Control System specifications for Hydraulic-Actuated, Axial and Axial/Torsional Load Frames

Control System specifications for Hydraulic-Actuated, Axial and Axial/Torsional Load Frames

NASA requires a control system for an existing, government owned, hydraulic-actuated, axial and axial torsional test stand(s). This control system shall include the specified interface cables and software but shall not include the personal computer or workstation if one is required. Specification of the appropriate personal computer to run this system shall be supplied.

The load frames to be upgraded are:

Three (3) Axial/Torsional load frames model 309.40 from MTS Systems with 500 kN capacity

One (1) Axial/Torsional load frame model 858 (with 359 model actuator) from MTS Systems with 25 kN capacity

Five (5) Axial load frames model 810 from MTS Systems with 100 kN capacity

Four (4) Axial load frames model 880 from MTS Systems with 250 kN capacity

The controller shall be make/model equivalent to the Moog Test Controller and Moog Integrated Test Suite by Moog Inc. Key features in this control system is the ability to provide both simple/quick setup of standard test sequences and the option for completely customizable programing of complex test sequences through an open interface.

If a different hardware and software package is proposed, then the controller system must have the functionality described below.

A. GENERAL REQUIREMENTS

1. The controller must have demonstrated pedigree in a research lab environment. If requested, the vendor shall supply contact information for existing customers in the aerospace or equivalent industries who will supply performance references.

2. The controller system (hardware and software) must be cleared through the NASA Supply Chain Risk Assessment

3. The control system shall include all the hardware and software necessary to control a government owned load frame test stand with one servo-actuated motion axis for axial load frame and two servo-actuated motion axes for axial/torsional load frames.

4. If specified for an axial load frame, the control system shall provide complete digital closed-loop command and feedback motion control at 2,000 Hz minimum communication rate for at least the following channels:

a. One (1) load (full bridge) conditioning channel

b. One (1) stroke (AC LVDT) conditioning channel

c. One (1) strain conditioning channel

OR if specified for an axial/torsion load frame, the control system shall provide complete digital closed-loop command and feedback motion control at 2,000 Hz minimum communication rate for at least the following channels:

a. Two (1) load (full bridge) conditioning channel

b. One (1) stroke (AC LVDT) conditioning channel

c. One (1) rotational (AC RVDT) conditioning channel

d. One (1) strain conditioning channel

5. The controller system shall interface with a frame-local hydraulic service manifold (HSM) and provide proportional control of hydraulic supply pressure and 2-stage servovalve(s)

6. The controller system shall provide signal conditioning based on at least the following transducers:

a. Full bridge load transducer (two for axial/torsional systems)

b. AC LVDT stroke transducer

c. AC RVDT rotational transducer for axial/torsional systems

d. DC extensometer transducer

e. Full bridge strain gauge transducer

7. The controller system shall provide signal conditioning based on at least

a. Two (2) +/-10V analog inputs (ADC)

b. Two (2) +/-10V analog outputs (DAC).

8. The controller system shall provide an easy to activate emergency stop capability.

9. The controller system shall be capable of performing a wide range of traditional and specialty mechanical test methods while providing control limits to protect samples, hardware, and personnel. Open interface access to test control is a key feature.

10. The controller system shall be built on an expandable and upgradeable architecture such that future modules can be added or upgraded in the existing hardware rack.

11. The control system shall incorporate a rugged design with ESD protection

12. Necessary interface cabling shall be provided for servo-hydraulic control, load cell, and actuator position sensing (LVDT).

13. Control interface specifications shall be provided to allow the government the ability to repair, fabricate, or purchase future cables for load cell, position sensing (LVDT), extensometer, strain gauge, and temperature interfaces.

B. CONTROLLER QUALITY SPECIFICATIONS

1. The controller shall provide simultaneous 24 bit signal resolution at 100 Hz bandwidth

2. The controller shall provide transducer calibration functions

3. The transducer measuring capability shall meet or surpass the following standards:

a. ASTM E-4

b. ISO 7500/1

C. REMOTE PENDANT

4. A hand set shall be provided for coarse and fine positioning of the actuator to facilitate test set-up.

5. The hand set may provide the location for the physical emergency stop input.

D. SOFTWARE

1. The controller software shall provide configuration, calibration, tuning, and test operations.

2. The controller software shall provide motion control and bumpless mode control switching

3. The controller software shall provide a test configuration and data acquisition interface that allows nested instructions and event trigger actions

4. The controller software shall provide features for performing real-time engineering calculations based on transducer response

5. The controller software shall provide features for real-time graphical representations based on transducer response and/or engineering calculations.

6. Transducer response and calculated results shall be stored in an ASCII or CSV format to any disk drive recognized by the computer, including networked drives.

7. The software shall accommodate an open source or open interface programing option for sophisticated user-defined test programs

E. COMPUTER INTERFACE

1. The control system shall interface with a Windows 10 operating system computer that will be furnished by the government

2. The vendor shall provide detailed computer specifications for optimum computer compatibility.

F. WARRANTY and QUALITY

1. 12 month warranty shall be given on software and all hardware.

2. 12 month system maintenance agreement shall be offered that includes software updates and phone support.

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