Systems and methods for controlling torsion material testing systems

Abstract

A method and system are provided for a torsion material testing system, the torsion material testing system including a rotatable actuator, such as a motor, configured to perform a torsion material testing operation. During the torsion material testing operation, a virtual interlock is configured to engage or disengage with the actuator to prevent or allow rotational movement of the actuator (e.g., in a set state or during the torsion material testing operation, respectively). Control circuitry is used to control the virtual interlock and the torsion testing system based on one or more operating states before, during, or after the material testing process.

Description

[0001] Cross-referencing related applications

[0002] This application is incorporated herein by reference in its entirety from U.S. Provisional Patent Application No. 63 / 090,020, entitled “Systems and Methods For Control Of A Torsional Material Testing System”, filed on October 9, 2020, and U.S. Patent Application No. 17 / 487,820, entitled “Systems and Methods for Control of a Torsional Material Testing System”. Background Technology

[0003] This disclosure relates generally to materials testing, and more specifically to systems and methods for materials testing systems including torsion testing systems.

[0004] General testing machines are used to perform mechanical tests on materials or components, such as compressive strength testing, tensile strength testing, or torsional strength testing. Summary of the Invention

[0005] Systems and methods for testing materials are disclosed, including a torsion material testing system, generally as shown in the figure and a description relating to at least one figure, as set forth more fully in the claims.

[0006] Instruction manual illustrations

[0007] These and other features, aspects, and advantages of this disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like reference numerals denote similar parts throughout the drawings, wherein:

[0008] Figure 1 Examples of test apparatuses for performing mechanical performance tests according to various aspects of this disclosure.

[0009] Figure 2 Based on all aspects of this disclosure, Figure 1 A block diagram of an exemplary embodiment of the testing apparatus.

[0010] Figure 3 Based on this disclosure, Figure 2 A block diagram of an exemplary implementation of a security system.

[0011] Figure 4 is a flowchart representing example machine-readable instructions according to various aspects of this disclosure, which can be generated by... Figure 3 The security processor executes to control Figure 1-3The status of the material testing system.

[0012] Figure 5 The present disclosure illustrates various aspects that can be used to implement Figure 1-3 An exemplary operator interface.

[0013] Figure 6 The present disclosure illustrates various aspects that can be used to implement Figure 1-3 Another exemplary operator interface.

[0014] Figure 7 The following are illustrated in the startup routine of a materials testing system according to various aspects of this disclosure. Figure 1 Exemplary material testing systems and Figure 5 and Figure 6 The user interface.

[0015] Figure 8 Various aspects according to this disclosure are shown. Figure 1 An exemplary material testing system and a material testing system in its setup state. Figure 5 and Figure 6 The user interface.

[0016] Figure 9 In accordance with all aspects of this disclosure, Figure 1 An exemplary material testing system and when the rotary actuator is jogged in a limited manner during a warning or test state. Figure 5 and Figure 6 The user interface.

[0017] Figure 10A , 10B 10C illustrates various aspects according to this disclosure. Figure 1 An exemplary material testing system and the transition from a setup state to a warning state and a test state to initiate material testing. Figure 5 and Figure 6 The user interface.

[0018] Figure 11A , 11B 11C illustrates various aspects according to this disclosure, Figure 1 An exemplary material testing system and how the rotary actuator returns to the desired state or position during the transition from a set state to a warning state and a test state. Figure 5 and Figure 6 User interface

[0019] These drawings are not necessarily drawn to scale. Where appropriate, similar or identical reference numerals may be used to denote similar or identical parts. Detailed Implementation

[0020] What is disclosed is a system and method for torsional strength testing. In particular, the disclosed torsional material testing system employs several safety modes and software architectures to ensure the safe operation of the system. For example, rotational motion is safely prohibited when the system is running in unrestricted or test modes, which is indicated to the operator through visual, auditory, or other suitable feedback.

[0021] When the system is operating in a restricted mode (e.g., disabled or set mode), the virtual interlock prevents powered movement of the rotary drive system. This allows the operator to interact with the system without unintentionally activating the torsional material testing system. In some examples, the rotary drive system (e.g., a rotary motor) allows for manual jogging. For instance, the virtual interlock can be activated to prevent powered movement of the rotary drive system while allowing physical rotation of the material under test.

[0022] In some examples, a motor brake is provided to lock the rotational movement of the rotary drive system motor. This brake can be implemented via hardware and / or software, manually and / or in response to a trigger. For example, when a material testing system is configured for axial setup or testing, but without rotational movement or torsional testing, a motor brake can be used to lock the rotary drive system.

[0023] In some examples, unrestricted modes (including test states) allow the motor to be jogged to move clockwise or counterclockwise, for example, by using a user interface (e.g., a remote device, control panel, connected computing platform, etc.). After the torsional material testing process, the rotary drive system can automatically or in response to user input return to the default or commanded position.

[0024] Traditional materials testing systems employ mitigation techniques, such as configured switches, guards, limited force control, motion limiting, and / or protection, to improve operational safety. However, traditional materials testing systems are often not consistently compliant with international standards. Traditional mitigation techniques require operators to place the system in appropriate operating modes, such as safe interaction or testing. Many traditional safety techniques can be implemented using off-the-shelf safety components, such as programmable logic controllers (PLCs) and / or relays. PLCs and relays typically add significant costs to materials testing systems.

[0025] The disclosed example materials testing systems embed or integrate internationally standardized safety systems. Because the safety systems are integrated into the materials testing systems, these disclosed example systems offer safety improvements at a lower cost than using off-the-shelf components, as the safety systems are integrated into the existing electronics, semiconductors, and / or circuit boards of the materials testing systems. This integration further improves reliability by reducing or eliminating external wiring between purchased safety components.

[0026] As described in more detail below, the disclosed example safety system for a materials testing system includes a machine status indicator that visually displays the status of the testing machine from the perspective of operational constraints. The disclosed example safety system for a materials testing system provides highly reliable and monitored activation mechanisms at the machine control point, which may include internal fault checking and / or power diagnostics within the materials testing system.

[0027] The disclosed material testing systems are designed for simple, simultaneous axial and torsional testing of equipment and / or components, but offer the flexibility to be used for purely axial or torsional testing. In some examples, the torsional material testing system controls and monitors the operating equipment, as well as safety systems and associated circuitry. The disclosed example material testing systems are compatible with interlocking protection systems with redundant or diversified contacts. Such protection systems comply with ISO safety standards through the use of redundancy, diversification, and / or dynamic real-time monitoring. The disclosed example material testing systems include redundant torsional material testing system monitoring. The shutdown circuitry of the disclosed example material testing systems complies with international safety standards, including ISO 13849-1.

[0028] Furthermore, conventional off-the-shelf safety relay assemblies used with PLCs employ an additional firmware layer within the PLC to stop the movement of moving parts in an emergency stop event. Exposed example safety systems for materials testing systems are configured to allow hardware (e.g., an emergency stop button) to directly shut off the power amplifier drive to the actuator, regardless of whether the embedded firmware within the safety processor is running.

[0029] Disabling circuits, actuators, and / or other hardware can be accomplished by hardware, software (including firmware), or a combination of hardware and software, and may include software control that physically disconnects, powers off, and / or restricts commands to activate the circuits, actuators, and / or other hardware. Similarly, enabling circuits, actuators, and / or other hardware can be accomplished by hardware, software (including firmware), or a combination of hardware and software, using the same mechanisms used for disabling. Firmware may include stored instructions, such as Security Level Embedded Software (SRESW) and / or Security Level Application Software (SRASW).

[0030] The publicly disclosed example material testing system conforms to European mechanical codes and follows the rules set forth in ISO 13849-1, which pertains to "Safety-Related Parts of Control Systems." The following functions, identified through system risk analysis, are integrated into the material testing system: The safety system provides a disabled drive state to remove energy from the drive crosshead, a disabled drive state to remove energy from the torsional material testing system, and a limited drive state for operational settings. In the limited drive state, the example safety system monitors the crosshead speed to keep it below the speed limit, monitors intentional manual movements (jogging) of the torsional material testing system, monitors commands for the torsional material testing system process, and / or monitors unintentional torsional movements.

[0031] The disclosed example material testing system also includes an unrestricted drive state, which allows the checks to be removed in the restricted drive state. In some examples, the unrestricted drive state can be entered via a dual activation mechanism, in which the material testing function is executed without the operation interacting with the system.

[0032] The disclosed example material testing system includes indicators of different states, such as disabled state, set state, warning state (e.g., restricted drive mode) and test state (e.g., unrestricted drive mode) on each machine, to clearly indicate when the operator can interact and when there is a hazard.

[0033] Disclosed example material testing systems include one or more stop functions configured to take precedence over the initiation and / or continuation of movement of components such as torsional material testing systems. Furthermore, the one or more stop functions can be redundantly configured in hardware, so that the stop functions can effectively disable the material testing system even if the software portion of the safety system is disabled. Examples of such stop functions included in the disclosed systems include interlocking protective devices and / or emergency stop switches.

[0034] Some publicly available example material testing systems include the selection and enforcement of a single control point for starting the material testing rack and / or the torsion material testing system. Some example systems provide power failure monitoring and / or protection to ensure the system ceases unrestricted operation and places the material testing system in a disabled drive state upon re-establishment of power. In some examples, the torsion material testing system automatically shuts off power in response to power failures.

[0035] The disclosed exemplary safety systems and materials testing systems include enhanced internal diagnostics and reporting of critical errors within the system to the operator, such as equipment malfunctions or conflicts between redundant inputs, outputs, and / or processes. Compared to conventional materials testing systems, the disclosed exemplary materials testing systems enable faster sample removal and / or insertion because the safety setup modes of the testing machine allow operator movement within the testing space without requiring the materials testing system to be disabled or protective doors to be installed. The disclosed exemplary systems further enhance operator safety when setting up and configuring the system within the testing space, at least in part due to the use of setup states that restrict the movement of the torsional materials testing system and / or limit the movements and / or forces that can be applied to or exerted by the torsional materials testing system.

[0036] The disclosed material testing systems and safety systems can be specifically configured for use in the disclosed example configurations to achieve defined risk mitigation. Compared to purchasing generic, off-the-shelf, discrete safety components, the disclosed material testing systems are significantly more efficient and targeted for material testing.

[0037] Disclosed material testing and safety systems are configured to return to a restricted state whenever the unrestricted state is no longer in active use, and / or require operators to intentionally take action to transition from the restricted to the unrestricted state. Example material testing and safety systems provide proactive warning notifications when the unrestricted state is activated. Example proactive warning notifications include those defined as notifications that appear and / or disappear at locations likely to be observed by the operator (e.g., as opposed to providing static labels or other static visual effects on the material testing system). Furthermore, the disclosed example notifications are visually intuitive, for example, by providing a commonly understood color scheme (e.g., green, yellow, red) to indicate the status of the material testing system.

[0038] In some examples, the operator interface includes a hazard indicator, wherein one or more processors are configured to control the hazard indicator when reducing limits on the actuator. Some examples also include a crosshead configured to move to position or apply force to the test material, wherein the actuator is configured to drive the crosshead, and the limits on the actuator in the set state include an upper limit on the rotational speed of the crosshead.

[0039] In some exemplary materials testing systems, the operator interface further includes one or more visual indicators configured to selectively highlight corresponding inputs among those selectable by the operator, wherein one or more processors are configured to control the one or more visual indicators to emphasize corresponding inputs based on the state of the materials testing system. In some examples, one or more processors are configured to transition the state from one of a plurality of restricted states to one of a plurality of unrestricted states in response to predefined inputs to the operator interface. In some examples, the operator interface includes a status indicator configured to output an indication of the current state of the materials testing system.

[0040] In the disclosed example, the material testing system includes a rotatable actuator configured to control an operator-accessible torsional test component of the material testing system, a virtual interlock configured to engage or disengage with the actuator to prevent or allow rotational movement of the actuator, and control circuitry. The control circuitry is configured to control the actuator to perform a material testing process, monitor multiple inputs related to the operation of the material testing system, identify the operating state of the material testing system from multiple predetermined operating states based on the multiple inputs and the material testing process, the multiple predetermined operating states including one or more of a disabled state, a set state, a warning state, or a test state, and control the virtual interlock based on the identified state.

[0041] In some examples, the virtual interlock is configured to prevent one or more of the power supply or control signals from activating the rotary motion of the actuator.

[0042] In some examples, the control circuitry is further configured to recognize the activation of the non-rotational test process and, in response, engage a brake to lock the actuator to prevent rotational movement. In one example, the non-rotational test process includes an axial test process. In another example, the non-rotational test operates in several predetermined operating states, including one or more of a disabled state, a set state, a warning state, or a test state.

[0043] In some examples, the operating state of the non-rotational test process takes precedence over the operating state of the torsional system. In some examples, when the non-rotational test process is running in the setup state, the control circuitry is configured to control the virtual interlock engagement to prevent the torsional system from undergoing dynamic rotational motion.

[0044] In the examples, the control circuitry is further configured to control the engagement or disengagement of the virtual interlock in response to signals from one or more sensors. In some examples, engagement of the virtual interlock corresponds to a restricted mode, such that a disabled state, a warning state, and a set state correspond to restricted modes that prevent actuator operation. In the examples, the restricted mode corresponds to applying a restriction to the actuator while the control circuitry does not control the actuator in response to an operational input. In the examples, the test state corresponds to an unrestricted mode that allows actuator operation, and the test state corresponds to reducing the restriction on actuator operation while controlling the actuator to perform a torsional material test process or jog or return.

[0045] In some examples, the limitation includes limiting the actuator's rotational speed, limiting the number of revolutions of the actuator, or limiting the actuator's rotational angle, or one or more of these. In some examples, the limitation is set to a specific threshold or to zero motion. In some examples, a virtual interlock is engaged and the brake is disengaged, and the actuator is configured to allow an operator to manually position the actuator in a set state.

[0046] In some examples, the control circuitry includes a control processor configured to perform control of the actuator, and one or more safety processors configured to perform actions such as monitoring multiple inputs, identifying the status of the material testing system, and controlling virtual interlocks.

[0047] In some publicly available examples, a material testing system includes a rotatable actuator configured to control a torsional test component accessible to the operator of the material testing system, a brake for preventing rotational movement of the rotatable actuator, a virtual interlock configured to engage or disengage with the actuator to prevent or allow rotational movement of the actuator, and control circuitry. The control circuitry is configured to control the actuator to perform a material testing process, monitor multiple inputs related to the operation of the material testing system, identify the operating state of the material testing system from multiple predetermined operating states based on the multiple inputs and the material testing process, the multiple predetermined operating states including one or more of a disabled state, a set state, a warning state, or a test state, and control the virtual interlock based on the identified state.

[0048] In some examples, the brake is configured to physically lock the actuator to prevent free rotational movement. In some examples, the brake is configured for manual engagement or disengagement. In some examples, the control circuitry is further configured to recognize activation of a non-rotational test procedure and, in response, engage the brake or a virtual interlock to lock the actuator to prevent free rotational movement.

[0049] In some cases, non-rotational testing procedures include axial testing procedures.

[0050] As used herein, "crosshead" refers to a component of a materials testing system that applies directional (axial) and / or rotational forces to the specimen. A materials testing system may have one or more crossheads, which may be located in any suitable position and / or orientation within the materials testing system.

[0051] Figure 1 This is an exemplary material testing system 100 for performing mechanical property tests. For example, this exemplary material testing system 100 may be a general-purpose testing system capable of performing static mechanical tests. The material testing system 100 may perform, for example, compressive strength tests, tensile strength tests, shear strength tests, flexural strength tests, flexural strength tests, tear strength tests, peel strength tests (e.g., adhesive strength), torsional strength tests, and / or any other compression and / or tensile tests. Additionally or alternatively, the material testing system 100 may perform dynamic tests.

[0052] The example material testing system 100 includes a test fixture 102 and a computing device 104 communicatively coupled to the test fixture 102. The test fixture 102 applies a load to a material under test 106 and measures the mechanical properties of the material under test, such as the displacement of the material under test 106 and / or the force applied to the material under test 106. Although the example test fixture 102 is shown as a two-column fixture, other fixtures, such as a single-column test fixture, may also be used. The example test fixture 102 may include one or more of the following: a rotary drive system 101 for rotating the material under test 106 to perform torsional material testing and / or a displacement strength testing system for applying force to the material under test 106.

[0053] Example computing device 104 can be used to configure test fixture 102 and control test fixture 102 and its components (e.g., test systems 233 and / or 236, such as...). Figure 2 The system receives measurement data (e.g., sensor measurements, such as force and displacement) and / or test results (e.g., peak force, fracture displacement, etc.) from the test fixture 102 for processing, display, reporting, and / or any other desired purpose. In some examples, an operator interface 107 is arranged on or near the material testing system 100. This interface 107 may present information about operating modes, testing procedures, material information, etc., and accept input and / or commands from the operator (as an alternative to or addition to the example operator interface 500).

[0054] Figure 2 yes Figure 1 A block diagram of an exemplary embodiment of the material testing system 100. Figure 2The example material testing system 100 includes a test fixture 102 and a computing device 104. The example computing device 104 may be a general-purpose computer, a laptop, a tablet, a mobile device, a server, an all-in-one computer, and / or any other type of computing device.

[0055] Figure 2 An exemplary computing device 104 includes a processor 202. The example processor 202 can be any general-purpose central processing unit (CPU) from any manufacturer. In other examples, the processor 202 may include one or more specialized processing units, such as a RISC processor with an ARM core, a graphics processing unit, a digital signal processor, and / or a system-on-a-chip (SoC). The processor 202 executes machine-readable instructions 204, which may be stored locally in the processor (e.g., in an included cache or SoC), random access memory 206 (or other volatile memory), read-only memory 208 (or other non-volatile memory, such as FLASH memory), and / or mass storage device 210. The example mass storage device 210 may be a hard disk drive, a solid-state drive, a hybrid drive, a RAID array, and / or any other mass data storage device.

[0056] Bus 212 enables communication between processor 202, RAM 206, ROM 208, mass storage device 210, network interface 214, and / or input / output interface 216.

[0057] Example network interface 214 includes hardware, firmware, and / or software to connect computing device 104 to communication network 218, such as the Internet. For example, network interface 214 may include wireless and / or wired communication hardware compliant with IEEE 202.X standards for sending and / or receiving communication data.

[0058] Figure 2Example I / O interface 216 includes hardware, firmware, and / or software to connect one or more input / output devices 220 to processor 202 for providing input to and / or output to processor 202. For example, I / O interface 216 may include a graphics processing unit for interfacing with a display device, a universal serial bus port for interfacing with one or more USB-compliant devices, FireWire, fieldbus, and / or any other type of interface. Example material testing system 100 includes a display device 224 (e.g., an LCD screen) coupled to I / O interface 216. Other exemplary I / O devices 220 may include a keyboard, keypad, mouse, trackball, pointing device, microphone, audio speaker, display device, optical media driver, multi-touch screen, gesture recognition interface, magnetic media driver, and / or any other type of input and / or output device.

[0059] Example computing device 104 can access non-transitory machine-readable medium 222 through I / O interface 216 and / or I / O device 220. Figure 2 Examples of machine-readable media 222 include optical discs (e.g., optical discs (CDs), digital multifunction / video discs (DVDs), Blu-ray discs, etc.), magnetic media (e.g., floppy disks), portable storage media (e.g., portable flash drives, secure digital (SD) cards, etc.), and / or any other type of removable and / or installable machine-readable media.

[0060] Figure 1 The example material testing system 100 further includes a test fixture 102 coupled to a computing device 104. Figure 2 In one example, test fixture 102 is connected via I / O interface 216, such as via a USB port, surge protector port, FireWire (IEEE 1394) port, and / or any other type of serial or parallel data port. In other examples, test fixture 102 is coupled directly to network interface 214 and / or I / O interface 216 via wired or wireless connections (e.g., Ethernet, Wi-Fi, etc.) or via network 218.

[0061] Figure 2The test fixture 102 includes a frame 228, a load unit 230, a displacement sensor 232, a torsional material testing system 233 (e.g., including a rotary drive system 101), a cross-shaped component loader 234, a material clamp 236, a control processor 238, and a safety system 240. The frame 228 provides rigid structural support for the other components of the test fixture 102 used for testing. The load unit 230 measures the force applied to the test material by the cross-shaped component loader 234 via a gripper 248. The cross-shaped component loader 234 applies force to the test material, while the material clamp 236 (also referred to as a gripper) holds or otherwise couples the test material to the cross-shaped component loader 234. Examples of cross-shaped component loaders 234 include a motor 242 (or other actuator) and a crosshead 244. The crosshead 244 couples the material clamp 236 to the frame 228, and the motor 242 moves the crosshead relative to the frame to position the material clamp 236 and / or apply force to the material being measured.

[0062] In some examples, a torsion testing system 233 may additionally or alternatively be included. The torsion testing system 233 includes a rotary motor 241 (or other actuator) and is configured to rotate the gripper 236, causing the crosshead to rotate relative to the frame 228 to position the material clamp 236 and / or apply force to the material under test. The rotary motor 241 and / or other components of the torsion testing system 233 may be manually configured, controlled by manual input, and / or automatically controlled by the control processor 238. The crosshead 244 and the gripper 236 are components accessible to the operator. Example actuators that may be used to provide force and / or motion to components of the material testing system 100 include electric motors, pneumatic actuators, hydraulic actuators, piezoelectric actuators, relays, and / or switches.

[0063] Depending on the mechanical properties being tested and / or the material being tested, the example gripper 236 may include a clamping plate, pliers, or other type of clamp. The gripper 236 can be manually configured, controlled by manual input, and / or automatically controlled by a control processor 238. The crosshead 244 and the gripper 236 are components accessible to the operator.

[0064] Example control processor 238 communicates with computing device 104, for example, to receive test parameters from computing device 104 and / or report measurements and / or other results to computing device 104. For example, control processor 238 may include one or more communication or I / O interfaces to allow communication with computing device 104. Control processor 238 may control torsion testing system 233 to increase or decrease the applied rotational force, the rotational speed and number of revolutions of the actuator, and / or the rotational angle from rotary motor 241. In some examples, control processor 238 controls cross-shaped component loader 234 to increase or decrease the applied force, controls clamp 236 to grip or release the material under test, and / or receives measurements from displacement sensor 232, load unit 230, and / or other sensors.

[0065] Example safety system 240 provides an additional layer of monitoring and control to test fixture 102. Safety system 240 monitors operator input and the status of test fixture 102. Figure 2 In the example, safety system 240 restricts user operation of test fixture 102 so that test fixture 102 can only be controlled by the user when the machine is in the appropriate state. In response to detecting one or more conditions, safety system 240 will automatically put test fixture 102 into a restricted state (e.g., a restricted setting state, disabling all power and movement that may lead to dangerous conditions, etc.).

[0066] Based on monitoring input signals from the material testing system 100, input signals from the safety system 240, and / or control signals from the control processor 238, the safety system 240 selectively adds, removes, increases, and / or decreases restrictions on the operation of the material testing system. The safety system 240 controls the operation of the material testing system 100 by determining a state from a plurality of predetermined states in which the material testing system 100 will operate at any given time. Example predetermined states include one or more restricted states, in which one or more operations of the material testing system 100 are restricted (e.g., disabled, limited, etc.), and one or more unrestricted states, in which the restrictions of the restricted states are reduced and / or removed. Figure 2 In one example, the safety processor 240 is attached to and / or interrupts the control processor 238's control over the torsion test system 233 and / or the fixture(s) 236. In some other examples, the safety system 240 may directly control the torsion test system 233 and / or the cross-shaped component loader 234 and / or the fixture(s) 236, while enforcing any applicable restrictions on the actuators.

[0067] Example limiting states include a set state, a warning state, and a disabled state. In the set state, the safety system 240 limits one or more actuators (e.g., motor 241 and / or clamping actuator 246) and controls (or allows control of) the actuators in response to an operational input. Example limits for motor 241 include an upper limit on the actuator's rotational speed, a limit on the number of revolutions of the actuator, and / or a limit on the rotational angle of the actuator relative to test fixture 102. In the disabled state, the safety system 240 limits the actuators, and the control processor 238 does not control the actuators in response to operational inputs (e.g., does not attempt to control motor 241, or prevents control of motor 241 by power-off).

[0068] The example non-restricted state includes a test state. In the example test state, the safety system 240 reduces restrictions on the actuator (e.g., motor 241) while the control processor 238 controls the actuator to perform a test (e.g., according to a material testing process or procedure executed by the control processor 238). In the test state, the control processor 238 can control the actuator to perform jogging actions such as rotating the motor 241, in which case the operation should not be physically close to the crosshead 244 and / or the pneumatic gripper 248.

[0069] Figure 2 The example material testing system 100 may further include one or more control panels 250, which include a plurality of status indicators 252 and one or more mode switches 254. The mode switches 254 may include buttons, switches, and / or other input devices located on the control panel. For example, the mode switches 254 may include buttons that control the motor 241 to jog (e.g., change the rotational position) the material under test via the gripper 248, mode control buttons that, when pressed together with another button, allow the safety system 240 to operate in an unrestricted state, and / or any other input device that results in operation in an unrestricted state.

[0070] Status indicator 252 corresponds to a set of predetermined states that safety system 240 can set material testing system 100 to (e.g., disabled, enabled, warning, and test states as described above). As described in more detail below, safety system 240 controls status indicator 252 to provide indication of the current state of material testing system 100 as determined by safety system 240. Status indicator 252 may include lights, displays, audio, mechanical systems, and / or any other indications identifiable by the operator.

[0071] Figure 3 yes Figure 2 A block diagram of an example implementation of the security system 240. (See diagram for example.) Figure 3 As shown, security system 240 includes security processor 302.

[0072] The example safety processor 302 includes multiple redundant processor cores 304a and 304b. The processor cores 304a and 304b execute redundant instructions 306a and 306b and receive redundant inputs, such that during normal operation of the test fixture 102, the processor cores 304a and 304b should produce substantially the same output. The safety processor 302 (e.g., through the redundant cores 304a and 304b) monitors multiple inputs and determines the state of the material testing system 100 based on these inputs. The safety processor 302 can compare the outputs of the redundant instructions 306a and 306b and control the state of the material testing system 100 based on the comparison of the outputs.

[0073] Example security processor 302 and / or redundant processor cores 304a, 304b may include a general-purpose central processing unit (CPU) from any manufacturer. In some examples, security processor 302 and / or redundant processor cores 304a, 304b may include one or more dedicated processing units, such as a RISC processor with an ARM core, a graphics processing unit, a digital signal processor, and / or a system-on-a-chip (SoC). Security processor 302 and / or redundant processor cores 304a, 304b execute machine-readable instructions, such as redundant instructions 306a, 306b, which may be stored locally in the processor (e.g., in an included cache or SoC), in a storage device, such as random access memory, read-only memory, and / or mass storage.

[0074] Redundant processor cores 304a, 304b and redundant instructions 306a, 306b allow the security system 240 to handle redundancy and / or a wide variety of inputs and outputs, providing a highly reliable and predictable system. Therefore, although in Figure 3 The diagram illustrates representative inputs and outputs, but these inputs and / or outputs can be replicated to support redundant processor cores 304a, 304b and redundant instructions 306a, 306b. The redundant instructions 306a, 306b executed by the safety processor 302 (e.g., embedded software, operating systems, and generated code) conform to flows outlined in international standards, including but not limited to ISO 13849-1, which pertains to "safety-related parts of control systems." While the example safety processor 302 includes multiple redundant processor cores, in other examples, the safety processor 302 may include a single processor core or multiple non-redundant processor cores.

[0075] Figure 3The safety system 240 further includes an actuator disable circuit 308 (e.g., a virtual interlock) that selectively disables the operation of the torsion test system 233. For example, engagement of the actuator disable circuit 308 may prevent the power amplifier 310 from supplying power to the motor 241 of the torsion test system 233. Alternatively or additionally, the actuator disable circuit 308 (or another actuator disable circuit) may prevent the clamping actuator 246 from supplying power to the pneumatic gripper 248. The power amplifier 310 receives input power and outputs power to the motor 242 to control the movement of the motor 241. The example actuator disable circuit 308 and power amplifier 310 can be implemented using a safety-graded safe torque cut-off (STO) high-reliability servo power amplifier. The control processor 238 can control the rotational movement of the motor 241 and the crosshead 244 via a motor control signal 312 sent to the power amplifier 310.

[0076] In response to an STO signal 314 from safety processor 302, actuator disable circuit 308 disables the connected actuator (e.g., rotary motor 241). For example, actuator disable circuit 308 may disconnect all energy to motor 241 (and / or other moving parts in material testing system 100) for a period less than a predetermined time. Example actuator disable circuit 308 may provide an STO feedback signal 315 to safety processor 302, indicating whether actuator disable circuit 308 is currently disabling the actuator. Safety processor 302 may compare STO signal 314 with STO feedback signal 315 to detect a fault.

[0077] In the example material testing system 100, in accordance with international standards, the movement of the rotary motor 241 and any internal components is stopped after the STO signal 314 is activated. Most subsystems of the safety system 240 disclosed herein activate the actuator disable circuit 308 to safely stop the rotational movement of the material holding system 236 and / or the material under test. Furthermore, the power amplifier 310 may include a motor braking circuit 316 to decelerate the motor 241 before the STO signal 314 is applied. The motor braking circuit 316 allows the motor 242 to stop in a more controlled manner by eliminating the continued movement due to mechanical inertia after the drive power is turned off. Using pre-disable braking reduces or minimizes the movement of the crosshead 244 after the motor 241 is de-energized. Therefore, the example actuator disable circuit 308 and motor braking circuit 316 provide a Class 1 stop as defined in the IEC 60204-1 standard, "Electrical Safety Standard for Machinery".

[0078] Example safety processor 302 monitors motor 241 and / or motor braking circuit 316 when pre-disabling braking occurs to confirm that motor 241 is braking. If safety processor 302 determines that motor 241 has not decelerated during braking, safety processor 302 performs brake fault mitigation to stop braking and immediately de-energize motor 241. By implementing brake fault mitigation in a two-stage disabling sequence, safety processor 302 can shorten the stopping distance in the event of brake failure. While the shortest stopping distance occurs when pre-disabling braking is active, a two-stage sequence involving ineffective pre-disabling braking can have a longer stopping distance than a single-stage sequence (e.g., only disconnection) when pre-disabling braking is not fully active. A secondary advantage of brake fault mitigation is that it allows for greater flexibility in implementing a two-stage disabling sequence, enabling a wider range of components and systems to be used in high-performance braking systems with a brake fault mitigation process that can detect brake system faults during the mitigation process.

[0079] Example safety system 240 further includes an emergency stop 318 (e.g., a button, switch, etc.) that provides an emergency stop input signal 320 to safety processor 302. Emergency stop 318 may be a manually operated emergency stop button, a supplementary type of safety function. Emergency stop 318 includes two redundant channels for signaling. Emergency stop 318 may include an emergency stop switch 322, an emergency stop detection circuit 324, and an actuator disable circuit 326. Emergency stop 318 can be independently controlled using the hardware and embedded software of safety processor 302. For example, in response to detecting an emergency stop input signal 320 from emergency stop detector 324, safety processor 302 sets the state of material testing system 100 to a disabled state and provides an emergency stop output signal 321 to emergency stop 318 (e.g., to emergency stop switch 322).

[0080] Emergency stop switch 322, in response to emergency stop output signal 321, controls actuator disable circuit 326 to control actuator disable circuit 314 and / or motor brake circuit 314 to stop motor 241 (e.g., via motor stop 243). Example actuator disable circuit 326 may have a first connection to motor brake circuit 314 and a second redundant connection to actuator disable circuit 308. When actuator disable circuit 326 is triggered, it activates motor brake circuit 314, delays for a period to allow braking to occur, and then activates actuator disable circuit 308 to de-energize the applicable actuator.

[0081] As an additional or alternative to control via the safety processor 302, the emergency stop switch 322 can directly drive the actuator disable circuit 308 within the power amplifier 310, for example, through a physical interruption of the STO signal 314 between the safety processor 302 and the actuator disable circuit 308. The safety processor 302 monitors the emergency stop detection circuit 324 and acts as a redundant monitor for the hardware. The safety processor 302 outputs the STO signal 314 to control the actuator disable circuit 308 to continue disabling the motor 241, so that when the emergency stop switch 322 is released, the material testing system 100 will remain disabled (e.g., in a restricted state) and require user interaction to re-enable the operation of the motor 241.

[0082] Example material testing system 100 (e.g., test fixture 102) is compatible with interlocking protection systems having redundant or diverse contacts. Example safety system 240 may include one or more protective devices 328 and protective interlocks 330 configured to provide physical and / or virtual barriers to prevent operator access to material testing system 100 when operating in an unrestricted state. For example, protective device 328 may include a physical barrier that opens and closes to control access to the volume around pneumatic gripper 248 and / or crosshead 244 (and / or other moving parts). In some examples, protective device 328 includes a motor brake 243 configured to engage manually and / or automatically. For example, motor brake 243 may be engaged by the operator and / or safety system 240 to physically prevent rotation of motor 241. Example physical barriers include protective doors that may use redundant safety switches to monitor whether the door to the protected volume is open or closed. Each door switch has mechanically connected normally open and normally closed contacts that can be dynamically pulsed (e.g., by the protective interlock 330) and / or otherwise received as input. The pulses allow for real-time rationality diagnostic checks of the protective door switches.

[0083] Alternatively or concurrently, the protective device 328 may include a virtual protective device that monitors the volume around the pneumatic gripper 248 and / or the crosshead 244 to prevent intrusion into that volume. Example virtual protective devices may include a light curtain, a proximity sensor, and / or a pressure pad. While the virtual protective device does not physically prevent entry, it outputs a protective signal to a protective interlock 330, which in turn outputs an interlock signal 332 (e.g., similar to the emergency stop switch 322 discussed above) to the safety processor 302 and / or the actuator disable circuit 308.

[0084] Interlock device 330 can trigger actuator disable circuit 308 to de-energize motor 242. In some examples, when the safety interlock 330 is no longer triggered, safety processor 302 controls the re-enablement of power amplifier 310 in a manner similar to the emergency stop switch 322 discussed above.

[0085] Alternatively, when an operator enters the protected volume of the material testing system 100, the example safety system 240 may default to a restricted “setting” state, thereby disabling or de-energizing the actuators of the system 100.

[0086] Example safety system 240 includes multiple status indicators 252 and mode switches 254. Example safety processor 302 monitors mode switches 254 by, for example, dynamically pulsed to mode switches 254 to generate or receive mode switch input signals 338 (e.g., one or more mode switch inputs for each mode switch 254). In some examples, mode switches 254 are high-reliability switches. Safety processor 302 may periodically, irregularly, in response to events (e.g., at startup of a material testing machine), according to a predetermined schedule, and / or at any other time, test mode switches 254 for short circuits or other fault conditions.

[0087] Example safety processor 302 controls status indicators 252 to indicate the status of material testing system 100 to the operator. For example, safety processor 302 may output indicator signal 342 to status indicators 252. If status indicators 252 are lamps, output indicator signal 342 may, for example, control the on / off, flashing, and / or any other output of each lamp. In some examples, safety processor 302 determines the status of the indicators via indicator feedback signal 340. Example indicator feedback signal 340 may indicate to safety processor 302 whether each status indicator 252 is on, off, short-circuited, open-circuited, and / or any other state or condition of status indicator 252. If the processor determines that one or more status indicators 252 are not in the appropriate state as commanded, safety processor 302 controls the material testing system to be in a restricted state to provide notification to the operator (e.g., via control panel 250 or other notification).

[0088] Safety system 240 includes a power monitor 344 to monitor the power sources (e.g., DC and AC power) supplying power to the components of material testing system 100. The power monitor 344 provides one or more power status signals 346 to safety processor 302 and / or watchdog circuit 362 (described below) to indicate whether the monitored power source is within its respective voltage and / or current range. If the power monitor 344 determines that one or more power sources are out of tolerance, safety processor 302 and / or watchdog circuit 362 can disable material testing system 100 and alert the operator.

[0089] The example safety system 240 further includes one or more speed sensors 348. The example speed sensors 348 may be integrated, redundant, and / or a variety of speed monitoring sensors. The speed sensors 348 provide a speed signal 350 to the safety processor 302, which represents the speed of the crosshead. The safety processor 302 monitors the speed signal 350 to ensure that the motor 241 does not exceed a speed limit determined by the machine's current operating mode (e.g., motor speed limit 352). For example, the value of the speed limit may depend on whether the material testing system 100 is in a limited or unlimited state. In some examples, two speed sensors operating on different principles may be used in the material testing system 100 to prevent sensors 348 from continuously failing for the same reason. The speed signal 350 of each speed sensor 348 is read and compared by the safety processor 302 to verify that the speed signals 350 are consistent. If the speed indicated by one speed sensor 348 differs from that of the other speed sensor 350, the safety processor 302 disables the material testing system 100 (e.g., via actuator disable circuit 308).

[0090] Exemplary motor motion limit 352 may include speed and / or rotation limits specifying a limit on the rotational speed or angle of motor 241. When motor motion limit 352 is reached, safety processor 302 stops the movement of motor 241. In some examples, motor motion limit 352 is a multi-level limit, where the number of limits triggered indicates how much motor motion limit 352 has been exceeded. In some examples, the first-level limit is processed by safety processor 302 to stop the operation of the applicable actuator (or all actuators), such as motor 241. When motor 241 continues to move beyond the first-level limit and reaches a second-level limit (e.g., further beyond the acceptable range than the first-level limit), motor motion limit 352 may trigger a direct connection (e.g., a hardware connection) to actuator disable circuit 308 and / or motor braking circuit 316, and / or actuator disable circuit 326 to trigger two-phase disable of motor 242.

[0091] When safety processor 302 controls material testing system 100 in a restricted state (e.g., during disabled, warning, or set states), safety processor 302 disables motor 241. Conversely, when safety processor 302 controls material testing system 100 in a test state, safety processor 202 provides control signal 356, enabling motor controller 354 to rotate test sample via motor 241 during testing. Example motor controller 354 may monitor torsion testing system 233 (e.g., via rotation sensor 358) to ensure motor 241 operates within predetermined limits and / or desired operating parameters. Motor controller 354 provides rotation signal 360 to safety processor 302 to verify that commands for speed, force, angle, etc., are in effect.

[0092] In some examples, the motor controller 354 is controlled by an operator using input from a foot pedal switch. For example, the foot pedal switch may include a separate switch for activating and deactivating the rotation of the motor 241. These switches may be mechanically linked switches, and pulses may be dynamically applied to the switches to check for proper functioning between them and / or to monitor for potential faults (e.g., electrical faults).

[0093] The safety processor 302 further controls the motor controller 354 to de-energize the motor 241 when the power supply to the material testing system 100 is disabled. For example, the safety processor 302 may control the motor 241 (e.g., via one or more programs, circuits, etc.) to enable activation when powered on, but deactivate the actuator under normal conditions, thereby preventing the motor 241 from rotating when the material testing system 100 is not powered.

[0094] Example safety system 240 further includes a watchdog circuit 362. The watchdog circuit 362 communicates with the safety processor 302 periodically, irregularly, in response to one or more events or triggers, and / or at any other time to verify the operation of the safety processor 302. For example, the safety processor 302 may convey a heartbeat signal, or a response to a challenge from the watchdog circuit 362, to indicate to the watchdog circuit 362 that the safety system 240 is operating normally. If the watchdog circuit 362 does not receive the expected signal from the safety processor 302, the watchdog circuit 362 disables the material testing system 100 and notifies the operator.

[0095] Example safety processor 302, example emergency stop 322, example protective interlock 330, example motor speed limit 352, and / or example watchdog circuit 362 are coupled (e.g., via hardware connection) to actuator disable circuit 326. When any of the safety processor 302, emergency stop 322, protective interlock 330, crosshead movement limit 352, and / or watchdog circuit 362 determines that a corresponding condition is met to disable the material testing system 100 (e.g., activation of emergency stop switch 322, tripping of protective device 328, exceeding rotational movement limit 352, and / or triggering of watchdog circuit 362), actuator disable circuit 326 activates motor brake circuit 316 and actuator disable circuit 308. Safety processor 302 can determine that the state of material testing system 100 is disabled.

[0096] Although the control processor 238 and security processor 302 are illustrated as separate processors in the example, in other examples, the control processor 238 and security processor 302 may be combined into a single processor or a group of processors that are not divided into control and security functions. Furthermore, the control processor 238, security processor 302, and / or combined processors may include non-processing circuitry, such as analog and / or digital circuitry, to perform one or more dedicated functions.

[0097] Figure 4A and 4B A flowchart representing example machine-readable instruction 400 is shown, which can be generated by... Figure 3 Security processor 302 executes to control Figure 1-3 The state of the torsional material testing system. Example instruction 400 can be executed to determine the state of the material testing system from a plurality of predetermined states, impose restrictions on the actuator (e.g., motor 241), and automatically set the state of the torsional material testing system to a restricted state (and / or one of a restricted state subgroup) in response to the completion of an action involving the control of the actuator.

[0098] In block 402, the material testing system 100 and / or one or more subsystems can be powered on. If the material testing system 100 is not powered, block 402 repeats until the material testing system 100 is powered on. When the material testing system 100 is powered on (block 402), in block 404, the safety system 240 sets the state of the material testing system 100 to a disabled state and disables one or more actuators (e.g., rotary motor 241, clamping actuator 246). For example, the safety system 240 can configure the actuator disable circuit 308 to default to de-energizing motor 241.

[0099] In block 406, the security processor 302 is initialized. For example, the security processor 302 may perform fault checks (e.g., checking for open and / or closed circuits in inputs, outputs, and / or attached devices), redundancy checks (e.g., determining that redundant inputs and / or redundant outputs are consistent), and / or other initialization procedures.

[0100] In block 408, security processor 302 determines whether any fault is detected in security system 240 (e.g., detected during initialization). If a fault is detected (block 408), security processor 302 outputs a fault alarm (e.g., via control panel 250, via computing device 104, etc.). Example instruction 400 can then terminate.

[0101] When no fault is detected (block 408), in block 411, the safety processor 302 determines whether operator input has been received to transition the material testing system 100 from a disabled state to a enabled state. For example, the safety processor 302 may request one or more specified inputs (e.g., pressing an unlock button) to transition from the disabled state. If no operator input has been received (block 411), block 411 is repeated while the material testing system 100 remains in disabled mode awaiting operator input.

[0102] Upon receiving operator input (block 411), in block 412, the safety processor 302 sets the state of the material testing system 100 to a set state. Based on the set state, the safety processor 302 enables actuators (e.g., motor 241), restricts actuators, and indicates a disabled state (which may include one or more subgroups, such as set or warning states, indicated, for example, by a status indicator 252). In some examples, the safety processor 302 controls one or more visual indicators on the control panel 250 to selectively highlight corresponding inputs (e.g., mode switch 254) that are selectable by the operator, based on whether the material testing system 100 is in a disabled or restricted state. For example, the safety processor 302 may control the visual indicators to highlight inputs that can be used by the operator in the set mode (e.g., manual rotation of the rotary drive system 101) and not highlight inputs that are not available in the set mode (e.g., jog function).

[0103] In block 414, safety processor 302 monitors input signals (e.g., sensor signals 320, 332, 338, 346, 350), feedback signals (e.g., feedback signals 315, 340, 360), and / or control signals (e.g., signals from control processor 238) of safety system 240. Safety processor 302 can monitor these signals, for example, to identify operator commands and / or conditions that will cause safety processor 302 to recognize changes in the state of torsion material testing system 233.

[0104] In block 416, safety processor 302 and / or control processor 238 determine whether an operator control signal has been received to drive the actuator under limiting conditions (e.g., at low speed or low pressure), thereby entering an unrestricted (or lower-restricted) state (e.g., a test state) without performing the test procedure. For example, the operator may select one or more mode switches 254 to rotate the crosshead 244 at a low jog speed via motor 241. If an operator control signal to drive the actuator has been received (block 416), in block 418, control processor 238 controls the actuator according to the limitations imposed by safety processor 302 (e.g., speed limit, force limit, operator permission limit).

[0105] In block 420, the security processor 302 outputs a controlled actuation indication. For example, the security processor 302 may control one or more status indicators 252 to blink, cause the computing device 104 to output an actuation indication, and / or provide any other indication.

[0106] In block 422, safety processor 302 monitors input signals (e.g., sensor signals 320, 332, 338, 346, 350), feedback signals (e.g., feedback signals 315, 340, 360), and / or control signals (e.g., signals from control processor 238) of safety system 240. In block 424, safety processor 302 determines whether actuation has ended. For example, safety processor 302 may apply a pulse to mode switch 254 to determine whether one or more operator control signals have changed, and / or monitor input and feedback signals to identify events that trigger protection and / or interlocks, faults, and / or any other event that would cause a drive interruption. If the drive has not ended (block 418), control returns to block 418 to continue controlling the actuator. When the drive ends (block 424), safety processor 302 returns control to block 412.

[0107] Turning Figure 4BIf no operator control signal has been received to drive the actuator (block 416), in block 426, the safety processor 302 and / or the control processor 238 determine whether an operator control signal has been received to drive the actuator under reduced restrictions (e.g., to perform a test procedure at high speed or high pressure). For example, operator input is received to enter a test state and perform a test. If no operator control signal has been received to drive the actuator in a reduced-restriction manner (block 426), control returns to block 412.

[0108] If an operator control signal has been received to drive the actuator with reduced constraints (block 426), in block 428, the safety processor 302 sets the material testing system 100 to the test state, clamps the actuator 246, and reduces the actuator's constraints. In some examples, the safety processor 302 causes the motor 241 and / or the clamping actuator 246 to be controlled by the control processor 238 in the test state. Example safety processor 302 further controls the status indicator 252 to indicate that the material testing system 100 is in the test state.

[0109] In block 430, safety processor 302 and / or control processor 238 determine whether an operator control signal has been received to initiate a torsional material test (e.g., with reduced constraints) and / or another action with reduced constraints (e.g., high-speed jogging of crosshead 244). For example, operator input and / or input from computing device 104 may be received to perform a programmed material test involving high rotational forces.

[0110] If an operator control signal has been received to perform a torsional strength material test and / or another action (block 430), in block 432, the safety processor 302 sets the state of the material testing system 100 to test state and enables actuators (e.g., motor 241, gripper actuator 246). Example: The safety processor 302 further controls the status indicator 252 to indicate that the material testing system 100 is in test state.

[0111] In block 434, control processor 238 controls actuators to perform programmed tests and / or another action (e.g., with reduced and / or eliminated constraints). In block 436, safety processor 302 outputs an indication that a material test is in progress. For example, safety processor 302 may control one or more status indicators 252 to blink, cause computing device 104 to output an unrestricted driven indication, and / or provide any other indication.

[0112] In block 438, safety processor 302 monitors input signals (e.g., sensor signals 320, 332, 338, 346, 350), feedback signals (e.g., feedback signals 315, 340, 360), and / or control signals (e.g., signals from control processor 238) of safety system 240. In block 440, safety processor 302 determines whether the torsional strength material test and / or other actions have ended. For example, safety processor 302 may apply a pulse to mode switch 254 to determine whether one or more operator control signals have changed, and / or monitor input and feedback signals to identify the triggering of protective devices and / or interlocks, malfunctions, and / or any other events that could cause a drive interruption. If the drive has not ended (block 440), control returns to block 434 to continue performing the material test and / or other actions.

[0113] When the drive has ended (box 440), the security processor 302 automatically changes the state to the restricted state and returns control to box 412.

[0114] Figure 5 An example operator interface 500 is shown, which can be used to implement Figure 2 and Figure 3 The control panel 250. The operator interface 500 can be attached to the example test fixture 102, located near the test fixture (e.g., Figure 1 The operator interface 500 may be located at a location remote from the test fixture 102. For example, the operator interface 500 may be implemented as a built-in control panel or switch on the base of the test fixture 102.

[0115] The example operator interface 500 includes multiple input devices (e.g., buttons, switches, etc.) that input to... Figure 2 and / or Figure 3 The control processor 238 and / or safety system 240 provide input. An example input device includes a status control button 502 that controls the transition from a restricted state (e.g., disabled state, warning state, and / or setting state) to a non-restricted state (e.g., test state) and may be needed to perform actions involving the non-restricted state. The status control button 502 can be considered an "unlock" button or a safety input for using the materials testing system in the non-restricted state.

[0116] Jog buttons 504 and 506 control the rotation of motor 241 to jog crosshead 244 (e.g., up or down, left or right, and / or other directions based on the relative orientation of the motor and crosshead). For example, motor 241 can rotate in the right-hand or left-hand rotation direction to achieve rotational movement of the crosshead. When pressed individually, jog buttons 504 and 506 control crosshead 244 to move at a low speed (e.g., determined by safety processor 302) in the right-hand and left-hand rotation directions. When jog buttons 504 and 506 are pressed simultaneously with status control button 502, safety processor 302 can reduce the speed limit on motor 241 and allow crosshead 244 to jog at a higher speed. Jog buttons 504 and 506 in the examples can serve as directional inputs. In some examples, operator interface 500 can control torsional material testing systems as well as non-torsional testing systems, such as the axial testing system disclosed herein.

[0117] As used in this article, "simultaneous" reception means that two inputs are activated or pressed at any given time, not that the two buttons must be pressed at exactly the same moment in the beginning.

[0118] The start button 508 controls the control processor 238 to initiate the material test. The return button 510 controls the control processor 238 to return the crosshead 244 to a predetermined rotational position; this action can be performed at low or high speeds. In some examples, the safety processor 302 requires the start button 508 and / or the return button 510 to be pressed together with the status control button 502. The stop button 512 controls the control processor 238 to stop or pause the running test. This can be achieved by including an emergency stop switch 514. Figure 3 Emergency stop switch 322.

[0119] The operator interface 500 further includes status indicators 516-522 to output indications of the current status of the material testing system 100. Example status indicators 516-522 are lights used to indicate each status of the material testing system 100 that can be determined by the safety processor 302. Figure 5In the example, the operator interface 500 includes a disabled status indicator 516, a set status indicator 518, a warning status indicator 520, and a test status indicator 522. Each of the status indicators 516-522 is illuminated when the safety processor 302 determines that the material testing system 100 is in the appropriate state, while status indicators 516-522 that do not correspond to the current state are off. Although illustrated as four separate indicators, a status indicator can be a single indicator (e.g., having one or more characteristics that change with the state), or two indicators, one corresponding to a restrictive state and one corresponding to a non-restrictive state. In some examples, the status indicators represent the operating status of the material testing system 100 and all subsystems (e.g., torsion and / or axial testing systems). In some examples, the status indicators represent the operating status of either the torsion testing system or the axial testing system. In some examples, two or more status indicators are presented, specific to a particular testing system.

[0120] Figure 6 Another exemplary operator interface 600 is shown, which can be used to implement Figure 2 and Figure 3 The control panel 250. This exemplary operator interface 600 may be a handheld device with a limited set of input devices (e.g., buttons, switches, etc.). The operator interface 600 may be attached to the example test fixture 102, located near the test fixture, and / or located away from the test fixture 102. The operator interface 600 includes status control buttons 602 (e.g., with...). Figure 5 The status control button 502 is similar to or the same as the status control button 502, the jog buttons 604 and 606 (e.g., similar to or the same as the jog buttons 504 and 506), the start button 608 (e.g., similar to or the same as the start button 508), and the return button 610 (e.g., similar to or the same as the return button 510).

[0121] Operator interfaces 500 and 600 may include custom buttons 612, which can provide the operator with additional or alternative functions. In some examples, the additional or alternative functions are subject to one or more constraint states. Figure 6 In the example, custom button 609 is configured as a rotary jog button, while custom button 611 is a rotary return button, both of which control motor 241 of the torsion material testing system 233.

[0122] Figure 7 The startup procedure of the materials testing system 100 is shown. Figure 1 Exemplary material testing system 100 and Figure 5 and 6The operator interface is as follows. The material testing system 100 is powered on and initialized in a disabled state, wherein the disabled indicator 516 is illuminated (e.g., emitting white light) to indicate that the material testing system is disabled. In some examples, only two indicators (restricted and unrestricted) are presented, such as when the interface is directed to the control of the torsion testing system 233. Furthermore, in Figure 1 and Figure 2 The user interface 700 executed on the computing devices 104, 200 also includes a prominent action indicator 702 indicating that the material testing system 100 is in a disabled state. The example operator interfaces 500 and 600 only illuminate or highlight buttons that provide a specific action when pressed. During the power-on phase (e.g., in the disabled state), only the status control button 602 is active. The disabled state may occur, in addition to the power-on event, when the protection system is triggered in response to any other event in which the fault and / or safety processor 302 responds by setting the state to a disabled state, i.e., when the emergency stop switch is triggered.

[0123] When the operator presses the status control button 602, the safety processor 302 changes the system to the setting state. Figure 8 It shows Figure 1 Exemplary material testing system 100 and Figure 5 and Figure 6 The operator interfaces 500 and 600 show the setup state of the material testing system 100. After the safety processor 302 sets the state to setup, it controls the setup indicator 518 to illuminate it (e.g., emitting blue or green light) to indicate the setup state to the operator. Additionally, the user interface 700 includes a prominent indicator 802 that indicates the material testing system 100 is in the setup state (e.g., ready to set up). In the setup state, additional control buttons are highlighted or illuminated (e.g., jog) to indicate that additional functions are now available. In some examples, a non-rotational testing system can operate in the setup state (e.g., an axial testing system), while the torsion testing system 233 remains in a restricted state.

[0124] Figure 9 When the crosshead is jogged 244 times under reduced constraints in test mode (or, in some examples, warning mode)... Figure 1 Exemplary material testing system 100 and Figure 5 and Figure 6 The operator interface. For example, in some applications, to eliminate the motivation to attempt to bypass the safety system 240, the safety processor 302 can reduce one or more restrictions in the test state to allow jogging of the crosshead 244. When the material testing system 100 is in Figure 9During the indicated test state, the operator can simultaneously press the status control button 602 and the jog button 609. In response to the combination of buttons 602 and 609, the control processor 238 controls the motor 241 to rotate the crosshead 244, and the safety processor 302 sets the status of the material testing system 100 to test state (or, in some examples, warning state) and reduces the constraints imposed on the motor 241. As a result, the motor 241 is allowed to rotate the crosshead in the commanded direction. The safety processor 302 will further control the test indicator 522 (or, in some examples, the warning indicator 520) to illuminate and / or flash, and the user interface software includes a highlighted hazard indicator 1002 indicating that the material testing system 100 is performing a jog motion. This indication may include text, flashing of indicator 1002 and / or test indicator 522 (or, in some examples, warning indicator 520), and / or any other highlighting. In some examples, the hazard indicator 1002 may continuously display an active warning label to warn of specific potential hazards.

[0125] If the operator releases the status control button 602, the jogging motion can continue in the test state with reduced constraints. When the operator releases the jogging button 609, the control processor 238 stops the jogging motion, and the safety processor 302 automatically sets the status of the material testing system 100 to the set state and restores the constraints. In some other examples, when the operator releases either the status control button 602 or the jogging button 609, the safety processor 302 automatically sets the status of the material testing system 100 to the set state and restores the corresponding constraints.

[0126] Figure 10A , 10B And 10C shows when the material testing is initiated by transitioning from a disabled and / or enabled state to a test state. Figure 1 Exemplary material testing system 100 and operator interfaces 500, 600. Figure 10A The example settings shown can be compared with Figure 8 The setup shown is similar or identical, except that the sample 106 is held in the clamp 248.

[0127] The operator can begin material testing by first pressing the status control button 602, and then pressing the start button 608. In response to pressing the status control button 602... Figure 10B The safety processor 302 controls the warning indicator 520 to illuminate, and the user interface 700 displays an indication 1304 of the test and / or warning status (e.g., a yellow border and / or active warning overlay). In response to the subsequent pressing of the start button 608, the safety processor 302 then switches to illuminating the test indicator 522. Figure 10CThe user interface 700 displays an indication 1306 of the test status (e.g., a red border and / or an active warning overlay). Then, when the safety processor 302 sets the status to the test state (e.g., unrestricted drive mode), the control processor 238 can continue executing the configured test. The overlay in the user interface 700 can be removed after a period of time to allow the user to observe the ongoing test measurements on the user interface 700. However, during the test, the safety processor 302 can continue to provide other visual, auditory, and / or other perceptible warnings (e.g., displaying or flashing the test indicator 522, displaying or flashing a red border on the user interface 700 as indication 1306).

[0128] In some examples, the control processor 238 may be configured with a test method that pauses the test so that the operator can interact with the specimen 106, such as removing the tensile tester. When the test reaches a point where interaction is required, the control processor 238 pauses the test (e.g., stops the drive of the motor 242). When the pause point is reached, the safety processor 302 sets the material testing system 100 to a set state, and the user interface 700 displays an indication that the test has been paused. Alternatively, the safety processor 302 may control the set indicator 518 to provide a visual indication (e.g., light up, flash) to indicate that the test has not been completed but is paused.

[0129] The operator can then resume the test by simultaneously pressing the status control button 602 (e.g., unlock) and the start button 608. The safety processor 302 and control processor 238 can then resume the test using the same sequence of indicators as when starting the test. In some examples, when the status control button 602 is pressed, the user interface 700 displays a warning message indicating that the system is in a warning state and that the test is paused.

[0130] Once the test is complete, the security processor 302 automatically sets the status to the setting state and applies the relevant restrictions.

[0131] Figure 11A , 11B Figure 11C illustrates the process of transitioning from the setup state to the test state to return the crosshead 244 to the desired position (e.g., radial and / or axial position). Figure 1 Exemplary material testing systems and Figure 5 and 6The operator interfaces 500 and 600 are used. After a previous test, the material testing system 100 is set to a set or disabled state, indicated by the illumination of the set indicator 518. The crosshead 244 can be positioned, for example, at the position where the previous test ended. In the set state, the operator is allowed to remove the sample and / or interact with the test fixture 102 and / or the operator interfaces 500 and 600 under the restrictions imposed by the safety processor 302.

[0132] When the operator is ready to return the crosshead 244 to the desired position (e.g., to run another test), the operator can begin the return by simultaneously or sequentially pressing the status control button 602 and the return button 611 (for rotary movement) and / or the return button 610 (for axial movement). The safety processor 302 controls the warning indicator 520 to illuminate in response to the pressing of the status control button 602. Figure 11B The user interface 700 displays an indication 1402 of the warning status (e.g., a yellow border and / or an active warning overlay). In response to a subsequent press of the return button 611 and / or 610, the security processor 302 then switches to illuminate the test indicator light 522. Figure 11C The user interface 700 displays an indication 1404 of the test status (e.g., a red boundary and / or active warning coverage). Then, while the safety processor 302 sets the status to the test state (e.g., unrestricted drive mode), the control processor 238 can continue to control the motor 241 to move the crosshead 244 to reduce or eliminate speed limiting conditions.

[0133] After the crosshead 244 reaches the desired position (e.g., the test start position), the safety processor 302 automatically sets the status to the set state.

[0134] Although the material testing system 100 continuously (e.g., constantly) enables and operates the safety functions, some parameters used by the safety system 240 can be adjusted to provide the desired interaction (e.g., a slower jog speed than the default jog speed). Example computing device 104 may allow an administrator or other authorized operator to control some parameters of the safety system 240.

[0135] Although computing system 104 can provide an interface for configuring security system parameters, the example computing system 104 does not participate in the execution of the parameters. To modify the parameters of security system 240 from the default parameters, an authorized operator or administrator may be required to enable a software security system that authenticates the authorized operator attempting to make modifications.

[0136] When the safety system is enabled, the operator can modify parameters such as jog rate, clamping pressure, control points (e.g., local or remote), interlock behavior (movable guards), and / or whether to discard notifications when performing operations such as initiating material testing. Before and / or after modification, the safety system requires input of valid authentication information to allow the setting changes to be submitted to the safety system 240 for execution. The safety system 240 can be disabled to store configuration changes, causing the state of the material testing system 100 to change to a disabled state.

[0137] The security system used for modification is a keyless system, which allows administrators or other authorized operators to configure the security system in a manner consistent with specific risk assessments and prevents standard operators from overturning these settings. Keyless management prevents accidental and / or intentional misuse that could occur in traditional security systems that use keys or select controls.

[0138] The methods and systems of this invention can be implemented in hardware, software, and / or a combination of hardware and software. The methods and / or systems can be implemented centrally or distributedly in at least one computing system, with different elements distributed across several interconnected computing systems. Any type of computing system or other device is suitable for performing the methods described herein. A typical combination of hardware and software may include a general-purpose computing system with a program or other code that, when loaded and executed, controls the computing system to perform the methods described herein. Another typical embodiment may include an application-specific integrated circuit or chip. Some embodiments may include a non-transitory machine-readable (e.g., computer-readable) medium (e.g., a FLASH drive, optical disc, magnetic disk, or the like) storing one or more lines of machine-executable code that causes the machine to perform the processes described herein. As used herein, the term "non-transitory machine-readable medium" is limited to include all types of machine-readable storage media and does not include propagated signals.

[0139] As used herein, the terms “circuit” and “circuit system” refer to physical electronic components (e.g., hardware) and any software and / or firmware (“code”) that can configure the hardware, be executed by the hardware, and or otherwise relate to the hardware. As used herein, for example, a particular processor and memory may constitute a first “circuit” when executing one or more lines of code, and a second “circuit” when executing a second or more lines of code. As used herein, “and / or” refers to any one or more items in a list connected by “and / or”. As an example, “x and / or y” refers to any element in the three-element set {(x),(y),(x,y)}. In other words, “x and / or y” means “one or both of x and y”. As another example, “x, y, and / or z” refers to any element in the seven-element set {(x),(y),(z),(x,y),(x,z),(y,z),(x,y,z)}. In other words, “x, y, and / or z” means “one or more of x, y, and z”. As used herein, the term "exemplary" means as a non-limiting example, instance, or illustration. As used herein, the terms "for example" and "e.g." list one or more non-limiting examples, instances, or illustrations. As used herein, a circuit is "operable" to perform a function as long as it includes the hardware and code necessary to perform that function (if necessary), regardless of whether the function is disabled or not enabled (e.g., through user-configurable settings, factory adjustments, etc.).

[0140] While this method and / or system has been described with reference to certain embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted without departing from the scope of this method and / or system. For example, blocks and / or components in the disclosed embodiments may be combined, divided, rearranged, and / or otherwise modified. Furthermore, many modifications can be made to suit particular situations or materials to the teachings of this disclosure without departing from its scope. Therefore, this method and / or system is not limited to the specific embodiments disclosed. Rather, this method and / or system will include all embodiments falling within the scope of the appended claims, both literally and under the doctrine of equivalents.

Claims

1. A material testing system, comprising: A rotatable actuator configured to control an operator-accessible torsional test component of the material testing system; A virtual interlock, configured to engage or disengage with the actuator to prevent or allow rotational movement of the actuator; A brake, the brake being configured to lock the rotational movement of the actuator; as well as The control circuit is configured as follows: Control the actuator to perform the material testing process; Monitor multiple inputs related to the operation of the material testing system; Based on the multiple inputs and the material testing process, the operating state of the material testing system is determined from multiple predetermined operating states, including one or more of the following: disabled state, setting state, warning state, or testing state. The virtual interlock is controlled based on a defined state. Determine the activation of the non-rotational test process; as well as In response, the brake is engaged to lock the actuator to prevent rotational movement.

2. The material testing system according to claim 1, wherein, The virtual interlock is configured to prevent one or more of the electrical or control signals from activating the rotational movement of the actuator.

3. The material testing system according to claim 1, wherein, The non-rotational testing process includes an axial testing process.

4. The material testing system according to claim 1, wherein, The non-rotation test is performed in multiple predetermined operating states, including one or more of the following: a disabled state, a setting state, a warning state, or a test state.

5. The material testing system according to claim 4, wherein, The operating state of the non-rotational test process takes precedence over the operating state of the torsion system.

6. The material testing system according to claim 4, wherein, When the non-rotational test process is run in the set state, the control circuit is configured to control the virtual interlock to engage in order to prevent the dynamic rotational motion of the torsional system.

7. The material testing system according to claim 1, wherein, The control circuit is also configured to control the virtual interlock to engage or disengage in response to signals from one or more sensors.

8. The material testing system according to claim 1, wherein, The engagement of the virtual interlock corresponds to a restricted mode, such that the disabled state, the warning state, and the set state correspond to the restricted mode that prevents the actuator from operating.

9. The material testing system according to claim 8, wherein, The limiting mode corresponds to imposing limiting conditions on the actuator when the control circuit does not respond to the operator's input to control the actuator.

10. The material testing system according to claim 8, wherein, The test state corresponds to an unrestricted mode that allows the actuator to operate, and the test state corresponds to reducing the restrictions on the operation of the actuator when controlling the actuator to perform a torsional material test process or jogging or returning.

11. The material testing system according to claim 9, wherein, The limiting conditions include limiting the rotational speed of the actuator, limiting the number of revolutions of the actuator, or limiting the rotational angle of the actuator, or one or more of these.

12. The material testing system according to claim 11, wherein, The restriction is set at a specific threshold or at zero motion.

13. The material testing system according to claim 1, wherein, The virtual interlock engagement and the brake disengagement, as well as the actuator, are configured to allow an operator to manually position the actuator in the set state.

14. The material testing system according to claim 1, wherein, The control circuit includes: A control processor, configured to perform control over the actuator; and One or more security processors are configured to perform the following actions: monitor the plurality of inputs, identify the status of the material testing system, and control the virtual interlock.

15. The material testing system according to claim 1, wherein, The brake is configured to physically lock the actuator to prevent free rotational movement.

16. The material testing system according to claim 1, wherein, The actuator is configured to be manually engaged or disengaged.

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