MTS Landmark Test System Operation Using MTS FlexTest Controller Software and MTS TestSuite Testing Software 100-275-889 B be certain.
© 2014 MTS Systems Corporation. All rights reserved. Original Instructions (English): 100-275-889 Trademark Information MTS, be certain., Bionix, ElastomerExpress, FlatTrac, FlexTest, Just In Case, LevelPlus, MTS Criterion, MTS EM Extend, MTS Insight, MTS Landmark, RPC, ServoSensor, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States.
Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................7 Before You Contact MTS.................................................................................................................7 If You Contact MTS by Phone..........................................................................................................9 Problem Submittal Form in MTS Manuals.............
Table of Contents Optimizing System Response Before Testing................................................................................55 Understanding and Resolving Error Conditions.............................................................................55 Running the Example HCF Test About This Chapter........................................................................................................................58 Test Procedure Overview....................................................
Table of Contents If Appropriate, Remove the Intact Specimen......................................................................98 If Appropriate, Remove the Broken Specimen..................................................................101 Recover from a Tripped Limit.......................................................................................................102 If Necessary, Recover from a Tripped Force Limit............................................................
Table of Contents 6
Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information. Technical support methods MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact Technical Support in one of the following ways.
Technical Support When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order paperwork. Example system number: US1.
Technical Support — Messaging applications If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your: • Site number • Email address • Name • Company name • Company address • Phone number where you can be reached If your issue has a case number, please provide that number. A new issue will be assigned a unique case number.
Technical Support • Record the name of the person who helped you. • Write down any specific instructions. After you call MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you have questions about the status of your problem or have additional information to report, please contact Technical Support again and provide your original case number.
Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.
Preface Warning: Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage. Caution: Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury or equipment damage, or could endanger test integrity.
Preface Electronic manual conventions This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.
Safety Topics: • • • • General Safety Practices...................................................................................................................16 Safety Practices Before Operating the System.................................................................................16 Safety Practices While Operating the System ..................................................................................21 Load Unit Hazard Labels..................................................................
Safety General Safety Practices If you have system related responsibilities (that is, if you are an operator, service engineer, or maintenance person), you should study this manual carefully before you attempt to perform any test system procedure. You should receive training on this system or a similar system to ensure a thorough knowledge of your equipment and the safety issues that are associated with its use.
Safety Read all manuals Study the contents of this manual and the other manuals provided with your system before attempting to perform any system function for the first time. Procedures that seem relatively simple or intuitively obvious can require a complete understanding of system operation to avoid unsafe or dangerous situations. Locate lockout/tagout points Know where the lockout/tagout point is for each of the supply energies associated with your system.
Safety Know electrical hazards When the system electrical power is turned on, minimize the potential for electrical shock hazards. Wear clothing and use tools that are properly insulated for electrical work. Avoid contact with exposed wiring or switch contacts. Whenever possible, turn off electrical power when you work on or in proximity to any electrical system component. Observe the same precautions as those given for any other high-voltage machinery.
Safety • Wear appropriate safety devices to protect your hearing. Escaping air or gas can create a noise level that can damage your hearing. • Ensure that all pressurized air or gas is bled out of a pneumatic or gas-charged device before you start to disassemble it. A thorough understanding of the assembly and its pressurized areas is necessary before you undertake any maintenance. Refer to the appropriate product information for the correct bleeding procedure.
Safety (see the System Documentation CD). Particles present in the hydraulic fluid can cause erratic or poor system response. Protect accumulators from moving objects For systems equipped with accumulators, protect accumulators with supports or guards. Do not strike accumulators with moving objects. This could cause the accumulator(s) to separate from the manifold resulting in equipment damage and personal injury.
Safety Safety Practices While Operating the System Wear appropriate personal protection Wear eye protection when you work with high-pressure hydraulic fluid, high-pressure air pressure, breakable specimens, or when anything characteristic to the specimen could break apart. Wear ear protection when you work near electric motors, pumps, or other devices that generate high noise levels. This system may create sound pressure levels that exceed 70 dbA during operation.
Safety Do not disturb sensors Do not bump, wiggle, adjust, disconnect, or otherwise disturb a sensor (such as an accelerometer or extensometer) or its connecting cable when hydraulic pressure is applied. Ensure secure cables Ensure that all cable connections (electrical supply, control, feedback, sensor, communications, and so forth) are either locking type, or are secured, to ensure that they cannot be disconnected by a simple act.
Safety Load Unit Hazard Labels Two sets of labels are used for the load frames: one set for North America and one set for rest of the world.
Safety Hazard Labels Rest of World (part number 100-164-565) Icon Description Failure to follow operating instructions can cause death or serious injury. Read and understand the operator’s manual before using this machine. Moving parts can crush and cut. Keep hands clear while operating machine. Pushing or striking load frame may cause it to tip over. Read the operator’s manual for moving instructions. Flying debris and loud noise hazard. Wear ear and eye protection.
Safety Icon Description Hydraulic pressure beyond rated working pressure can rupture components, cause severe personal injury, and damage equipment. Do not exceed 21 MPa (3000 psi) rated working pressure. Hazard Label for HSM Needle Valve Adjustment Icon Description The HSM needle valve is factory adjusted and should not be adjusted in the field except by MTS Field Service Engineers.
System Introduction Topics: • • • • • • About This Manual.............................................................................................................................28 About Other MTS Documentation.....................................................................................................28 System Overview...............................................................................................................................29 Load Frame Overview.............................
System Introduction About This Manual This manual is for operators of MTS Landmark Systems.
System Introduction System Overview Station Components Item Name Description 1 MTS FlexTest (Series 793) controller software - Station Manager application MTS FlexTest software enables you to control the load frame via the controller from the user interface PC. This manual focuses on the use of the MTS FlexTest Station Manager Application that is used for station setup.
System Introduction Load Frame Overview Introduction The load unit consists of the load frame plus additional parts, such as hydraulic crosshead lifts and control modules. Load units come in different sizes and configurations. The following illustration shows a typical load unit with common accessories. Component Identification Load Frame Front and Rear View Item Component Description 1 Crosshead Moves up and down the columns to accommodate specimens of different lengths.
System Introduction Item Component Description 4 Load Frame Control Module Contains the crosshead lift controls as well as the Emergency Stop switch. 5 Grip Control Module Contains hydraulic pressure gages as well as controls to clamp and unclamp hydraulic grips. 6 Hydraulic Crosshead Locks Clamps the crosshead to the columns. (Optional) 7 Force Sensor (Load Cell) Sends a signal proportional to the forces being applied to it back to the interface PC via the controller.
System Introduction Series 370 Load Unit Controls Item Control Description 1 Upper hydraulic grip controls Item 1 controls clamping and unclamping the optional upper hydraulic grip. Item 1A adjusts the upper grip clamping rate. Item 1B is the upper grip pressure gage. 2 Lower hydraulic grip controls Item 2 controls clamping and unclamping the optional lower hydraulic grip. Item 2A adjusts the lower grip clamping rate. Item 2B is the lower grip pressure gage.
System Introduction Item Control Description 7 Actuator velocity limiting switch Controls actuator velocity. There are two positions: • • One for reduced fluid flow to the actuator resulting in slow speed of the actuator rod for specimen installation. One for full fluid flow resulting in normal, high-speed testing operation.
System Introduction Opening a Station Using the Open Station window, you can select a configuration and a parameter set. You can also select an interlock chain, although it is common practice to select Interlock 1. Using the Main Window to Open Other Windows While the main window provides access to nearly all of the Station Manager application's functionality, the Example HCF Test and most other tests require only limited interaction with the main screen.
System Introduction Setting Limits Setting limits helps prevent specimen damage and injury. You can set limits using the Limits tab of the Station Setup window. Setting Up Meters Meters allow you to monitor displacement and forces. Using the following windows, you can set up multiple meters and arrange them to your liking. Meter types include Timed, Running Max/Min, and Peak/Valley.
System Introduction Applying Power to the Station The interlock and power sections of the main window are located together for convenience. There, you can reset or override interlock conditions as well as power up the hydraulic pump unit (HPU) and hydraulic service manifold (HSM). Moving the Actuator During setup, you must move the actuator so that you can clamp the specimen in the grip. The Manual Command window allows you to move the actuator directly, or in fine or super fine increments.
System Introduction Setting Up a Scope The scope provides a graphical display of the channels of your choosing. During station setup, the scope is often used to compare the input signal to the feedback signal. This activity is essential to setting tuning parameters and helps ensure good system response. Using the Function Generator The function generator allows you to input a signal to the specimen so that you can monitor the feedback. This is necessary when tuning the system.
System Introduction MTS TestSuite Test Software - MTS Multipurpose (MP) Express Application Purpose The MTS Multipurpose (MP) Express application is used to perform the following: • • • • Selecting a Test Setting Test Parameters Running a Test Generating a Report The MP application windows associated with each task are shown below. Selecting a Test Selecting a test is done via the MTS TestSuite MP Express main window.
System Introduction Setting Test Parameters Once the test is selected, MTS TestSuite MP Express provides you an opportunity to set test parameters via the Setup Variables window. Running a Test Running a test involves clearing any interlock conditions, powering up the HPU and HSM if necessary, and pressing the Run button. MTS TestSuite MP Express allows you to monitor the test using the tabs found in the main window.
System Introduction Generating a Report When the test is complete, you can generate an Excel report based on one of the Excel templates stored with the test.
System Introduction MTS Landmark Test System Operation | 41
Key Concepts Topics: • • • • • • • • • • • • About This Chapter............................................................................................................................44 Understanding Your MTS Software...................................................................................................44 Understanding MTS File Types.........................................................................................................46 Understanding the Control Loop......................
Key Concepts About This Chapter This chapter, as well as the information in the Safety chapter, contains information you should know before you attempt to run tests with your MTS Landmark System. This information applies to the typical system used as an example in this manual. For information that applies to other tests or system configurations, see: • The individual component products manuals included in the System Documentation found under the Start Menu on the user interface PC.
Key Concepts • • • • Applying hydraulic pressure to the station Positioning the actuator to install the specimen Offsetting the weight of fixtures so those values do not appear in test data Adjusting gain to optimize system response MTS TestSuite Test Software and the MTS TW Express application MTS TestSuite software includes several applications. Depending on your installation, MTS TW Elite, MTS TW Express, and so on are accessible from the Start menu or desktop icons.
Key Concepts Switching Between Station Manager and TWX When Running Tests Item Description 1 Station Manager Main Window 2 Task Bar 3 Set Up Tests Using the Station Manager Application 4 TWX Main Window 5 Station Manager Minimized on Task Bar 6 Run Tests Using TWX and the Station Manager Application Understanding MTS File Types File Types When setting up and running tests, you interact with a number of different file types: 46 | MTS Landmark Test System Operation
Key Concepts Station File Types File Type Description MTS FlexTest Project Files A FlexTest project is a collection of files related to the station configuration. When you open a configuration, it opens in the context of its parent project. Files associated with configurations, such as sensor calibration files and parameter sets, are linked to configurations within the project directory. FlexTest projects are not associated with MTS TestSuite projects.
Key Concepts File Type Description Test Template Files Test Template files are command files created with TW Elite for performing tests on Station Configurations. Test Template files contain only test definition information. MTS TestSuite Test Template Icon Test Procedure Files Test Procedures files are similar to Test Template files, but include a container that stores test data and results.
Key Concepts How MTS Files Work Together The basic workflow is as follows: • • • • • • You use the Station Manager application to open a Station Configuration. You select a Parameter Set (which includes specific Sensor Calibration files) for your Station Configuration. You use the Station Manager application to optimize your Station Configuration for the test you desire to run.
Key Concepts Item Description 2 Controlling Element 3 Controlled Element 4 Command The controlling element is the computer, the digital controller, and the MTS Station Manager application. The controlling element produces a control signal (Command) that represents the direction and amount of force the actuator should apply to the specimen. The controlled element comprises the servovalve, the hydraulic actuator, and the specimen itself.
Key Concepts Basic Closed-Loop Control in MTS Landmark Systems 1. You input a compressive command by adjusting the Manual Command slider control in the Station Manager application. 2. The Station Manager application (program source) instructs the digital controller to generate a signal that represents the direction and amount of force the actuator needs to apply to the specimen to accommodate your command. 3. The digital controller generates this command and sends it to the servovalve.
Key Concepts Understanding Control Channels and Control Modes Control Channel Control channels command actuator movement by providing a valve driver signal to the servovalve. The servovalve causes the actuator to move, which applies forces to the specimen. Control Modes A control channel includes one or more control modes. Control modes determine how the commanded force is applied to the specimen. Control modes typically include force and displacement.
Key Concepts Sensor Limits One type of detector is a limit detector for sensor input signals. Each sensor can have a high and a low limit which you can enable separately. When a sensor exceeds (or trips) its upper or lower limit, the selected detector action occurs. Detector Actions The effect a tripped detector has on the system depends on the action you select.
Key Concepts For load frames with base mounted actuators (as used by the typical system in this manual), the load train consists of all the components between the actuator’s piston rod (the component that moves up and down) and the crosshead. This typically includes the lower grip, the specimen, the upper grip, and the force sensor (load cell), as shown.
Key Concepts needed unless a component in the load train changes dimensions substantially. On the load frame used in the typical system in this manual, you use the hydraulic lift and lock controls on the load frame control panel to position the crosshead. Positioning the Actuator to Install the Specimen You typically position the actuator every time you install a specimen.
Key Concepts Example When you launch the Station Manager application and open a configuration, the configuration opens in an interlocked state by design. To help you identify this error condition, the system lights the Interlock indicator in the main window, and also writes a “Software Interlock” entry into the Message Log, To resolve this condition, you simply press the Reset control in the Station Manager main window.
Running the Example HCF Test Topics: • • • • • • • • About This Chapter............................................................................................................................58 Test Procedure Overview..................................................................................................................58 Prepare for Specimen Installation.....................................................................................................59 Install the Specimen................
Running the Example HCF Test About This Chapter This chapter describes how to set up and run the Example HCF Test using the typical MTS Landmark system shown in the System Overview section. Adapting This Chapter to Your System If your system contains the same components as the typical system described in this manual, you can follow the instructions without modification to run the Example HCF Test. In some cases, your system may vary from the typical system shown.
Running the Example HCF Test c) Adjust Limits for the Test (p. 89) d) Show Station Manager Scope and Meters for the Test (p. 90) e) Minimize Station Manager (p. 91) 4. Run the Test a) Open the MPX Application (p. 92) b) Select the Test (p. 92) c) If Necessary, Correct Any Resource Errors (p. 93) d) Create a New Test Run (p. 93) e) Run the Test (p. 94) f) Review the Results (p. 95) g) Generate a Report (p. 96) h) Save the Test and Minimize MPX (p. 96) 5. Remove the Specimen a) Remove Displacement Limits (p.
Running the Example HCF Test The controller power switch is located on the back of the controller. Open Station Manager 1. Close any open applications on the computer desktop. This prevents possible confusion from having multiple stations open. 2. Select All Programs > MTS 793 Software > Station Manager. This launches communication between the computer and the MTS controller. 3. If necessary, select a project. It is common practice to keep all files in Project1.
Running the Example HCF Test Note: This window may not appear in all cases. 5. Select a configuration and parameter set. Under normal circumstances, you would select a configuration file and parameter set recommended by the experts in your lab. However, for this example HCF test, select the Training config.cfg configuration but do not click OK yet Parameter sets are found in the lower left corner of the Open Station window.
Running the Example HCF Test Turning the HSM off removes power from the actuator so that it cannot move unexpectedly during load frame inspection or specimen installation. Note: It is acceptable to leave the pump (HPU) on as it may be needed for other stations and also leaves power to the hydraulic grips for specimen installation. 7. Identify the current configuration and parameter set. The configuration and parameter set currently in use is shown in the title bar of the Station Manager application.
Running the Example HCF Test a) Select Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Displacement. b) Confirm that the sensor serial number found under the Sensor tab in your software matches the LVDT serial number found on your load frame (the tag is typically located on the back). This ensures that your configuration file matches your hardware and that you are able to collect valid data. 2.
Running the Example HCF Test To delete a meter, click the meter title bar, and then click the Delete button in the setup menu. 3. Set up a Running Max/Min Displacement Meter. Use the following parameters: • • • • Meter Type — Running Max/Min Channel — Ch1 (or other depending on your configuration) Signal — Displacement Engineering Units — mm A running max/min meter provides the history of sensor extremes that the meter has read since it was last reset. 4. Set up a Running Max/Min Force Meter.
Running the Example HCF Test Use the following parameters: • • • • Meter Type — Timed Channel — Ch1 (or other depending on your configuration) Signal — Displacement Engineering Units — mm A timed meter provides the current reading of the sensor. 6. Set up a Timed Force Meter. Use the following parameters: • • • • Meter Type — Timed Channel — Ch1 (or other depending on your configuration) Signal — Force Engineering Units — kN 7. Align the meters.
Running the Example HCF Test Set Limits for Specimen Installation You can reduce the chances of specimen damage or injury by setting limits that control the amount of force read at the sensor. However, even with limits set, do not rely solely on the force sensor to protect you from injury. 1. Set the displacement limits to a wide range that will not interfere with specimen installation. This is acceptable because this example tension test uses no fixturing that requires protection.
Running the Example HCF Test Note: For this test, MTS has determined that a setting of +5 kN will prevent damage to the system and the specimen. Item Description 1 Type here and press Enter Note: You must press Enter after typing numerical entries for them to be accepted. a) Select Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force > Limits, click the Channel Input Signals button, and then click the Limits tab.
Running the Example HCF Test For specimen installation, select a low compression limit to reduce the chance of specimen damage or injury. While -0.05 kN is shown here as an example, you should use a limit that adheres to your lab's specimen installation guidelines. a) Enter -.050 kN in the Lower Limit text box (a negative number indicates compression). Be sure to press Enter after typing in the limit. b) Once again, select Interlock for the Lower Action. Zero the Force Signal 1. Select Exclusive Control.
Running the Example HCF Test Upon initial setup, the force signal meter displays the weight of the grip and associated hardware. a) Open the Inputs: Axial Force window by selecting Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force and clicking the Channel Input Signals button. b) Select the Offset/Zero tab and then click the Auto Offset button to zero the force meter.
Running the Example HCF Test a) Do this by changing the drop-down selection box to Tuning in the Station Manager application main window. b) Enter the password Tuning (case sensitive) when prompted. 2. Set Displacement tuning parameters. a) Open the Tuning: Ch1 Displacement window by selecting Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Displacement, clicking the Tuning Fork icon, and selecting the Adjustments tab.
Running the Example HCF Test a) Similarly, open the Tuning: Ch1 Force tab by selecting Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force. b) Use the following parameters for this hard specimen test: • • • • • • • P Gain — 1 I Gain — 1 D Gain — 0 F Gain — 0 F2 Gain — 0 Proportional FF Gain — 0 FL Filter — Set to maximum positive value 4. Retain the Tuning user access level.
Running the Example HCF Test f) g) h) i) Move the Specimen into the Upper Grip Using Displacement Control (p. 77) Switch to Force Control (p. 77) Clamp the Specimen in the Upper Grip (p. 78) Check and Reset Meter History (p. 78) Power up the Pump and HPU 1. Correct any interlock conditions. If a limit has been exceeded, see Recover from a Tripped Displacement Limit or Recover from a Tripped Force Limit . 2. Power up the HPU (hydraulic pump unit) and HSM (hydraulic service manifold).
Running the Example HCF Test Note: All interlock conditions will not reset until the pump is on. Position the Actuator Using Displacement Control In this step you will position the actuator for the start of the test. Warning: Do not move the control slider until the crush zone is clear, and you can monitor actuator movement. Unskilled movement of the actuator can result in machine damage or personal injury.
Running the Example HCF Test Manual Command Slider Function Item Description Explanation 1 Drag slider for "high gear" "High gear." Slider movement is proportional with actuator movement. Use with extreme caution. 2 Click between ticks for "low gear" "Low gear." Incremental movement based on settings for the slider control. Multiple incremental movements can be made by holding down the mouse button. 3 Click arrow for "super low gear" "Super low gear.
Running the Example HCF Test a) Select Station Manager > Display > Station Setup > Channels > Displacement> Offset/Zero. b) Click the Auto Offset button to zero displacement. Clamp the Specimen in the Lower Grip 1. Clamp the specimen in the lower grip. Using a tool to hold the specimen, clamp the specimen in the lower grip using the controls on the MTS Landmark load frame.
Running the Example HCF Test a) Now that your hands are no longer required to be near the specimen, increase the force lower limit to a value that will allow clamping of the specimen in the upper grip. b) Select Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force, click the Channel Input Signals button, and then select the Limits tab. c) Enter -1 kN in the Lower Limit text box and ensure that Interlock is selected for the Action.
Running the Example HCF Test a) Unlock the crosshead clamps, and then move the crosshead up or down so that there is about 25 mm (1 inch) clearance between the upper grip and the specimen. b) Once properly positioned, reclamp with the crosshead lock control. Move the Specimen into the Upper Grip Using Displacement Control Displacement control is used to move the specimen into the upper grip.
Running the Example HCF Test c) Set Manual Cmd to 0.00 kN. Clamp the Specimen in the Upper Grip Using the limits that you set earlier and having the load frame in force control during clamping help ensure that excessive force is not imparted on the specimen during clamping. Nevertheless, there may be times when you have to recover from a tripped limit that occurs during the clamping process. Instructions for that situation are provided below. 1. Clamp the specimen in the upper grip.
Running the Example HCF Test Now that specimen installation is complete, reset meter history by navigating to Station Manager > Display > Meters and clicking the Reset button. Prepare to Run the Test Preparing to run the test consists of the following steps: a) Perform Basic Performance Tuning (p. 79) b) Switch to Peak Valley Meters (p. 88) c) Adjust Limits for the Test (p. 89) d) Show Station Manager Scope and Meters for the Test (p. 90) e) Minimize Station Manager (p.
Running the Example HCF Test a) To open the Tuning: Ch1 Force window, select Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force and then click the Tuning Fork icon. b) Review the following parameters for this hard specimen test. The following is a good place to start for a HCF test with a hard specimen. • • • • • • • P Gain — 1 I Gain — 1 D Gain — 0 F Gain — 0 F2 Gain — 0 Proportional FF Gain — 0 FL Filter — Set to maximum positive value. 3.
Running the Example HCF Test This introduces a force waveform to the specimen. a) In the Station Manager main window, click the Function Generator button. b) Set up a force wave form using the following parameters: • • • • • • • • Channel — Ch1 (or other depending on your configuration) Control Mode — Force Command Type — Cyclic Target Setpoint — +2 kN Amplitude — 1 kN Frequency — 1 Hz Wave Shape — Ramp Compensator — None 5. Open a Station Manager Scope.
Running the Example HCF Test Set up a Scope to compare the command signal to the resulting feedback. In the Station Manager main window, click the Signal Scope button. Enlarge the scope if necessary, and then set up the scope as follows: Y1 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Command Unit — kN Units/div — 0.5 Offset — 2 Y2 parameters: • • • • • Channel — Ch1 (or other depending on your configuration) Signal — Force Unit — kN Units/div — 0.
Running the Example HCF Test Click the Program Run button to apply the force waveform to the specimen. If necessary, clear any interlock conditions. 8. Adjust P Gain.
Running the Example HCF Test Correct P Gain Excessive P Gain a) Open the Tuning: Ch1 Force window found by selecting Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force, clicking the Tuning Fork icon, and selecting the Adjustments tab. b) Compare your Scope display to the preceding examples of P gain found in the following displays. If necessary, adjust the P gain for the Force channel.
Running the Example HCF Test Note: The scope display shows how well the feedback signal is following the command signal. You should strive for a good match to the "Correct P Gain" example, realizing that perfect adjustment is not possible. 9. Switch to the sine wave. a) In the Station Manager main window, click the Function Generator button. b) Stop the Function Generator by clicking the Stop button, and then change the wave shape from ramp to Sine. c) Click the Program Run button to run the sine wave.
Running the Example HCF Test Important: Do not adjust P gain when you switch to the sine wave form, as instability could result. 10. Adjust I Gain.
Running the Example HCF Test Excessive I Gain a) Navigate to the Tuning: Axial Force window found by selecting Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force, clicking the Tuning Fork Icon, and selecting the Adjustments tab. b) Compare your graph to the examples of I gain found in the following displays. If necessary, adjust the I gain for the Force channel. Note: When adjusting, do not go all the way to zero or you could trip the force limit.
Running the Example HCF Test Click the Program Stop button to turn off the Function Generator. Switch to Peak Valley Meters The Running Max/Min meters served well during specimen installation; however, now that you will be applying a force waveform to the specimen, you need meters that will show you results as they change over time. Peak/Valley meters provide a better indication of how the system is performing over time. 1. Switch Ch1 Displacement to a Peak/Valley Meter.
Running the Example HCF Test a) If you find the values in the Meters window changing at a rate less than the frequency of the Function Generator, double the Sensitivity. b) If you find the values changing at a rate faster than the frequency, halve the Sensitivity. Repeat this process until you are satisfied with the results. 4. Switch Ch1 Force to a Peak/Valley Meter and adjust Sensitivity. Use the same procedure to change the top axial force meter to Peak/Valley meter type.
Running the Example HCF Test a) From the Station Manager main window, select Display > Station Setup, and click the Channel Input Signals button. b) Select the Force channel. c) Select the Limits tab. d) Use the following parameters: • • Ch1 Force (Upper Limit, Upper Action) — 15 kN, Interlock Ch1 Force (Lower Limit, Lower Action — (-1.00) kN, Interlock Show Station Manager Scope and Meters for the Test Show Station Manager Scope and Meters.
Running the Example HCF Test It is common practice to use the Scope and Meters from the Station Manager application to show what is happening on the physical equipment. Ensure that the Scope and Meters you set up earlier are up and running. Minimize Station Manager The Station Manager application must be running underneath the MPX application in order to run tests. Minimizing the Station Manager application clears the desktop while leaving it running for the MPX application. 1.
Running the Example HCF Test Run the Example HCF Test Running the example HCF (high cycle fatigue) test consists of the following steps: a) Open the MPX Application (p. 92) b) Select the Test (p. 92) c) If Necessary, Correct Any Resource Errors (p. 93) d) Create a New Test Run (p. 93) e) Run the Test (p. 94) f) Review the Results (p. 95) g) Generate a Report (p. 96) h) Save the Test and Minimize MPX (p. 96) Open the MPX Application Open the MTS Multipurpose (MP) Express application.
Running the Example HCF Test From the TestSuite main window, select Tests > Example HCF Force Test to load the test. If Necessary, Correct Any Resource Errors Ensure that MTS FlexTest (Series 793) and MTS TestSuite resource names match. a) From the MTS TestSuite main window, open the Resources tab by selecting Example HCF Force Test > Resources. b) If the MTS FlexTest resource names do not match, red error symbols will denote the validation errors.
Running the Example HCF Test a) From the MTS TestSuite main window, click the New Test Run icon. The Setup Variables window appears. b) Use the parameters shown, and then click OK to continue. 2. Review the status information. Review the status information that appears. If necessary, use the Edit Parameters button to make corrections. Otherwise, click Run Test to continue. Run the Test Run the test.
Running the Example HCF Test a) From the MTS TestSuite controller panel, reset the interlock if necessary. b) Power up the HPU and HSM by clicking the Power Low and Power High buttons in sequence. Use the button in the lower right corner of the Power Panel to access the HPU power buttons. c) Click the Run button. The test will start. Run the test a total of five times to complete 1000 cycles. Review the Results Review the test results.
Running the Example HCF Test Generate a Report Generate a report. a) In the MTS TestSuite main window Explorer panel under Test Runs, select the test run for which you want to run a report. b) Right click and select Generate Report. c) Select the template you wish to use and click Generate Report. Save the Test and Minimize MPX The Station Manager application is used to remove the specimen, so the test can be saved and the MPX application minimized. 1. Save the test.
Running the Example HCF Test Remove the Specimen Removing the specimen consists of the following steps: a) Remove Displacement Limits (p. 97) b) Switch to Running Max/Min Displacement and Force Meters (p. 97) c) If Appropriate, Remove the Intact Specimen (p. 98) d) If Appropriate, Remove the Broken Specimen (p. 101) Remove Displacement Limits Remove displacement limits. Because the actuator may retract at the conclusion of the test, begin by removing the displacement limits.
Running the Example HCF Test Because you are no longer imparting a waveform on the specimen, change the displacement Peak/Valley meters to Running Max/Min Meters to monitor history during specimen removal. a) From the Station Manager application main window, click the Meters button. b) Click in the title bar of each Peak/Valley meter and change Meter Type to Running Max/Min. 2. Switch to a Running Max/Min Force meter.
Running the Example HCF Test a) From the Station Manager application main window, click the Manual Command button to bring up manual controls. b) Select the following parameters: • • • Channel — Ch1 (or other depending on your configuration) Control Mode — Force Enable Manual Command — Checked c) Type 0.00 in the Manual Cmd text box and press Enter. 3. Switch to Displacement control mode. This prevents unwanted movement of the actuator.
Running the Example HCF Test a) From the Station Manager application main window, click the Manual Command button to bring up manual controls. b) Select the following parameters: Channel: Ch1, Control Mode: Displacement, Enable Manual Command: Checked. c) Using the slider control, slowly retract the actuator until you have enough clearance to remove the specimen. 6. Turn off the HSM. This is a safety precaution to take before nearing the crush zone.
Running the Example HCF Test If Appropriate, Remove the Broken Specimen Use this procedure only if the specimen is broken at the conclusion of the test run. If the specimen is still intact, see If Appropriate, Remove the Intact Specimen (p. 98). 1. Select Exclusive Control. 2. If necessary, retract the actuator. Note: The actuator may retract on its own when the HSM turns off due to the interlock condition caused by exceeding the displacement limit.
Running the Example HCF Test Using a tool that keeps your hands clear of the actuator, grasp the specimen half in the upper grip and release the grip. Repeat the procedure for the lower grip. That completes the Example HCF Force Test. Recover from a Tripped Limit Recovering from a tripped limit may consist of one of the following steps: a) If Necessary, Recover from a Tripped Force Limit (p. 102) b) If Necessary, Recover from a Tripped Displacement Limit (p.
Running the Example HCF Test a) Disable the force lower limit so that you are able to reposition the grip and reset the interlock. b) Select Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force. c) Click the Channel Input Signals button to display the Inputs: Axial Force window. d) Set Lower Limit: Lower Action to Disabled. 3. Reset the Interlock. In the Station Manager application main window, click the Reset button to clear the interlock. 4.
Running the Example HCF Test In the Station Manager application main window, click the Manual Control button. In the Manual Controls window, reset Manual Cmd to 0. 6. Reset the meters. Reset meter history by selecting Station Manager > Display > Meters and clicking the Reset button. 7. Reset the Lower (Compression) Limit. a) Navigate to Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force > Limits. b) Enter -0.
Running the Example HCF Test Using the controls on the load frame, release the upper grip. 9. If necessary, repeat the upper grip clamping process. If Necessary, Recover from a Tripped Displacement Limit There are a number of possible causes for a tripped displacement limit. For example: • • • The actuator may have retracted below the lower displacement limit during specimen installation. The actuator may have retracted when the specimen broke at the conclusion of the test.
Running the Example HCF Test 2. Set Manual Command to Displacement. a) b) c) d) In the Station Manager application main window, click the Manual Control button. Ensure that Exclusive Control is checked. In the Manual Controls window, select a Control Mode of Displacement. Ensure that Enable Manual Command is checked. 3. Reset/Override the Interlock.
Running the Example HCF Test In the Station Manager application main window, click the Manual Control button. Move the actuator to within acceptable limits while the interlock is overridden.
Maintenance Topics: • • • Routine Maintenance Overview Checklist.......................................................................................110 Maintenance Intervals.....................................................................................................................113 Daily Inspections.............................................................................................................................
Maintenance Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 40 80 Annually 500 1000 1,500 2,000 Check that Actuator Platen Area is Clean X 1 Monitor Filter Indicators X Check Hoses/Cables/Connectors X Check Crosshead/Lifts/Supports X Check Actuator to be Dry X Check Hydraulic Service Manifold X Check Lift Seal Condition to be Dry
Maintenance Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 40 Annually 80 500 1000 1,500 2,000 Lock Seal Condition is Dry MTS MTS MTS MTS MTS Crosshead Columns are Clean MTS MTS MTS MTS MTS Column Abrasions are Acceptable MTS MTS MTS MTS MTS Crosshead Speed is Appropriate MTS MTS MTS MTS MTS Crosshead Unlock Causes Program Interlock MTS MTS MTS MTS MTS Load frame Support Airbags/Pads MTS MTS MTS MTS MTS Crosshead
Maintenance Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 500 1000 1,500 2,000 MTS MTS MTS MTS Cursory Check of Hydraulic Service Manifold MTS MTS MTS MTS Monitor Filter Indicators MTS MTS MTS MTS Manifold Hose Connections are Tight MTS MTS MTS MTS Accumulator Connections are Dry MTS MTS MTS MTS Accumulator Connections are Tight MTS MTS MTS MTS Accumulator Caps/Guards are Present MTS MTS MTS MTS Oil on the Gas Side of
Maintenance Calendar Time using 8 hour Running Time rate per day Daily Weekly Biweekly Running Time-Hours 8 40 80 Annually 500 1000 1,500 2,000 Overall System Condition is Acceptable to Use MTS MTS MTS MTS Turning Parameters are Appropriate/System Stable MTS MTS MTS MTS E-Stop is Working if Applicable MTS MTS MTS MTS Response to Full Stroke Waveform, Visual and Audible MTS MTS MTS MTS Valve Balance check displacement control MTS MTS MTS MTS Valve Dither Response MTS MTS
Maintenance Load Unit Maintenance Intervals What to Do When to Do It Make daily inspections Before the start of each day’s testing. Clean the load unit columns When the columns become greasy or dirty. Prevent rust Depends on the operating environment; more often in humid environments. Maintain airmount pressures When the load unit sits unevenly. Perform label inspection At least once a month. Adjust the hydraulic locks When the crosshead sticks or moves jerkily on the column.
Maintenance Daily Inspections Before the start of each day’s testing, do a quick inspection of the load unit. Following are typical things that should be checked daily: • Ensure that there are no leaks from lifts or locks. • Check the drip pan and ensure that there are no leaks from the actuator, hydraulic service manifold, servovalve, or accumulators. • Ensure that electrical connections are tight, with no frayed or poorly routed cables.
Decommissioning Topics: • Decommission.................................................................................................................................
Decommissioning Decommission The decommissioning process is performed when the system is going to be moved or taken out of service. Disassembly is required when performing either of these tasks. 1. Remove specimen and fixtures. Large grips should be removed if the load frame is going to be tipped over. 2. Move the actuator piston rod down to its lowest position, fully into the cushion. 3.
Decommissioning Warning: Residual hydraulic pressure can produce a high pressure spray. You could be cut by this spray or hydraulic fluid could be forced into your skin. Do not continue with this procedure unless the system has been isolated from hydraulic pressure for at least 20 minutes. Always be cautious when you loosen any hydraulic connection or remove bolts or screws from any hydraulic component. Always allow fluid pressure to dissipate slowly until completely vented before continuing to loosen.
Index Index 793 software, See MTS FlexTest (Series 793) controller software A accumulators 31 actions detector 53 actuator decommissioning 118 maintaining 111 moving 106 positioning 55 retracting 99, 101 velocity limiting switch 33 application MTS Multipurpose (MP) Express 29, 33 Station Manager 29 Application Log MPX 56 Auto Offset 68, 74 C cables maintaining 112 calibration file 62 channels control 52 closed-loop control 49 command signal 50 computer turning on 59 configuration files 47 identifying 62
Index files (continued) report 48 sensor calibration 47 test procedure 48 FlexTest, See MTS FlexTest (Series 793) controller software force control using 77 force sensor (load cell) calibration interval 114 calibration verification 63 form problem submittal 10 Function Generator running 82 sine wave 85 turning off 87 G grip controls 32 decommissioning 118 lower 54 maintaining 113 pressure adjust 32 releasing 99–101, 104 upper 54 H hazard labels 23 hoses maintaining 112 HPU powering up 72 HSM maintaining 1
Index modes control 52 MTS 793 software, See MTS FlexTest (Series 793) controller software MTS FlexTest (Series 793) controller software configuration files 47 project files 47 sensor calibration files 47 MTS Multipurpose (MP) Express application opening 92 project files 47 typical tasks 38 MTS TestSuite software 29, 44 MTS TW Express application 45 O offset auto 74 overriding interlocks 106 overview testing 58 P P Gain adjusting 83 parameter sets identifying 62 parameters editing Station Manager applicat
Index system (continued) tuning, See tuning System Documentation CD 28 T technical support 7 template reports 96 test parameter editing Station Manager application 93 results 95 running 94 selecting MTS Multipurpose (MP) Express application 93 status information 94 test procedure files 48 testing overview 58 TestSuite, See MTS Multipurpose (MP) Express tripped limit causes 102, 105 overriding 106 recovering from 102, 105 resetting 103 tuning adjusting I Gain 86 124 tuning (continued) adjusting P Gain 83
MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within U.S. or Canada) Phone:952-937-4000 (outside the U.S. or Canada) Fax 952-937-4515 E-mail: info@mts.com Internet: www.mts.
