Dual power supply for hydraulic actuator system

Abstract

A power and signal distribution hub is provided for providing power and operating signals to a plurality of channels of a test system to operate one or more hydraulic actuators to apply a load to a test article. The power and signal distribution hub includes a first power supply and a second power supply connected to share a power load of the test system, the first power supply and the second power supply configured to distribute power to a plurality of channels of the test system. The monitoring circuit of each power supply is configured to monitor operation of its respective power supply and to provide a signal indicative of its power supply operating outside of the normal operating parameters of the power supply.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 581,476, filed on September 8, 2023, entitled “DUAL ELECTRICAL POWER SUPPLIES FOR A HYDRAULIC ACTUATOR SYSTEM,” the contents of which are incorporated herein by reference in their entirety. Background Art

[0003] The following discussion is provided for general background information only and is not intended to be used as an aid in determining the scope of the claimed subject matter.

[0004] In a test system, the test articles being tested are very expensive and in some cases the load on the test articles needs to be reduced quickly and efficiently to prevent damage to the test articles. Operating the test system power supply outside of normal operating parameters may result in non-representative unloading, thereby causing damage to the test articles. Summary of the invention

[0005] The Summary and Abstract of the Invention herein are used to introduce a selection of concepts in a simplified form, which are further explained in the Detailed Description below. The Summary and Abstract are not intended to identify key features or essential features of the claimed subject matter, nor are they intended to be used to help determine the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all of the disadvantages noted in the Background.

[0006] In one aspect, a power and signal distribution hub is provided for providing power and operating signals to multiple channels of a test system to operate one or more hydraulic actuators to apply a load to a test article. The power and signal distribution hub includes a first power supply and a second power supply, the first power supply and the second power supply are connected to share the power load of the test system, and the first power supply and the second power supply are configured to distribute power to multiple channels of the test system. The monitoring circuit of each power supply is configured to monitor the operation of its corresponding power supply and provide a signal to indicate when it is detected that its power supply is operating outside the normal operating parameters of the power supply.

[0007] Embodiments may include one or more of the following features. Each monitoring circuit may include multiple relays connected to its power supply. Once the second power supply fails, the power load shared by the second power supply failure can be borne by the first power supply. Both the first power supply and the second power supply can be used to provide power for the inrush current when the test system is started, and wherein, in normal operation, a single power supply in the first power supply and the second power supply can provide power for the test system. Each of the power supplies can be electrically connected to the solenoid of each channel, the valve of each channel, and the control logic of each channel. The power and signal distribution hub can be configured to provide a signal indicating the failure of the first power supply to an external controller, and receive a command signal from the external controller to use the second power supply to control the load from each actuator on the test article in the test system. The power and signal distribution hub can be configured to receive a feedback signal of the state of the controlled unloading for the load on the test article, and provide a state signal of the controlled unloading to the external controller. The power and signal distribution hub can be configured to receive an interlock unloading signal from an external controller in the event of a controlled unloading failure and provide interlock unloading power to each valve, solenoid and control logic of each associated actuator of the test system to interlock unload the load from each actuator on the test article.

[0008] In another aspect, a method of distributing signals and power to channels of a test system to operate one or more hydraulic actuators to apply a load to a test article includes: providing power to the channels of the test system using a pair of power supplies connected to share the load of power provided to the test system. Monitoring the power supplies for proper operation. Upon detecting that one of the pair of power supplies is operating outside of proper operation, providing a signal indicating the operation.

[0009] Method embodiments may include one or more of the following features. Monitoring may be performed by a monitoring circuit of each power supply in the pair of power supplies, each monitoring circuit being configured to monitor the operation of its corresponding power supply, each monitoring circuit having a plurality of relays coupled to its power supply. The method may include a working power supply in the pair of power supplies assuming the load shared by the other power supply in the case of a failure of the other power supply in the pair of power supplies. Providing power may further include providing power to the solenoid of each channel, the valve of each channel, and the control logic of each channel. Providing a signal indicating a failure of one power supply in the pair of power supplies may include providing a signal indicating a failure of one power supply in the pair of power supplies to an external controller. The method may include receiving a command signal from an external controller to initiate a controlled unloading of a load on a test article in a test system. The method may include providing a state signal of a controlled unloading to an external controller. The method may include receiving an interlock unloading signal from an external controller when the controlled unloading fails; and providing an interlock unloading power to a valve of an actuator of the test system to interlock unloading of a load from each actuator on the test article.

[0010] The present disclosure is not intended to describe every disclosed embodiment or every implementation of the power and signal distribution hub as described herein. Numerous other novel advantages, features, and relationships will become apparent as the description proceeds. The following figures and descriptions more particularly illustrate illustrative embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a block diagram of a power and signal distribution hub system according to an embodiment of the present disclosure;

[0012] Figure 2 is a block diagram of an operating environment in which embodiments of the present disclosure may be utilized; and

[0013] Figure 3 is a flowchart of a method according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0014] Embodiments of the present disclosure provide a reliable power supply including redundant power supplies suitable for mitigating single power supply failures that might otherwise place a control system of a test system in an adverse condition, potentially causing damage to a test article.

[0015] Figure 1 The power and signal distribution hub 150 is shown in FIG. The power and signal distribution hub 150 is configured to provide power to the test system 100 ( Figure 2) to operate one or more (typically multiple) hydraulic actuators to apply a load to a test article. In one embodiment, the power and signal distribution hub 150 includes a first power supply 152 and a second power supply 154. The power supplies 152 and 154 are connected to share the power load of the test system 100. The first power supply 152 and the second power supply 154 are configured to distribute power to multiple channels of the test system 100. In one embodiment, the power and signal distribution hub 150 provides power for eight channels of the test system, but this should not be considered limiting.

[0016] In one embodiment, a single one of the two power supplies is sufficient to provide full power to operate the test system 100 .

[0017] The monitoring circuit 156 of each power supply 152, 154 is configured to monitor the operation of its corresponding power supply. Each monitoring circuit 156 provides a signal 158, which indicates that its power supply is operating outside the normal operating parameters of its power supply. In one embodiment, the signal 158 indicates that its corresponding power supply is faulty. In one embodiment, each monitoring circuit 156 includes a plurality of relays 160 coupled to its power supply. In one embodiment, the relays 160 are solid-state switching devices. Further, a visual indicator of the power supply status can be provided.

[0018] In an operating state under normal operation of the test system 100, the total power load of the test system 100 for controlling one or more actuators is shared between the power supplies 152 and 154, wherein the output terminals of the power supplies 152 and 154 are connected in parallel. Once the monitoring circuit 156 detects that one of the power supplies in a pair of power supplies is operating outside its normal operating parameters, the full load or total load is borne by the power supply that is not outside its normal operating parameters. For example, once the second power supply 154 fails or other operating conditions that produce a predetermined operating condition occur, the first power supply 152 bears the shared load, and vice versa. The normal operating parameters of the power supply can be set or provided in any number of ways without departing from the scope of the present disclosure. In one embodiment, the monitoring circuit 156 is used to detect a complete failure of its power supply. This is a configuration that may be adopted in a power and signal distribution hub that may operate in a test system. However, in another embodiment, the monitoring circuit 156 can detect parameters (such as but not limited to voltage, current, temperature, etc.) outside its normal operating state, and the detection result can start another power supply to bear the total power load.

[0019] In one embodiment, each of the power supplies 152, 154 is electrically coupled to a plurality of channels of the test system 100. In one embodiment, the number of channels is eight, but it should be understood that a greater or lesser number of channels may be employed without departing from the scope of the present disclosure. In one embodiment, the solenoids for each channel, the valves for each channel, and the control logic for each channel are all powered by the power and signal distribution hub 150, which obtains power from the power supplies 152 and 154. In one embodiment, a single one of the power supplies 152, 154 is sufficient to provide power to all channels coupled to the power and signal distribution hub 150 and all solenoids, valves, and control logic for each channel.

[0020] The power and signal distribution hub 150 is configured to provide a signal 158 to the external controller 130 via the communication link 160 indicating that either the first power supply 152 or the second power supply 154 is operating outside of normal operating parameters, and the power and signal distribution hub 150 is also configured to receive a command signal from the external controller 130 via the communication link 160 to controllably unload the load on the test article from each actuator of the test system 100 using the second power supply 154 or the first power supply 152, respectively, in the event of a failure of one of the power supplies 152, 154. The controlled unloading operating state is when the controller 130 can provide a command signal to each valve of each associated actuator to reduce the load provided by the actuator.

[0021] In one embodiment, the power and signal distribution hub 150 is further configured to receive feedback signals 162 on the channels of the test system 100 (one of which is Figure 1 The feedback signal 162 may come from, for example, but not limited to, a load sensor, a displacement sensor, a hydraulic pressure sensor, other contact sensors, etc. Of particular importance are feedback sensors that indicate the load on the test article, such as a load sensor that directly measures the load applied by the actuator, or a hydraulic pressure signal that indicates the load applied by the actuator. Such feedback signal 162 particularly indicates the state of the controlled unloading of the load on the test article.

[0022] The power and signal distribution hub 150 is further configured to provide a controlled unloading status signal 164 to the external controller 130, in one embodiment through channel communication lines 166 and 168, in one embodiment through channel communication lines for four channels. In the event that the controlled unloading is unsuccessful, one or more status signals 164 can trigger the system controller 130 to issue an interlock unload signal through the communication line 160, thereby causing an interlock command signal to be provided to each valve of each actuator. When each valve receives the interlock command signal, the valve controls the associated actuator to reduce the load difference applied by the actuator on the test article. Compared to the controlled unloading operating state in which the controller 130 continues to provide a command signal to each valve to reduce the load difference applied by each associated actuator, when the interlock command signal is issued, each valve of each actuator will operate the actuator to reduce the load difference without further command signals from the controller 130. In this case, the interlock unloading power is supplied by the working power supply to each valve, each solenoid and each control logic of each associated actuator of the channel connected to the power and signal distribution hub 150 of the test system 100. The operation of the controller 130, and in particular the operation of each valve of the actuator, is described in the co-pending provisional patent application entitled “CONTROLLED LOAD ABORT IN AN ACTUATOR SYSTEM” with serial number 63 / 581,465 filed on September 8, 2023, the contents of which are incorporated herein by reference in their entirety.

[0023] In one embodiment, both the first power supply and the second power supply are used to provide power for the surge current at startup of the test system 100. In startup operation, the startup or surge current may exceed the power available from a single power supply 152 or 154. In one embodiment, in normal operation after the initial surge current is used, a single power supply as the first power supply 152 or the second power supply 154 is able to provide full power for all channels of the test system during normal operation, controlled unloading state, or interlocked unloading state. A failure of one of the power supplies 152, 154 at startup will be detected by its monitoring circuit 156, so the failure at startup will not cause damage to the test article.

[0024] In one embodiment, two or more power supplies 152, 154 are coupled to a main power supply, such as utility power, line power, mains power, etc. However, in one embodiment, one or more of the power supplies 152, 154 may be a battery or other power supply (battery, gas engine, etc.), depending on the test system operating with the power and signal distribution hub.

[0025] Further, where two power supplies are mentioned and discussed, it should be understood that this means two or more. That is, more than two power supplies can be used in the same manner without departing from the scope of the present disclosure. In one embodiment, each power and signal distribution hub (if more than one is present) has sufficient power to supply startup and normal operating power to eight channels. It should be understood that each power and signal distribution hub includes an output card or module, wherein each card or module has multiple channels, such as eight channels, and the power and signal distribution hub can have more than one or more output cards or modules. The power and signal distribution hubs can be further connected together, such as in a daisy chain manner, in order to operate a test system that requires additional channels (beyond the capabilities of a single power and signal distribution hub). For example, in one embodiment, additional power and signal distribution hubs can be linked to up to 250 channels or more. In such a chain, one or more power and signal distribution hubs may be powered by a pair of first and second power supplies; however, in another embodiment, each power and signal distribution hub 150 may have its own pair of first and second power supplies 152 and 154. In either case, the system controller 130 operates to receive signals from each power supply present and control each power and signal distribution hub 150. In such a configuration, detection of a power supply failure in any linked power and signal distribution hub triggers the system controller 130 to perform a controlled unloading (or interlocked unloading if the controlled unloading does not work) of the load on the test article using the available power supply of the power and signal distribution hub that is still in operation, and generally to perform a controlled unloading of the load associated with the power and signal distribution hub that may be powered by two power supplies. Since the test article may be very valuable, it is important not to damage the test article. Therefore, it is important to be able to command the actuator to apply the load to a no-load state or at least a reduced load state on the test article. This is achievable using embodiments of the present disclosure because a second power supply is provided in the event of a power supply failure, the second power supply being fully capable of providing power to the power and signal distribution hub 150 to operate the valves of each actuator to achieve the desired unloading of the test article.

[0026] Figure 2 A representative operating environment for an embodiment of the power and signal distribution hub 150 is shown in more detail in FIG. Figure 2A system 100 for monitoring and unloading a load on a test article is shown, the system including a power and signal distribution hub 150. In one embodiment, the system 100 includes a hydraulic assembly 110 and a system controller 130. In one embodiment, the hydraulic assembly 110 includes a control valve 112 configured to control the load in a hydraulic actuator 120 coupled to the test article. The hydraulic assembly 110 further includes a pair of pressure sensors 114 configured to detect and transmit the pressure in each associated hydraulic actuator 120. An isolation valve 116 is provided to selectively isolate the control valve 112 from a hydraulic source 140 of hydraulic pressure for each associated hydraulic actuator 120. In this case, the control valve 112 can then locally reduce the load acting on the test article by the actuator 120 in an interlock unloading operating state in accordance with instructions executed by a local processor in the control valve without further instruction from the system controller 130.

[0027] In one embodiment, the system controller 130 is configured to determine a load difference in at least one of a calculated load at a control valve 112 of a hydraulic actuator 120 of the test system 100 and a calculated load on a load sensor 122 coupled to the hydraulic actuator. In a first method of unloading the load on the test article by each actuator coupled to the test article, the system controller 130 is further configured to initiate a controlled unloading of the load on the test article via the system controller 130 when the determined load difference reaches a first level. The controlled unloading is performed during a flow mode of the system, that is, when the hydraulic source 140 is coupled to the system 100 and the valve operation of each control valve 112 is controlled by the system controller 130. The first level may be referred to as a stop level. If the stop level controlled unloading does not work, the controller 130 is further configured to interlock the load on the test article by sending a command to each control valve 112 of each actuator 120 that needs to unload the load on the test article when the determined load difference reaches a second level higher than the first level, at which time the load on the test article is unloaded using valve controlled unloading or interlocked unloading.

[0028] In one embodiment, the control valve 112 further includes a valve local controller 113 for receiving pressure from the pressure sensor 114 and valve firmware 115, the valve local controller 113 being operable by the local controller 113 and configured to reduce the load difference on the piston of the hydraulic actuator 120. In one embodiment, unloading the load of the actuator by executing the firmware 115 by the valve local controller 113 to control the operation of its associated actuator 120 is performed without further input from the system controller 130.

[0029] In one embodiment, system controller 130 is an external controller that runs software to operate test system 100 based on a test program in system computer 131, which provides a user interface to a user for configuring, operating, and monitoring testing of test articles.

[0030] In the test system 100, a plurality of control valves 112 may be connected to a plurality of hydraulic actuators 120 that provide loads to different locations or portions of the test article. For example, a series of eight hydraulic actuators 120 may be controlled by eight hydraulic assemblies. The load sensor 122 of each hydraulic actuator 120 is configured to provide a load signal 163 to the system controller 130. The pressure sensor 114 and the control valve 112 are also configured to provide a load signal 162 to the system controller 130. Typically, each control valve 120 is provided with an isolation valve 116. When the test article is tested according to the desired test procedure (i.e., normal operation), the system controller 130 controls the operation of each isolation valve 116 and the control valve 112 in a "flow mode".

[0031] In one embodiment, system 100 further includes a power and signal distribution hub 150 coupled between system controller 130 and hydraulic assembly 110 .

[0032] Figure 3 , a method 300 for distributing signals and power to channels of a test system to operate one or more hydraulic actuators to apply a load to a test article is shown in a flowchart form. In one embodiment, the method 300 includes, in box 302, providing power to the channels of the test system using a pair of power supplies connected to share the power load provided to the test system. In box 304, monitoring whether the power supplies 152, 154 are operating correctly, and in box 306, providing a signal indicating that one of the power supplies 152, 154 of the pair of power supplies is operating outside its correct operation. In one embodiment, the monitoring is performed by a monitoring circuit of each power supply in a pair of power supplies. Each monitoring circuit is configured to monitor the operation of its corresponding power supply. In one embodiment, each monitoring circuit has a plurality of relays configured to monitor. In such an embodiment, the current from the corresponding power supply is monitored, and the interruption of the current trips the relay to disconnect. This indicates that the power supply is operating outside the normal operating parameters, thereby triggering the signal 158. As described elsewhere, correct operation can include operating outside a predetermined parameter set, a complete or partial failure of the power supply, etc.

[0033] At block 308 , one of the working power supplies of the pair of power supplies assumes the load shared by the other power supply of the pair in the event that the other power supply of the pair fails or operates outside of its normal operating parameters.

[0034] In one embodiment, providing power as shown in block 302 further includes providing power to eight channels coupled to the power and signal distribution hub 150 and includes providing power to the solenoids, valves, and control logic of each channel.

[0035] In one embodiment, providing a signal indicating that the power supply is operating outside of its normal operating parameters includes providing a signal to the external controller 130. In one embodiment, the method 300 further includes, at optional block 310, receiving a command signal from the external controller 130 to initiate a controlled unloading of the load on the test article in the test system 100. The method may further include, at optional block 312, providing a status signal of the controlled unloading to the external controller 130. The method may further include receiving an interlock unloading signal from the external controller 130, and providing an interlock unloading power to the valves of the actuators 120 of the test system 100 to interlock unload the load from each actuator 120 of the test article. In one embodiment, such an interlock unloading signal is provided in response to feedback indicating that the controlled unloading is not properly alleviating the load on the test article in the test system 100. In one embodiment, the controlled unloading is commanded by the system controller 130 when the load difference reaches a first stop level, and the interlock unloading is commanded when a higher second interlock load difference is reached.

[0036] It should be noted that in different figures, the same or similar elements use the same reference numerals.It should also be understood that the terms used herein are used to describe the purpose of the embodiment, and the term is not intended to be restrictive.Unless otherwise indicated, ordinal numbers (e.g., first, second, third, etc.) are used to distinguish or identify different elements or steps in a group of elements or steps, and do not provide sequence or numerical restrictions for the elements or steps of its embodiments.For example, "first", "second" and "third" elements or steps do not necessarily appear in this order, and its embodiments are not necessarily limited to three elements or steps.It should also be understood that, unless otherwise indicated, any label (such as "left", "right", "front", "back", "top", "bottom", "forward", "reverse", "clockwise", "counterclockwise", "up", "down") or other similar terms (such as "upper", "lower", "back", "front", "vertical", "horizontal", "proximal", "distal", "middle", etc.) are used for convenience, and are not intended to, for example, imply any specific fixed position, orientation or direction.Alternatively, such labels are used to reflect, for example, relative position, orientation or direction. It is also to be understood that the singular form "a," "an," or "the" include plural referents unless the context clearly dictates otherwise.

[0037] Thus, embodiments of the present disclosure provide methods and systems for providing dual power supplies that share the load such that a single power supply failure is mitigated and protection is provided for a test article being tested in a test system.

[0038] The subject matter disclosed above should be considered illustrative and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments that fall within the scope of the present disclosure. Therefore, to the maximum extent allowed by law, the scope of the present disclosure will be determined by the broadest permissible interpretation of the appended claims and their equivalents and shall not be restricted or limited to the above detailed description.

Claims

1. A power and signal distribution hub for providing power and operating signals to a plurality of channels of a test system to operate one or more hydraulic actuators to apply a load to a test article, the power and signal distribution hub comprising: a first power supply and a second power supply, the first power supply and the second power supply connected to share a power load of the test system, the first power supply and the second power supply configured to distribute power to the plurality of channels of the test system; as well as A monitoring circuit for each power supply is configured to monitor operation of its respective power supply and provide a signal indicating when it detects that its power supply is operating outside of normal operating parameters of the power supply.

2. A power and signal distribution hub as claimed in any preceding claim, wherein: Each monitoring circuit includes a plurality of relays coupled to its power supply.

3. A power and signal distribution hub as claimed in any preceding claim, wherein: Once the second power supplier fails, the shared power load is borne by the first power supplier.

4. A power and signal distribution hub as claimed in any preceding claim, wherein: Both the first power supply and the second power supply are used to provide power for an inrush current when the test system is started up, and wherein, in normal operation, a single one of the first power supply and the second power supply is capable of providing power to the test system.

5. A power and signal distribution hub as claimed in any preceding claim, wherein: Each of the power supplies is electrically coupled to the solenoids of each channel, the valves of each channel, and the control logic of each channel.

6. A power and signal distribution hub as claimed in any preceding claim, wherein: The power and signal distribution hub is configured to provide a signal to an external controller indicating a failure of the first power supply and to receive a command signal from the external controller to controllably unload the load from each actuator on the test article in the test system using the second power supply.

7. A power and signal distribution hub as claimed in any preceding claim, wherein: The power and signal distribution hub is configured to receive feedback signals for a status of the controlled unloading of the load on the test article and to provide status signals of the controlled unloading to the external controller.

8. A power and signal distribution hub as claimed in any preceding claim, wherein: The power and signal distribution hub is configured to receive an interlock unloading signal from the external controller in the event of a failure of the controlled unloading and to provide interlock unloading power to each valve, solenoid and control logic of each associated actuator of the test system to interlock unload the load from each actuator on the test article.

9. A method of distributing signals and power to channels of a test system to operate one or more hydraulic actuators to apply a load to a test article, the method comprising: providing power to the channels of the test system using a pair of power supplies connected to share a power load provided to the test system; monitoring whether the power supply is operating correctly; as well as A signal indicative of the operation is provided upon detection of one of the pair of power supplies operating outside of proper operation.

10. The method of claim 9, wherein: Monitoring is performed by a monitoring circuit of each power supply of the pair of power supplies, each monitoring circuit being configured to monitor operation of its respective power supply, each monitoring circuit having a plurality of relays coupled to its power supply.

11. The method of any one of claims 9 to 10, further comprising one working power supply of the pair of power supplies assuming the load shared by the other power supply of the pair of power supplies in the event of failure of the other power supply of the pair of power supplies.

12. The method according to any one of claims 9 to 11, wherein: Providing power further includes providing power to a solenoid for each channel, a valve for each channel, and control logic for each channel.

13. The method according to any one of claims 9 to 12, wherein: Providing a signal indicative of a failure of the one of the pair of power supplies includes providing a signal indicative of a failure of the one of the pair of power supplies to an external controller.

14. The method of any one of claims 9 to 13, further comprising receiving a command signal from the external controller to initiate a controlled unloading of a load on a test article in the test system.

15. The method of any one of claims 9 to 14, further comprising: providing a status signal of the controlled unloading to the external controller; and / or When the controlled unloading fails, receiving an interlock unloading signal from the external controller; and / or Interlock unloading power is provided to valves of the actuators of the test system to interlock unload the load from each actuator on the test article.

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