SOW FPL - EMRSL FT100 2022_Final.doc

STATEMENT OF WORK

HYDRAULIC SERVO CONTROLLER

FOREST PRODUCTS LABORATORY, MADISON, WI

A. General:

This request covers providing, installing, testing, and calibrating equipment for a 6-station, 7-channel hydraulic/servo controller at the Forest Products Laboratory (FPL), Engineering Mechanics and Remote Sensing Laboratory (EMRSL).

B. Background:

The EMRSL at FPL performs materials testing on wood, wood products, and component materials. This mission-critical research informs national building codes and design methods for designers, educators, industry partners, industry corporations, and the American public. In executing this research program, a significant portion of the mechanical and structural testing within EMRSL is performed using MTS hydraulic testing systems. EMRSL has extensive MTS hydraulic testing machinery to perform middle to large scale (up to 2.5 MN) mechanical testing. The hydraulic system is currently operated by a FlexTest 60 controller that is at hardware expansion capacity and has been modified to control additional hydraulic stations.

C. Summary of Work:

The proposed system works in conjunction with the existing FlexTest 60 (FT60) controller components and a new FlexTest 100 (FT100) controller such that the FT100 will be populated with both existing FT60 electronics and additional electronic components to be purchased and installed. The system will comprise of two functioning test controllers according to the following assumptions and considerations:

1. The current location and position of the PWB boards and I/O carrier boards within the FRONT of the FT60 controller be kept "AS IS"; and physically removed from the FT60 controller and placed into this new FT100 controller. Currently there are 5 populated I/O carrier boards that will be moved.

2. The current location of the two Analog Output boards on the REAR of the FT60 controller be kept "AS IS"; and physically removed from that controller and placed into this new FT100 controller

3. The existing external cabling that goes out to the actuators/load cells and other components be re-used and moved over to the new FT100 controller. HPU Control cabling for both a 505.60 and 505.20 will be re-used.

4. Move one 494.74 from the FT60 to this FT100, for a total quantity of three 494.74 boards in the FT100 for control of 6 Hydraulic Service Manifolds (HSMs). The FT100 in its completed state will have 7 channels and 6 HSM control stations.

5. The existing FT60 controller chassis will be reconfigured to run a single existing 312.21 load frame and 505.20 HPU. The controller will be single channel, single station, with 8 analog inputs and 8 analog outputs. It will also be configured with a Handset local control.

D. Servo-hydraulic controller general features:

1. Controller shall provide real-time closed-loop control, with transducer conditioning and function generation to drive various types of servo-actuators and support a wide array of configurations including axial and axial/torsional load units, uniaxial and multiaxial test systems, structural test actuators and electrodynamic systems. Controller must integrate and interface with the Programmable Logic Controllers (PLCs) within MTS 505.20 and 505.60 Hydraulic Pressure Units (HPUs), and associated MTS HSMs. This controller shall be easily re-configured and provide the ability to re-assign hardware allocation without having to move things around in the chassis. Also, the processors must be field-upgradeable, making it simple to add capacity when necessary.

· Digital Universal Conditioners (DUCs) accommodate a wide range of transducers, including AC and DC devices

· Broad array of conditioning modules provides increased flexibility

· Modular hardware design allows for more flexible management of control resources

· Total capability to provide up to 8 Test Stations, 16 Control Channels, 40 conditioned Transducer inputs, 64 auxiliary data inputs, 10 VME BUS slots, 10 powered and 2 unpowered Transition bus slots when fully populated.

· Optional compensation techniques optimize control, even for challenging tests and difficult specimens

· Excitation sensing verifies proper voltage to the transducer, regardless of cable length

· HPU control and monitoring, HSM control for high and low pressure.

· Excitation loss detection minimizes the chance for errors in the event of cable breaks

· Includes SCADA Control Software E. Controller components specific features:

· Voltage Kit (Power Cord): North America, 100 - 120 V (AC) (NEMA 5-15)

· 494.10 Chassis: 1

· 494.45 Analog Input (A/D): 3

· 494.46 Analog output cards (D/A): 3

· 494.40 I/O Carrier Modules: 3

· 494.47 Dual UART / Encoder Interface: 1

· Front Blank quantity: 10

· Remaining Mezzanines slots for future additions: 32

· 494.74 HSM Transition Modules: 2

· 494.75 Analog Input (A/D) Transition Modules: 3

· 494.76 Analog Output (D/A) Transition Modules: 3

· Total Transition Module Slots: 6

· Rear Blank quantity: 5

· Remaining Transition Module Slots: 5

· Included E-Stop Cable length: 15 feet

· 494.16 Valve Driver/DUCs: 1

· 494.26 Dual DUCs: 1

F. Onsite Installation, Commissioning, Calibration, and Training:

· Travel Expense.

· Onsite installation: include 8 additional installation hours for reconfiguring the existing FT60 controller’s hardware into the new FT100 chassis, and 12 installation hours to reconfigure the FT60 controller to operate the load frame.

· Onsite Calibration:

· Axial Force Calibration, 0-22 kip – (1 load frame)

· Axial Force Calibration, 0-110 kip – (5 each)

· Axial Force Calibration, 0-550 kip – (3 each)

· Onsite Calibration, LVDT / Temposonic Displacement transducer – (9 total; 8 actuators, 1 load frame)

· Calibration Standards Fee

· Onsite Basic Operator Training

· MTS FlexTest 100 Supervisor Basic Operator Training

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