¶ 相关文件：
¶ Component Test；Damper Test；Elastomer Test
¶ Damper Test_MaxwellDyno；Damper Test_Roehrig
¶ 1. Component Test
The term “Component” encompasses dampers and elastomers.
Component Test is a specialist Pulsar module for performing tests to characterise dampers and elastomers. It uses the Pulsar Inductive User Interface model to walk users step-by-step through what is a complicated configuration - test - analysis procedure.
¶ 1.1 Organisation And Management of tests, And General Usage.
Component Test uses the concepts of Projects to aid organisation and management of tests.
All aspects of the test are recorded, allowing users to recall part and test specifications and test data for past tests. Past tests may be re-run, and re-analysed. Comments for projects, test specifications, and parts are supported.
The current state of the application is always saved, and work on specifying a test can be broken off and then resumed at any point. This makes returning to working on Component Test a breeze!
¶ 1.2 Multistation and Endurance Damper Test Machines
We have not yet done a multistation or endurance machine with Pulsar software. I’m expecting to deal with this as/when we get close to an order.
Multistation machines are usually used for endurance testing and vice versa although the software issues/features could be divided into multistation and endurance.
Multistation Machines
In the past we’ve done multistation machines with 2, 4 and 6 stations. Hopefully any new software could deal with n stations.
Being multistation doesn’t really affect the test or test specification it just means we’ve got multiple load channels in the data files (and possibly multiple temperatures). Having multiple load channels makes the results display more complex i.e. we’ve now got 4 load tables and 4 sets of force Vs displacement loops. If it’s a 7 speed test you get 7 x 4 = 28 loops per test and there has to be a method of selecting what to put on any graph.
Endurance Test Machines
In its simplest form this means software that will create a sine-on-sine (heterodyne) test where every so often the sine-on-sine stops and a performance test occurs. Pulsar currently offers an endurance test with a performance test before and after x cycles of sine-on-sine.
The performance test is the same as what we currently do i.e. upto 15 speeds with some options like preload/friction and priming.
As usual most people have their own variation which makes it impossible to do something general! The last time I was involved with an endurance test machine (5 years ago) some people were still happy to do sine-on-sine with regular performance tests. Some of our other customers did tests based on blocks of single sine i.e. x cycles at x1 Hz and x2 mm, followed by y cycles at y1 Hz and y2 mm and then repeat. I’ve never seen anyone do it but some people have mentioned the possibility of using file data in the endurance sections.
Unfortunately endurance testing usually introduces a whole raft of other things:
The machines often include an actuator (hydraulic, pneumatic or weights and springs) to apply sideload. If this needs to be controlled by the software then the test specification gets more complex. The first machines I worked on measured and controlled the average sideload. Peugeot needed to measure/control the sideload individually. Some customers (Peugeot) like to do blocks of sine on the sideload and others are happy with constant sideload.
The endurance section usually puts a great deal of energy into the dampers and hence they have to be cooled. In some cases forced air cooling will work but often water cooling is required. The cooling usually has to be turned on and off so the software monitors the damper temperature(s) and switches it on/off. Most customers were happy with an on/off control algorithm based on the average temperature; Peugeot wanted the temperature controlled individually using a PID alogrithm this made the hardware and software more complex. In some cases cooling is not an issue because the custumer is happy to use constant cooling, in other words they turn it on at the start of the test and leave it on.
In some cases it is necessary to cycle variable dampers through their settings as the endurance test progresses. Peugeot also needed the performance tests repeated for each setting (how many graphs?).
Various people wanted to include various different bits of information in their test results, stuff like the operator or damper serial number. We've had to do different things for different people.
Various complications can arise if not all the stations are used. Maybe they only want to test 2 dampers or a damper breaks and has to be removed. If we're controlling temperature all the dampers need to be similar which is not the case if one has been removed or is not working correctly (could the thermocouple be moved to one of the other dampers). I think the standard sideloading mechanism requires all the dampers to be present.
Underpeak limits are important for detecting failed dampers. An underpeak limit can be configured to activate when a damper is no longer generating enough load.
Endurance tests can be very long (more than a week) so managing the test integrity is very important. If a test stops for some reason such as a damper breaking then it needs to be possible to see where the test got to and restart with the remaining dampers. If the controller crashes we need to know where the test got to and be able to start it again. (If something goes wrong with a performance test you can just do it again.)
Basic Endurance Damper Test Machine Features
I’ve created a list of basic features that could form the starting point for discussions with anyone who wants endurance damper test software. We can invent a price to go along with this list a basic features and adjust the price as/when the customer asks for extras.
Please mention any omissions or things that should/could be extra!
Sine-on-sine (or single sine) endurance section with upto 10 equally spaced performance tests.
Performance test is upto 15 speeds and can include preload(gas)/friction and priming.
Upto 4 dampers (we'll try and make the number of dampers unrestricted in the software but lets try and charge extra for more than 4).
Supports on/off temperature control based on average temperature. You specify the upper temperature and lower temperature for the endurance section as well as a temperature for the performance i.e. the temperature will be allowed to fall before conducting the performance test. Cooling is switch on/off with a single digital output.
Static sideload applied during the endurance section based on the average across all dampers. Note, the main reason for working with an average is because that's how the sideloading actuator works, there is only one actuator.
¶ 2. Damper Test
Part Configuration Parameters
Component Temperature - Controls climatic chamber temperature.
Side Load - Applies a lateral force to the damper.
Damper Current - Controls current to damper.
Priming
Will “exercise” the specimen to remove friction and achieve steady-state behaviour.
Pre-Load & Friction Testing
Uses a low-velocity, triangular displacement input at a specified frequency and amplitude to measure friction.
The Pre-Load is the mean load in the cycle
This can be performed about different displacement mean-levels. The Pre-load / Mean Displacement relationship characterises the effective “spring-rate” of the component.
Muli-Speed Tests
A series of Sinusoidal displacement inputs. User specifies maximum displacement, frequency, duration and mean-level.
Graphical “limits” can be specified to highlight exessive compression and rebound forces.
Fade Test
Repeats the Multi-speed test after first warming the specimen to a specified temperature. The specimen is warmed by “exercising” it.
Running Tests
Tests are run from a simple "one-touch" panel allowing the user to Start, Stop, Abort and Park.
Progress is displayed in a progress panel.
Test Evaluation
Test Data is displayed in tabular and graphical form in a seperate window.
There are 3 graphical display options: Force/Displacement, Force/Velocity and Peak Force/Peak Velocity.
Data can be "smoothed" over specified number of data points.
Force/Velocity relationship can be extrapolated in cases where max. Velocity can not be achieved.
For extreem non-linear characteristics, a displacement envelope can be specified from where the max.force is measured.
Sets of data can be appended to a "Batch Results" table for wider comparison and analysis.
Damper Test_MaxwellDyno
Damper Test_Roehrig
¶ 3. Elastomer Test
An elastomer is a material with both elastic and rigid properties. Our package is an analysis tool to measure how the material varies under test conditions.
Part Configuration Parameters
Component Temperature - Controls climatic chamber temperature.
Current - Controls current to specimen.
Test Configuration
A series of Sinusoidal displacement inputs. User specifies whether the test is constant velocity or displacement ( the software calculates and displays the equivalent velocity or displacement at each frequency ).
User specifies frequency range and increment and mean operating load or displacement.
Running Tests
Tests are run from a simple "one-touch" panel allowing the user to Start, Stop, Abort and Park.
Progress is displayed in a progress panel.
Test Evaluation
Software calculates Dynamic Stiffness, Loss Angle, Elastic Stiffness and Damping Factor over the frequency range.
This can be displayed in graphical or tabular format.
