MTS Series 793 Controller Overview

Transcription

m
be certain.
100-162-928 H
Copyright information
Trademark information
© 2011 MTS Systems Corporation. All rights reserved.
MTS, FlexTest, RPC, Temposonics, and TestWare are registered trademarks of
MTS Systems Corporation; MPT, Station Builder, Station Manager, and TestStar
are trademarks of MTS Systems Corporation within the United States. These
trademarks may be protected in other countries.
Microsoft, Windows, and Windows NT are registered trademarks of Microsoft
Corporation. All other trademarks or service marks are property of their
respective owners.
Proprietary information
Software use and license is governed by MTS’ End User License Agreement
which defines all rights retained by MTS and granted to the End User. All
Software is proprietary, confidential, and owned by MTS Systems Corporation
and cannot be copied, reproduced, disassembled, decompiled, reverse
engineered, or distributed without express written consent of MTS.
Software validation and
verification
MTS software is developed using established quality practices in accordance
with the requirements detailed in the ISO 9001 standards. Because MTSauthored software is delivered in binary format, it is not user accessible. This
software will not change over time. Many releases are written to be backwards
compatible, creating another form of verification.
The status and validity of MTS’ operating software is also checked during
system verification and routine calibration of MTS hardware. These controlled
calibration processes compare the final test results after statistical analysis
against the predicted response of the calibration standards. With these established
methods, MTS assures its customers that MTS products meet MTS’ exacting
quality standards when initially installed and will continue to perform as intended
over time.
Publication information
MANUAL PART NUMBER
PUBLICATION DATE
MTS 793 SOFTWARE RELEASE
100-162-928 H
July 2011
Version 5.35 or later
Contents
Technical Support 7
How to Get Technical Support
Before You Contact MTS
7
8
If You Contact MTS by Phone
9
Problem Submittal Form in MTS Manuals
10
Preface 13
Before You Begin
Conventions
13
14
Documentation Conventions
Chapter 1
14
Introduction 17
Learn About Your Controller Here
New Features in Version 5.30
Chapter 2
17
17
Controller Hardware 19
Controller Overview
19
About MTS FlexTest Models 40/60/100/200 Controllers
FlexTest GT Controller Description
22
FlexTest SE Controller Description
25
FlexTest IIm Controller Description
30
Controller Hardware Options
About TEDS Sensors
20
32
34
Contents
3
Chapter 3
Controller Software 35
Model 793.00 System Software Bundle
35
Software Options Available with Key Codes
37
Software Options Available on Separate Media
Chapter 4
Operation Concepts 43
Operational Overview
About Projects
42
43
46
Understanding Projects
46
Using Project Manager to Modify Projects
About Hardware Interface Files
Understanding Hardware Interface Files
About Station Configurations
48
49
49
51
About the Station Builder Application
51
Using the Station Builder Application to Create Station Configurations
Station Builder Application Window
53
About Assigning Parameters to Station Configurations
About Parameter Sets
54
54
Using the Station Manager Application to Create Parameter Sets
Station Manager Application Windows
About Compensators
About Test Designs
58
64
64
Designing Tests with the Basic TestWare Application
Designing Tests with MultiPurpose TestWare
MPT Process Types
About Running Tests
66
73
76
Understanding Files Used for Testing
76
77
Monitoring Test Information
Contents
65
69
MultiPurpose TestWare Windows
4
55
59
Understanding Test Design Files
Test Desktop
52
78
Chapter 5
Installed 793 Files 83
File Types and Locations
83
About System Information 83
About Controller Information
About Project Information
About Program Information
Chapter 6
84
85
86
Perform a Practice Test 87
About Setting Up a Practice Test
Steps to Run a Test
Chapter 7
87
89
Documentation 97
Series 793 Controller Manuals
Other 793 Documents
97
99
Other MTS Documents Included with Your System
100
Index 101
Contents
5
6
Contents
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.
If you cannot find answers to your technical questions from these sources, you
can use the internet, e-mail, telephone, or fax to contact MTS for assistance.
Technical support
methods
MTS 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.
www.mts.com
The web site provides access to our technical support staff by means of an online
form:
www.mts.com > Contact MTS > Service & Technical Support button
E-mail
Telephone
Fax
Outside the U.S.
[email protected]
MTS Call Center 800-328-2255
Weekdays 7:00 A.M. to 5:00 P.M., Central Time
952-937-4515
Please include “Technical Support” in the subject line.
For technical support outside the United States, contact your local sales and
service office. For a list of worldwide sales and service locations and contact
information, use the Global MTS link at the MTS web site:
www.mts.com > Global MTS > (choose your region in the right-hand
column) > (choose the location closest to you)
Technical Support
7
Before You Contact MTS
MTS can help you more efficiently if you have the following information
available when you contact us for support.
Know your site
number and system
number
The site number contains your company number and identifies your equipment
type (such as material testing or simulation). The number is typically written on a
label on your equipment before the system leaves MTS. If you do not know your
MTS site number, contact your sales engineer.
Example site number: 571167
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: US1.42460
Know information from
prior technical
assistance
Identify the problem
8
Technical Support
If you have contacted MTS about this problem before, we can recall your file
based on the:
•
MTS notification number
•
Name of the person who helped you
Describe the problem and know the answers to the following questions:
•
How long and how often has the problem occurred?
•
Can you reproduce the problem?
•
Were any hardware or software changes made to the system before the
problem started?
•
What are the equipment model numbers?
•
What is the controller model (if applicable)?
•
What is the system configuration?
Know relevant
computer information
Know relevant
software information
For a computer problem, have the following information available:
•
Manufacturer’s name and model number
•
Operating software type and service patch information
•
Amount of system memory
•
Amount of free space on the hard drive where the application resides
•
Current status of hard-drive fragmentation
•
Connection status to a corporate network
For software application problems, have the following information available:
•
The software application’s name, version number, build number, and (if
available) software patch number. This information can typically be found
in the About selection in the Help menu.
•
The names of other applications on your computer, such as:
–
Anti-virus software
–
Screen savers
–
Keyboard enhancers
–
Print spoolers
–
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
•
Name
•
Company name
•
Company address
•
Phone number where you can be reached
If your issue has a notification number, please provide that number. A new issue
will be assigned a unique notification number.
Technical Support
9
Identify system type
Be prepared to
troubleshoot
Write down relevant
information
After you call
To enable the Call Center agent to connect you with the most qualified technical
support specialist available, identify your system as one of the following types:
•
Electromechanical material test system
•
Hydromechanical material test system
•
Vehicle test system
•
Vehicle component test system
•
Aero test system
Prepare to perform troubleshooting while on the phone:
•
Call from a telephone close to the system so that you can implement
suggestions made over the phone.
•
Have the original operating and application software media available.
•
If you are not familiar with all aspects of the equipment operation, have an
experienced user nearby to assist you.
In case Technical Support must call you:
•
Verify the notification number.
•
Record the name of the person who helped you.
•
Write down any specific instructions.
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 notification number.
Problem Submittal Form in MTS Manuals
Use the Problem Submittal Form to communicate problems with your software,
hardware, manuals, or service that are not resolved to your satisfaction through
the technical support process. The form includes check boxes that allow you to
indicate the urgency of your problem and your expectation of an acceptable
response time. We guarantee a timely response—your feedback is important to
us.
10
Technical Support
Access the Problem Submittal Form:
•
In the back of many MTS manuals (postage paid form to be mailed to MTS)
•
www.mts.com > Contact Us > Problem Submittal Form button (electronic
form to be e-mailed to MTS)
Technical Support
11
12
Technical Support
Preface
Before You Begin
Safety first!
Other MTS manuals
Before you 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 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.
In addition to this manual, you may receive additional manuals in paper or
electronic form.
You may also receive an MTS System Documentation CD. It contains an
electronic copy of the manuals that pertain to your test system, such as:
•
Hydraulic and mechanical component manuals
•
Assembly drawings
•
Parts lists
•
Operation manual
•
Preventive maintenance manual
Controller and application software manuals are typically included on the
software CD distribution disc(s).
Preface
13
Conventions
Conventions
Documentation Conventions
The following paragraphs describe some of the conventions that are used in your
MTS manuals.
Hazard conventions
Hazard notices may be embedded in this manual. These notices contain safety
information that is specific to the activity 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 all directions and recommendations.
Three different levels of hazard notices may appear in your manuals. Following
are examples of all three levels.
Note
For general safety information, see the safety information provided with
your system.
DANGER
Danger notices indicate the presence of a hazard with a high level of risk which,
if ignored, will result in death, severe personal injury, or substantial property
damage.
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.
Notes
Notes provide additional information about operating your system or highlight
easily overlooked items. For example:
Note
Special terms
14
Preface
Resources that are put back on the hardware lists show up at the end of
the list.
The first occurrence of special terms is shown in italics.
Conventions
Illustrations
Electronic manual
conventions
Hypertext links
Illustrations appear in this manual to clarify text. They are examples only and do
not necessarily represent your actual system configuration, test application, or
software.
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.
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.
Preface
15
Conventions
16
Preface
Chapter 1
Introduction
MTS Series 793 Controllers are supplied with several manuals—each pertaining
to a primary attribute of the Controller, such as hardware, control software,
application software, utility software, and more.
This manual integrates descriptions of all of these attributes to help you learn
about your Controller as efficiently as possible. It is a not a “how-to” manual, it is
a learning manual.
Software is introduced
in the order you use it
In this manual, the various software applications included with your Controller
are described in the order you typically use them to perform tests.
For instance, the section that describes station configurations introduces the
Station Builder application; the section that describes test designs introduces the
Basic TestWare and MultiPurpose TestWare applications.
Practice test
procedure
This manual includes a practice test procedure. By performing this procedure you
will become familiar with many of the activities typically performed while
testing.
If you are an existing user of Series 793 Controllers, you will find several
enhancements and additions included in Version 5.30.
•
Added support for CANdb databases to the 793.25 CANBus interface
option.
•
Added Series 793 Software support for 2500 processors.
•
Added several enhancements for the Model 793.100 Hybrid Simulation
(Internal Model) and Model 793.101 Hybrid Simulation (External Model)
options.
Introduction
17
18
Introduction
Controller Overview
Chapter 2
Controller Hardware
Controller Overview
MTS controllers equipped with Series 793 Software are referred to as MTS Series
793 Controllers.
Types of MTS Series
793 Controllers
MTS offers several types of Series 793 Controllers. This manual pertains to the
following:
•
MTS FlexTest Series 40/60/100/200 Controllers
•
FlexTest GT Controllers
•
FlexTest SE Controllers (Basic, Plus, and 2-Channel models)
•
FlexTest IIm Controllers
For information about the hardware included in FlexTest GT, FlexTest SE, and
FlexTest IIm Controllers, see the MTS Models FlexTest IIm/GT/SE Controller
Hardware manual (PN 100-147-133). For more information on Series 494
controllers, see the MTS Models FlexTest®40/60/100/200 Controller Hardware
manual (PN 100-187-204).
Closed loop control
MTS Series 793 Controllers provide closed-loop control of the mechanical and
hydraulic components of a test system.
Simple Control diagram
When reduced to its basic
form, a Series 793 test
system typically includes
these elements. (The
command can also be
provided by the function
generator or MultiPurpose
TestWare).
Basic
TestWare
application
Station
Manager
application
Feedback
Source
Command
Source
Summing and
Conditioning
Controller Hardware
19
About MTS FlexTest Models 40/60/100/200
Types of MTS Series
793 Controllers
MTS offers several types of Series 793 Controllers. This manual pertains to the
following:
•
MTS FlexTest Series 40/60/100/200 Controllers
•
•
FlexTest SE Controllers (Basic, Plus, and 2-Channel models)
•
FlexTest IIm Controllers
Note
For information about the hardware included in FlexTest GT, FlexTest
SE, and FlexTest IIm Controllers, see the MTS Series 793 Controller
Hardware manual (PN 100-147-133). For more information on Series
494 controllers, see the Series 494 Controller Hardware manual (PN
100-187-204).
About MTS FlexTest Models 40/60/100/200 Controllers
MTS FlexTest Models 40/60/100/200 Controllers are generally used in
servohydraulic test systems. They provide real-time closed-loop control, with
transducer conditioning and function generation to drive various types of servoactuators.
A FlexTest Controller consists of:
•
One or more Series 494 Hardware chassis that contain controller hardware.
•
A computer workstation that runs MTS controller applications.
Controller capabilities
PARAMETER
FLEXTEST
40
FLEXTEST
60
FLEXTEST
100
FLEXTEST
200
2
Up to 6*
Up to 8
Up to 8
Control Channels
Up to 4
Up to 8
Up to 16
Up to 40
Conditioned
Transducer Inputs
Up to 12
Up to 24
Up to 40
Up to 80
Auxiliary Data Inputs
Up to 16
Up to 32
Up to 64
Up to 96
Test Stations
*With On/Off Hydraulic Service Manifolds only
20
Controller Hardware
About MTS FlexTest Models 40/60/100/200
FlexTest 40
FlexTest 60
Back
(3 VME slots)
FlexTest 100
Front
(6 VME slots)
Front
(10 VME slots)
Back
(8 transition slots,
7 powered)
Back
(12 transition slots, 10 powered)
FlexTest 200
Front
(20 VME slots)
Back
(20 transition slots, 19 powered)
FlexTest Models 40/60/100/200 Controllers
Controller Hardware
21
FlexTest GT Controllers are PC-based multi-station digital controllers consisting
of:
•
A PC running Series793 Software
•
A FlexTest GT Controller chassis equipped with Series 493 electronics
•
An optional Handset
These components work together to control up to eight channels on up to four
independent stations.
Typical FlexTest GT
configuration
are typically used for
component or structural
testing applications.
22
Controller Hardware
Typical FlexTest GT
configuration
About DUCs
The controller chassis is typically equipped with the following Series 493 Plug-In
Modules (32 maximum):
•
One valve driver module per control channel (two-stage or three-stage)
•
Two digital universal conditioners (DUCs) per control channel
•
Hydraulic service manifold (HSM) and hydraulic power unit (HPU)
interlock modules
The Model 494.25 Digital Universal Conditioners (DUCs) condition AC and DC
transducers. You can use the same DUC to condition an LVDT (AC transducer)
for one test, and then to condition a load cell (DC transducer) for another test.
Model 494.25 DUCs are full range conditioners. This means DUCs accurately
cover the full scale of the transducer, which eliminates the need to select between
ranges for transducers. DUCs also provide the resolution and repeatability
required for measuring small percentages of their total range.
Controller Hardware
23
Hardware options
•
Additional Model 494.25 DUCs
•
Model 494.26 Dual DUC
•
Model 494.21 Multi-Range DUC with Acceleration Compensation, which
provides conditioning and accelerometer compensation in a single card
•
Auxiliary analog-to-digital (A/D) inputs
•
Set of 16 digital inputs and 16 digital outputs for user-defined operation
•
Encoders
Controller
backpanel
FlexTest GT Controller
chassis
24
Controller Hardware
The FlexTest SE Controller is a fully-digital PIDF controller that is available in
three configurations:
FlexTest SE Basic
•
FlexTest SE Basic
•
FlexTest SE Plus
•
FlexTest SE 2-Channel
The FlexTest SE Basic is a stand-alone controller equipped with a multicolor
display panel and direct-access menu keys. It does not require a PC to operate; a
special form of MTS Series 793 Software is stored directly on its internal flash
memory.
The FlexTest SE Basic Controller is equipped with its own manual (FlexTest SE
User Information and Software Reference, PN 100-149-574).
FlexTest SE Controller
With the FlexTest SE Basic
model, you perform all
operations from the front
panel controls shown here.
For the FlexTest SE Plus and
models, you typically perform
most operations from a PC
loaded with Series 793
Software.
Controller Hardware
25
Automated FlexTest
SE Controllers
The FlexTest SE is available in two automated configurations, the FlexTest SE
Plus and the FlexTest SE 2-Channel.
The FlexTest SE Plus and FlexTest SE 2-Channel Controllers include:
•
A PC with Series 793 Software
•
FlexTest SE Controller equipped with Series 493 Electronics
FlexTest SE Plus
The FlexTest SE Plus
provides one control
channel, as shown in
this axial load unit
example.
The FlexTest SE 2-Channel
provides two control
channel, as shown in this
axial-torsional load unit
example.
26
Controller Hardware
Using Plus and 2Channel Controllers in
the Basic mode
Supplemental interface
for specimen handling
If desired, the FlexTest SE Plus and FlexTest SE 2-Channel Controllers can also
be used without PCs (in the FlexTest Basic configuration). The Controller is fully
capable of system control without the PC.
For FlexTest SE Plus and FlexTest SE 2-Channel controllers you typically use:
•
The FlexTest SE front panel controls to facilitate specimen loading
•
The Station Manager application running on the PC as the primary test
interface
You can position the FlexTest SE Controller near your load frame or test fixture
with an adjustable arm or a portable test stand. This eliminates the need for a
Remote Station Controller (RSC).
Controller Hardware
27
Booting the controller in the automated mode disables several of the menus on
the front panel of the controller. These menus are used for testing in nonautomated FlexTest SE Basic models. To compensate for the disabled front-panel
menus, you use the Station Manager application interface on the PC to set up and
run tests.
The PC manages
testing. You use a PC
loaded with Series 793
Software to design and
run tests.
28
Controller Hardware
The FlexTest Controller
manages specimen
installation. You use the
FlexTest SE Controller to
position the actuator when
loading specimens.
Typical FlexTest SE
Plus configuration
Options
FlexTest SE Plus Controllers typically support one channel on one station, and
include the following:
•
VME processor capable of an update rate of 6kHz, along with a two-stage or
three-stage valve driver, and two digital universal conditioners
•
One analog input and three analog outputs
•
Digital inputs and outputs (for interlocks or user-defined purposes)
•
Serial interface for temperature control
•
Up to three additional DUCs
•
Six auxiliary analog-to-digital input channels
•
Test stand (adjustable arm or portable stand) for the FlexTest SE Controller
FlexTest SE
Controller backpanel
Typical FlexTest SE 2Channel configuration
For more information
The FlexTest SE 2-Channel Controller is designed for two-channel, singlestation test applications. FlexTest 2-Channel Controllers include the following
additions to the FlexTest SE Plus configuration:
•
Two two-stage or three-stage valve drivers
•
Four digital universal conditioners (DUCs)
For more information on DUCs, see “About DUCs” on page 23.
Controller Hardware
29
FlexTest IIm Controllers are PC-based multistation digital controllers consisting
of two major hardware components:
•
A PC running Series 793 Software
•
A FlexTest IIm Controller chassis, equipped with Series 497 Electronics
FlexTest IIm Controllers support up to sixteen control channels on up to four
independent stations.
Typical FlexTest IIm configuration
FlexTest IIm Controllers are typically used for
component or structural testing applications
that require higher channel counts.
30
Controller Hardware
FlexTest IIm Console
Each FlexTest IIm console houses the following rack-mount components:
•
497.01 Analog Chassis equipped with a complement of Series 497 valve
drivers and conditioners, supporting up to 16 channels of control
•
497.05 Hydraulic Control Panel, which controls at least one Hydraulic
Power Unit (HPU) or actuator manifold
•
498.22 Test Processor Chassis
•
16 inputs and 16 outputs of user DIO
The FlexTest IIm Controller is available in a full-bay (vertical) console, a tabletop console, or a roll-around console.
Per channel resources
-One valve driver output
-One D/A output
-One A/D input
-One AC conditioned input
-Two DC conditioned inputs
Controller Hardware
31
Remote Setpoint
Adjust (RSA)
Model 494.05 Handset
The Remote Setpoint Adjust control allows you to use one or more encoders on a
station to control the setpoints of control channels (available for FlexTest IIm and
FlexTest GT Controllers only).
The Handset provides a portable control interface for performing basic test
operations such as:
•
Moving the actuator to install the specimen
•
Monitoring sensors
•
Zeroing sensors
•
Resetting and overriding interlocks
•
Applying and removing hydraulic pressure from the station
•
Starting and stopping tests
The Handset is lightweight and can be placed on a table or mounted on a stand in
close proximity to the test frame to facilitate specimen loading.
Password protection
Other features
32
Controller Hardware
The test designer can enable Handset operation at any access level. Access is set
on the Handset Options page in the Station Options window of the 793 Station
Manager application.
•
The Handset can be configured to operate only in the displacement control
mode.
•
The manual command control auto-disables after 90 seconds to minimize
inadvertent operation.
Programmable Display.
Shows sensor output and
the current control mode.
You can use it to zero
sensors and change
control modes.
*MC SN1 Ch1
>Displ 130.5
-Force 200 kN
Exclusive Control
Interlock Indicators
Thumbwheel. Manually
positions the actuator when
Manual Command is enabled
Hydraulics Indicator
Manual Command
Interlock Reset/Override
Program Run/Stop/
Hold Controls
Hydraulics Off
Model 494.05 Handset
Controller Hardware
33
About TEDS Sensors
About TEDS Sensors
Note
Only controllers that use Series 494 Hardware support the use of MTS
TEDS (transducer electronic data sheet) sensors.
TEDS sensors have built-in memory chips that store basic TEDS information
(manufacturer, model, number, and serial number).
When you connect an initialized TEDS device to a conditioner, the Station
Manager application reads the basic TEDS information from the device, and a
sensor assignment window appears.
The sensor file list in this window only lists sensor files that match the basic
TEDS information, conditioner type, and dimension. The sensor assignment
window contains the same sensor assignment list found in the Station Setup
window.
TEDS devices
34
Controller Hardware
Available TEDS devices include:
•
MTS sensors that include basic TEDS information saved in an integral
TEDS chip that is built into the sensor.
•
MTS TEDS Transducer ID modules that include a chip that stores basic
TEDS information for a specific sensor. The TEDS module connects to the
sensor.
Chapter 3
Controller Software
This section contains descriptions of the software included with MTS 793
Controllers. Regardless of the differences in hardware between one controller
and another, all MTS 793 Controllers are equipped with MTS 793 Software.
Multitasking Windows
environment
MTS 793 Software runs on the Windows operating system, which is
multitasking. This means you can run more than one 793 application at a time.
For instance, you can design a test configuration at the same time you are running
a test. Also, while running a test, you can adjust control parameters in response to
test events.
All MTS Series 793 Controllers are equipped with the Model 793.00 System
Software bundle. The System Software bundle contains applications that perform
activities centered around maintaining servo control of a test station. These
applications include the following:
•
Project Manager
•
Station Builder
•
Station Manager
•
Basic TestWare
•
Station Desktop Organizer
•
Hwi File Editor
•
Controller Management Tool (FlexTest SE Controllers only)
MTS also offers optional control and application software.
Project Manager
A test data management application that allows you to create and configure
Series 793 Projects, start Series 793 applications, and edit System Settings.
Projects make data organization easy. You can configure Series 793 Projects to
organize data around specific tests, users, applications, or stations.
Controller Software
35
Station Builder
Station Manager
A station design application that allows you to allocate controller resources, such
as valve drivers, conditioners, digital inputs, and so forth, to station configuration
files. You define parameters for the resources in the station configuration with the
Station Manager application. This application is password protected.
A sophisticated controller application whose primary function is to maintain
station servocontrol while allowing you to perform typical test operations, such
as:
•
Creating parameter sets that define and optimize the operational
characteristics, such as sensor ranges and conditioner gains, of the station
resources in your station configuration files
•
Monitoring the various analog and digital signals sent to and from your
controller
•
Monitoring station interlocks and controlling hydraulic or
electromechanical station power
•
Managing tests with run, hold, and stop controls
Basic TestWare
A test design application that allows you to create monotonic and cyclic tests and
to acquire data.
Station Desktop
Organizer
A software utility that allows you to manage the windows and displays
associated with Series 793 Software. This utility is useful for reducing screen
clutter when you work with multiple stations simultaneously.
Hwi File Editor
A software utility that allows you to create and edit hardware interface (.hwi)
files. Hwi files are text files that define the internal components—or resources—
available to MTS Series 793 Controllers. Resource examples include
conditioners, valve drivers, digital inputs, and so forth. The text description of a
resource in an .hwi file includes proximity information, such as the location of
the slot in the chassis in which the resource is installed, and the rear-panel
connectors through which it can be accessed.
Controller
Management Tool
A software utility that allows you to perform a variety of maintenance activities
on FlexTest SE Controllers, including updating the executable software stored on
the controller flash-disk, installing and backing up user files, and assigning
various controller attributes, such as regional settings, passwords, and multi
controller setup.
Note
36
Controller Software
The Controller Management Tool pertains to FlexTest SEs only.
For more information about using Station Manager to assign parameters to
station configurations, see “About Assigning Parameters to Station
Configurations” on page 54.
For more information about using Basic TestWare to create test designs, see
“Designing Tests with the Basic TestWare Application” on page 65.
For more information about using Station Manager to execute tests, see “About
Running Tests” on page 76.
Your Series 793 Controller may be equipped with optional software that aids or
enhances station servo control. These features are available as keyed options on
the standard Series 793 System Software installation CD.
Model 793.02
Calculations
The Model 793.02 Calculations option allows you to assign a calculated analog
input for control feedback or data acquisition. Calculated input values are
determined by applying a user-defined mathematical equation to the specified
signal values. You assign mathematical functions with an integrated equation
editor.
You use the Station Builder application to assign calculated input resources to
control modes, stabilization feedback, external command inputs, and auxiliary
inputs.
The Station Manager application creates calculated input channels from input
resources that are mapped to calculated input resources.
Model 793.03
Calculations with
Outputs
The Model 793.03 Calculations with Outputs option provides an output signal
with which you can drive a hardware resource (for example, a valve driver). Each
calculated output signal specified in the Station Builder application is defined by
an equation created in the Station Manager application.
You can also assign a control channel to a virtual output resource to create a
“virtual channel.” The output of a calculated channel is not defined by an
equation or assigned to hardware. Its output is used by a calculated output
resource that can be used to drive hardware such as a servovalve.
Controller Software
37
Model 793.04 PC-PerStation Kit
The PC-Per-Station Kit allows you to use up to four PCs with your FlexTest IIm,
or FlexTest GT Controller. Multiple PCs linked to a single controller allows
different operators to run their assigned stations without having to share PCs. It
also decreases downtime since multiple operators can run different tests
simultaneously (at their assigned stations) through a single controller.
The PC-Per-Station kit
allows each test station to
have its own PC. (Test
stations are equipped with
separate hydraulic service
manifolds.)
Model 793.05/.06/.07/
.08/.18 Compensators
38
Controller Software
Compensators compare your command with the corresponding sensor feedback
to ensure that the command is fully applied to the specimen. If the sensor
feedback indicates the specimen is not reaching the commanded levels, the
compensator alters the command until the desired result is achieved.
Each type of compensator uses a different technique to achieve the commanded
levels. Certain compensators work more effectively than others for specific
applications. The following compensators are available as Series 793 Software
options:
Model 793.10
MultiPurpose TestWare
(MPT)
•
Model 793.05 Amplitude Phase Control (APC) Compensator
•
Model 793.06 Adaptive Inverse Control (AIC) Compensator
•
Model 793.07 Arbitrary End-level Control (ALC) Compensator
•
Model 793.08 Peak Valley Phase Control (PVP) Compensator
•
Model 793.18 Adaptive Harmonic Cancellation (AHC)
A sophisticated general purpose test design application that allows you to build
test procedures by defining and linking modular test activities (called processes)
together in a “drag and drop” environment. You can also assign serial or parallel
trigger relationships between processes to accommodate conditional test events.
MPT allows you to link function generation, data acquisition, event, and trigger
elements to quickly build virtually any test procedure.
MPT is required to execute many Series 793 niche-specific applications, as noted
in the application descriptions that follow.
For specific instructions about using MPT, see the MultiPurpose TestWare
Application Software manual (PN 100147131).
Note
Model 793.11
Profile Editor
Model 793.12
Trend Monitoring
MultiPurpose TestWare is standard with FlexTest IIm systems.
A stand-alone waveform design application that allows you to create arbitrary
waveforms (referred to as profiles). You can create block arbitrary and phase
profiles, and analyze the waveforms with the graphical preview feature. Once
created, you play out the profiles with the MultiPurpose TestWare application,
using the Profile process.
A specialized analysis application that allows you to monitor trend data that has
been recorded in real time. This application works with the MultiPurpose
TestWare application, using the Trend process.
Controller Software
39
Model 793.14
Fatigue Monitoring
A specialized analysis application that allows you to monitor fatigue data that has
been recorded in real time. This application works with the MultiPurpose
TestWare application, using the Fatigue process.
Model 793.15
Degree of Freedom
Control (DOF)
DOF control (available with Series 793 Software version 4.0 and later) provides
a coordinate system in which actuators act in groups to produce movement in six
degrees of freedom (vertical, longitudinal, lateral, roll, pitch, yaw). The feedback
and command are converted from actuator coordinates at the start and finish of
the control loop. Specifically, the raw actuator feedback signals are converted to
DOF coordinates. The controller then closes the loop using these DOF
coordinates. The DOF controller outputs are then combined to provide individual
actuator valve commands.
Model 793.16
Three Variable Control
(TVC)
TVC control (available with Series 793 Software version 4.0 and later) provides
simultaneous control of displacement, velocity, and acceleration variables. It
combines the command and feedback signals of all three control variables to
provide the needed system performance, emphasizing displacement at low
frequencies, velocity at middle frequencies, and acceleration at high frequencies.
This tailors the frequency stability characteristics of the wave generator to
achieve the best performance across the spectrum.
Model 793.21 Cascade
Control
The Model 793.21 Cascade control mode is typically used for testing that
requires a high degree of stability under dynamic conditions.
This control mode uses two control loops. The output of the outer control loop is
used as the input to the inner control loop, as if it were the final control element.
Model 793.23 MPT
Variables
The Model 793.23 MPT Variables feature provides test designers with the
capability to define test parameter variables. With this feature, test designers can
create tests in which the operator enters test parameter variables in just one place.
When this is done, all related variables in the test are updated automatically
without the operator having to open each associated process individually. This
can significantly reduce test design and setup time and reduce setup errors.
This feature includes an MPT Calculation process that allows test designers to
add mathematical operators to variable parameters.
Another process, Set Controller Value, allows you to set values for the
calculation parameter and calculation variable values defined in the station
configuration. When the process is triggered, the values set in this process
override their associated values inc the station configuration.
40
Controller Software
Model 793.25 CAN Bus
Support
Model 793.26 Signal
Based Command
Model 793.71 Time
History Playout (THP)
The Model 793.25 CAN Bus feature supports CAN bus devices. CAN bus is a
computer network protocol and bus standard that allows devices to communicate
with each other without a host computer. You can use CAN Bus resources in
control loops and event-action sequences.
The Model 793.26 Signal Based Command process allows you to generate
command based on signal values specified in a predefined lookup table. The
lookup table is contained in a tab-delimited text file which defines the
relationship between command and signal values.
An MPT process that allows you to drive a test system equipped with an MTS
Remote Parameter Control (RPC) time history file.
Model 793.72 Time
History Playout with
Data Acquisition (THD)
An MPT process that allows you to acquire and digitize analog test response data
in the MTS RPC III file format and floating point time history files. RPC analysis
software allows you to calculate the system transfer function of the system with
the digitized file.
Model 793 Multibox
Option
The Model 793 Multibox Option allows the use of networked chassis to provide
additional hardware resources.
Model 793.100/101
Hybrid Simulation
The Model 793.100 Hybrid Simulation (Internal Model) and Model 793.101
Hybrid Simulation (External Model) options allow 793 software and hardware to
interface with simulation models.
For more irnformation about compensators, see “About Compensators” on page
59.
For more information about creating test procedures with MPT, see “About
Running Tests” on page 76.
Controller Software
41
MTS has additional application software designed for use with Series 793
Controllers, and is continually developing more. These applications are not
available as keyed options on the standard Series 793 System Software
installation CD; they are distributed on separate media. The following
descriptions are just a few examples of optional Series 793 applications (contact
MTS for a complete list).
Model 793.20 HighCycle, Low-Cycle, and
Advanced Low Cycle
Fatigue
An MPT process that allows you to define, execute, and analyze constant
amplitude, high-cycle and low-cycle fatigue tests. This software offers predefined
test templates to facilitate the execution of ASTM E606 Room Temperature
trapezoidal wave shape LCF, and E466 HCF test standards. It provides real-time
display of hysteresis loops and a variety of other plots to let you monitor and
record the progress of your test. It also supports transition from LCF to load
controlled HCF testing so you can collect critical LCF test information, then
quickly run your test to failure, maximizing your test throughput.
Model 793.31 Dynamic
Characterization
An MPT process that allows you to characterize the dynamic properties of
elastomeric materials and components. You can sweep temperature, frequency,
dynamic amplitude, mean level, and phase between multiple control channels
simultaneously. It also allows you to nest sweeps.
42
Model 793.33 Static
Deflection
An MPT process that allows you to characterize the static deflection properties of
elastomeric materials and components. You load the specimen between
predefined load or displacement end levels and acquires subsequent timed data.
Then this software calculates the stiffness of the sample as a cord or tangent
modulus during the loading or unloading portion of the test, or as an average of
the two. Finally, the process compares the calculated stiffness to predefined
limits. It can also compare individual load and displacement data pairs to
predefined envelopes for quality control applications.
Model 793.40 Fatigue
Crack Growth
An MPT process that allows you to quickly set up and run tests to accurately
measure the crack growth rate of materials. It includes several powerful
capabilities, such as delta K control, as well as compliance and visual
measurement of crack length. With the visual method this software allows you to
hold the test, make the measurement, change parameters, and resume the test. This
software includes a predefined test template for fast, accurate execution of ASTM
E647-91 fatigue crack growth rate tests. It provides real-time analysis of crack
length versus cycles, and da/dN versus delta K. It can be configured to run delta K
controlled and constant Kmax controlled crack propagation tests to obtain the
material response for the specific conditions of interest.
Controller Software
Chapter 4
Operation Concepts
This section provides conceptual information about using 793 Software
components to perform specific test activities.
The following pages provide a high-level overview of the steps required to set
up, design, and run a test.
Setting Up A Project
Project
Manager
application
Project 1
Project 2
Project 3
To start a testing session, you create (or select) a place to keep the files you will
be generating while testing, such as test design files and test data files. This place
is referred to as a “Project.”
Creating a Station Configuration
hwi
Station
Builder
application
Hardware
Interface
file
Station Config
file 1
Station
Config file 2
Station
Config file 3
Next, you use the Station Builder application to allocate resources from your
Hardware interface file to create individual Station Configuration files.
Operation Concepts
43
Assigning Parameters to the Station Configuration
PARM
PARM
PARM
Parameter
Parameter
Parameter
Station
Station
set
2
set
1
set 3
Config
Manager
file
application
Next, you load a station by selecting a Station Configuration file with the Station Manager application.
You assign parameters of the resources in Station Configuration file to optimize performance according
to your test requirements.
Creating a Test Design
PARM
Station
Manager
application
Station Config
file with
Parameter set
MultiPurpose
TestWare
application
Test
Procedure
file 1
Test
Procedure
file 2
Test
Procedure
file 3
Next, you create a test program. To do this, you select your Station Configuration file and desired
parameter set with the Station Manager application. Then from the Station Manager application, you
select the desired test design application, such as Basic TestWare or MPT, and create test design files.
Running a Test
PARM
Station
Manager
application
Station Config
file with
Parameter set
MultiPurpose
TestWare
application
Test
Procedure
file
Test Data
file
Finally, with all of the files open, you start the test from the Station Control panel of the Station Manager
application. Test Data files are generated according to the type of test design application you used to
create your test design file.
44
Operation Concepts
For more information on creating a station configuration, see “About Station
Configurations” on page 51.
For more information on assigning parameters to the station configuration, see
“About Assigning Parameters to Station Configurations” on page 54.
For more information on creating a test design, see “About Test Designs” on
page 64.
For more information on running a test, see “About Running Tests” on page 76.
Operation Concepts
45
About Projects
About Projects
A Series 793 Project folder (or Project for simplicity) contains the various types
of information you typically acquire while testing.
Project 1
Project folders contain various
files centered around test
design and test execution.
Projects also contain settings
that include references to
common support file stored
elsewhere (as shown to the
right). Project folders are
displayed with a double-red line
notation.
Project folder icon
Files referenced in Projects
scf
Project 2
Station
Config files
Calibration
files
MPT Test
Procedure file
templates
Project 3
Projects are displayed on your system as modified folder icons, as shown to the
left. Each Project folder contains a collection of information related to testing.
The information is organized into predefined subfolders, as shown in the
expanded Sample Project below.
Project folders contain
predefined subfolders.
46
Operation Concepts
Projects include information:
Benefits of Projects
Your initial Project
•
Required to perform tests, such as configuration files and test design files;
and
•
Generated by testing, such as test data, scope images, and specimen files.
•
Captured as a result of unexpected shutdowns (Shutdown Recorder
directory)
The Project Manager (and the ability to create Projects) became available in
version 4.0 of Series 793 System Software. Projects offer the following benefits:
•
Projects separate user information from system and controller information.
This eliminates confusion about where your test files are stored, and allows
you to set file access privileges for individual users.
•
Projects allow different users to keep the information in their projects
separate from one another.
•
Projects allow you to use standard Windows features to add security to,
duplicate, and archive the information stored in them.
•
Projects are configurable, allowing you to match your Project with your test
environment.
The Series 793 Installation Wizard automatically creates an initial Project (with
the default name of Project1), and gives you the option of assigning it as the
default Project.
Note
If you have never used Project Manager to assign a default Project but
one is assigned (you are not prompted to select a Project when starting
Series 793 applications), this option was probably selected during
installation.
Upgrade installations
For upgrade installations, you have the option of copying all of your existing test
design and test data files from their original locations to the initial Project (the
files are copied, not moved, so the original files will remain in their original
locations).
For more information on how projects separate user information from system and
controller information, see “About Project Information” on page 85.
Operation Concepts
47
Every Project contains a Project Settings file. Most Project settings are folder
path specifications. To configure Projects, you use the Project Manager
application to edit the Project Settings file. A Project Settings file acts like a
switchboard that directs the flow of information within a Project.
The Project Manager also allows you perform other tasks, such as editing system
wide settings and starting Series 793 applications, but its primary function is to
configure Projects.
When you set up and configure projects with Project Manager you are not
required to apply power to your station or handle station hardware—you are
simply creating files.
Default Projects.
You can use the Project
Manager application to
assign a default Project.
Default Projects open
automatically when you
start Series 793
applications.

Project
Manager
application
Project 1
Project 2
Project 3 set as the
default Project.
Default Projects are
displayed with a
checkmark notation.
You can configure Projects in a variety of ways to suit your specific needs. For
instance:
•
You could set up one Project to acquire all of the test data generated by a
specific operator (example: “Ken’s Project”).
•
You could set up another Project to acquire all of the test data generated by
multiple operators from a specific specimen (example, “Shock Absorber
Project”).
Projects make this type of data organization easy. You can configure Projects to
organize data around specific tests, users, applications, or stations. A Project is a
custom portal to your test system.
48
Operation Concepts
The resources in your Station Builder application resource lists are defined by the
hardware interface file (or .hwi file) installed with your system software.
Resource examples include conditioners, valve drivers, digital inputs, and so
forth. The .hwi file defines what internal components are available to your
controller, which controller slots they are installed in, and which rear-panel
connectors they are accessed through.
hwi
Hardware
Interface
file
The Hardware Interface file represents all of the hardware resources available to
your test system.
Hardware interface file
syntax
Hardware interface files (.hwi) are text files. The text description of a resource in
an .hwi file includes proximity information, such as the location of the slot in the
chassis in which the resource is installed, and the rear-panel connectors through
which it can be accessed. The text in hardware interface files uses precise syntax
which must be followed when editing the text directly.
.hwi file and the
Station Builder
application
You use the Station Builder application (one of the applications included with
MTS 793.00 System Software) to define test stations by allocating some or all of
the resources listed in the .hwi file.
Initial .hwi file
The .hwi file associated with a given controller is typically created at MTS
according to the resources included with the controller. It may be necessary to
edit this file if system resources are added, removed, or repositioned in the
controller chassis.
Operation Concepts
49
Editing .hwi files with
the Hwi File Editor
MTS has a software utility for editing .hwi files, called the Hwi File Editor. This
utility minimizes the chance of introducing syntax errors when making changes
to existing .hwi files or creating new .hwi files.
The built-in logic of the Hwi File Editor streamlines the process of adding new
resources. For instance, when you add or remove analog resources from an .hwi
file, the .hwi file Editor has a fill down function that automatically assigns proper
channel numbers and resource names.
If you add new hardware to your system because of a need for additional
conditioning, you can use the Hwi File Editor to reflect those changes in your
system .hwi file.
In addition to the Hwi File Editor, you can create or edit .hwi files with any text
editor, such as Microsoft Notepad.
50
Operation Concepts
About the Station Builder Application
The Station Builder application defines the parts of a station configuration from a
pool of system resources listed in the hardware interface file. With the Station
Builder application, you can allocate all or a portion of your system resources to
create station configuration files.
hwi
Station
Builder
application
Hardware
Interface
file
Station
Config
file
Station
Config file
A Station Config file can represent only a portion of the total
resources available in the Hardware Interface file.
Initial station
configuration
MTS typically installs Series 793 Software for you and supplies your controller
with a station configuration. You use the Station Builder application to modify
your initial station configuration when replacing or adding resources.
Operation Concepts
51
Using the Station Builder Application to Create
Using the Station Builder Application to Create Station Configurations
When you create station configurations with the Station Builder application, you
are not required to apply power to your station or handle station hardware--you
are simply creating files.
To create a station configuration, you allocate controller resources such as valve
drivers, conditioners, analog I/O, digital I/O, and hydraulic control resources to
create the following:
•
Channels—used to control an independent quantity, such as force or
displacement, on the test fixture.
•
Auxiliary Inputs—used to monitor signals for data acquisition or display. As
an option, you can create a calculated input resource for auxiliary inputs.
•
Readouts—used to send analog signals to external readout devices such as
oscilloscopes and meters.
•
Digital Inputs—used to receive digital logic signals from external devices.
As an option, you can create a calculated input resource for digital inputs.
•
Digital Outputs—used to send digital logic signals to external devices. As
an option, you can allocate a resource for “virtual” digital outputs not tied to
hardware, but available for use in other calculations.
•
Calculated Analog Outputs—this option is used to apply user-defined,
algebraic formulas to selected output signal values to generate new,
calculated output signal values.
•
Calculated Analog Inputs—this option is used with calculated resources to
apply user-defined, algebraic formulas to selected input signal values to
generate new, calculated input signal values.
•
Remote Setpoints—used to set up the Remote Setpoint Adjust (RSA)
controls (optional, stand-alone hardware controls used to control actuator
setpoints).
Once you have allocated the resources you need, you can save your configuration
file (it acquires a “.cfg” extension).
Where station
configurations are
stored
52
Operation Concepts
By default, configuration files are located at C:\MTS 793\Controllers\Controller
Name (for example, FlexTest GT)\Config. Configuration files are referenced
from the Project you selected when you started the Station Builder application.
(You can change where your station configurations are saved by changing your
Project settings with the Project Manager application.)
The Station Builder application has one main window that enables you to create
station configurations.
Station Builder application main window
Menu bar
Toolbar
Tree view of
station
resources
Lists of
system
resources
Operation Concepts
53
About Assigning Parameters to Station
About Assigning Parameters to Station Configurations
About Parameter Sets
In the pretest phase, you use the Station Manager application to optimize how the
parts of your system work together. A product of the pretest phase is a parameter
set that you save with the station configuration.
A parameter set adapts the way the resources in your station configuration
operate to suit your test requirements. Parameters include everything from tuning
values to detector settings. When you change these settings from their default
values, you create a unique parameter set for the station configuration.
PARM
Station
Manager
application
Parameter
set 1
Station
Config
file
PARM
PARM
Parameter
set 2
Parameter
set 3
Creating parameter sets. You use the Station Manager application to create Parameter
sets. Parameter sets define the operation characteristics of the resources in the selected
Station Config file. You can create up to 15 parameter sets for a Station Configuration.
PARM
Selecting Parameter sets. When you start the
Station Manager application, you select a Station
Config file, and then you select the desired
parameter set for the Station Config file.
PARM
PARM
PARM
54
Operation Concepts
Station Config
file paired with a
parameter set.
Using the Station Manager Application to Create
Using the Station Manager Application to Create Parameter Sets
When you optimize your station configuration with the Station Manager
application, you perform many of the activities required to perform a test: You
apply power to the station, manually position the actuator, apply tuning
programs, monitor waveforms, and so forth. While doing these activities you
adjust parameter values accordingly, which you save with your station
configuration.
You typically perform the following activities to optimize a station configuration
while creating a parameter set.
Creating sensor files
Balancing the
servovalve
To begin creating a parameter set, you typically:
•
Create and assign calibration files for sensors with on-board conditioning
•
Adjust conditioner values for sensors with external conditioning
For optimal system performance, you should check and adjust the servovalve
before performing tests.
Balancing the servovalve is the process of optimizing communication between
the valve driver and servovalve. During installation, your servovalve is typically
balanced at its midstroke position. The signal values in your parameter set reflect
that initial procedure. For optimal performance, you should balance the
servovalve again after you position the actuator to the test start position.
Adjusting dither
You may also need to adjust dither. Dither is a low-amplitude, high-frequency
sine wave that the controller applies to the servovalve spool. Dither keeps the
spool in motion so it operates smoothly and doesn’t stick to its cylinder walls. It
is especially useful for tests that use small amplitude commands.
Setting detectors
Before installing the specimen, you should set detector limits and actions to
minimize the risk of injury to yourself and damage to your specimen. After you
install the specimen, you adjust your detectors to accommodate your test design.
Tuning control modes
You need to install the specimen before you adjust force tuning because force
turning involves every element of the force-train, and requires closed-loop
control.
Operation Concepts
55
To complete this task, make sure the force tuning values established in your
parameter set are suitable for the test you are about to run. To do this, you
typically:
•
Create and apply a simple tuning program with the function generator
•
Evaluate the current force tuning values by comparing command and
feedback signals
•
Make Proportional (P) gain and Integral (I) gain adjustments to achieve
optimal force tuning
Displacement tuning values typically do not require frequent adjustment.
Optimal force tuning values, however, are a function of specimen compliance,
which tends to change over time, or even from test to test. Because of this, it is
good practice to tune the force control mode often. You should also tune the force
control mode whenever you make any change to the force train, such as changing
gripping fixtures.
Verifying calibration
adjustments
You can verify the calibration of your force sensor (load cell) by performing a
shunt calibration. It is good practice to perform a shunt calibration before you
begin a test to ensure accurate test data.
After your force sensor is calibrated for the first time (or when it is fully
recalibrated), someone will perform a shunt calibration to create a reference
value that will be stored in the calibration file of the force sensor.
You periodically compare this reference value with the values you obtain when
performing subsequent shunt calibrations. This validates the current state of
calibration of the force sensor.
Saving station views
To avoid reopening windows and displays each time you reopen a station
configuration, you save the desktop layout as a station view. When you restore a
saved view, the windows reposition automatically.
Each time the Station Manager application closes, it saves the current station
view as the default view. When you reopen the station it appears with the
windows repositioned as they were when the station was last closed. This allows
you to revert to the last saved station view.
You can also restore a default view by selecting Restore Default View. This
function repositions the station windows to where they were the last time the
station was closed.
56
Operation Concepts
Where parameter sets
are stored
A station parameter set is not a discrete file that you can see on your desktop. It is
a discrete attribute set that is saved within a station configuration by the Station
Manager application. By default, configuration files are located at C:\MTS
793\Controllers\Controller Name (for example, FlexTest GT)\Config.
Configuration files are referenced from the Project you selected when you started
the Station Builder application. (You can change where your station
configurations are saved by changing your Project settings with the Project
Manager application.)
Recovery information
generated by
unexpected shutdowns
Series 793 controllers (except for FlexTest SE controllers) are equipped with a
Shutdown Recorder. With the Shutdown Recorder, you can capture data
surrounding unexpected shutdowns. Shutdown recorder data is stored in volatile
processor memory, or in an optional PMC flash module. If the configuration is
associated with a Project, shutdown recorder data is stored in the Project’s
Shutdown Recorder directory. You can import and analyze shutdown data with
spreadsheet applications such as Microsoft Excel.
Operation Concepts
57
With the Station Manager application, you can perform the following to optimize
your station configuration prior to running tests.
•
Load and reload stations
•
Perform system calibration and tuning
•
Configure limit and error detectors
•
Define and apply an algebraic formula to a signal in order to generate a
calculated signal value
•
Configure signal compensation and stabilization
•
Control hydraulic pressure to the test station
•
Apply simple programs with the built-in function generator
All of the Station Manager application settings can be saved to a station
parameter set.
Station Manager
application main
window
Menu bar
Toolbar
Application control bar
Station Controls panel
Message pane
58
Operation Concepts
About Compensators
Station Setup window
About Compensators
Compensators are control techniques that improve the tracking and accuracy of
your controller. They play an important role in optimizing system performance.
Various compensators are available to suit specific test requirements.
Null Pacing
Null pacing ensures that desired levels are achieved on the initial command pass
without over programming the input.
Null pacing provides the following benefits:
•
Works with cyclic or random profiles
•
Works with linear or non-linear specimens
•
Optimizes performance to reproduce wave shape or to maximum test speed
without regard for wave shape
Null pacing is typically used in tests in which the wave shape is not important,
and you want to complete the test as quickly as possible while meeting every
peak within the specified tolerance. Null pacing can adjust the speed of the
command, using maximum performance of the mechanical system. It is also used
in tests in which every peak must be achieved within a specified tolerance, but
overshooting cannot be tolerated.
Operation Concepts
59
About Compensators
Amplitude and Phase
Control (APC)
The Amplitude and Phase Control (APC) compensator monitors feedback from
sine and sine tapered commands for amplitude roll-off and phase lag. APC works
well when you need to control the amplitude of the fundamental frequency
component.
APC provides the following benefits:
Peak/Valley
Compensation (PVC)
•
Boosts the command amplitude if roll-off is detected
•
Alters the command phase if phase lag is detected
Peak/Valley Compensation monitors cyclic command feedback for any
amplitude roll-off or mean-level divergence. PVC is typically used in cyclic or
block cyclic tests with >10 cycles per block, and is widely used compensator for
cyclic and block cyclic durability testing.
PVC provides the following benefits:
Peak Valley Phase
Control (PVP)
•
Corrects for peaks and mean level in cyclic waveforms
•
Works with linear and non-linear specimens.
The Peak/Valley Phase (PVP) compensator combines amplitude and phase
(APC) with Peak/Valley Compensation (PVC) algorithms to improve the
amplitude and phase tracking of the command/feedback. PVP corrects for phase
as well as amplitude and mean
PVP is important for multi-channel tests in which phase relationships must be
maintained, and in which the specimen is pre-loaded or the feedback waveform
may be distorted
PVP is typically used in multichannel block cyclic (>10 cycles per block) tests in
which phasing and mean levels must be compensated, in addition to amplitude.
Adaptive Inverse
Control (AIC)
AIC is a linear compensation technique that senses the frequency content of the
drive signal, automatically generates an inverse filter, and then filters the
command to achieve the desired response.
AIC provides the following benefits:
•
Uses an inverse model to improve tracking in linear systems
•
Compensates for amplitude and phase, and matches signal shape
AIC is most effective with random or time history signals with broad-band
frequency content
60
Operation Concepts
About Compensators
AIC is typically used in tests on linear specimens in which road profiles
developed on a separate system must be accurately reproduced without having to
iterate.
AIC is also used on fast sine sweeps, particularly when the sweep rate is too fast
(>1Hz/s) for APC, and on any component being tested with random or time
history signals on a linear system.
Extended AIC (AICX)
AICX is an extended version of AIC for use with MTS Series 494 hardware
(basic AIC is typically used with MTS Series 493 hardware).
AICX compensation offers the following benefits over AIC:
Arbitrary Level Control
(ALC)
•
Performs bulk processing in the background, which decreases sensitivity to
the processor load
•
Handles low coherence areas better and often allows compensation through
the region of low coherence
•
Allows the use of significantly higher FIR filters with less impact on
performance.
ALC is an adaptive compensation technique that improves the tracking accuracy
of spectrum profiles played out with the MultiPurpose TestWare application. This
technique is also known as “from-to matrix compensation.”
ALC works with linear or nonlinear specimens, and can be used with cyclic
waveforms or random profiles
ALC provides the option to have the test frequency adjusted to suit mechanical
system capability (to optimize frequency as well as amplitudes to minimize test
time)
Operation Concepts
61
About Compensators
ALC is typically used in matrix depletion fatigue tests where only one or two
cycles of a particular amplitude are executed before new amplitudes are
introduced.
Example of
feedback dropping
off in a test
waveform without
ALC compensation.
The same waveform
with ALC
compensation
Adaptive Harmonic
Cencellation (AHC)
Adaptive Harmonic Cancellation (AHC) works with Amplitude Phase Control
(APC) to minimize spurious harmonic distortion.
Note
The adaptive harmonic canceller function can only be enabled if
Amplitude Phase Control (APC) is on.
Adaptive Harmonic Cancellation allows you to set up adaptive harmonic
cancellers to reduce or cancel spurious harmonics in the feedback when
programming sine waves. This approach injects input harmonics into the
controller command waveform with just the right phase and amplitude to cancel
the feedback harmonics.
62
Operation Concepts
About Compensators
Adaptive Harmonic Cancellation is typically used when programming with pure
sinewave commands or sine sweeps in acceleration control. Also, ALC is
typically used in high-frequency MAST systems for ground vehicle testing.
How AHC Works
Because cancellation occurs at the system output by means of a signal at the
system input, the phase response of the system must be known. The control
system model, or “model” for short, is an adaptive finite-impulse-response (FIR)
filter, and provides the phase response. Before you turn cancellation on, you must
train the system phase response by commanding the system with a sine sweep or
a random signal over the frequency range of operation.
Operation Concepts
63
About Test Designs
About Test Designs
Understanding Test Design Files
MTS Series 793 Software offers several applications you can use to create test
design files. When you save test design files, they are automatically stored in the
current Project.
Note
The Basic TestWare application is the only test design application that
comes standard with Series 793 Software.
PARM
Station
Manager
application
Station Config
file with
Parameter set
Basic TestWare
application
MPT
application
MPT with optional
MPT process
Profile Editor
application
64
Operation Concepts
Test files
(.tst)
Test
Procedure
files (.000)
You create Test files with Basic
TestWare, which you can use to
create simple monotonic and cyclic
test designs. You select the Basic
TestWare application within the
Station Manager application, which
opens against the current station
configuration.
You create Test Procedures with MPT
processes, which are modular test
activities you can use to create
complex test designs. You select MPT
within the Station Manager
application, which opens against the
current station configuration.
You can purchase specialized
processes for MPT which you can
combine with standard MPT
processes. This allows you to create
Test
Procedure Test Procedures with unique
files (.000) capabilities.
Profiles
(.blk)
You create Profiles with the Profile
Editor. Profiles are custom
waveforms you play out in MPT Test
Procedures. The Profile Editor is a
stand-alone application (you do not
open it against a station
configuration), though you must be
aware of station resources when
designing Profiles.
The Basic TestWare application is included in the Series 793 System Software
bundle, and is the easiest software tool for creating simple monotonic and cyclic
test designs that do not require complex signal management or mode switches.
An on-screen panel lets you create tests by defining the rate, frequency,
amplitude, and mean for sine, triangle, square, and ramp command signals. You
can turn on peak detectors to monitor for signal changes.
You can also collect data from any signal you have defined in your system,
including peak/valley, min/max, timed data, and level crossing data.
After you configure your test, you can save it to a Basic TestWare application test
file (or .tst file).
About test files
A test file typically includes the following types of test configuration
information:
•
Test command (command type, test channel definition)
•
Data acquisition definition (type, signals, buffer size/type)
•
Data file definition (file name, data header, file format)
By default, Basic TestWare application test files are saved to the “BTW” folder in
the Project folder you selected when you started the Station Manager application.
Operation Concepts
65
MultiPurpose TestWare (MPT) is a powerful and flexible application that enables
you to quickly and easily define complex test designs.
MPT allows you to
create complex test
designs with discrete
processes. Each
process represents an
individual test activity.
This diagram shows
how a test waveform
may correlate to
individual process icons.
ramp to
mean
hold at
mean
cycle and
acquire data
hold at
mean
return from
mean
Time
Sequencing test
activities. This diagram
shows how each
process is sequenced to
achieve test objectives.
For instance, the timed
data acquisition process
(icon with clock)
executes in parallel to
the cyclic command
process.
Defining parameters.
This diagram shows
examples of parameters
assigned to individual
processes. This defines
test levels.
level: 0 N
level:
300 N
waveform:
sinusoidal
level:
300 N
time:
10 sec
amplitude: 2mm
time:
10 sec
level: 0 N/mm
frequency:10 Hz
cycles:2000
acquisition:
1 millisecond
time between
points
66
Operation Concepts
Types of information in
MPT test procedures
Working with
Processes
An MPT test procedure contains two types of information:
•
Process information, which defines your processes (command, data
acquisition, signal monitoring, and so forth) and the sequence in which each
process executes
•
MPT application information, which includes test unit and dimension
assignments, the behavior of hold and resume functions, the data file format,
and so on
You begin designing a test procedure by selecting the processes you want
included. Available processes are displayed as icons on the Process Types palette.
You select the icon you want, drag it to the table, and drop it in place.
A test procedure may consist of a single process, or it may be more complicated,
containing multiple function generation processes sequenced with multiple data
acquisition processes. You can also create group processes and treat them as a
single process in your test procedure.
MPT provides an easy-to-use “drag-and-drop” environment for creating and
automating test procedures. With MPT, you link processes—including function
generation, data acquisition, events and triggers—to build virtually any test
procedure.
Connecting the
Processes
You control the order in which processes execute by connecting them with other
processes. Each process has a Start list box, which lists triggers that can start it,
and an Interrupt list box, which lists triggers that can stop it prematurely.
Defining Process
Parameters
For each process, you define the specific test parameters to run the test, such as
ramp time, end levels, and more. Different sets of parameters can be saved to
define several different test procedures—all performing the same type of test, but
with different frequencies, numbers of cycles, and so on.
Working with MPT
Variables
Normally, when you enter a value for a parameter in a process, you can change
the value only by opening the process dialog when the test is stopped and the test
procedure is unlocked. In this sense, the parameter value is “fixed.”
With the MPT Variables feature, you can associate a specific parameter of a test
process with a variable. This allows you to change the variable in the Variable
Editor without opening the associated process window.
Operation Concepts
67
For example, suppose you create a test procedure that includes several command
processes that all use the same frequency. Rather than entering a frequency value
for each process separately, you could associate all the frequency parameters
with a “Frequency” variable. Then, between tests (with the test stopped and the
test procedure unlocked) you could use the Variable Editor to change the
frequency value of all the processes at the same time without opening any of their
individual dialogs.
Using MPT Variables
with the Operator
Information process
By adding an Operator Information process to a test procedure, you can change
variable values while the test is running.
When the test procedure is running and the Operator Information process is
triggered, it displays a run-time window. This window requires the operator to
type the information specified by the test designer.
As the test designer, you can choose the type of information displayed in the runtime window, including predefined variables. You can choose which variables the
operator can change in the window.
You can control when the operator has the ability to change variables by
strategically placing Operator Information processes in the test procedure, or by
nesting them in a repeating Group process.
Using MPT Variables
with the MPT Calculation
process
68
Operation Concepts
You can add mathematical operators to variables to create calculated variables.
You can do this in two ways, depending on test design considerations:
•
By using the Variables Editor to add calculations to individual parameters in
process windows
•
By adding the MPT Variables process to the test procedure in the MPT
Procedure Editor
MPT Process Types
MPT Process Types
Command Processes
ICON
PROCESS NAME
DESCRIPTION
Segment Command
Produces a monotonic command signal.
Cyclic Command
Produces a cyclic command signal.
Dwell Command
Produces a dwell (or hold) command signal.
Profile
Produces a command signal based on the contents of a “profile”
created with a text editor or the Profile Editor application.
External Command
Enables a command signal from an external program source.
Sine Sweep
Produces a cyclic command signal that sweeps from one
frequency to another.
Signal Based Command
Allows you to generate command based on signal values
specified in a predefined lookup table. The lookup table is
contained in a tab-delimited text file which defines the
relationship between command and signal values.
Profile with ALC (Optional)
Produces an ALC compensated command signal based on the
contents of a “profile” created with a text editor or the Profile
Editor application.
Cyclic with ALC (Optional)
Produces an ALC compensated cyclic command signal.
Time History Output
(Optional)
Produces a command signal based on an MTS RPC II or RPC III
time history file. This process can also perform time history data
acquisition synchronized with the command.
Road Surface Output
(Optional)
Produces a command signal that controls multiple station
channels with an MTS RPC II, RPC III, or RPC Pro Road
Surface file.
Operation Concepts
69
MPT Process Types
Data Acquisition Processes
ICON
70
PROCESS NAME
DESCRIPTION
Peak/Valley Acquisition
Records the peak/valley data for each cycle execution.
Timed Acquisition
Records data at user-specified time intervals.
Max/Min Acquisition
Records data at the highest peak and lowest valley during the life
of the process.
Level Crossing Acquisition
Records data each time the selected signal changes by a
specified amount.
High Speed Timed
Acquisition
Records bursts of data at a high rate.
Cyclic Acquisition
Monitors sensor feedback that results from cyclic command.
This process acquires data from feedback according to equal
changes in time, equal changes in amplitude, changes in time and
amplitude, or signal reversals.
Fatigue (Optional)
Accumulates cycles in a histogram, then calculates damage
based on the data on that histogram. The damage number is also
sent to the Fatigue Monitoring application.
Time History Input
(Optional)
Acquires and digitizes multiple channels of analog test response
data in the RPC III file format.
Trend (Optional)
Calculates statistical values on time series data. The values are
then stored to disk. It is also sent to the Trend Monitoring
application.
Operation Concepts
MPT Process Types
Event Processes
ICON
PROCESS NAME
DESCRIPTION
Data Limit Detector
Monitors one or more signals for sensor limits you specify.
Digital Input Detector
Detects digital transition states from external devices.
Operator Event
Enables operator interaction during the test. (For example,
Operator events can display buttons the operator must click to
continue the test.).
Peak/Valley Change
Detector
Detects changes in the peak and valley amplitudes of cyclic
waveforms.
Program Event
Triggers other processes based on user-defined changes in the
test state.
Periodic Time Event
Triggers other processes based on user-defined time events.
Failure Detector
Triggers other processes based on user-defined changes in the
response of the physical specimen.
External Command Processes
ICON
PROCESS NAME
DESCRIPTION
Digital Output
Controls digital outputs.
Temperature Control
Programs and/or controls an external temperature controller.
Operation Concepts
71
MPT Process Types
Other Processes
ICON
72
PROCESS NAME
DESCRIPTION
Program Control
Performs user-defined program actions such as Program Hold,
Program Resume, Interlock, and user defined actions.
Group
Defines a process sub-group that can contain one or more other
processes.
MPT Calculation
Adds mathematical functions to variable parameters.
Operator Information
Enables operator data entry (to be written to a data file) during
the test.
Start Application
Triggers another application to start during the test.
Send Mail
Allows you to send email with a predefined message and a
specimen log attachment.
Controller Value
Allows you to set calculation parameters that can replace
existing calculation parameters defined with the Station
Manager application. You may enter fixed calculation parameter
values or assign variables.
Auto Offset
Allows you to zero input signals that are not being used for the
active control mode.
Data Display
Plots data signals on-screen during the test.
Operation Concepts
MPT control panel
The MPT control panel appears in the application area of the Station Manager
application, as shown.
MPT main window is
nested within the
Station Manager
application main
window.
When you select the
MPT application from
the Station Manager
application, the run,
stop, and hold controls
on the Station Controls
panel pertain to running
MPT test procedures.
Operation Concepts
73
Procedure Editor
The MPT Procedure Editor contains a table on which you build MPT test
procedures by selecting, assigning parameters to, and sequencing individual test
processes. Test processes represent individual test activities.
Navigation
pane
Status and progress indicators
A blue arrow pointing toward a process (not
shown) indicates it is executing. This lets you
watch the progress of a test.
Procedure
table
Process parameter
pane
A red “X” next to a process indicates it has been
disabled.
A green arrow pointing downward next to a
process indicates it will start and then issue its
done signal immediately, without performing its
programmed activity (the process is “passed
through”).
74
Operation Concepts
Process Palette
The Process Palette displays the types of processes you can drag to the Procedure
Editor.
Process Palette
Individual processes are arranged
on the palette by type.
You can double-click a process on
the Process Palette to copy an
instance of it to the table on the
Procedure Editor, or you can use
the drag-and-drop method.
Operation Concepts
75
About Running Tests
About Running Tests
Understanding Files Used for Testing
During the testing phase, the Station Manager application controls how the parts
of the system work together to maintain precision servo control. Command is
typically provided by an application such as Basic TestWare or MultiPurpose
TestWare.
PARM
Station Manager
application
Station Config file with Test design application Test design
Parameter set
(for example, BTW or file
MPT)
Test data
file
You start the test from the Station Control panel of the Station Manager application. Test Data files are
generated according to the type of test design application you used to create the test design file.
Test data
file
76
Operation Concepts
Your
Project
The test design file, along with the
generated test data, are automatically
stored in the selected (or default) Project
folder.
Test Desktop
Test Desktop
With the Station Manager application window controls, you can perform the
following to run tests:
•
Load and reload stations
•
Configure limit and error detectors
•
Control hydraulic pressure to the test station
•
Manage the execution of the Basic TestWare and MultiPurpose TestWare
applications
•
Monitor signals on the built-in scopes and meters
Windows typically open while running a test.
The windows shown here all display some element of status while a test is
in progress, and can be displayed on the desktop until the test is complete.
This example shows an MPT test in progress.
Meters display the numeric value of
selected signals.
The Station Manager application main
window displays interlock and limit
status; counters; run, stop, and hold
status; and generated messages.
Operation Concepts
77
The Scope displays the waveforms
of selected signals.
MTS Series 793 Software includes several features for monitoring test signals
and test progress.
MPT Counters
78
Run time counter
The Run Time counter displays the elapsed time of the current test since the last
time it was reset.
Channel counters
Channel Counters display a cumulative count of segments or cycles that have
been applied to a specific channel since the start of the test.
Operation Concepts
Sequence counters
Sequence Counters display the progress of individual processes within the test.
They can be especially useful for procedures that contain nested groups, because
you can configure them to show test progress within the nested structure of the
procedure.
This sample procedure includes a group process
labeled “Cooling Cycles,” which contains four
nested processes (with indented label names,
“Trigger at 75C,” and so forth.)
Name displays the assigned process label
Current displays the current value of the counter
Target displays the assigned number of times
the process should execute (or repeat), or the
number of cycles to be executed.
Input signals
The Station Signals panel displays all of the input signals of the station with their
current values.
Operation Concepts
79
Meters display
The Meters window can display up to 16 meters per station simultaneously. The
following data can be displayed for any defined input signal:
•
Timed data
•
Peak/valley data
•
Mean/amplitude data
•
Maximum/minimum values
Meters can be aligned on the desktop vertically, horizontally, or in a grid. Meter
displays can be sized to your preference.
Scope display
The Scope window in the Station Manager application is an oscilloscope. You
can use it to plot signals against time, frequency, and against each other. You can
create up to four scopes per station, and add up to four signal pairs per scope.
Note
For a description of individual controls and indicators on the Scope, see
the MTS Series 793 Control Software manual (PN 100-147-130).
You can adjust trace time and scaling in the same way you can with an
oscilloscope. You can also select auto-scaling and resetting.
You can use the Program Control feature of the scope to automatically start the
scope when you start the test.
You can also use the scope to plot one channel versus another, and to plot in the
frequency domain rather than the time domain.
Data point display box
80
Operation Concepts
The scope also allows you to pan trace history, and for Series 793 Software
version 4.0 or later, you can also pick and view individual data points.
When you place the cursor on the trace, it becomes a crosshairs. With the
crosshairs, you can select individual data points on the trace and see their precise
coordinates on the axes in the associated display box.
Marker delta display
Marker coordinates
display
New marker with data
point display box
Operation Concepts
81
82
Operation Concepts
Chapter 5
Installed 793 Files
When you install Series 793 Software on your PC (version 4.0 and later), the files
are installed at the following default locations:
•
C:\MTS 793
•
C:\Program Files\MTS 793
The files and folders included in a Series 793 installation fall in one of the
following categories:
•
System information
•
Controller information
•
Project information
•
Program information
About System Information
Folders and files at the root of a Series 793 installation can be thought of as
“system” information.
System information is available to all users and workstations in the system.
Installed 793 Files
83
Individual Projects in the Projects folder can access common information at this
level. For instance, all Projects can access:
•
Calibration data that applies to test system conditioners and sensors in the
Calibration Files folder.
•
Station configurations and supporting files in the Controllers folder.
•
The MultiPurpose TestWare test procedure template (default.000) in the
MPT folder.
•
The Project template in the Project Templates folder.
This architecture facilitates archiving and back-up functions by limiting the
amount of information stored in Projects.
Folders and files in the Controllers folder, such as the Config folder and the
hardware interface file (.hwi), can be thought of as “controller” information.
Controller information pertains to files and settings that apply to the specific
physical controller (or controllers) included with your test system.
This organization separates Project information from files and settings that are
specific to the controller, such as the hardware interface file (.hwi) and controller
settings files.
84
Installed 793 Files
Folders and files within specific Project folders, including the BTW, ImportExport, MPT, Profiles, and Scope Images folder, and the project settings file
(project.793settings), can be thought of as “project” information.
Project information is stored directly in individual Project folders.
References to other
types of information
Individual Project folders also include references to other types of Series 793
information. When viewed from the Project Manager application, referenced
information is displayed in folders with arrow annotations, as shown.
Installed 793 Files
85
Folders and files within the Program Files folder include executables, the unit
definition (.udf) files, user documentation (PDFs), and readme files. This
information is replaced when you install a Series 793 Software upgrade.
86
Installed 793 Files
Chapter 6
Perform a Practice Test
This section includes step-by-step instructions for performing a practice test. The
purpose of this procedure is simply to help you learn how to use your system.
While performing this test you will:
•
Select a Project at the beginning of the test, and review test data stored in the
Project at the end of the test.
•
Set limits and manually position the actuator to install the specimen.
•
Apply hydraulic power to the test system.
•
Adjust force tuning controls.
•
Monitor test signals on the Meters and Scope.
•
Create a test design file with the Basic TestWare application.
•
Start and stop the test.
Before you can perform this test, you need to determine the setup status of your
system.
If MTS has set up
your controller
MTS customers typically receive their Series 793 Controller in the following
state:
•
An initial Project, station configuration file, and parameter set has been
created.
•
The sensors are calibrated and the servovalve is adjusted.
•
The displacement tuning parameters are optimized. (The force tuning
parameters can also be optimized, but typically need to be adjusted for
individual specimens, and often between tests.)
If MTS has performed these activities for your controller, you can run a practice
test.
If MTS has not performed these activities for your controller, you must perform
the following activities before performing the test.
87
If you are going to set
up your controller
If you are installing Series 793 Software on your system and setting up your
controller yourself, you'll need to do the following before performing the practice
test:
•
Install Series 793 Software
•
Set up a Project (typically performed during software installation)
•
Create a station configuration file
•
Calibrate the sensors
•
Perform servovalve adjustments
•
Tune the system
To perform the Series 793 Software installation, see the Installation Instructions
readme file on the Series 793 System Software CD, and follow the installation
wizard.
To perform the remaining tasks, see the MTS Series 793 Tuning and Calibration
manual.
You may also find it necessary to see the following manuals:
88
•
MTS Series 793 Utility Software manual—To setup or edit the hardware
interface file to reflect any hardware changes to your system.
•
MTS Series 793 Control Software manual—To find detailed information
about using Series 793 Software controls.
•
Other MTS manuals—You can receive additional MTS manuals that
provide instructions for maintaining and operating your test system.
Steps to Run a Test
Steps to Run a Test
WARNING
Improper controller setup can result in unexpected actuator movement.
Unexpected actuator movement can injure personnel and damage test
equipment.
Ensure that your controller is set up properly before attempting to perform a test.
1. Power up the controller chassis and PC.
2. Start the Station Manager application and select a Project.
A.
From your desktop, start the Station Manager application:
Start > Programs > MTS 793 Software name (for example, FlexTest
GT) > Station Manager
B.
As the Station Manager application loads, you will be prompted to
select a Project. Select the existing Project that was created for your
system.
3. Apply hydraulic pressure.
When you power up your controller, the hydraulic interlock will be set.
Perform the following on the Station Controls panel:
A.
Clear system interlocks.
Click Reset. If the interlock indicator lights again, determine the cause
of the interlock and correct it before proceeding.
B.
If HPU controls are present, click the
(Low) and then
(High) buttons.
C.
If HSM controls are present, click the
(Low) and then
(High) buttons.
4. Adjust force tuning.
A.
From the toolbar, select an access level of Tuning (or higher). You will
have to enter the password created at installation.
B.
From the Application control bar, select the Function Generator.
89
Steps to Run a Test
C.
D.
Select the following settings in the Function Generator.
CONTROL
SETTING
Channel
Channel 1
Control Mode
Force
Command Type
Cyclic
Target Setpoint
0 kN
Amplitude
10% of full scale
Frequency
1 Hz
Wave Shape
Ramp
Compensator
None
From the Station Manager application toolbar, select the Scope.
WARNING
A crush zone exists between the actuator and any equipment in the path of
its movement.
A crush zone exists between the actuator and any equipment in the path of
its movement. Immediate and unexpected actuator response is possible
when you apply hydraulic pressure to your system.
Stay clear of the actuators when applying hydraulic pressure. Do not place any
part of your body in the path of a moving actuator.
90
Steps to Run a Test
E.
Install a dummy specimen that has a compliance similar to the test
specimen.
•
From the Station Controls panel toolbar, click the Manual Command
icon
.
•
Click to select the Enable Manual Command check box.
•
Select the Displacement control mode.
•
Adjust the Manual Command slider to position the actuator while
installing the specimen.
•
Switch to the Force control mode.
F.
Adjust the P Gain and D Gain tuning controls.
•
Start the Function Generator by clicking the Program Run control
and observe the resulting waveform on the Scope.
•
From the Display menu, select Station Setup.
•
From the tree view, expand Channels, then select Channel 1.
•
Click the Tuning icon
•
Increase the P Gain control until you see a little overshoot and a little
ringing on the Scope.
•
Slowly increase the D Gain control to reduce the overshoot and
ringing. Keep in mind that small adjustments of D can have large
effects on your system.
•
Repeat P Gain and D Gain adjustments until you achieve an optimum
waveform
to display the tuning adjustment controls.
Overshoot
Ringing
91
Steps to Run a Test
The middle waveform is
the optimum waveform. In
some cases the
waveform will have no
overshoot or ringing.
High
Rate (D)
Low
Gain (P)
High
5. Install the test specimen.
A.
Select the Displacement control mode for test specimen installation.
B.
Install the test specimen.
•
Turn on the Manual Command control on the Station Controls panel.
•
Adjust Manual Command to position the actuator as required.
C.
Switch to the force control mode.
6. Set test limits and actions.
From the Station Controls panel, click the Detectors icon.
Set upper and lower limits and associated actions to accommodate your test
as desired.
For instance, you may want to adjust displacement limit detectors to limit
piston rod travel. This stops the test when the specimen is on the threshold
of complete failure.
Also, you may want to adjust force limit detectors to stop the test if the
piston rod applies an excessive amount of force to the specimen. This
minimizes the chance of inadvertent damage to the load cell and specimen.
Finally, you may want to adjust error detectors to stop the test if the error
between command and feedback becomes excessive. This stops the test
when your station can no longer deliver programmed loads.
92
Steps to Run a Test
7. Set up the test monitor.
Set up the Meters and Scope as desired to monitor test signals.
8. Set up a test program.
A.
From the Application control bar, select Basic TestWare.
B.
In the Command tab, set the following:
Note
Ensure that the Target Setpoint and Amplitude values are appropriate for
your particular specimen.
CONTROL
SETTING
Type
Cyclic
Channel
Channel 1
Control Mode
Force
Target Setpoint
Guideline: 25% of full scale
Amplitude
Guideline: 10% of full scale
Frequency
1 Hz
Wave Shape
Sine Tapered
Compensator
None
Start Action
Disabled
Done Action
Disabled
93
Steps to Run a Test
C.
D.
E.
94
In the Data Acquisition tab, set the following:
CONTROL
SETTING
Type
Timed
Signals Included
Channel 1 Output
Time Between
Points
default
Buffer Size
2048
Buffer Type
Linear
In the Data File tab, set the following:
CONTROL
SETTING
Destination File
Test Default
Data Header
Enter “First Test”
Data File Mode
Append
Data File Format
Plain
Close the Test Setup window.
Steps to Run a Test
9. Start the test.
A.
Ensure that the following are true:
•
Interlocks are cleared
•
High hydraulic pressure is applied to the station
•
Load tuning parameters are optimized
•
The test specimen is installed
•
Limits are set and actions are assigned
•
The test program is set up
•
The scope and meters are set up to monitor the test as desired
B.
On the Station Controls panel, press the Program Run button to start
the test. When desired, press the Program Stop button to end the test.
10. Review test data.
A.
Start the Project Manager application and select the current Project.
B.
Click on the BTW folder to view the name of the associated data file.
C.
Click on the data file to review its contents in the view pane.
95
Steps to Run a Test
96
Chapter 7
Documentation
The following describes the manuals that may accompany a 793 Controller
(applies to 793 Software version 5.1 and later).
MTS Series 793 Control
Software manual
Contains user information and software reference for the applications in the
Model 793.00 System Software bundle. This includes the following applications:
•
Project Manager
•
Station Builder
•
Station Manager
•
Basic TestWare
•
Station Desktop Organizer
Together, these applications perform activities centered around maintaining servo
control of the test station. This manual includes information for optional
compensators.
MTS MultiPurpose
TestWare and Series
793 Application
Software manual
(optional)
Contains user information and software reference for Model 793.10
MultiPurpose TestWare and other Series 793 application software which provide
enhanced test design, data monitoring, and analysis capability for MTS Series
793 Controllers. This manual includes information on the following applications:
•
Model 793.11 Profile Editor
•
Model 793.12 Trend Monitor
•
Model 793.13 Data Acquisition Plotting
•
Model 793.14 Fatigue Monitoring
•
Model 793.19 Run Time Ramp
•
Model 793.71 Time History Playout
•
Model 793.72 Time History Data Acquisition
Documentation
97
MTS Series 793 Utility
Software manual
Contains information about the MTS .hwi file Editor and MTS Controller
Management Tool software utilities. The .hwi file Editor manual contains
instructions for creating and editing hardware interface files, which define the
hardware resources available for your test system. The Controller Management
Tool manual contains instructions for servicing MTS FlexTest SE Controllers.
Note
This manual is available only in electronic form in the Portable Document
File format (PDF).
MTS Series 793 Tuning
and Calibration manual
Contains servovalve adjustment, tuning, and calibration procedures for the Series
493 and 497 electronics included in Series 793 Controllers.
MTS Model 493.04 PCPer-Station manual
Contains setup information for the Model 793.04 PC-Per-Station option, which
allows you to use up to four PCs with one controller.
MTS Model 493.05
Remote Station
Controller (RSC) manual
MTS Model 494.05
Handset manual
MTS Series 793 Control
Software Options
manual
Contains user information for the portable RSC, which allows you to perform
station activities away from the PC.
Contains user information for the portable Handset, which allows you to perform
station activities away from the PC.
Contains user information for Model 793.15 Degree of Freedom Control and
Model 793.16 Three Variable Control software options.
MTS Models FlexTest
IIm/GT/SE/ Controller
Hardware manual
Contains installation, cabling, jumpering, and hardware interface information for
MTS 793 Controllers equipped with Series 493/497/497 electronics.
MTS Models FlexTest
40/60/100/200 Controller
Hardware manual
Contains installation, cabling, jumpering, and hardware interface information for
MTS 793 Controllers equipped with Series 494 electronics.
MTS FlexTest SE Users
manual (FlexTest SE
Controllers only)
Contains user information and procedures for performing common tasks with
MTS FlexTest SE Controllers, in both the stand-alone and automated
configurations. It includes descriptions of all front panel controls, displays, and
optional features. It also describes how the FlexTest SE Controller interacts with
MTS 793 control and application software when used in the automated
configuration.
98
Documentation
Note
Note
File format (PDF).
File format (PDF).
Other 793 Documents
Other 793 Documents
Readme Files
All applications included in the Series 793 System Software bundle (and all
optional applications) are supplied with a separate Readme file. Readme files
contain late breaking application features, and known problems and workarounds.
To access Series 793 readme files, select:
Start > Programs > MTS 793 Software name (for example, FlexTest GT) >
Readme Files
Series 793 Installation
Instructions
The MTS Series 793 System Software CD includes an installation wizard. The
opening display of the wizard provides access to a document (PDF format) that
describes how to install Series 793 Software on your PC.
Troubleshooting
Information
Two troubleshooting documents, “Debugging Boot Problems” and
“Troubleshooting Network Problems” are provided to help you install and boot
Series 793 Software in a variety of network environments.
To access troubleshooting files, select:
Start > Programs > MTS 793 Software name (for example, FlexTest GT) >
Service Tools.
Documentation
99
System reference
manual (optional)
If you have purchased a test system, it may include a set of system reference
manuals that pertain to the hardware components in your test system, such as
fixturing, hydraulic power supplies, actuators, and so forth. System reference
manuals are bound in grey three ring binders, and are organized with tabbed
dividers. Each tabbed section may contain product manuals, system level
drawings (such as wiring diagrams and schematics), or parts lists.
Operation and
maintenance manuals
Some test systems include an operation guide that describes how to use your
controller to perform tests on specific types of test fixtures. Test systems may
also include maintenance and hardware setup information.
100
Safety manual
The Safety manual contains general safety practises for working with
servohydraulic test equipment. You should read and understand the information
in this manual before using your system.
MTS System
Documentation CD
Your test system may also include an MTS System Documentation CD. This CD
contains an electronic copy of all MTS manuals that pertain to your test system,
including controller manuals, hydraulic and mechanical component manuals,
assembly drawings and parts lists, and operation and preventive maintenance
manuals.
Documentation
Index
Symbols
C
.hwi file 49
.hwi files created by MTS 49
calculated analog inputs 52
calculated analog outputs 52
CAN Bus support 41
channel counters 78
closed loop control 19
compensation
Adaptive Inverse Control (AIC)
about 61
control diagram 19
Control Panel 73
control panel 74, 75
controller hardware options 32
controller information 84
Controller Management Tool 36
Controller Value 72
create a station configuration 43
create a test program 44
creating a parameter set 54
creating parameter sets 54
creating sensor files 55
Cyclic Acquisition process 70
Cyclic Command process 69
Cyclic with ALC process 69
Numerics
497.01 Analog Chassis 29, 31
497.05 Hydraulic Control Panel 31
498.22 Test Processor Chassis 31
A
about program information 86
About Running Tests 76
About Test Designs 64
Actuator Position Control 33
Adaptive Inverse Control 60
Adaptive Inverse Control (AIC)
about 61
adjust
conditioner value 55
adjusting dither 55
AIC 60
ALC 61
Amplitude and Phase Control 60
APC 60
Application Controls panel
MultiPurpose TestWare 73, 74, 75
applications included with System Software 49
Arbitrary Level Control 61
Auto Offset 72
automated FlexTest SE Controllers 26
auxiliary analog-to-digital (A/D) inputs 24
auxiliary inputs 52
B
balancing the servovalve 55
Basic TestWare 36
D
Data Display process 72
Data Limit Detector process 71
data point display box 80
default projects 48
defining parameters 66
defining Process Parameters 67
Definition 55
definition of hwi files 36, 49
demo
mode 55
designing tests with MultiPurpose TestWare 69
detectors
specimen installation 55
Digital Input Detector process 71
digital inputs 52
Digital Output process 71
digital outputs 52
Digital Universal Conditioners 23
disabled icon 74
Index
101
dither
adjusting 55
Dither amplitude 55
DOF 40
DUCs 23
Dwell Command process 69
input signals 79
installation instructions 99
E
learn about your controller here 17
Level Crossing Acquisition process 70
Editing hwi files with the Hwi File Editor 50
execution icon 30
External Command process 69
M
F
Failure Detector process 71
Fatigue process 70
files referenced in Projects 46
FlexTest GT Controller 22
FlexTest II CTC Controller 30
FlexTest IIm Console 31
FlexTest IIm Controller 30
FlexTest SE 2-Channel 25
FlexTest SE Basic 25
FlexTest SE Controller 25
FlexTest SE Controller backpanel 29
FlexTest SE Users manual 98
G
Graphic 55
Group process 72
H
Hardware Interface File 49
hardware interface file syntax 49
High Speed Timed Acquisition process 70
I
initial .hwi file 49
initial .hwi files created by MTS 49
Initial Project 47
initial station configuration 51
102
Index
L
manuals 97
marker coordinates display 81
Max/Min Acquisition process 70
Meters display 80
Model 494.21 Multi-Range DUC with Acceleration
Compensation 24
Model 494.25 Digital Universal Conditioners 23
Model 494.26 Dual DUC 24
Model 793.00 System Software bundle 37
Model 793.02 Calculations 37
Model 793.03 Calculations with Outputs 37
Model 793.04 PC-Per-Station Kit 38, 98
Model 793.05/.06/.07 /.08 Compensators 38
Model 793.10 MultiPurpose TestWare (MPT) 39
Model 793.100 Hybrid Simulation (Internal Model) 41
Model 793.101 Hybrid Simulation (External Model) 41
Model 793.11 Profile Editor 39
Model 793.12 Trend Monitoring 39
Model 793.14 Fatigue Monitoring 40
Model 793.15 Degree of Freedom Control 40
Model 793.16 Three Variable Control 40
Model 793.20 High-Cycle, Low-Cycle, and Advanced Low
Cycle Fatigue 42
Model 793.21 Cascade Control 40
Model 793.23 MPT Variables 40
Model 793.25 CAN Bus support 41
Model 793.26 Signal Based Command 41
Model 793.31 Dynamic Characterization 42
Model 793.33 Static Deflection 42
Model 793.40 Fatigue Crack Growth 42
Model 793.71 Time History Playout 41
Model 793.72 Time History Playout with Acquisition 41
MPT control panel 73
MPT Counters 78
MPT main window 73
MPT test procedures 67
MTS Models FlexTest 40/60/100/200 Controller Hardware
manual 98
MTS Models FlexTest IIm/GT/SE Controller Hardware
manual 98
MTS System Documentation CD 100
MultiPurpose TestWare
Station Manager, starting in 73, 74, 75
MultiPurpose TestWare application software manual 97
MultiPurpose TestWare Windows 76
run time counter 78
N
S
Null Pacing 59
Safety manual 100
saving station views 56
Scope display 80
Segment Command process 69
selecting Parameter sets 54
Send Mail 72
sensor calibration files 55
adjust conditioner value 55
externally-conditioned sensors 55
sequence counters 79
sequencing test activities 66
Series 793 Control Software manual 97
Series 793 Installation Instructions 99
servovalve balance
definition 55
Set Controller Value process 40
set up a project 43
setting detectors 55
shunt calibration 56
shutdown data 57
Shutdown Recorder 57
Shutdown Recorder directory 47
Signal Based Command 69
Sine Sweep process 69
Software Options 42
Start Application process 72
Station Builder 36
Station Builder application and hwi files 49
Station Builder main window 53
Station Config file 51
Station Desktop Organizer 36
Station Manager 36
Station Manager main window 58
Station Manager windows 58
Station Views
about 56
saving and restoring 56
Status and progress indicator 74
Status and progress indicators 74
Supplemental interface 27
system information 83
system reference manual 100
System Software and hwi files 49
O
Operation and maintenance manuals 100
Operation Concepts 43
Operator Event process 71
Operator Information process 72
Optimizing Station Configurations 54
P
pass-through indicator 74
PC-Per-Station 98
Peak Valley Phase Control 60
Peak/Valley Acquisition process 70
Peak/Valley Change Detector process 71
Peak/Valley Compensation 60
Periodic Time Event process 71
practice test procedure 17
Procedure Editor 74
Process Palette 75
Profile process 69
Profile with ALC process 69
Program Control process 72
Program Event process 71
program information 86
programmable display 33
project folders 46
project information 85
Project Manager 35
PVC 60
PVP 60
R
Readme Files 99
readouts 52
recovery information 57
Remote Setpoint Adjust 32
Remote Station Controller 32
Road Surface Output process 69
RSA 32
run a Test 44
T
TEDS sensor 34
Temperature Control process 71
test files 65
TestStar IIs Controller description 35
Index
103
text description of an hwi resource 36, 49
THD 41
THP 41
Time History Input process 70
Time History Output process 69
Timed Acquisition process 70
Trend process 70
troubleshooting information 99
Tuning and Calibration manual 98
tuning control modes 55
TVC 40
types of information in MPT test procedures 67
Types of MTS 793 Controllers 20
typical FlexTest IIm configuration 30
U
understanding Projects 46
Understanding Station Configurations 51
understanding test design files 64
Utility Software manual 98
V
valve balance 55
Variables 67
Verifying calibration adjustments 56
W
windows typically open while running a test 77
working with processes 67
104
Index
m
MTS Systems Corporation
14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: 800-328-2255
(within the U.S. or Canada)
Phone: 952-937-4000
(outside the U.S. or Canada)
Fax: 952-937-4515
E-mail: [email protected]
Internet: www.mts.com
ISO 9001 Certified QMS

MTS Series 793 Controller Overview

Transcription

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