Ipc Uts001 1v25e

IPC Global ®
Universal Testing Software

UTS Test No 001
Tuning
Version: 1V25 Issue date: December 2, 2011
© IPC Global 2010
© IPC Global UTS 001
ABN 92 168 265 156 Tuning
Document History
Table 1 – Document History
Date S/W Doc Description Author
Rev Rev
27/4/06 1v0 1v0 Created from K. de Vos’ UTM Tuning Test S. Brede
6/7/2010 1V25 1V25 Re-format and version = test version S. Brede
23/3/2012 1V25 1V25a Naming convention update S. Brede
19/5/2014 1V25 1V25b ABN update S. Brede
6/6/2014 1V25 1V25C Company Details Updated S. Brede
23/1/2015 1V25 1V25d Controls Logo added S. Brede
21/7/2015 1V25 1V25e Front Page updated and graphics reformat and index. S. Brede
© Copyright
This document is protected by copyright and the information contained herein is confidential. The
document may not be copied and the information herein may not be disclosed except by written
permission of and in a manner permitted by the proprietors of IPC Global Pty Ltd.
Version 1V25 Page i

Created using IPC Software Reference Template 1V0 Printed 21/07/2015
ABN 92 168 265 156 Tuning
Table of Contents
1 INTRODUCTION ........................................................................................................................................................1
1.1 Scope ............................................................................................................................................................1
1.2 Document Overview ....................................................................................................................................1
1.3 Referenced Documents. ..............................................................................................................................1
1.4 Document Location .....................................................................................................................................1
1.5 Terminology. ................................................................................................................................................1
2 INTRODUCTION ........................................................................................................................................................2
2.1 Closed Loop Servo Control.........................................................................................................................2
2.2 Tuning Concepts .........................................................................................................................................3
2.3 Proportional Loop Gain ..............................................................................................................................3
2.4 Error Time Constant (Integral) ...................................................................................................................3
2.5 Mass Compensation (Derivative) ................................................................................................................3
3 SETUP INFORMATION ............................................................................................................................................4
3.1 System Requirements. .................................................................................................................................4
3.2 Software Installation ....................................................................................................................................4
3.3 General. ........................................................................................................................................................4
3.4 IMACS Channel Assignment .....................................................................................................................4
4 MENUS AND OPTIONS............................................................................................................................................5
4.1 File Menu. ....................................................................................................................................................5
4.2 Run Menu ....................................................................................................................................................6
4.3 Options Menu..............................................................................................................................................6
4.4 View Menu ...................................................................................................................................................7
5 SETTING UP A TEST ................................................................................................................................................8
5.1 Setting the Test Pages. .................................................................................................................................8
5.2 The Setup Page - Basic .................................................................................................................................9
5.3 The setup Page – Advanced Acquisition. ...................................................................................................9
5.4 The Loading Page ......................................................................................................................................10
5.5 Data Display Page. .....................................................................................................................................12
5.6 Tuning Page. ..............................................................................................................................................12
6 RUNNING THE TEST ..............................................................................................................................................14
6.1 Setting up the hardware.............................................................................................................................14
6.2 Start the test. ..............................................................................................................................................14
6.3 Review the results and fine tuning the waveshape. ..................................................................................14
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List of Figures
Figure 2-1 Closed Loop Servo Control. .................................................................................................... 2
Figure 4-1 Options Menu .......................................................................................................................... 6
Figure 4-2 Hardware Options Menu ......................................................................................................... 6
Figure 4-3 View Menu ............................................................................................................................... 7
Figure 5-1 Configuration Page .................................................................................................................. 8
Figure 5-2 Normal Setup Page ................................................................................................................... 9
Figure 5-3 Advanced Acquisition ............................................................................................................ 10
Figure 5-4 Loading Page........................................................................................................................... 11
Figure 5-5 Data Display Page ................................................................................................................... 12
Figure 5-6 Tuning Page ............................................................................................................................ 13
List of Tables
Table 1 – Document History...................................................................................................................... i
Table 2 Referenced Documents ................................................................................................................ 1
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ABN 92 168 265 156 Tuning
1 INTRODUCTION
1.1 Scope
This document provides the necessary information to operate the IPC Global UTS 001
Tuning Test.
1.2 Document Overview
This document is the software reference manual for the UTS 001 Tuning Test. It also
provides background information for the user.
1.3 Referenced Documents.

Other documents referred to within this document.
Document Name. Document Title
UTS Soft.pdf UTS General Software Reference
Table 2 Referenced Documents

1.4 Document Location
The source for this document is located on the IPC server as:
R:\Source\UTS Source\Software source code Delphi7\001 Tuning
Facility\Help\UTS001 1v25d.docm
Where R:=Controlled\Engineering
1.5 Terminology.
Note the term CDAS (Control and Data Acquisition System) refers generally to IPC
Global’s system control electronics hardware.
The term IMACS (Integrated Multi-Axis Control System) refers to IPC Global’s second
generation CDAS.
For all practical purposes within this document the terms are interchangeable.
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2 INTRODUCTION
In many material tests, particularly where loading pulses of specified wave shape are used, it
is important to provide accurate control of both load amplitude and wave shape. Servo
controlled material testing machines offer the capability of accurate loading wave shape
control over a wide range of frequencies, in either continuous or pulsed operating modes.
This procedure for feedback control performance tuning provides guidance on achieving
these requirements with the IPC digital servo controlled systems.
2.1 Closed Loop Servo Control
Pressure
Supply
Actuator
Error Servo
Amplifier Driver Servo
Input Valve
Demand
+ Piston
-
Transducer
Feedback
Amplifier Transducer
Figure 2-1 Closed Loop Servo Control.
A typical closed loop servo system is shown in Fig.1. A signal from a transducer which
measures the loading waveform (feedback) is connected to a summing junction within the
IMACS enclosure, where it is compared with the required input (demand) signal. The
difference between these two signals (control error) is used to drive the servo valve to
regulate the flow of hydraulic fluid or air pressure in a direction to minimise the error.
If the transducer is measuring the position of the output shaft then the control error signal
can be expressed as follows:-
Control ERROR = Input DEMAND - Position FEEDBACK
The system is then operating under position feedback control or “closed loop” control, and
automatically adjusts the output waveshape to match the desired input “demand”
waveshape. Also, if the position transducer is substituted for one of a different type, such
as a load cell, the system will automatically control the load on the specimen. The same
may be said of any type of transducer that can sense an action generated by the actuator.
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e.g. extensometer, crack growth monitor. A loading frame with a servo-controlled actuator
and fitted with position, load and strain transducers may allow any of these to be selected
to control the movement of the actuator. When using the load transducer for control, it
must be remembered that the specimen and parts of the loading frame are included in the
control loop. Specimens and load frames may be rigid or compliant and thus their
characteristics affect the response of the system.
Further, the choice of control transducer affects the response. When in load control, a
constant load is maintained on the specimen, irrespective of specimen deformation and
thus the system behaves like a dead weight testing machine with a very 'soft' characteristic.
When in strain control with an extensometer fitted across the sample gauge length, the
system will sense the specimen extension directly, irrespective of any compliance that may
be in the loading frame, thus the system acts like a very rigid machine with a very
compliant specimen. i.e. It has a very "hard" characteristic.
2.2 Tuning Concepts
In order to be able to optimise the system response over a wide range of application
requirements a three term proportional, integral and derivative (PID) controller is used as a
feedback control compensator. This effectively splits the control error signal into three
components, a proportional component, its integral and derivative. The PID controller
provides independent adjustment of the level or ”gain” of each component.
It is necessary that the overall system response be optimised for the particular test
conditions prevailing. The optimum “gain” settings are dictated by the requirements of the
test and by the characteristics of the load and loading equipment. (Grips, transducers,
specimen etc.)
It is often more convenient to define the proportional, integral and derivative gain terms of
the PID controller as Proportional Loop Gain, Error Time Constant and Mass
Compensation, which lead to a better understanding of their functions. These are detailed
as follows.
2.3 Proportional Loop Gain
The Proportional Loop Gain component of the feedback control compensation essentially
gives an output which is directly 'proportional' to the Control Error. The Control Error is
defined as the difference between the requested value and the actual feedback transducer
value. Some level of Proportional Loop Gain is always needed to ensure control system
stability.
2.4 Error Time Constant (Integral)
This component of the feedback control compensation ensures that the servo system
reaches a zero error condition in a given time.
2.5 Mass Compensation (Derivative)
This component of the feedback control compensation provides an anticipatory output,
which is added to compensate for the weight of any platens, load cells, grippers etc. This
term improves the transient or step response of the control system as well as increasing the
high frequency performance.
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3 SETUP INFORMATION
3.1 System Requirements.
IPC Global UTS test software will function correctly on a PC with the following minimum
specification.
 Pentium-3 or Pentium-4 personal computer at 1GHz or higher.
 256 Mb main memory.
 Monitor display resolution of 1024 x 768
 Asynchronous RS232, USB (recommended) serial port or Ethernet.
 20 GB hard disk space.
 Microsoft Windows operating systems XP or Windows 7(32 or 64 bit)
Note Windows 8 use is not recommended at this time as the UTS software suite has not
been exhaustively evaluated on this platform.
3.2 Software Installation

The UTS002 software application uses the InstallShield installation utility. To install the
application simply invoke the compressed distribution file on the media supplied. The
installation program will guide the user through all required steps in the procedure.
3.3 General.
The tuning test is a standalone test which enables the equipment user to quickly establish a
set of parameters (PID values for displacement, force or other loading system) as a
reference to test the performance of an installed system. The user can generate and save
templates with specific control parameter settings to permit standard test conditions to be
set for various situations and loading types.
Together with reference specimens this allows the user to check their UTM system with
confidence.
3.4 IMACS Channel Assignment

The following channel assignments are used for actuator performance tuning.
Actuator displacement transducer Channel A
Force load cell: Channel B
External displacement/strain transducer: Channel C
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4 MENUS AND OPTIONS.

For general information about the menus & options please refer to the UTS General
Software Reference Manual.
4.1 File Menu.
Several sub menus exist under the File Menu. The most important are
4.1.1 System Setup
The system setup sub menu is where basic transducer channel allocation and calibration
file loading is achieved.
Along with the Configuration page of the Main Screen this is where system parameters are
stored.
4.1.1.1 Communications parameters
These are set in the Communication window. Select the connection appropriate to your
system (Com 1 or USB are the 2 most common options)
4.1.1.2 Allocation information
This is set in the Allocation window. Here the relationship between transducers and the
corresponding IMACS channel is configured along with the loading of the calibration files
for each transducer used. Unless all allocations are completed you will not be able to open
a levels screen. An error message “invalid control input assignment” or similar will appear.
Drag the values from the Axis and Virtual lines of the table to the Input boxes in the upper
part of the window for the allocated lines. e.g. Control-1 is normally assigned to Input A1A
(Displacement) and Control-2 is assigned to A1B (Force). Unless otherwise specified the
gain is usually set to X1 for all channels. Fill in the appropriate channel allocations for any
other functions defined.
Navigate to the C:\IPC global UTS\Calibration folder and drag the appropriate
calibration files to the function lines in the upper part of the window.
4.1.1.3 The CDAS tab
This tab is used for applying default parameters to each axis of the IMACS. Items such as
A channel PID values, Dither Frequency and Amplitude, and Manual Jog limits for
channels A, B & C, Fast and Slow Jog Rates and power supply low pressure settings are
applied here. These values are initially read from the connected IMACS and can be
modified and updated to the IMACS. If you modify any item you must click Apply and
respond Yes for the change to be applied to the IMACS hardware before clicking on
another Axis or leaving the tab.
4.1.1.4 The Loading Control tab
Allows the user to insert machine test limits. These limit the travel of transducers under
test conditions. This page can also be reached directly from the main screen by clicking on
the 6th button along the top.
4.1.2 Template load/save.

This item allows the user to load saved templates and save templates after modification or
new templates they have created.
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4.2 Run Menu

This contains copies of the Start and Stop buttons of the Main screen.
4.3 Options Menu.
Figure 4-1 Options Menu

4.3.1 Generally the options should be set as follows
 Ask for Data File (uncheck) this is used when you wish to save the data. If
unchecked then the data will be saved as Default.D001 and will overwrite any
existing data of that name.
 Strict template rules should be left unchecked as if checked when you click
“NEW” any changes made to the template data since it was load will be lost. If
unchecked when NEW is clicked the operator is given the choice to save template
changes before proceeding.
 Advanced Acquisition allows the user to modify the number of channels to be
monitored and change the sample rates from standard.

Shared Interface when checked permits the test to share parameters with third
party programs such as Labview.
4.3.2 Hardware Options.
In this sub menu the operator tells the IMACS what the hardware
configuration of his UTM system is.
The options are self-explanatory and should be set to conform to
the user’s hardware.
Confining cell options are for manually opened and closed cell
(e.g. Tri-axial cell) or Automatic (e.g. SPT).
Figure 4-2 Hardware Options Menu
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4.4 View Menu

The view menu allows the user to view various sub windows
The first 3 are replicated by radio buttons on the main page.
Figure 4-3 View Menu
4.4.1 Transducer Levels.

This displays the transducer levels screen.
4.4.2 Virtual Pendant.
4.4.3 Machine Limits
4.4.4 Expand Chart Size
This toggles the page information on and off to increase and decrease the chart size in the
window.
4.4.5 Default window size
This restores the Test window to its default size.
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5 SETTING UP A TEST
After setting the displacement and force transducer information in the System Setup
allocation page the next step is to configure the test itself.
5.1 Setting the Test Pages.
5.1.1 Configuration.
The Configuration page should look similar to below.
Figure 5-1 Configuration Page
5.1.1.1 New channel Definition

Type your description of the new channel’s function (e.g. pressure#2)
5.1.1.2 Function
Select between Acquisition Only, Axis 1 Control, New Axis Control.
5.1.1.3 Insert channel
Inserts the new channel whose definition was created in the 2 previous steps.
5.1.1.4 Delete channel
Highlight a channel and press Delete channel to remove it.
5.1.1.5 Channels and axes count
Displays the current number of configured axes and channels. Note there can be more
than one control on an axis (e.g. axis 1 typically has a displacement and force control
assigned).
5.1.1.6 Control tabs
For each controlled axis a Control tab appears to the right of the Channel description
window. Here you tell the program how many loading blocks and shapes to allocate to the
channel and whether pressing the Start button
 Loading blocks
Select the number of loading blocks you wish the test to have on this axis. For tuning
usually only one block is required.
 Shapes
Selects the number of wave shapes (1 to 4) available for the axis. In the loading page the
actual shapes are attached to buffer numbers.
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 Start enables controller

Does this mean that when start is pressed that this axis control is activated? Perhaps there
are times when you don’t want to create a whole new test if you don’t want axis 2
controlled (e.g. confining pressure).
5.2 The Setup Page - Basic

On this page the user sets the repetition period of the desired waveshape. You may also
add comments on this. The repetition period should be equal to or greater than the Shape
Width set on the Loading Page.
Figure 5-2 Normal Setup Page

5.2.1 Comments
Allows the user to insert comments into the test data file
5.2.2 Date/Time
Displays the Date and Time of the displayed data test run from the data file
5.2.3 Data File
The data filename for the displayed data
5.2.4 Template File
The template file used for the displayed data file.
5.2.5 Data Acquisition
Allows the user to set the pulse repetition period. This should be equal to or
greater than the sum of the Width parameters in the Loading|Axis|Block tabs.
5.2.6 Global Filter
Determines the averaging applied to the data from the IMACS.
5.3 The setup Page – Advanced Acquisition.
If the Advanced Acquisition Options is checked (under the Options menu). Additional
data acquisition options appear.
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Figure 5-3 Advanced Acquisition

5.3.1 Data Acquisition
Sample Interval
Defines the time between each sample measurement.
Number of Samples.
Defines the number of samples to be taken between triggers. Note the
product of Sample interval and number of samples must be equal to or less
than the retrigger interval for correct operation.
Trigger Skip Count
This counts the number of triggers to be “skipped before restarting the
loading sequence. It is useful for allowing a sample to relax for differing
times on different test runs without having to create a whole new test.
Channel select window.
In this window check the boxes of the channels you wish displayed.
Reducing the number of channels displayed reduces the amount of data
traffic from the IMACS to the PC and reduces the risk of data loss in older
PCs.
5.4 The Loading Page

This page contains most of the setup information required for the test. The page contains
an Axis tab for each control axis defined in the Configuration page.
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Figure 5-4 Loading Page

Each Axis sub-page contains a Shapes tab as well as a Block tab for every block permitted
for that axis as detailed in the Configuration page.
5.4.1 Shapes Tab.
The Shapes tab allows the user to define which shapes are loaded into which buffer for
that Axis. This permits the user to change shapes merely by changing the buffer number on
the Block Tab|Shape box.
5.4.2 Block tab
The Block tab has several subdivisions
 Control Function. This sets whether the displacement or force channel is the
controlling channel for actuator movement.
 Implementation
 Tuning. This is where initial PID values are entered for the test. These are adjusted “on
the fly when the test is running by accessing the Tuning Page.
 Block Transfer Limits. These decide if and when the test transfers to the next control
block. Transferring to Block 0 ends the test.
 Loading Function. This defines what type of Loading is performed by the test.
o Ramp – set a target displacement or force and a required time to achieve.
o Rate – set a rate of change of displacement or force.
o Shape – defined waveshape from the Shapes sub page are allocated to one of 4
buffers from which they are selected for the test. See the Shapes sub page for
shape details.
o Values can be relative to current actuator position or force or absolute. Min
and Max values are also set.
 Shape. This is where the desired waveshape is selected by choosing the buffer depicting
the waveshape. The period of the waveshape is also set here and whether it is inverted
or normal; and whether ALC is used. Note the period of the waveshape must be equal
to or less than the Data Acquisition retrigger interval set on the Setup Page. Varying
these 2 items can allow the system to relax or return to a steady state between pulse
applications. e.g. a haversine pulse of 1000ms width is retriggered every 2000ms allows
for 1000ms relaxation time.

ABN 92 168 265 156 Tuning
5.5 Data Display Page.

This page controls how the data is displayed in the lower window area. Here all the
charting options are set. They may be changed at any time even whilst a test is running.
Figure 5-5 Data Display Page

For every channel selected on the Setup Page (or all channels if Advance Acquisition is
OFF) a tab is displayed in this page. Each Tab contains the charting options for that
control or data channel.
The tabs contain checkboxes to determine which side of the chart the vertical axis
information is displayed, the plot colour, whether gridlines are displayed for that chart
item and auto or manual scaling options.
Also shown on this page are 3 counters.
 Scan error Count – don’t know.
 Pulse Error Count – Number of pulses where errors were detected.
 Pulse Count – Total number of pulses so far in this test run.
5.6 Tuning Page.

Once a test is started the Tuning page becomes visible. This page permits the user to vary
the PID values whilst observing their effect in the chart area below.
Chart updates take 2-3 cycles to appear depending on several factors such as the time in the
cycle the change was made, the communication speed with the IMACS, the speed of the
PC and what other applications are running.

ABN 92 168 265 156 Tuning
Figure 5-6 Tuning Page

An Axis tab for each control axis appears on the page.
Within each Axis tab there is a Block tab showing the control channel on that axis (e.g.
force, displacement) and the current PID values for that channel. Up and down buttons
beside each value enable it to be changed dynamically whilst the results can be viewed on
the chart below.

ABN 92 168 265 156 Tuning
6 RUNNING THE TEST

6.1 Setting up the hardware.
Once the software is setup the user can now set the hardware into the required
configuration for tuning. (see Figure 5-6 above for typical test data display)
6.2 Start the test.
Once the hardware is setup correctly the test is started by clicking on the Start Radio
button. When Pressed the Tuning tab appears allowing the PID values to be “tuned”.
6.3 Review the results and fine tuning the waveshape.
Using the following figures as a guide adjust the PID values to achieve the best waveshape.
Chart updates take 2-3 cycles to appear depending on several factors such as the time in the
cycle the change was made, the communication speed with the IMACS, the speed of the
PC and what other applications are running.
Input step function between Proportional Gain too high Proportional Gain too low
1Hz and 5 Hz at approx 5%
amplitude.
Correct Proportional Gain. Correct Proportional Gain and

Adjust Derivative to reduce Derivative.
initial overshoot to a minimum.
Integral Time Constant too Integral Time Constant too Correct output
high. low.
- END -


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Universal Testing Software

Version 1V25 Page i

Version 1V25 Page ii

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1.3 Referenced Documents.

Table 2 Referenced Documents

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Figure 2-1 Closed Loop Servo Control.

Control ERROR = Input DEMAND - Position FEEDBACK

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3.2 Software Installation

3.4 IMACS Channel Assignment

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4 MENUS AND OPTIONS.

4.1.2 Template load/save.

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4.2 Run Menu

4.3 Options Menu.

Figure 4-1 Options Menu

Figure 4-2 Hardware Options Menu

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4.4 View Menu

Figure 4-3 View Menu

4.4.1 Transducer Levels.

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Figure 5-1 Configuration Page

5.1.1.1 New channel Definition

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 Start enables controller

5.2 The Setup Page - Basic

Figure 5-2 Normal Setup Page

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Figure 5-3 Advanced Acquisition

5.4 The Loading Page

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Figure 5-4 Loading Page

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5.5 Data Display Page.

Figure 5-5 Data Display Page

5.6 Tuning Page.

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Figure 5-6 Tuning Page

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6 RUNNING THE TEST

Correct Proportional Gain. Correct Proportional Gain and

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