MTS TestLine Test System Operation Using MTS FlexTest Controller Software and MTS TestSuite Testing Software 100-275-890 A be certain.
© 2014 MTS Systems Corporation. All rights reserved. Original Instructions (English): 100-275-890 A—May 2014—MTS TestSuite Multipurpose 2.6 or later / 793 Controller Software 5.7 or later Trademark Information MTS, be certain., Bionix, ElastomerExpress, FlatTrac, FlexTest, Just In Case, LevelPlus, MTS Criterion, MTS EM Extend, MTS Insight, MTS Landmark, RPC, ServoSensor, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States.
Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................7 Before You Contact MTS.................................................................................................................7 If You Contact MTS by Phone..........................................................................................................9 Problem Submittal Form in MTS Manuals.............
Table of Contents Station Equipment Checkup..........................................................................................................50 Turn on the Controls............................................................................................................50 Open the Station Manager Application...............................................................................51 Verify Calibration Files.......................................................................................
Table of Contents Decommissioning Decommission the System..........................................................................................................
Table of Contents 6
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.
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.
Safety Topics: • • • General Safety Practices...................................................................................................................16 Safety Practices Before Operating the System.................................................................................16 Safety Practices While Operating the System ..................................................................................
Safety General Safety Practices If you have system related responsibilities (that is, if you are an operator, service engineer, or maintenance person), you should study this manual carefully before you attempt to perform any test system procedure. You should receive training on this system or a similar system to ensure a thorough knowledge of your equipment and the safety issues that are associated with its use.
Safety Read all manuals Study the contents of this manual and the other manuals provided with your system before attempting to perform any system function for the first time. Procedures that seem relatively simple or intuitively obvious can require a complete understanding of system operation to avoid unsafe or dangerous situations. Locate lockout/tagout points Know where the lockout/tagout point is for each of the supply energies associated with your system.
Safety Know electrical hazards When the system electrical power is turned on, minimize the potential for electrical shock hazards. Wear clothing and use tools that are properly insulated for electrical work. Avoid contact with exposed wiring or switch contacts. Whenever possible, turn off electrical power when you work on or in proximity to any electrical system component. Observe the same precautions as those given for any other high-voltage machinery.
Safety • Wear appropriate safety devices to protect your hearing. Escaping air or gas can create a noise level that can damage your hearing. • Ensure that all pressurized air or gas is bled out of a pneumatic or gas-charged device before you start to disassemble it. A thorough understanding of the assembly and its pressurized areas is necessary before you undertake any maintenance. Refer to the appropriate product information for the correct bleeding procedure.
Safety (see the System Documentation CD). Particles present in the hydraulic fluid can cause erratic or poor system response. Protect accumulators from moving objects For systems equipped with accumulators, protect accumulators with supports or guards. Do not strike accumulators with moving objects. This could cause the accumulator(s) to separate from the manifold resulting in equipment damage and personal injury.
Safety Safety Practices While Operating the System Wear appropriate personal protection Wear eye protection when you work with high-pressure hydraulic fluid, high-pressure air pressure, breakable specimens, or when anything characteristic to the specimen could break apart. Wear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. This system may create sound pressure levels that exceed 70 dbA during operation.
Safety 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 hydraulic pressure is applied. Ensure secure cables Ensure that all cable connections (electrical supply, control, feedback, sensor, communications, and so forth) are either locking type, or are secured, to ensure that they cannot be disconnected by a simple act.
System Introduction Topics: • • • • About This Manual.............................................................................................................................24 About Other MTS Documentation.....................................................................................................24 System Overview...............................................................................................................................25 Software Overview...................................
System Introduction About This Manual This manual is for operators of MTS TestLine systems.
System Introduction System Overview Station Components Item Name Description 1 High Pressure Hand Valve The high pressure hand valve allows you to control pressure to the HSM. Ensure that the hand valve is off when you are setting up the system and when your hands are near the actuator. 2 Hydraulic Service Manifold (HSM) The hydraulic service manifold (HSM), also called the actuator manifold, is a hydraulic component that controls hydraulic pressure to one work station.
System Introduction Item Name Description HSM contains the ports to provide hydraulic filtration, the use of accumulators, and hydraulic solenoid valves to control the hydraulic pressure to the work station. The basic function of the HSM is to provide line pressure regulation including on/off control. 3 Actuator with Linear Variable The actuator is used to impart force on a specimen. Differential Transformer (LVDT) An actuator consists of a cylinder that contains a piston.
System Introduction Item Name Description 7 Controller The controller provides the necessary interface between the PC and the load frame. 8 Remote E-stop The remote E-stop quickly turns off the HSM and/or (depending on your lab setup) the HPU when you press the red button. Twist the button clockwise to reset. 9 Handset The handset enables you to reset interlocks, manually move the actuator, as well as start, pause, and stop tests. It also has a display that shows relevant information.
System Introduction • • • Moving the actuator (for specimen installation) Using the function generator Setting tuning parameters The Station Manager application windows associated with each task are shown below. Opening a Station In the Open Station window, you can select a configuration and a parameter set. You can also select an interlock chain, although it is common practice to select Interlock 1.
System Introduction Setting Limits Setting limits helps prevent specimen damage and injury. You can set limits using the Limits tab in the Station Setup window.
System Introduction Setting Up Meters Meters allow you to monitor displacement and forces. Using the following windows, you can set up multiple meters and arrange them to your liking. Meter types include Timed, Running Max/Min, and Peak/Valley. Applying Power to the Station The interlock and power sections of the main window are located together for convenience. There, you can reset or override interlock conditions as well as power up the hydraulic pump unit (HPU) and hydraulic service manifold (HSM).
System Introduction Moving the Actuator During setup, you must move the actuator so that you can clamp the specimen in the grip. The Manual Command window allows you to move the actuator directly, or in fine or super fine increments. Setting Up a Scope The Scope provides a graphical display of the channels of your choosing. During station setup, the Scope is often used to compare the input signal to the feedback signal.
System Introduction Using the Function Generator The function generator allows you to input a signal to the specimen so that you can monitor the feedback. This is necessary when tuning the system. The controls for the function generator are found in the main window.
System Introduction Setting Tuning Parameters Tuning parameters are found in the Station Setup window. You can enter tuning parameters on the Adjustments tab. MTS TestSuite Test Software - MTS Multipurpose (MP) Express Application Purpose The MTS Multipurpose Express (MPX) application is used to perform the following: • • • • Selecting a test Setting test parameters Running a test Generating a report The MPX application windows associated with each task are shown below.
System Introduction Correcting Resource Errors Depending on your station configuration, the resources in the test may not match the resources for the station. Resource errors are marked with a white X encircled in red. Correct the errors by changing test resources so that they match those of the station. Creating a New Test Run Click the New Test Run button to create a new test run.
System Introduction Setting Test Parameters Once the test is selected, MTS TestSuite MPX provides you an opportunity to set test parameters via the Setup Variables window. Running a Test Running a test involves clearing any interlock conditions, powering up the HPU and HSM if necessary, and clicking the Run button. MTS TestSuite MP Express allows you to monitor the test using the tabs found in the main window.
System Introduction 36 | MTS TestLine Test System Operation
Key Concepts Topics: • • • • • • • • • About This Chapter............................................................................................................................38 Understanding Your MTS Software...................................................................................................38 Understanding MTS File Types.........................................................................................................40 Understanding the Control Loop............................
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 TestLine system. This information applies to the typical system used as an example in this manual. For information that applies to other tests or system configurations, see the individual component products manuals included in the System Documentation found under the Start Menu on the user interface PC.
Key Concepts • • Offsetting the weight of fixtures so those values do not appear in test data Adjusting gain to optimize system response MTS TestSuite Test Software and the MTS Multipurpose Express (MPX) application MTS TestSuite software includes several applications. Depending on your installation, you may be able to access MTS Multipurpose Elite, MTS Multipurpose Express, MTS Fatigue Analyzer, and so on from the Start menu or desktop icons.
Key Concepts Switching Between Station Manager and MPX When Running Tests Item Description 1 Station Manager Main Window 2 Task Bar 3 Set Up Tests Using the Station Manager Application 4 MPX Main Window 5 Station Manager Minimized on Task Bar 6 Run Tests Using MPX and the Station Manager Application Understanding MTS File Types File Types When setting up and running tests, you interact with a number of different file types: 40 | MTS TestLine Test System Operation
Key Concepts Station File Types File Type Description MTS FlexTest Project Files A FlexTest project is a collection of files related to the station configuration. When you open a configuration, it opens in the context of its parent project. Files associated with configurations, such as sensor calibration files and parameter sets, are linked to configurations within the project directory. FlexTest projects are not associated with MTS TestSuite projects.
Key Concepts File Type Description Test Template Files Test Template files are command files created with Multipurpose Elite for performing tests on Station Configurations. Test Template files contain only test definition information. MTS TestSuite Test Template Icon Test Procedure Files Test Procedures files are similar to Test Template files, but include a container that stores test data and results.
Key Concepts How MTS Files Work Together The basic workflow is as follows: • • • • • • You use the Station Manager application to open a Station Configuration. You select a Parameter Set (which includes specific Sensor Calibration files) for your Station Configuration. You use the Station Manager application to optimize your Station Configuration for the test you desire to run.
Key Concepts Closed Loop Control Step-by-Step The following closed-loop diagram illustrates how the system operates when you use the Manual Control panel in the Station Manager application to apply a compressive force to the specimen. Assume that the system is in Force Control. Basic Closed-Loop Control in MTS Testline Systems 1. You input a compressive command by adjusting the Manual Command slider control in the Station Manager application. 2.
Key Concepts Understanding Control Channels and Control Modes Control Channel Control channels command actuator movement by providing a valve driver signal to the servovalve. The servovalve causes the actuator to move, which applies forces to the specimen. Control Modes A control channel includes one or more control modes. Control modes determine how the commanded force is applied to the specimen. Control modes typically include force and displacement.
Key Concepts Sensor Limits One type of detector is a limit detector for sensor input signals. Each sensor can have 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. Detector Actions The effect a tripped detector has on the system depends on the action you select.
Key Concepts Why Tuning Is Beneficial Tuning optimizes system response by adjusting the system so that its servoloop responds accurately to its command signal. When you tune, you are setting the stability and optimizing the response of the servocontrol loop. Proper tuning improves the performance of your MTS system in the same way that performing a tune-up on an automobile improves its performance.
Running the Example HCF Test Topics: • • • • • • • • About This Chapter............................................................................................................................50 Test Procedure Overview..................................................................................................................50 Station Equipment Checkup..............................................................................................................50 Install the Specimen...............
Running the Example HCF Test About This Chapter This chapter describes how to set up and run the Example HCF Test using a typical MTS TestLine system. Adapting This Chapter to Your System The system shown in this chapter uses typical TestLine components. This procedure is intended to be an example that shows the details involved with running a common test. Because it is likely that your system varies from the typical system shown, you will need to adapt the concepts shown.
Running the Example HCF Test The controller power switch is located on the back of the controller. Open the Station Manager Application 1. Close any open applications on the computer desktop. This prevents possible confusion from having multiple stations open. 2. Select All Programs > MTS 793 Software > Station Manager. This launches communication between the computer and the MTS controller. Alternatively, you can click the Station Manager desktop icon if one exists.
Running the Example HCF Test 3. If necessary, select a project. It is common practice to keep all files in Project1. If you find this acceptable, at the Select Project window, select Project1. Otherwise enter your own project name for the project. Note: The Select Project window will not appear if you selected Project1 as the default project when you installed the MTS TestSuite application. 4. If necessary, select a controller.
Running the Example HCF Test Parameter sets are found in the lower left corner of the Open Station window. For this example HCF test, select the HardSpecimenTuning parameter set and click Open. A set of windows may open based on the last user’s window setup. Minimize any windows that come up, as you will be bringing them up as appropriate. 6. Ensure that the HSM (hydraulic service manifold) is off. Turning the HSM off removes power from the actuator so that it cannot move unexpectedly.
Running the Example HCF Test a) Select Station Setup button> Channels > Ch1 (or other depending on your configuration) > Displacement > Channel Input Signals button > Sensor tab. b) Confirm that the sensor serial number found under the Sensor tab in your software matches the LVDT serial number found on your actuator (the tag is typically located on the back or bottom of the actuator). This ensures that your configuration file matches your hardware and that you are able to collect valid data. 2.
Running the Example HCF Test Verify That the System Is Ready for Use Before operation, take a moment to familiarize yourself with the system while verifying that all components are properly connected. 1. Verify that the hydraulic pressure (P), return (R), and drain (D) lines are connected. 2. Verify that the supply side HSM pressure (P), return (R), and drain (D) lines are connected. 3. Verify that the output side HSM pressure (P), return (R), and drain (D) lines are connected.
Running the Example HCF Test 4. Verify that the actuator hydraulic pressure (P), return (R), and drain (D) lines are connected. 5. Verify that the actuator force sensor (FS), servovalve (SV), and displacement sensor (DS) signal cables are connected.
Running the Example HCF Test Set Initial Limit and Error Detectors You can reduce the chances of equipment damage or injury by setting limit and error detectors. Warning: Setting limits and error detectors can help reduce the chance of equipment damage or injury. Unexpected actuator movement can cause equipment damage or injury. Do not rely entirely on limit or error detectors when gaining control of the actuator.
Running the Example HCF Test a) Select Station Setup button > Channels > Ch1 > Displacement > Channel Input Signals Button > Limits tab. b) Set the Upper Limit to 25 mm. Note: You must press Enter after entering the value in the text box. c) d) e) f) Set the Upper Limit Action to Interlock. Set the Lower Limit to -25 mm. Set the Lower Limit Action to Interlock. Ensure that the actuator will be able to move 50 mm in each direction without contacting any obstructions.
Running the Example HCF Test a) Select Station Setup button > Channels > Ch1 > Force > Channel Input Signals Button > Limits tab. b) Set the Upper Limit to .05 kN. c) Set the Upper Limit Action to Interlock. d) Set the Lower Limit to -.05 kN. e) Set the Lower Limit Action to Interlock. 3. Set error detectors to 20% of half range to trip the interlock if the actuator goes unstable.
Running the Example HCF Test These error detector limits will be used throughout setup, tuning, and testing. a) b) c) d) Click the Detectors button in the Station Manager main window. Select All Detectors > Error Detectors tab. Set the Ch 1 Displacement Outer Error and Inner Error to 7 mm (20% of half range). Set the Ch 1 Force Abs. Outer Error and Inner Error to 1 kN (20% of half range).
Running the Example HCF Test a) Open the Tuning: Ch1 Displacement window by selecting Station Setup button> Channels > Ch1 (or other depending on your configuration) > Displacement, clicking the Tuning Fork icon, and selecting the Adjustments tab.
Running the Example HCF Test a) Similarly, open the Tuning: Ch1 Force tab by selecting Station Setup button > Channels > Ch1 (or other depending on your configuration) > Force, clicking the Tuning Fork button, and selecting the Adjustments tab. b) Use the following parameters for this hard specimen test: • • • • • • • P Gain — 1 I Gain — 1 D Gain — 0 F Gain — 0 F2 Gain — 0 Proportional FF Gain — 0 FL Filter — Set to maximum positive value 4. Retain the Tuning user access level.
Running the Example HCF Test Leave the Operator Type selection set to Tuning because you will do more tuning once the specimen is installed. Power Up the Pump and HSM HPU setups vary considerably by lab. This document describes a typical HPU setup. For information on your particular system, consult your lab experts or system documentation. 1. Correct any interlock conditions. If a displacement limit has been exceeded, see If Necessary, Recover from a Tripped Displacement Limit (p. 113). 2.
Running the Example HCF Test a) Select the Exclusive Control check box. b) For the HPU, click the Power Low, and then Power High buttons. c) For the HSM, click Power Low only. Verify Control of the Actuator In this step you will position the actuator for the start of the test. Warning: Verifying control requires movement of the actuator. Unexpected movement of the actuator can result in equipment damage or personal injury. Ensure that the area is clear and that you can see what you are doing.
Running the Example HCF Test a) In the Station Manager main window, click the Manual Command button. b) Select the following: 1. Channel — Ch1 (or other depending on your configuration) 2. Control Mode — Displacement 3. Enable Manual Command checkbox — Checked Manual command is automatically matched to feedback when the HSM is cycled to Low Power to ensure that the actuator does not move before desired. 2. Familiarize yourself with the slider control.
Running the Example HCF Test 3. Verify polarity. a) Move the actuator about 10 mm in the positive direction. The actuator should extend. Note: If a displacement limit trips, see If Necessary, Recover from a Tripped Displacement Limit (p. 113). b) Move the actuator about 10 mm in the negative direction. The actuator should retract. c) If the polarity is incorrect, have the engineer on the project correct the system polarity.
Running the Example HCF Test 2. Set up a force waveform using the Function Generator. This introduces a force waveform to the specimen. a) In the Station Manager main window, click the Function Generator button. b) Set up a force waveform using the following parameters: • • • • • • • • Channel — Ch1 (or other depending on your configuration) Control Mode — Displacement Command Type — Cyclic Target Setpoint — 0.000 mm Amplitude — 2.000 mm Frequency — 1 Hz Wave Shape — Ramp Compensator — None 3.
Running the Example HCF Test Set up a Scope to compare the command signal to the resulting feedback. Enlarge the scope if necessary, and then set up the scope as follows: Y1 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Command Unit — mm Units/div — 1.0000 Offset — 0.0000 Y2 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Displacement Unit — mm Units/div — 1.0000 Offset — 0.0000 Time: • Trace Time — 5.0000 s 5.
Running the Example HCF Test 6. Run the Function Generator. Click the Program Run button to apply the force waveform to the specimen. If necessary, clear any interlock conditions. 7. Adjust P and I Gain. a) Adjust P and I gain in the following window based on the instructions in Steps b, c, and d.
Running the Example HCF Test b) If P gain is insufficient, as shown, gradually increase P gain until the scope looks like that in step d.
Running the Example HCF Test Insufficient P Gain c) If P gain is excessive and goes unstable, as shown, decrease your P gain by 20%.
Running the Example HCF Test Excessive P Gain d) Adjust P gain until your scope looks similar to the illustration below.
Running the Example HCF Test Correct P Gain Note: The scope display shows how well the feedback signal is following the command signal. You should strive for a good match to the "Correct P Gain" example, realizing that perfect adjustment is not possible. 8. When you are done adjusting the Displacement P Gain, adjust the Displacement I Gain to 25% of the P Gain value.
Running the Example HCF Test 9. Turn off the Function Generator. Click the Program Stop button to turn off the Function Generator. Position the Actuator Using Displacement Control In this procedure you will position the actuator for the start of the test. Warning: Verifying control requires movement of the actuator. Unexpected movement of the actuator can result in equipment damage or personal injury. Ensure that the area is clear and that you can see what you are doing.
Running the Example HCF Test Set the displacement limits to +40 mm and -40 mm so that you can achieve full extension and retraction. 2. Use manual command to find the actuator travel end points. a) Using Manual Command, fully extend the actuator. Extend the actuator fully, and then measure the length of the actuator so that you can later determine where to set your limit detectors. Note: If a displacement limit trips, see If Necessary, Recover from a Tripped Displacement Limit (p. 113).
Running the Example HCF Test Retract the actuator fully, and then measure the length of the actuator so that you can later determine where to set your limit detectors. 3. Position the actuator at the mid-point of its travel. Calculate the mid-point. Move the actuator to the calculated mid-point to place the actuator at mid-travel. 4. Click Auto Offset so that mid-travel represents 0 mm displacement. Turn Off Hydraulic Power 1. Turn off the HSM.
Running the Example HCF Test Set HSM power to low, and then to off. If needed for other stations, the HPU can be left on. 2. As an added precaution, set the handvalve (1) to off.
Running the Example HCF Test Install the Specimen Set Up Meters for Specimen Installation 1. Click the meters button in the Station Manager application. 2. If more than one meter appears, delete the extra instances so that only one meter remains. To delete a meter, click the meter title bar, and then click the Delete button in the setup menu. 3. Set up a Running Max/Min Displacement Meter.
Running the Example HCF Test A running max/min meter provides the history of sensor extremes that the meter has read since it was last reset. 4. Set up a Running Max/Min Force Meter. Use the following parameters: • • • • Meter Type — Running Max/Min Channel — Ch1 (or other depending on your configuration) Signal — Force Engineering Units — kN 5. Set up a Timed Displacement Meter.
Running the Example HCF Test Use the following parameters: • • • • Meter Type — Timed Channel — Ch1 (or other depending on your configuration) Signal — Force Engineering Units — kN Zero Displacement and Force Signals With the actuator at mid-travel and no force on the load cell, zero the displacement and force signals. 1. Auto offset the Displacement signal. a) Click the Station Setup button. b) Select Channels > Ch1 > Displacement > Channel Input Signals button > Offset/Zero tab.
Running the Example HCF Test a) If necessary, click the Station Setup button. b) Select Channels > Ch1 > Force > Channel Input Signals button > Offset/Zero tab. c) Click the Auto Offset button. Install the Specimen 1. If necessary, install the load cell on the actuator and connect the load cell signal cable. 2. Install the threaded rod into the load cell.
Running the Example HCF Test 3. Connect the specimen to the load cell. 4. Connect the angle bracket to the specimen.
Running the Example HCF Test 5. Make sure that the system is properly aligned, and then tighten the specimen angle bracket to the test bed. 6. Tighten the actuator angle bracket to the test bed.
Running the Example HCF Test Prepare To Run Test Set Limits for Tuning During tuning, it is possible for the system to go unstable. Setting limits just outside expected values for tuning helps prevent specimen and equipment damage if something unexpected happens. 1. Set narrow displacement limits.
Running the Example HCF Test Because the specimen is fixed solidly in place, you can set narrow displacement limits that will trip if anything breaks. a) b) c) d) e) f) Click the Station Setup button. Select Channels > Ch1 > Displacement > Channel Input Signals button > Limits tab. Set the Upper Limit to 5 mm. Set the Upper Action to Interlock. Set the Lower Limit to -5 mm. Set the Lower Action to Interlock. 2. Set force limits that are just outside the expected values for tuning.
Running the Example HCF Test The expected force range for tuning is 0.1 kN to 0.5 kN. However, the specimen is currently at zero Force so that must be accommodated. For this example choose limits from -0.6 kN to 0.6 kN. a) b) c) d) e) f) If necessary, click the Station Setup button. Select Channels > Ch1 > Force > Channel Input Signals Button > Limits Tab. Set the Upper Limit to 0.6 kN. Set the Upper Action to Interlock. Set the Lower Limit to -0.6 kN. Set the Lower Action to Interlock.
Running the Example HCF Test Click the Reset button. If the interlock will not reset, there is likely an interlock condition that has not been corrected. 3. Open the handvalve (1). 4. Power up the HPU (hydraulic pump unit) and HSM (hydraulic service manifold).
Running the Example HCF Test a) Select the Exclusive Control check box. b) For the HPU and HSM, click the Power Low, and then Power High buttons. Check for Force Control Drift Around Zero The tuning parameters that you set up earlier were conservative to help ensure that the system does not go unstable. However, because of this, you may encounter some force control drift on power up. This will be visible in the Scope or you may trip a force limit.
Running the Example HCF Test a) Y1 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Command Unit — kN Units/div — 0.2000 Offset — 0.0000 b) Y2 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Force Unit — kN Units/div — 0.2000 Offset — 0.0000 c) Time • Trace Time — 5.0000 s 3. Check for drift around zero.
Running the Example HCF Test This example was not stable enough with the initial cold settings. As a result, the scope showed force decreasing to -0.6 kN which eventually tripped the lower force limit. 4. Adjust P and I gain in small increments until the drift around zero is corrected.
Running the Example HCF Test For this example, P gain was increased in increments of 1 until the drift around zero was corrected with a P gain of 4. I gain was then set to 25% of the P gain or 1. 5. Using the Scope, verify that the corrective action was effective.
Running the Example HCF Test As you can see in the preceding illustration, the system is performing much better with the P gain set to 4. Note: Every system is different and requires unique tuning settings. MTS recommends starting with P Gain at 1 and incrementing by 1 until drift around zero is sufficiently reduced. Starting at higher values is not recommended because the system could go suddenly unstable. Perform Basic Force Performance Tuning To perform basic performance tuning: 1.
Running the Example HCF Test This introduces a force waveform to the specimen. a) In the Station Manager main window, click the Function Generator button. b) Set up a force waveform using the following parameters: • • • • • • • • Channel — Ch1 (or other depending on your configuration) Control Mode — Force Command Type — Cyclic Target Setpoint — +0.3000 kN Amplitude — 0.2000 kN Frequency — 1 Hz Wave Shape — Ramp Compensator — None 3. Open a Station Manager Scope.
Running the Example HCF Test Set up a Scope to compare the command signal to the resulting feedback. Enlarge the scope if necessary, and then set up the scope as follows: Y1 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Command Unit — kN Units/div — 0.1000 Offset — 0.3000 Y2 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Force Unit — kN Units/div — 0.1000 Offset — 0.3000 Time: • Trace Time — 5.0000 s 5.
Running the Example HCF Test 6. Run the Function Generator. Click the Program Run button to apply the force waveform to the specimen. If necessary, clear any interlock conditions. 7. Adjust P and I Gain. a) Adjust P and I gain in the following window based on the instructions in Steps b, c, and d.
Running the Example HCF Test b) If P gain is insufficient, as shown, gradually increase P gain until the scope looks like that in step d.
Running the Example HCF Test Insufficient P Gain c) If P gain is excessive and goes unstable, as shown, decrease your P gain by 20%.
Running the Example HCF Test Excessive P Gain d) Adjust P gain until your scope looks similar to the illustration below.
Running the Example HCF Test Correct P Gain Note: The scope display shows how well the feedback signal is following the command signal. You should strive for a good match to the "Correct P Gain" example, realizing that perfect adjustment is not possible. 8. When you are done adjusting the Force P Gain, adjust the Force I Gain to 25% of the P Gain value.
Running the Example HCF Test 9. Turn off the Function Generator. Click the Program Stop button to turn off the Function Generator. Check and Reset Meter History Check meter history after tuning to ensure that the specimen was not damaged during tuning. 1. Check meter history.
Running the Example HCF Test Note: Acceptable limits are dependent on the specimen you are using for the test. For detailed information, consult your lab experts or a materials handbook. 2. Reset meter history. Now that specimen installation is complete, reset meter history by navigating to Station Manager > Display > Meters and clicking the Reset button. Set Limits for the Test The test will cycle the specimen between 0.25 kN and 0.75 kN.
Running the Example HCF Test For this example choose limits from -0.6 kN to 1.0 kN. a) b) c) d) e) f) If necessary, click the Station Setup button. Select Channels > Ch1 > Force > Channel Input Signals button > Limits tab. Set the Upper Limit to 1.0 kN. Set the Upper Action to Interlock. Set the Lower Limit to -0.6 kN. Set the Lower Action to Interlock. Minimize Station Manager The Station Manager application must be running underneath the MPX application in order to run tests.
Running the Example HCF Test 2. Minimize the Station Manager application by clicking the Minimize button in the upper right corner. 3. Verify that the Station Manager application is still running by checking for it in the task bar. You can maximize the Station Manager application at any time by clicking the Station Manager button in the task bar. Run the Example HCF Test Open the MPX Application 1. Open the MTS TestSuite Multipurpose Express (MPX) application.
Running the Example HCF Test Select All Programs > MTS TestSuite > Multipurpose Express. 2. Alternatively, you can open the MPX application by clicking on a desktop icon. The desktop icon has the advantage in that it opens a particular configuration. 3. If a desktop icon does not exist, you can create one using the MPX application.
Running the Example HCF Test Select the Test From the TestSuite main window, select Tests > Example HCF Force Test to load the test. If Necessary, Correct Any Resource Errors 1. Find resource errors. a) In the MTS MPX main window, click the Resources tab. b) Look for the white Xs encircled in red. 2. Correct any resource naming conflicts by updating the MPX name to match the controller resource name.
Running the Example HCF Test In this example, MPX had the axial channel named "Axial" while the controller had the axial channel named "Ch 1." By changing the MPX names to "Ch 1," the resource naming errors were eliminated. Create a New Test Run 1. Power up the system. a) For the HPU, click Low, and then High. b) For the HSM, click Low, and then High. 2. Click the New Test Run icon.
Running the Example HCF Test 3. Enter the test parameters as shown in the following window. 4. Review the status information. Review the status information that appears. If necessary, click the Edit Parameters button to make corrections. Otherwise, click Run Test to continue.
Running the Example HCF Test Run the Test 1. Run the test. a) If necessary, click the Reset button to reset the interlock. b) Ensure that both the HPU and HSM are on high power. c) Click the Run (green arrow) button. 2. Verify that the test parameters are correct, and then click Run Test. The 1000 cycle test requires you to click Run Test after every 200 cycles. 3. After the test has run all 1000 cycles, click Close.
Running the Example HCF Test Generate a Report 1. From the MPX application Explorer panel, select Example HCF Force Test > Test Runs > Test Run 8, and then right-click and select Generate Report. 2. Select the template you wish to use, and click Generate Report. The Excel report appears.
Running the Example HCF Test Save the Test and Minimize MPX The Station Manager application is used to remove the specimen, so the test can be saved and the MPX application minimized. 1. Save the test. If desired, save the test with a new name to preserve the original test. 2. Minimize the MPX application.
Running the Example HCF Test Click the Minimize button in the upper right corner of the MPX application. Remove the Specimen 1. Turn off the HSM. Set HSM power to low, and then to off. If needed for other stations, the HPU can be left on. 2. As an added precaution, set the handvalve (1) to off.
Running the Example HCF Test 3. Loosen the specimen angle bracket from the test bed fastener. 4. Remove the angle bracket from the specimen fasteners.
Running the Example HCF Test 5. Remove the specimen from the load cell. If Necessary, Recover from a Tripped Displacement Limit If a displacement limit is exceeded, use the following procedure to recover. 1. Enable Manual Command Displacement mode.
Running the Example HCF Test a) b) c) d) In the Station Manager application main window, click the Manual Command button. Ensure that Exclusive Control is checked. In the Manual Command window, select a Control Mode of Displacement. Ensure that Enable Manual Command is checked. 2. Check the current position of the actuator. 3. Check current displacement limits.
Running the Example HCF Test b) Check the current upper and lower limit settings to identify the acceptable range for the actuator. Adjust the limits if incorrect. If correct, continue to the next step. c) Notice, that in this example, the upper limit is red. This indicates that the upper limit has tripped. d) For this example, the limits are correct. Proceed to the next step. 4. Reset/Override the interlock.
Running the Example HCF Test In the Station Manager application main window, click the Manual Command button. Move the actuator to within acceptable limits while the interlock is overridden.
Maintenance Topics: • • • Routine Maintenance Overview Checklist.......................................................................................118 Maintenance Intervals.....................................................................................................................120 Daily Inspections.............................................................................................................................
Maintenance Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 Monitor filter indicators. X 40 500 1000 1,500 2,000 Check actuator. MTS MTS MTS MTS Check that actuator area is dry. MTS MTS MTS MTS Check that actuator travel area is clear. MTS MTS MTS MTS Check that piston rod wear is acceptable.
Maintenance Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 40 80 Annually 500 1000 1,500 2,000 Check that manifold hose connections are tight. MTS MTS MTS MTS Check that accumulator connections are dry. MTS MTS MTS MTS Check that accumulator connections are tight. MTS MTS MTS MTS Check that accumulator caps/guards are present. MTS MTS MTS MTS Check that there is oil on the gas side of the piston.
Maintenance Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 40 80 Annually 500 1000 1,500 2,000 Check response to full stroke waveform, visual and audible. MTS MTS MTS MTS Check displacement control valve balance. MTS MTS MTS MTS Check valve dither response. MTS MTS MTS MTS Maintenance Intervals The following table lists the recommended interval for each of these procedures.
Maintenance What to Do When to Do It Perform Model 252 Servovalve maintenance: adjust After the valve balancing procedure (electrical mechanical null. compensation) has been completed and the results are judged unsatisfactory. Perform sensor calibration. Calibration intervals depend on system requirements and are typically performed during scheduled maintenance by MTS trained personnel. Sensors can include an LVDT, load cell, and extensometer.
Decommissioning Topics: • Decommission the System..............................................................................................................
Decommissioning Decommission the System The decommissioning process is performed when the system is going to be moved or taken out of service. Disassembly is required when performing either of these tasks. 1. 2. 3. 4. Remove the specimen and fixtures. Move the actuator piston rod down to its fully retracted position. Turn off the HSM. Turn off the HPU or shut off valves if the unit is connected to a hard line distribution system.
Decommissioning • When removing the hydraulic components, ensure that you have drain pans and towels available that are sufficient to handle the drain volume of the item you are disconnecting. • Use safe practices when removing hydraulic components and allow any trapped or latent pressure to dissipate safely through a loosened connection before removing the component. • Cap each hose, port, and hardline component. 9.
Index Index 793 software, See MTS FlexTest (Series 793) controller software A actions detector 46 actuator hydraulic lines 56 maintaining 118 positioning 76 signal lines 56 application MTS Multipurpose (MP) Express 26–27 Station Manager 26 Application Log MPX 47 auto offset 76, 80 C cables maintaining 119 calibration file 53 channels control 45 closed-loop control 43 command signal 43 computer turning on 50 configuration files 41 configuration set identifying 53 control channels 45 closed-loop 43 displac
Index force sensor (load cell) (continued) calibration verification 54 form problem submittal 10 function generator 32 Function Generator running 69, 95 turning off 74, 100 G load cell (force sensor) calibration interval 121 log application MTS Multipurpose (MP) Express application 47 file 47 message 46–47 LVDT 26 LVDT (displacement) sensor calibration interval 121 calibration verification 53 gain adjusting 90 H hand valve 25 handset 27 handvalve opening 63 hoses maintaining 119 HPU powering up 63, 87 H
Index O overview testing 50 P P gain correct 73, 99 excessive 72, 98 insufficient 71, 97 P Gain adjusting 69, 95 parameter set identifying 53 parameter sets 41 parameters editing Station Manager application 106 test 35 password tuning 60 performance tuning, See tuning polarity verifying 66 program sources MTS FlexTest function generator 67, 92 project files 40 selecting Station Manager application 52 pump powering up 63, 87 R report 35 reports generating 109 template 109 resource errors 34 resources in c
Index test (continued) selecting MTS Multipurpose (MP) Express application 105 status information 107 test parameters 35 test procedure files 42 testing overview 50 TestSuite, See MTS Multipurpose (MP) Express tuning adjusting P Gain 69, 95 basic performance 66, 92 initial 60 parameters displacement 60 130 tuning (continued) parameters (continued) force 61 password 60 user access level 60 U user access level tuning 60 W waveform 47, 67, 92
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