = 970 --------J w = 16.6 ---------I 171 0.
Actuator Specifications Actuator Dimensional Drawing Actuator Dimensions and Weights A B C D E MODEL IN. MM IN. MM IN. MM IN. MM IN. MM 215.32 1.50 38.1 7.875 200.0 10.00 254 1.175 29.8 3.130 79.5 215.35 2.251 57.1 7.875 200.0 10.00 254 2.275 57.8 3.130 79.5 215.41 2.251 57.1 7.875 200.0 10.00 254 2.275 57.8 3.130 79.5 215.42 2.251 57.1 7.875 200.0 10.00 254 3.275 83.2 3.130 79.5 215.45 3.751 95.3 9.875 250.8 12.25 311 2.775 74.5 4.
Options Specifications Options Specifications Specifications for the most common options available for use with the Series 215 Rotary Actuators are described below. Foot Mounting The foot mounting option is used for easy attachment of the actuator to a reaction base and also provides some flexure capability.
Options Specifications Foot Mounting Dimensions and Ratings MODEL A B C D IN. MM IN. MM IN. MM IN. MM 215.32 6.25 158.8 0.75 19 5.00 127 17.00 432 215.35 6.25 158.8 0.75 19 5.00 127 17.00 432 215.41 6.50 166.4 1.00 25 5.00 127 19.50 495 215.42 6.50 166.4 1.00 25 5.00 127 19.50 495 215.45 7.75 196.8 1.50 38 6.00 152 22.00 559 215.51 7.75 196.8 1.50 38 6.00 152 22.00 559 MODEL E F G THRUST LOAD* H (MAXIMUM) IN. MM IN. MM IN.
Options Specifications Foot Mounting Specification Drawing Reaction Bracket Specification Drawing Series 215 Rotary Actuator Product Manual Introduction 21
Reaction Brackets Reaction Brackets Reaction brackets provide a torsionally rigid connection between the torque cell and the reaction base. Brackets provide some flexural capability and readily accept MTS torque cells. Reaction Bracket Dimensions and Ratings MODEL A B C D E F IN. MM IN. MM IN. MM IN. MM IN. MM IN. MM 215.32 6.25 158.8 0.75 19 5.00 127 17.00 432 12.00 304.8 3.75 92.3 215.35 6.25 158.8 0.75 19 5.00 127 17.00 432 12.00 304.8 3.75 92.3 215.41 6.
Reaction Bases Reaction Bases Reaction bases are constructed of heavy-duty steel and designed for high torsional stiffness. They readily accept MTS rotary actuators and reaction brackets. When used with MTS reaction brackets and foot mounting options, the stiffness/flexural capability is adequate to prevent excessive actuator side loads. (However, a review of thrust loads should be made.
Diaphragm Flexures Diaphragm Flexures As described in the “Test Setup Considerations” section, one or two diaphragm flexures are used when large thrust and side loads are encountered on test setups having both the rotary actuator and the reaction bracket rigidly mounted to the reaction base. The flange adapter option is required to attach the diaphragm flexure to the actuator. The flexure attaches readily to torque cells.
Flange Adapters Diaphragm Flexure Specification Drawing Flange Adapters A flange adapter may be used to mount the specimen to the actuator. Adapter mounting position is adjustable. The actuator shaft may extend beyond the adapter, be flush with it, or be recessed into it. Diameter A may be used as a shallow pilot. Flange Adapter Dimensions and Inertia MODEL A B C D IN. MM IN. MM IN. MM IN. MM 215.32 2.2511 57.2 4.00 102 2.25 57 2.99 75.9 215.32 2.2511 57.2 5.00 127 2.25 57 2.
Flange Adapters E F THREAD SIZE IN. MM IN. MM LBM·IN.2 KG·M2 215.32 5/16-18 0.63 16.0 3.25 82.5 14.4 0.00421 215.32 3/8-16 0.75 19.1 4.25 107.9 21.8 0.00639 215.41 3/8-16 0.75 19.1 4.25 107.9 21.8 0.00639 215.42 5/8-11 0.75 19.1 6.50 165.1 208 0.0608 215.45 5/8-11 1.25 31.8 6.50 165.1 273 0.0799 215.51 3/4-10 1.50 38.1 8.00 203.2 737 0.216 MODEL G ROTATIONAL INERTIA Dimensions are subject to change without notice.
Hazard Placard Placement Safety Information Hazard Placard Placement Hazard placards contain specific safety information and are affixed directly to the system so they are plainly visible. Each placard describes a system-related hazard. When possible, international symbols (icons) are used to graphically indicate the type of hazard and the placard label indicates its severity.
Hazard Placard Placement LABEL DESCRIPTION CAUTION High drain pressure can cause rod seal damage and hydraulic oil leakage. Remove drain line shipping cap and connect drain hose before operating. Part # 045-283-501 Attached mass warning. Do not exceed maximum attached mass.
Hazard Placard Placement LABEL DESCRIPTION Hydraulic Actuator ID tag lists the following: Part # 037-588-801 • Model number • Serial number • Assembly number/Rev • Force • Effective Area • Static Stroke • Dynamic Stroke • Hydrostatic/Non-Hydrostatic Pressure icon. Can be used alone, or in conjunction with pressure rating label (Part # 57-238-5xx). Part # 57-237-711 Part # 57-238-5xx Series 215 Rotary Actuator Product Manual Pressure rating.
Hazard Placard Placement 30 Safety Information Series 215 Rotary Actuator Product Manual
Installation This section describes the procedures for installing the Series 215 Rotary Actuator and optional equipment onto a base plate or T-slot table. It also includes instructions for aligning the components of the rotary actuator test system after they have been installed or moved.
Actuator Installation Actuator Installation Typically, the Series 215 Rotary Actuator is first bolted to a foot mounting assembly, then positioned on a base plate or T-slot table and secured with lightly lubricated mounting bolts. The foot mounting dimensions and ratings must match the actuator in use. After completing the alignment of force train components, torque the bolts to the correct values.
Reaction Bracket and Torque Cell Installation MTS Base Plate and Reaction Bracket Reaction Bracket Ratings and Mounting Bolt Torque Value MODEL REACTION BRACKET RATING TORQUE CELL TO REACTION BRACKET TORQUE VALUE REACTION BRACKET TO BASE OR TSLOT TABLE TORQUE VALUE LBF·FT. N·M LBF·FT. N·M LBF·FT. N·M 215.32 2000 0.226 18 24.0 150 204 215.35 5000 0.560 35 47.0 150 204 215.41 10,000 1.130 35 47.0 150 204 215.42 20,000 2.260 170 230.0 150 204 215.45 50,000 5.
Diaphragm Flexure Installation Diaphragm Flexure Installation Depending upon user requirements, the end of the actuator rotor shaft can extend beyond the flange, be flush with it, or be recessed into the flange adapter to allow the use of the inside diameter as a pilot diameter. Diaphragm flexures are used to reduce the potentially damaging effects of large axial and lateral deflections of the actuator rotor shaft.
Component Alignment on an MTS Base Plate Note In each of the following procedures the base plate or T-slot table must be flat to within 0.015 mm/m (0.002 in./ft). Component Alignment on an MTS Base Plate Rotary actuator testing systems equipped with an MTS base plate and reaction bracket combination are pre-aligned. The following procedure describes the alignment process used when you wish to increase or decrease the distance between the actuator and the torque cell.
Adjusting Actuator and Torque Cell Concentricity 2. Rotate the V-block around the rotor shaft circumference while simultaneously reading the pilot diameter runout on the face of the torque cell flange. Check the reading at top and bottom positions. A. Variation between the actuator reading and the torque cell flange face must differ by less than 0.0508 mm (0.002 in.). B. Height adjustments are made by loosening and repositioning the torque cell.
Adjusting Actuator and Torque Cell Centerline Adjusting Actuator and Torque Cell Centerline Angularity The final alignment procedure adjusts for centerline angularity deviations between the actuator rotor shaft and the torque cell flange face. Do not apply hydraulic pressure to the system unless the servovalve command (DC error) has been zeroed. If the servovalve command (DC error) does not equal zero when hydraulic pressure is applied to the system, equipment damage or personal injury can result.
Adjusting Actuator and Torque Cell Centerline 38 Installation Series 215 Rotary Actuator Product Manual
Thrust and Side Load Characteristics Operation This section discusses the calculations and precautions that must be considered in order to produce accurate test results and help protect equipment and personnel. Though some of the calculations included in this section may not be required by specific test situations, it is recommended that you read each section and ensure that the actuator will be operated within the limits of its thrust load, side load, and rotational inertia ratings.
Definition of Useful Mathematical Terms mounted in a force train using a 215 Rotary Actuator, the shaft expansion would exert a resultant force of 6,000 lbs. on the actuator bearings. To confine the resultant force to an acceptable maximum requires the addition of diaphragm flexures to the force train. Multiplying the stiffness of the diaphragm flexure by the amount of specimen expansion will give the thrust load imposed on the actuator bearings.
Definition of Useful Mathematical Terms Mathematical Terms (part 2 of 3) TERM DEFINITION ES Modulus of elasticity of the base plate or 2 TERM DEFINITION L2 Length of test specimen (mm) (in.). Do not include specimen adapter plates unless their compliance is equal to or greater than that of the specimen. LF Distance between flexing points of diaphragm flexures. M Bending moment on test specimen with no flexures (N·m) (lbf·in.). 2 T-slot table, shear (N/m ) (lb/in.
Test Setup Using No Flexures Mathematical Terms (part 3 of 3) TERM DEFINITION TERM DEFINITION s Distance between front and rear bearings (mm) (in.). θF1 Maximum horizontal angular deflection of standard flexures (rad). SB Bending stress on test specimen due to θF2 Maximum angular deflection of diaphragm flexures (rad). base plate twisting (N/m2) (psi).
Test Setup Using No Flexures Sample calculation The previous figure illustrates the forces and measurements pertinent to the calculations. Refer to the appropriate tables for ratings and dimensions of the Model 215.45 Rotary Actuator used in the example. The following procedure uses sample values. When performing the calculations to determine the anticipated test forces, the values appropriate to your specific test should be substituted for the sample values. In addition, the example uses U.S.
Test Setup Using No Flexures Then: 44 Operation B. Calculate the value of k2, the lateral stiffness of a solid cylindrical specimen, by using the formula: C. Substitute the calculated values for k1, k2, and the example values into the original equation to compute the side load (P).
Test Setup Using No Flexures The value of 862 lbf is the side load (P) imposed on the test specimen and actuator by base plate twist. Calculate bending moment Calculate the bending moment (M) on the test specimen with no flexures installed by using the following formula: The value of 4310 lbf-in. is the bending moment exerted on the actuator shaft and specimen. For this example, P = 862 or 12% of side load capacity, and M = 4310 or 10% of bending moment capacity.
Test Setup Using Standard Flexures on the test specimen which can invalidate the test results or cause premature failure of the specimen. To reduce these loads requires the use of flexure options or a stiffer mounting surface. Test Setup Using Standard Flexures The following figure shows an example of a test setup in which flexures are integral on both the actuator foot mounting and the reaction bracket. Flexures are used to reduce excessive side load forces applied to an actuator or specimen.
Test Setup Using Standard Flexures kF1 = Angular horizontal stiffness of actuator and reaction bracket (N·m/rad) (lbf·in./rad): M1 = Bending moment on actuator and reaction bracket with standard flexures installed (N·m) (lbf·in.): MF1 = Maximum horizontal bending capacity of standard flexures (N·m) (lbf·in.). M2 = Bending moment on specimen with standard flexures installed (lbf·in.
Test Setup Using Standard Flexures Calculate angle of flex Calculate the angle of flex (q) imposed on foot mounting and reaction bracket flexures by using the following formula: Compare angular deflection Compare the maximum horizontal angular deflection of the standard flexures value (K = qF1= 0.006 rad.) with the calculated angle of flex imposed on foot mounting and reaction bracket flexures (q=0.000107 rad.) to determine if the flexures are adequate.
Test Setup Using Standard Flexures Calculate bending moment (M1) Calculate the bending moment (M1) that is applied to the actuator and reaction bracket when equipped with standard flexures. Calculate bending moment (M2) Calculate the bending moment (M2) induced in the test specimen with standard flexures installed by using the following formula: Calculate specimen stress Calculate the additional stress (SB) induced in the specimen due to base plate twist by using the following formula: The value 12.
Test Setup Using Diaphragm Flexures specimen which can invalidate the test results or cause premature failure of the specimen. Test Setup Using Diaphragm Flexures If the values derived from the calculations in “Test Setup Using Standard Flexures” section indicate that diaphragm flexures must be used to reduce side loads to acceptable levels, then the following calculations should be performed to ensure that the selected diaphragm flexures are adequate.
Test Setup Using Diaphragm Flexures Sample calculation The previous figure illustrates the forces and measurements pertinent to the calculations. Refer to the appropriate tables for ratings and dimensions of the Model 215.45 Rotary Actuator used in the example. The following calculations use values derived from the sample calculations performed previously. Using the preceding formulas and following values calculate Δ (centerline offset) and then θ (angle of flex on flexures).
Test Setup Using Diaphragm Flexures Calculate centerline offset Calculate the center line offset (∆) between actuator and reaction bracket due to base plate twist by using the following formula: Calculate flex angle Calculate the angle of flex (q) imposed on each diaphragm flexure by using the following formula: Compare angular deflection Compare the maximum horizontal angular deflection of the diaphragm flexures (qF2=0.015 rad.
Test Setup Using Diaphragm Flexures Calculate bending moment (M2) Calculate the bending moment (M2) that is induced in the test specimen with diaphragm flexures installed by using the following formula: Calculate specimen stress Calculate the additional stress (SB) induced in the specimen due to base plate twist by using the following formula: The value 10.4 psi represents the amount of stress experienced by the specimen under test and is an acceptable stress level.
Summary of Side Load Calculations Summary of Side Load Calculations This section contains a brief summary of side load calculations made before beginning a test. Side load calculations excluding flexures The following formulas are used in preliminary calculations to determine if forces generated exceed the actuator rating, thus requiring the addition of flexures. 1.
Summary of Side Load Calculations Side load calculations when using standard flexures The following calculations are used when flexures are installed on the foot mounting and reaction bracket. 1. Calculate the center line offset (∆) between the actuator and reaction bracket due to base plate twist by using the following formula: 2. Calculate the angle of flex (θ) imposed on standard flexure by using the following formula: 3.
Summary of Side Load Calculations 7. Calculate the stress (SB) induced in the specimen due to base plate twist by using the following formula: Side load calculations using diaphragm flexures The following calculations are used when diaphragm flexures are coupled to the ends of a specimen. 1. Calculate the center line offset (∆) between actuator and reaction bracket due to base plate twist by using the following formula: 2.
Rotational Inertial Rotational Inertial This subsection describes how to calculate the total rotational inertia of the Series 215 Rotary Actuator, specimen, and optional equipment. High rotational speeds or large-diameter flexures and specimens can cause large torques even though the masses involved are quite small.
Determining Maximum Rotational Inertia (JT) Rotational Inertia for Actuator Components 215.45 171 0.0500 273 0.0799 960 0.281 215.51 284 0.0831 737 0.216 1400 0.410 1.
Determining Maximum Rotational Inertia (JT) 3. After calculating the total rotational inertia (JT), compare the value to the maximum allowable JT for the specific actuator and servovalve combination indicated in the following. If the maximum allowable JT is exceeded, the test setup must be altered to reduce the total rotational inertia or an additional restraint must be provided to keep the actuator rotor vane from impacting the internal actuator rotor vane stops at full velocity.
Rotational Inertia Control Options Rotational Inertia Control Options If the anticipated rotational inertia (JT) exceeds the maximum levels, then steps must be taken to control actuator motion and limit servovalve pressure. Contact MTS Systems Corporation for information on available actuator cushions and cross port relief valves.
Routine Maintenance Maintenance This section contains information regarding routine maintenance, problem diagnosis, actuator seal replacement, and actuator disassembly. Procedures in this section assume that the operator is familiar with all operating aspects of the system electronic console and all interlock restrictions that apply to the hydromechanical equipment. Routine Maintenance Series 215 Rotary Actuators are designed for extended periods of operation without extensive maintenance requirements.
Actuator Performance Checks If measured cross vane flow exceeds recommended values in either direction, refer to the “Excessive Cross Vane Flow” section. WARNING Do not apply hydraulic pressure to the system unless the servovalve command (DC error) has been zeroed. If the servovalve command (DC error) does not equal zero when hydraulic pressure is applied to the system, equipment damage and/or personal injury can result.
Actuator Performance Checks Excessive cross vane flow Excessive cross vane flow, as measured during actuator performance checks, may indicate actuator component damage or excessive wear. Above normal cross vane flow typically indicates that the actuator rotor or cylinder has been damaged. Actuator disassembly to inspect actuator components and wear surfaces may be required. Contact MTS for assistance.
Actuator Inspection Actuator Inspection When the actuator is disassembled, it is recommended that the individual parts of the actuator be examined for excessive wear and scratches or pitting. Give particular attention to the actuator rotor shaft and radial bearings. Rotor shaft inspection Examination of the actuator rotor shaft should include the following: 1. Check the rotor shaft for surface wear.
Actuator Inspection Actuator Rotor Dimensions DIMENSION A MODEL MAXIMUM MINIMUM IN. MM IN. MM 215.32, 215.35 1.5010 38.125 1.5007 38.118 215.41, 215.42 2.2511 57.178 2.2508 57.170 215.45 3.7512 95.280 3.7509 95.273 215.51 3.7512 95.280 3.7509 95.273 DIMENSION B MODEL 215.32,215.35, MAXIMUM MINIMUM IN. MM IN. MM 0.0010 0.025 0.0007 0.018 0.0012 0.03 0.0009 0.023 215.41, 215.42 215.45,215.51 DIMENSION C MODEL NOMINAL IN. MM 215.32 1.175 29.845 215.35, 215.
Actuator Inspection 66 Maintenance Series 215 Rotary Actuator Product Manual
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