MTS Landmark Test System Operation Using MTS FlexTest Controller and MTS TW Testing Software 100-276-004 A be certain.
© 2014 MTS Systems Corporation. All rights reserved. Original Instructions (English): 100-276-004 A MTS TestSuite TW 2.3 or later with 793 Controller Software 5.8 or later Trademark Information MTS, be certain., Bionix, ElastomerExpress, FlatTrac, FlexTest, Just In Case, LevelPlus, MTS Criterion, MTS EM Extend, MTS Insight, MTS Landmark, RPC, ServoSensor, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States.
Table of Contents Table of Contents Technical Support How to Get Technical Support.........................................................................................................7 Before You Contact MTS.................................................................................................................7 If You Contact MTS by Phone..........................................................................................................9 Problem Submittal Form in MTS Manuals.............
Table of Contents Optimizing System Response Before Testing................................................................................61 Understanding and Resolving Error Conditions.............................................................................61 Running the Example Tension Test About This Chapter........................................................................................................................64 Test Procedure Overview................................................
Table of Contents If Appropriate, Remove the Broken Specimen..................................................................109 Recover from a Tripped Limit.......................................................................................................110 If Necessary, Recover from a Tripped Force Limit............................................................110 If Necessary, Recover from a Tripped Displacement Limit...............................................
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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 Tension 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 in 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 TW Express (TWX) Application Common Windows When running tests, you can expect to perform many of the activities shown in the list below. This section introduces you to the software screens associated with those activities.
System Introduction Clearing Interlocks To clear interlocks, first correct any interlock conditions (for example, turning on the pump), and then click the Reset button to clear any interlocks. Running the test The buttons in the Test Controls panel allow you to run a test. Use the green arrow (Run the Test) button to start a test. Entering Variable Values The test designer may have added prompt dialogs for variable values. If so, they appear automatically as the test is run.
System Introduction Comparing Test Runs Select the Compare checkbox next to a test run to see the test run in the graph. Excluding Test Runs If there is a problem with a test run, you can exclude it from calculations and statistical results by tagging the test run.
System Introduction Adding and Ordering Data Fields Right-click anywhere in the Results panel to show the Set Result Variables window. This window allows you to add fields to the Results panel. Once they are added, you can use the Set Variable Order window to arrange the variables that are shown in the Results panel. Access the Set Variable Order window by selecting Define > Variables, and then right-clicking anywhere in the Variables panel.
System Introduction Displaying Additional Statistical Data The statistical data shown in the Statistics panel can be configured using the Configure Statistics window. Right-click in the Statistics Panel to show the Configure Statistics window.
System Introduction Configuring Charts Right-click a chart to configure it.
System Introduction Switching Views You can show up to four views at a time. If more than four views have been created, you can switch between them by right-clicking a view and selecting Switch to View.
System Introduction Adjusting Variables and Recalculating Results You can adjust variables even after a test is run. To do so, enter the corrected value, and then press Enter to recalculate results. This can be helpful in correcting errors or performing "what if" analysis. If you wish to revert to the original value, simply click the Reset button.
System Introduction Saving Display Configurations Once you have the display configured the way you like it, you can save it so that you switch between displays. Generating a Report You can generate an individual report for each test run, or you can produce a single report for all test runs as shown here.
System Introduction MTS Landmark Test System Operation | 47
Key Concepts Topics: • • • • • • • • • • • • About This Chapter............................................................................................................................50 Understanding Your MTS Software...................................................................................................50 Understanding MTS File Types.........................................................................................................52 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 • • 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: 52 | 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 (For example, Actuator) 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 (For example, Force or Displacement) A control channel includes one or more control modes. Control modes determine how the commanded force is applied to the specimen.
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 and the crosshead. This typically includes the lower grip, the specimen, the upper grip, and the force sensor (load cell), as shown.
Key Concepts 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. On the typical system used as an example in this manual, you use the Manual Command panel in the Station Manager application to position the actuator. If your system includes a Model 494.
Key Concepts 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, click the Reset button in the Station Manager main window.
Running the Example Tension Test Topics: • • • • • • • • About This Chapter............................................................................................................................64 Test Procedure Overview..................................................................................................................64 Prepare for Specimen Installation.....................................................................................................65 Install the Specimen............
Running the Example Tension Test About This Chapter This chapter describes how to set up and run the MTS SH Tension Test (Simplified) 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 Tension Test. In some cases, your system may vary from the typical system shown.
Running the Example Tension Test d) Show Station Manager Scope and Meters for the Test (p. 96) e) Minimize Station Manager (p. 97) 4. Run the Test a) Open the TWX Application (p. 98) b) Select the Test (p. 100) c) Switch to Round Specimen Geometry (p. 100) d) If Necessary, Correct Any Resource Errors (p. 101) e) Run the Test (p. 103) f) Review the Results (p. 104) g) Save the Test and Minimize TWX (p. 104) 5. Remove the Specimen a) Remove Displacement Limits (p.
Running the Example Tension Test The controller power switch is located on the back of the controller. Open the Station Manager Application 1. Close any open applications on the computer desktop. This prevents possible confusion from having multiple stations open. 2. Select All Programs > MTS 793 Software > Station Manager. This launches communication between the computer and the MTS controller. 3. If necessary, select a project. It is common practice to keep all files in Project1.
Running the Example Tension 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 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 Tension 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 Tension 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 on 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 Tension 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 Tension 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 Tension 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 Tension 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 Tension 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.
Running the Example Tension Test Upon initial setup, the force signal meter shows 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 Tension 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 button, and clicking the Adjustments tab.
Running the Example Tension 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: Important: The following numbers were appropriate for the example test on a typical system. You will need to adapt these entries to your specimen, test, and system.
Running the Example Tension Test c) d) e) f) g) h) i) Zero Displacement (p. 80) Clamp the Specimen in the Lower Grip (p. 81) Position the Crosshead (p. 82) Move the Specimen into the Upper Grip Using Displacement Control (p. 83) Switch to Force Control (p. 84) Clamp the Specimen in the Upper Grip (p. 84) Check and Reset Meter History (p. 85) Power up the Pump and HPU 1. Correct any interlock conditions. If a limit has been exceeded, seeIf Necessary, Recover from a Tripped Force Limit (p.
Running the Example Tension Test Note: All interlock conditions will not reset until the pump is on. Position the Actuator Using Displacement Control Position the actuator for the start of the test. Warning: Manual control of the actuator is required for specimen installation. Unskilled movement of the actuator can result in equipment damage or personal injury. Ensure that the area is clear, that you can see what you are doing, and that you have the necessary skill to proceed safely. 1.
Running the Example Tension 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.
Running the Example Tension Test 2. 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. You should position the specimen in the grip so that about 1/5th (see the following photo) of the un-necked portion of the specimen is showing.
Running the Example Tension Test Important: You should use a tool that is softer than the specimen to ensure that you do not damage the specimen. Plastic tongs or pliers are best. 2. Reset the Force Lower (Compression) Limit. 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.
Running the Example Tension Test Item Description 1 Crosshead Lock 2 Crosshead Lift a) Unlock the crosshead clamps, and then move the crosshead up or down so that there is about 25 mm (1 in) 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 Tension Test Important: Your station setup will determine whether you have to move in the positive or negative direction. Switch to Force Control Switching to force control helps ensure that you do not impart excessive force on the specimen during installation. Once in force control, the controller will follow your positioning commands while working to maintain the force that you specify—in this case 0.00 kN. 1. In the Station Manager main window, click the Manual Command icon. 2.
Running the Example Tension Test Using the controls on the MTS Landmark load frame, slowly clamp the specimen in the upper grip. 2. If necessary, recover from a tripped limit (otherwise proceed to the next step). Clamping can result in tripping a force or displacement limit. See If Necessary, Recover from a Tripped Force Limit (p. 110) or If Necessary, Recover from a Tripped Displacement Limit (p. 113).
Running the Example Tension Test Prepare to Run the Test Preparing to run the test consists of the following steps: a) Perform Basic Performance Tuning (p. 86) b) Switch to Peak Valley Meters (p. 94) c) Adjust Limits for the Test (p. 95) d) Show Station Manager Scope and Meters for the Test (p. 96) e) Minimize Station Manager (p. 97) Perform Basic Performance Tuning Use the following guidelines for basic performance tuning. 1. Select the Tuning user access level.
Running the Example Tension 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. 3. Disable manual command. This allows the function generator to control the system. a) In the Station Manager main window, click the Manual Command button. The Manual Commands window appears. b) Click to clear (uncheck) the Enable Manual Command check box. 4. Set up a force waveform using the Function Generator.
Running the Example Tension Test • • • Frequency — 1 Hz Wave Shape — Ramp Compensator — None Important: It is important to have Compensator set to None. If it is left on, it can negate the function generator signal. 5. Open a Station Manager Scope. Click the Scope button in the Station Manager main window. 6. Set up the Scope. Set up a Scope to compare the command signal to the resulting feedback. In the Station Manager main window, click the Signal Scope button.
Running the Example Tension Test • • Units/div — 0.5 Offset — 2 Time: • Trace Time — 5.0 s 7. Run the Function Generator. 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 Tension 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 clicking 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 Tension 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 Tension 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 Tension 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 button, and clicking 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: Do not adjust all the way to zero or you could trip the force limit. 11.
Running the Example Tension 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 Tension 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 Tension Test Important: The following numbers were appropriate for the example test on a typical system. You will need to adapt these entries to your specimen, test, and system. • • Ch1 Displacement (Upper Limit, Upper Action) — 100 mm, Interlock Ch1 Displacement (Lower Limit, Lower Action) — (- 20) mm, Interlock 2. Adjust force limits so that they are just outside expected values for the tension test.
Running the Example Tension Test Note: Your meter readings will reflect your station and will be different from those shown. 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. Turn Exclusive Control off by clearing the check box. 2. Minimize the Station Manager application.
Running the Example Tension Test Click the minimize button in the upper right corner of the Station Manager application. 3. Verify that the Station Manager application is still running by checking for it in the task bar. You can maximize Station Manager at any time by clicking the Station Manager button in the task bar. Run the Example Tension Test Running this Example Tension test consists of the following steps: a) Open the TWX Application (p. 98) b) Select the Test (p.
Running the Example Tension Test Note: It is acceptable to leave the pump (HPU) on as it may be needed for other stations. 2. Open the TWX application by selecting All Programs > MTS TestSuite > TW Express. Another way to open the TWX application is by clicking the TWX icon on your computer desktop.
Running the Example Tension Test Select the Test Select the MTS SH Tension (Simplified) template. In the MTS TWX main window, select MTS Templates > TW - Hydraulic > MTS SH Tension (Simplified) to load the test. Switch to Round Specimen Geometry The MTS SH Tension (Simplified) test is set up for rectangular specimen geometry. Because this example uses a round specimen, you will need to switch to round specimen geometry. 1. In the TWX main window, select Define > Variables.
Running the Example Tension Test 2. 3. 4. 5. Select Area from the list of variables. For the Option property, select Round. For the Unit property, select (mm²). Click the Apply button. If Necessary, Correct Any Resource Errors Ensure that MTS FlexTest (Series 793) and MTS TWX resource names match. 1. Find resource errors by looking for the white X encircled in red.
Running the Example Tension Test In the MTS TWX main window, open the Resources tab by selecting Define > Resources. 2. Correct any resource naming conflicts by updating the TWX name to match the controller resource name. In this example, TWX had the axial channel named "Axial" while the controller had the axial channel named "Ch 1." By changing the TWX names to Ch 1, the resource naming errors were eliminated.
Running the Example Tension Test Run the Test 1. Run the test. a) From the MTS TWX 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. If appropriate, 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. 2. Enter the specimen diameter (in this case 5 mm), and click OK. 3.
Running the Example Tension Test Return to zero? prompt until you are confident that returning to the zero position will produce no specimen or equipment damage. Review the Results At the conclusion of the test, view any of the results windows found under the MTS TWX Review tab for test details. Note: For a sequenced example regarding how to get the most out of the TWX Review tab, see Review Tab and Example Procedure Overview (p. 118).
Running the Example Tension Test In the TWX main window, select File > Save. 2. Minimize the TWX application. Click the minimize button in the upper right corner of the TWX application. Remove the Specimen Removing the specimen consists of the following steps: a) Remove Displacement Limits (p. 105) b) Switch to Running Max/Min Displacement and Force Meters (p. 106) c) If Appropriate, Remove the Intact Specimen (p. 107) d) If Appropriate, Remove the Broken Specimen (p.
Running the Example Tension Test 2. Select the Displacement channel. 3. Click the Limits tab. 4. Set the Ch1 Displacement Upper Action and Lower Action to Disabled. Switch to Running Max/Min Displacement and Force Meters 1. Switch to a Running Max/Min Displacement meter. 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.
Running the Example Tension Test Also change the force Peak/Valley meters to Running Max/Min Meters to monitor history during specimen removal. a) In 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. If Appropriate, Remove the Intact Specimen Use this procedure only if the specimen is intact at the conclusion of the test run.
Running the Example Tension Test 4. Release the upper grip. Use the controls on the load frame. 5. Retract the actuator. a) In the Station Manager application main window, click the Manual Command button to open the Manual Command window. 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.
Running the Example Tension Test This is a safety precaution to take before nearing the crush zone. Note that turning the HSM off removes power from the actuator, while leaving hydraulic power to the grips. 7. Release the lower grip and remove the specimen. Using a tool that keeps your hands clear of the actuator, grasp the specimen and release the lower grip. That completes this Example test.
Running the Example Tension Test Note: The actuator may retract on its own when the HSM turns off due to the interlock condition caused by exceeding the displacement limit. a) In the Station Manager main window, click the Manual Command button to open the Manual Command window.
Running the Example Tension Test • • • Clamping a grip may result in a force spike higher than expected. Your test limits may not have been set high enough. The specimen may break, resulting in the end of the test. Rather than cover all possibilities, this section addresses the first case only. Adapt this procedure as necessary to recover from other cases. 1. Evaluate if the specimen has been damaged. a) Check meter history to see if acceptable force limits for the specimen have been exceeded.
Running the Example Tension Test In the Station Manager application main window, click the Reset button to clear the interlock. 4. Re-power the HPU and HSM. In the Station Manager application main window, click the Power Low button, and then the Power High button for the HPU and HSM. 5. Reset Force control to zero. 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.
Running the Example Tension Test a) Navigate to Station Manager > Display > Station Setup > Channels > Ch1 (or other depending on your configuration) > Force > Limits. b) Enter -0.05 kN in the Lower Limit text box and ensure that Interlock is selected for the Action. 8. Release the upper grip. Using the controls on the load frame, release the upper grip. 9. If necessary, repeat the upper grip clamping process.
Running the Example Tension Test 1. Check current displacement limits. a) In the Station Manager application main window, select Display > Station Setup > Displacement > Channel Input Signals. b) Click the Limits tab. c) Check the current upper and lower limit settings to identify the acceptable displacement range for the actuator. Adjust the limits if necessary. 2. Set Manual Command to Displacement. a) b) c) d) In the Station Manager application main window, click the Manual Command button.
Running the Example Tension Test In the Station Manager application main window, click the Reset/Override button three times to override the interlock for 21 seconds, and then power up the HPU and HSM. 4. Move the actuator to within acceptable displacement limits. In the Station Manager application main window, click the Manual Command button. Move the actuator to within acceptable limits while the interlock is overridden.
Reviewing, Analyzing, and Reporting Data Topics: • • Review Tab and Example Procedure Overview..............................................................................118 Example Analysis Procedure...........................................................................................................
Reviewing, Analyzing, and Reporting Data Review Tab and Example Procedure Overview After a test run finishes, test results are automatically shown on the Review tab of the main display. You can use controls in the Review tab to: • • • • • Configure displays to view data for individual or multiple test runs. Compare test runs to one another. Perform “what if” scenarios by adjusting variable values and recalculating results. Generate reports. Export raw data.
Reviewing, Analyzing, and Reporting Data Another way to open the TWX application is by clicking the TWX icon on your computer desktop. 2. Open the example test. a) In the TWX main window, select Tests > MTS SH Tension (Simplified).
Reviewing, Analyzing, and Reporting Data b) Click the Review tab. The review screen appears populated with tests runs. Five test runs shown are provided by MTS for training purposes. 3. Compare all test runs.
Reviewing, Analyzing, and Reporting Data Upon opening the Review tab, only the selected test run is graphed. Compare all test runs on the same graph by selecting the Compare check box next to each test run. Graphs for each test run are plotted in the Load versus Extension panel. 4. Exclude invalid test runs. In this example, Test Runs 1 and 4 had problems associated with them. a) Exclude those two test runs from the statistical data by selecting the Tagged check box next to each test run.
Reviewing, Analyzing, and Reporting Data b) Exclude Test Runs 1 and 4 from the graph by clearing (unchecking) the Compare boxes next to Test Runs 1 and 4. 5. Set up autotag.
Reviewing, Analyzing, and Reporting Data Another way to eliminate problem test runs is to set up autotag. Autotag uses rules to exclude errant test runs from the statistical results panel and reports. a) Open the autotag window by right-clicking anywhere in the leftmost panel and selecting Configure Autotag Rules. b) Set up a rule.
Reviewing, Analyzing, and Reporting Data 1. Add a rule. Click the green + sign in the upper right corner of the Configure Autotag Rules window. 2. Enter a variable. Click the Variables tab, and then select PeakStress from the list. PeakStress appears in the Calculation panel. 3. Enter a function and a value. In the Calculation panel, enter PeakStress>1250000000 immediately following PeakLoad. 4. Enter an error message. Enter >1.25 kN/(mm²) in the Error Message text box. 5. Click Close.
Reviewing, Analyzing, and Reporting Data Test Runs 1 and 4 are automatically tagged and excluded from the statistical results and reports. Note: Autotag does not work with fields that have non-numeric data. Always review autotagging results to ensure the results are as expected. 6. Add and order data fields shown in the Results panel. This step demonstrates how to set up the Results panel to your liking. a) Add the Yield Index field to the Results panel. 1. Right-click anywhere inside the Results panel.
Reviewing, Analyzing, and Reporting Data b) Move the Yield Index column between the Modulus and Test Run End Reason columns. 1. Select the Define tab, right-click anywhere in the panel, and select Set Variable Order.
Reviewing, Analyzing, and Reporting Data 2. In the Variable Type drop-down list, select Result. 3. Use the up and down arrows on the right side of the Set Variable Order window to move Yield Index between the Modulus and Test Run End Reason columns. 4. Click OK when complete. The updated list appears.
Reviewing, Analyzing, and Reporting Data 7. Show additional statistical data and reorder as desired. You can also configure the fields in the statistical results panel to your liking. a) Add Minimum and Maximum values to the statistical results. 1. Right-click anywhere within the statistical results panel and select Configure Statistics. 2. Move Minimum and Maximum from the Available to the Selected list using the right arrow.
Reviewing, Analyzing, and Reporting Data 3. Use the up and down arrows to order the fields as desired. 4. Click OK when complete. Maximum and Minimum appear in the Statistical Results panel. 8. Add and configure views. You can show up to four views at a time. You can also add additional views and switch to them as desired. a) Switch to four panel view by clicking the Four Panel View button in the toolbar.
Reviewing, Analyzing, and Reporting Data b) Add and configure a view to show load vs. extension in inches and pounds force. 1. Right-click the lower right panel. Select Views > Add View > Array-Variable Marker Chart for Multiple Runs. 2. Accept the default name for the panel. The chart appears in the four panel view. 3. Right-click the new chart and select Configure Chart.
Reviewing, Analyzing, and Reporting Data 4. For the Y Array drop-down list, select Load. 5. Select the X Array check box and select Extension in the corresponding drop-down list.
Reviewing, Analyzing, and Reporting Data 6. In the Y Axis group Display Unit drop-down list, select lbf (pounds force). 7. In the X Axis group Display Unit drop-down list, select in (inches). 8. Click OK. The configured chart appears. If no traces appear in the chart, you may need to select a test run to show the traces for the compared test runs. c) Switch views. Right-click the chart you just created, and select Views > Switch to View > Variable-Column Table for Multiple Runs. The selected view appears.
Reviewing, Analyzing, and Reporting Data 9. Adjust a variable and recalculate. You can adjust variables after performing test runs to do “what if” analysis or to correct errors (for example, an incorrect value for diameter). a) Select a test run. For this example, select Test Run 5. b) In the Variable Table view, scroll down to Diameter and change the value from 5.000 mm to 6.000 mm. Clicking anywhere else on the screen enters the value and updates any dependent calculated values.
Reviewing, Analyzing, and Reporting Data c) If desired, reset the Diameter to its original value by clicking the Reset button in the Reset Value field. A confirmation window appears. 10. Save the current display configuration once you have the display configured as desired.
Reviewing, Analyzing, and Reporting Data a) Click the Actions button and select Display > Save Display As. b) Enter a display name and click OK. 11. Switch between display configurations. Once display configurations are saved, you can switch between them. a) Click the Actions button and select Display > Switch to Display. Select Default Layout. b) The Default Layout appears.
Reviewing, Analyzing, and Reporting Data 12. Generate a report for the selected test runs. a) Select Test Runs 2, 3, and 5, and then click the Generate a report for the selected test run(s) button. Note: Hold down the Shift key while clicking to select multiple test runs. An Excel report file is generated for each test run that was selected.
Reviewing, Analyzing, and Reporting Data 13. Generate a report for all test runs. a) Click the Generate a report that includes all test run(s) button.
Reviewing, Analyzing, and Reporting Data b) Review the single Excel report file that is generated for all test runs (excluding those that were tagged). 14. Copy and paste data into another application.
Reviewing, Analyzing, and Reporting Data Data from the Results or Statistics panel can be copied to other applications including Microsoft Word, Excel, and Notepad. a) Select the rows in the Results or Statistics panel you wish to copy. For this example, select Test Runs 2, 3, and 5, right-click any selected row, and then select Copy. Note: Hold down the Shift key while clicking to select multiple rows. b) Open the application into which you want to paste the data. For this example, open Word.
Reviewing, Analyzing, and Reporting Data You can also export raw test data for a test run to a tab-delimited .txt file. You can select formatting, units, data acquisition, and signal options. a) Select the desired test run. For this example, select Test Run 2, right-click the selected row, and then select Export Raw Data. b) Select the desired options in the Export Raw Data window. For this example, select the default values and then click OK. A message box lets you know that the text file was created.
Reviewing, Analyzing, and Reporting Data c) The file can be found in the following directory: C:\MTS TestSuite\Data Files\. d) Use Notepad to view the data.
Reviewing, Analyzing, and Reporting Data 142 | MTS Landmark Test System Operation
Maintenance Topics: • • • Routine Maintenance Overview Checklist.......................................................................................144 Maintenance Intervals.....................................................................................................................147 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 the 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. Lock the crosshead.
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 59 actuator decommissioning 152 maintaining 145 moving 115 positioning 61 retracting 108–109 velocity limiting switch 33 analysis procedure data 118 application MTS Multipurpose (MP) Express 33 MTS TW Express 29 Station Manager 29 Application Log TWX 62 Auto Offset 74, 80 autotag rules 123 setting up 122 C cables maintaining 146 calibration file 68 channels control 58 charts adding and configuri
Index documentation on mts.
Index load frame controls 31 maintaining 144 load train 59 log application TWX application 62 file 62 message 59, 62 LVDT (displacement) sensor calibration interval 148 calibration verification 68 M maintenance intervals 147 routine checklist 144 manual overview 28 Manual Command disabling 87 setting 114 slider 79 manual displacement control 79 manuals 7 Message Log 59, 62 meters aligning 71 checking history 85 Peak/Valley 94–95 resetting 75, 85, 112 Running Max/Min 70, 106 Sensitivity 94 setting up 69 Tim
Index sensor (continued) extensometer calibration interval 148 force (load cell) calibration interval 148 calibration verification 69 limits setting for running a test 95 setting for specimen installation 72 zeroing, See Auto Offset Series 793 software, See MTS FlexTest (Series 793) controller software servovalve 31 sets parameter 53 signal command 56 sine wave 91 software MTS FlexTest (Series 793) controller 29, 33 MTS TestSuite 29, 33 specimen clamping 81 evaluating damage 111 removing broken 109 removing
Index Z zero sensor zero (continued) sensor (continued) Auto Offset 80 See also Auto Offset 159
Index 160
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