Dynamic test system control valve adapter

Abstract

An adapter for connecting to a test station control valve includes a control input, a control output, a power input, and a first power output. The control input is configured to receive a valve control signal, and the control output is coupled to the control input and configured to connect to a valve control input of the control valve. The power input is configured to receive power from a power source, and the first power output is coupled to the power input and configured to connect to a valve power input of the control valve. The adapter further includes a fuse connected in series between the power input and the first power output, a position input configured to connect to a valve position output of the control valve and a position output coupled to the position input, and / or an enable / disable input and an enable / disable output.

Description

Technical Field

[0001] The embodiments of this disclosure relate generally to a test station of a dynamic testing system, and more specifically, to the speed control of a hydraulic actuator of the test station. Background Technology

[0002] Dynamic testing systems, such as those developed by MTS Systems, include test stations that perform various tests by applying loads and displacements to the test object using hydraulic actuators. Test stations may include, for example, vehicle test stations that apply simulated driving conditions to moving vehicles, or building test stations that apply simulated seismic activity to buildings.

[0003] The actuators at the test station are driven by a flow of hydraulic fluid. The actuation performed by each actuator is controlled using a control valve (e.g., a proportional control valve), which regulates the flow rate and direction of the hydraulic fluid through the actuator. Control signals and power from the test station are transmitted to each control valve via a series of cables over a distance potentially exceeding 150 feet.

[0004] Upgrading the existing legacy control valves at the test station may be desirable. However, the existing legacy cables used at the test station may not support this upgrade. Therefore, such a control valve upgrade may require the replacement of expensive legacy cables. Summary of the Invention

[0005] Embodiments of this disclosure relate to an adapter for connection to a test station control valve configured to control fluid flow through a hydraulic actuator; an assembly including the adapter; and a test station including the adapter. The adapter facilitates connection between legacy cables and the control valve.

[0006] An example of an adapter includes a control input, a control output, a power input, and a first power output. The control input is configured to receive a valve control signal, and the control output is coupled to the control input and configured to connect to a valve control input of the control valve. The power input is configured to receive power from a power source, and the first power output is coupled to the power input and configured to connect to a valve power input of the control valve. Embodiments of the adapter also include a fuse connected in series between the power input and the first power output, a position input configured to connect to a valve position output of the control valve, a position output coupled to the position input, and / or an enable / disable input and an enable / disable output.

[0007] Examples of components include an adapter and a control valve. The adapter includes a control input, a control output, a power input, and a first power output. The control input is configured to receive a valve control signal, and the control output is coupled to the control input. The power input is configured to receive power from a power source, and the first power output is coupled to the power input. Embodiments of the adapter also include a fuse connected in series between the power input and the first power output, a configured position input and a position output coupled to the position input, and / or an enable / disable input and an enable / disable output. The control valve includes a valve control input connected to the control output and a valve power input connected to the first power output.

[0008] An example of a test station for a dynamic testing system includes a hydraulic actuator configured to drive the actuation of a test object using a flow of hydraulic fluid, a test station controller configured to transmit control signals via a control cable based on a test procedure, a power supply configured to supply power, an adapter, and a control valve. The adapter includes a control input coupled to the control cable and configured to receive control signals from the test station controller, a control output coupled to the control input, a power input configured to receive power from the power supply, and a first power output coupled to the power input. Embodiments of the adapter also include a fuse, a position input and a position output, and / or an enable / disable input and an enable / disable output connected in series between the power input and the first power output. The control valve includes a valve housing, a valve body contained within the housing and having a position for controlling the flow rate and direction of the hydraulic fluid, a valve control input coupled to the control output, a valve power input coupled to the first power output, and a valve controller configured to control the position of the valve body based on a control signal received at the valve control input.

[0009] This summary is provided to present, in a simplified form, the selection of concepts further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that address any or all the shortcomings mentioned in the background art. Attached Figure Description

[0010] Figure 1 This is a simplified diagram of an example of a dynamic testing system according to an embodiment of the present disclosure.

[0011] Figure 2 and Figure 3 This is a schematic diagram of an example of a test station according to an embodiment of the present disclosure.

[0012] Figure 4This is a simplified diagram of an adapter for connecting a control valve to a conventional cable according to an embodiment of the present disclosure.

[0013] Figure 5 This is a simplified diagram of an example of an adapter connected to a control valve, according to an embodiment of the present disclosure.

[0014] Figure 6 This is a simplified diagram of an example controller according to an embodiment of the present disclosure. Detailed Implementation

[0015] Embodiments of this disclosure are described more fully below with reference to the accompanying drawings. Elements identified by the same or similar reference numerals refer to the same or similar elements. However, various embodiments of this disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of this disclosure to those skilled in the art.

[0016] The functions described herein can be performed by a single controller, multiple controllers, or at least one controller. As used herein, when one or more functions are described as being performed by a “controller” (such as a specific controller, one or more controllers, or at least one controller), embodiments include functions performed by a single controller or processor, or multiple controllers or processors, unless otherwise stated. Furthermore, as used herein, when multiple functions are performed by at least one controller, all functions can be performed by a single controller, or some functions can be performed by one controller while others can be performed by another controller. Therefore, performing one or more functions by at least one controller does not require all functions to be performed by every single controller.

[0017] Figure 1 This is a simplified diagram of an example of a dynamic testing system 100 according to an embodiment of the present disclosure. The testing system 100 may include one or more test stations 102, each of which may be configured to perform a test or condition simulation by applying force and / or displacement to a test object 103 (e.g., a car, a building, etc.) using a hydraulic actuator 104 driven by a flow 106 of hydraulic fluid.

[0018] Flow 106 may be provided based on hydraulic fluid flow 108 generated by one or more hydraulic power units (HPUs) 110. System 100 may include an accumulator 116 that stores pressurized hydraulic fluid received from HPU 110 and discharges hydraulic fluid flow 118, which can be used to form flow 106 supplied to test station 102. System 100 may include a distributor 120 that receives hydraulic fluid flow from HPU 110 and / or accumulator 116 and distributes hydraulic fluid flow 106 to test station 102. Other configurations of system 100 may be used to supply the required hydraulic fluid flow 106 to test station 102.

[0019] System 100 may be a closed system in which a low-pressure hydraulic fluid flow 106' discharged from test station 102 returns, for example, via a combined return flow 124 to HPU 110 through hydraulic distribution system 120.

[0020] The system controller 126 can be operated to control various aspects of the system 100, including the functions of the HPU 110, valve control (e.g., valve control of the accumulator and / or distributor) and / or other aspects of the system 100, to supply the required hydraulic fluid flow 106 to the test station 102.

[0021] Figure 2 This is a schematic diagram of an example of a test station 102 according to an embodiment of the present disclosure. As described above, the test station 102 includes a plurality of hydraulic actuators 104, such as hydraulic actuators 104 AD, configured to apply force and / or drive motion to the test object 103. Each of the hydraulic actuators 104 AD is driven by a corresponding flow portion 106 AD of a flow 106 of hydraulic fluid, the flow 106 of which is powered by a hydraulic power unit 110 ( Figure 1 One or more of the following are generated.

[0022] Each test station 102 may include a test station controller 130, which is typically configured to perform tests on the test object 103, for example, based on the execution of a test program stored in a non-transitory computer-readable medium. In response to the execution of the test program, the test station controller 130 conventionally controls the actuator 104 to apply force and / or motion to the test object 103 by controlling the hydraulic fluid flow 106 AD through a corresponding control valve 132.

[0023] The computing device 134 can be configured to generate a graphical user interface through which a user can interact with and / or control the test station 102, execute test programs, view data, and / or perform other tasks, such as through a series of communications with the test station controller 130.

[0024] For example, one or more safety input valves 136 (such as solenoid valves) may control the high-pressure hydraulic fluid flow 106 input to test station 102, such as in response to a control signal from test station controller 130, system controller 126, or another suitable device (e.g., an emergency stop device). Each safety input valve 136 has a fully open state, which provides a virtually unrestricted path for the hydraulic fluid flow 106 to travel to test station 102. Valve 136 also has a closed or substantially closed state, in which valve 136 blocks or substantially blocks the hydraulic fluid flow 106 to test station 102. The solenoid of valve 136 may have a default state or a de-energized state corresponding to the closed or substantially closed state.

[0025] Figure 3 This is a simplified diagram of an example of a test station 102 according to an embodiment of the present disclosure. As described above, the test station 102 includes a test station controller 130 and at least one hydraulic actuator 104 and its corresponding control valve 132. Although for the sake of simplicity, Figure 3 Only a single hydraulic actuator 104 and control valve 132 pair are shown in the diagram; however, it should be understood that test station 102 may include two or more actuators 104 and corresponding control valves 132, such as... Figure 2 As shown.

[0026] Control valve 132 for each hydraulic actuator 104 operates to control the flow rate (e.g., gallons per minute) of hydraulic fluid received from high-pressure source 137 (e.g., one or more HPUs 110 or accumulators 116) and flowing to actuator 104, and to discharge flow 106' to low-pressure reservoir 138 (e.g., back to reservoir of HPU 110). Additionally, control valve 132 controls the direction of flow through hydraulic actuator 104 to control the actuation applied to test object 130.

[0027] In one example, the hydraulic actuator 104 includes a cylinder 140 and an actuator rod 142 having a piston 144 housed within the cylinder 140. The cylinder 140 includes a first port 146 and a second port 148 through which a flow 106 of hydraulic fluid travels. A valve 132 controls the direction of the flow 106 of hydraulic fluid through the first port 146 and the second port 148 to control the direction of movement of the actuator rod 142 and the flow rate of the hydraulic fluid flow 106, which controls the speed at which the actuator rod 142 moves relative to the cylinder 140.

[0028] Control valve 132 can take any suitable form. Examples of control valve 132 include servo valves or solenoid valves configured to provide the aforementioned variable flow and directional control. Figure 3As shown, control valve 103 typically includes electronics 150, valve body 152, and valve body actuator 154. Valve body 152 has an adjustable position that controls the direction and flow rate of hydraulic fluid 106. For example, valve body 152 may be in the form of a spool valve, and valve body actuator 154 may be in the form of a servo mechanism. An example of this type of control valve 132 is described in U.S. Publication No. 2016 / 0123355. Electronics 150 is configured to control valve body actuator 154 to adjust the position of valve body 152 in response to actuator command signal 156.

[0029] During the execution of the test procedure, the test station controller 130 issues a reference signal 164 relating to the desired actuation to be performed on the test object 103 by the hydraulic actuator 104. Each actuator 104 includes an actuation sensor 166 configured to sense parameters of the actuation performed by the actuator 104, such as displacement and / or force, and to issue a feedback signal 168 indicating the sensed parameters. The actuation sensor 166 may include, for example, a displacement sensor 166A, such as a linear variable differential transformer, configured to detect displacement and / or movement of the actuator rod 142 relative to the cylinder 140, and to generate a feedback signal 168A indicating the detected displacement and / or movement; and / or a load unit 166B configured to detect forces applied by the actuator 104 to, for example, the test object 103, and to generate a feedback signal 168B indicating the detected force. Figure 3 As shown. The conventional regulator circuit 169 can be used to process signals 168A and / or 168B (e.g., amplify, filter, etc.) to produce the final feedback signal 168.

[0030] Actuator controller 170 is configured to compare a reference signal 164 and a feedback signal 168 corresponding to each actuator 104 and issue a differential signal 172 to the corresponding control valve 132. Electronics of the control valve 132 (such as valve controller 174) adjust the flow rate and / or flow direction of the fluid flow 106 based on the differential signal 172 to produce the desired actuation. While actuator controller 170 in Figure 3 The actuator 104 is shown as receiving a single reference signal 164 and issuing a single differential signal 156 corresponding to the depicted actuator 104, but the actuator controller 170 can be configured to receive multiple reference signals 164 for each hydraulic actuator 104 of the test station 102 from the test station controller 130 and issue differential signals 172 to control the corresponding valve 132.

[0031] Test station 102 has been in use for many years and can utilize conventional control valve 132, which is controlled by the transmission of differential signal 172 and power via corresponding conventional control cable 176, such as... Figure 3 As shown. For example, when the control valve is a 252 series servo valve manufactured by MTS Systems, the conventional cable 176 can be in the form of a shielded multi-conductor transmission cable, which supplies the analog current drive control signal and power (e.g., + / -250mA) required by the conventional control valve.

[0032] Newer control valves (such as the 255 Series servo valves from MTS Systems, servo proportional valves from Domin (e.g., SxPRO), and other modern control valves) are often incompatible with the legacy cables 176 used in many existing test stations 102. For example, legacy cables 176 may not be able to fully connect to modern control valves (e.g., fewer pins), may not be able to supply the required signal or power, and / or may be unsuitable for other reasons. Therefore, when test station 102 upgrades to newer control valves, legacy cables 176 typically must be replaced with newer cables. Due to the length and location of cables 176 within test station 102, this can be a complex and costly process, often hindering control valve upgrades.

[0033] Embodiments of this disclosure relate to an adapter that allows upgrading a conventional control valve 132 without upgrading the corresponding conventional cable 176. For example... Figure 4 As shown in the simplified diagram, adapter 180 is typically configured to connect between conventional cable 176 and control valve 182. Control valve 182 can be an upgraded, modern control valve with unique functions and input / output characteristics compared to conventional control valve 132. Therefore, control valve 182 can replace... Figure 2 One or more control valves 132 in the test station 102 shown are operated to control the flow 106 to one or more actuators 104.

[0034] Control valve 182 may include features similar to those of conventional control valve 132, such as valve body 152 and valve body actuator 154, which operate in a manner similar to their counterparts in conventional control valve 132. Control valve 182 also includes electronics 184, which may be configured to perform functions similar to those of electronics 150 in conventional control valve 132. However, electronics 184 may have different inputs and / or outputs and may be configured to perform functions not performed by electronics 150 in conventional control valve 132.

[0035] Figure 5 This is a simplified diagram of an example of an assembly including an adapter 180 connected to a control valve 182, according to an embodiment of this disclosure. The input and output terminals shown can take any suitable form, each of which can be accommodated in a suitable connector.

[0036] In some embodiments, adapter 180 includes a control input 186 and a control output 188. The control input 186 receives a control signal 172 from a conventional cable 176. The control signal 172 is supplied to a control valve 182 via the control output 188, such as at the control input 190. Electronics 184 of the control valve 182 (such as a valve controller 192) are configured to control the valve body 152 based on the control signal 172 as described above.

[0037] In some embodiments, control valve 182 has different power requirements than conventional control valve 132. Adapter 180 may include a power input 193, which may be coupled to a suitable power source 194 and configured to supply the required power. The power feed 195 received at power input 193 is fed to a power output 196, which may be connected to the power input 197 of valve electronics 184. In one example, power source 194 provides a 24 VDC power feed 195 and a current of up to 2.0 amps, and may power other components of test station 102, such as other adapters 180.

[0038] In one embodiment, adapter 180 includes a fuse 198 positioned in series between a power input terminal 188 and a power output terminal 194. The fuse 198 is configured to trip in response to a transient power surge to protect valve electronics 184.

[0039] Adapter 180 may include one or more additional power input terminals 188 and / or power output terminals 194. For example, adapter 180 may include a second power output terminal 196' connected to power input terminal 193, such as... Figure 5 As shown, or connected to a separate power input (not shown). Fuse 198' can be used to provide transient power surge protection to any component that receives power through power output 196'.

[0040] In some embodiments, the control valve 182 includes a position sensor 200 configured to detect the position of the valve body 152, such as its position relative to the housing 202 of the valve 182, and output a sensor signal 204 indicating the detected position, such as... Figure 4 As shown. Electronic device 184 (such as valve controller 192) is configured to generate position signal 206 based on sensor signal 204 indicating the detected position of valve body 152. Position signal 206 can be conducted through position output 208 of valve 182 and received by adapter 180 at position input 210. Position signal 206 can be fed to position output 212 of adapter 180, which can be coupled to test station controller 130. Figure 2(or another controller of test station 102.)

[0041] In one embodiment, the position signal 206 transmitted through position output 208 is an analog signal having a voltage representing the position of valve body 152, and adapter 180 includes an analog-to-digital (A / D) converter 214 that converts the analog position signal into a digital signal, which is then fed to position output 212. A / D converter 214 can be powered using power received at one of the power inputs 188 of adapter 180.

[0042] In some embodiments, the control valve 182 includes an enable / disable (E / D) input 216 that receives an E / D signal 218, such as an E / D signal from the test station controller 130 or another controller of the test station 102. Figure 5 As indicated in the diagram. E / D signal 218 is transmitted from input 216 to E / D input 220 of control valve 182 via E / D output 222 of adapter 180. When E / D signal 218 has a first state (e.g., logic low voltage), electronics 184 or valve controller 192 disables valve body actuator 154 from moving valve body 152 relative to housing 202, and when E / D signal 218 has a second state (e.g., logic high voltage), electronics 184 or valve controller 192 allows valve body actuator 154 to adjust the position of valve body 152 based on control signal 172.

[0043] Adapter 180 can also be configured to connect to data communication channel 222 (e.g., Ethernet (EtherCAT®), Controller Area Network (CAN), etc.) used by test station 102 to transmit data 223. Figure 4 As shown. Adapter 180 may include a communication port 224 connected to data communication channel 222 and a communication port 226 to which components of test station 102 can be connected, such as the communication port 228 of valve electronics 184, etc. Figure 5 As shown.

[0044] Adapter 180 may include a housing 230 that supports and / or surrounds its components. Each of the input terminals (e.g., control input 186, power input 193, etc.), output terminals (e.g., position output 212), and communication ports (e.g., communication ports 224 and 226) may have a corresponding connector, or one or more of the input terminals, output terminals, and ports of adapter 180 may be combined in a single connector. Housing 230 may also include one or more cables with connectors that support one or more of the input terminals, output terminals, and / or ports of adapter 180.

[0045] For example, housing 230 may include connector 232, which includes a control input terminal 186 for easy connection to conventional cable 176, such as... Figure 5 As shown. The adapter housing 230 may also include a connector 234, which includes a control output terminal 188 and a power output terminal 196, and is configured to be coupled to a control input terminal 190 and a power input terminal 197 of the valve electronics 184. The housing 230 may include a cable with a connector 232 to facilitate connection to the cable 176, and / or a cable with a connector 234 to facilitate connection between the connector 234 and the valve 182.

[0046] The controllers of system 100 (such as system controller 126, test station controller 130, actuator controller 170, valve controllers 174 and 192, etc.) may take any suitable form to provide the various functions described herein, such as Figure 6 The exemplary controller 240 shown herein has the following functions. Controller 240 may include one or more processors 242 and memory 244. The one or more processors 242 are configured to perform the various functions described herein in response to the execution of instructions (such as test programs) contained in memory 244.

[0047] One or more processors 242 may be components of one or more computer-based systems and may include one or more control circuits, a microprocessor-based engine control system, and / or one or more programmable hardware components, such as a field-programmable gate array (FPGA). Memory 244 represents local and / or remote memory or computer-readable media. Such memory 244 includes any suitable computer-readable media conforming to the subject matter of this patent and does not include transient waves or signals. Examples of memory 244 include conventional data storage devices such as hard disks, optical disks, optical storage devices, magnetic storage devices, and / or other suitable data storage devices. Controller 240 may include circuitry 246 by one or more processors 242 for receiving input signals 248, issuing control signals 250, and / or transmitting data 252, such as in response to the execution of instructions stored in memory 244 by one or more processors 242.

[0048] Although embodiments of the present disclosure have been described with reference to preferred embodiments, those skilled in the art will recognize that changes in form and detail may be made without departing from the spirit and scope of the present disclosure.

Claims

1. An adapter for connection to a test station control valve configured to control fluid flow through a hydraulic actuator, the adapter comprising: A control input terminal, configured to receive valve control signals; A control output terminal, which is coupled to the control input terminal and configured to be connected to the valve control input terminal of the control valve; A power input terminal, configured to receive power from a power source; A first power output terminal is coupled to the power input terminal and configured to be connected to the valve power input terminal of the control valve; as well as At least one of the following components: A fuse, wherein the fuse is connected in series between the power input terminal and the first power output terminal; A position input terminal and a position output terminal, wherein the position input terminal is configured to be connected to the valve position output terminal of the control valve, and the position output terminal is coupled to the position input terminal; as well as Enable / disable input terminals and enable / disable output terminals.

2. The adapter according to claim 1, wherein, The adapter includes the fuse.

3. The adapter according to claim 1, wherein, The adapter includes the position input terminal and the position output terminal.

4. The adapter according to claim 1, wherein, The adapter includes the enable / disable input terminal and the enable / disable output terminal.

5. The adapter of claim 3 further includes an analog-to-digital converter connected in series between the position input and the position output, and configured to convert an analog signal received at the position output into a digital signal, the digital signal being transmitted to the position output.

6. The adapter according to claim 1, wherein, The control output terminal and the first power output terminal are housed in a single connector.

7. The adapter according to claim 1, further comprising a housing surrounding a coupling portion between the control input terminal and the control output terminal, and a coupling portion between the power input terminal and the first power output terminal.

8. The adapter according to claim 1, wherein, The control input is configured to be coupled to a Controller Area Network (CAN) bus or an Ethernet network for control automation technology (EtherCAT).

9. The adapter according to claim 1 further includes a second power output terminal coupled to the power input terminal.

10. A component comprising: The adapter includes: A control input terminal, configured to receive valve control signals; A control output terminal, which is coupled to the control input terminal; A power input terminal, configured to receive power from a power source; A first power output terminal, which is coupled to the power input terminal; and At least one of the following components: A fuse, wherein the fuse is connected in series between the power input terminal and the first power output terminal; Position input and position output terminals; and Enable / disable inputs and enable / disable outputs; and Control valve, the control valve comprising: The valve control input terminal is connected to the control output terminal; and The valve power input terminal is connected to the first power output terminal.

11. The component of claim 10, wherein, The adapter includes the fuse.

12. The component of claim 10, wherein: The adapter includes the position input terminal and the position output terminal; and The control valve includes a valve position output terminal connected to the position input terminal of the adapter.

13. The component of claim 10, wherein: The adapter includes the enable / disable input terminal and the enable / disable output terminal; and The control valve includes a valve enable / disable input connected to the enable / disable output of the adapter.

14. The component of claim 10, wherein, The control output terminal and the first power output terminal are housed in a single connector.

15. The component of claim 10, wherein, The control valve includes: valve housing; Valve body, the valve body being contained within the housing and having a position for controlling the flow rate and direction of hydraulic fluid; and A valve controller configured to control the position of the valve body based on a control signal received at the valve control input.

16. A test station for a dynamic testing system, comprising: A hydraulic actuator configured to drive actuation of a test object using a flow of hydraulic fluid; A test station controller, configured to transmit control signals via a control cable based on a test program; A power source, configured to supply power; The adapter includes: A control input terminal, which is coupled to the control cable and configured to receive a control signal from the test station controller; A control output terminal, which is coupled to the control input terminal; A power input terminal, configured to receive power from the power source; A first power output terminal, which is coupled to the power input terminal; and At least one of the following components: A fuse, wherein the fuse is connected in series between the power input terminal and the first power output terminal; Position input and position output terminals; and Enable / disable inputs and enable / disable outputs; and Control valve, the control valve comprising: valve housing; A valve body, which is contained within the housing and has a position for controlling the flow rate and direction of the hydraulic fluid; The valve control input terminal is coupled to the control output terminal; The valve power input terminal is coupled to the first power output terminal; and A valve controller configured to control the position of the valve body based on the control signal received at the valve control input.

17. The test station according to claim 16, wherein, The adapter includes the fuse.

18. The test station according to claim 16, wherein: The adapter includes the position input terminal and the position output terminal; and The control valve includes a valve position output terminal connected to the position input terminal of the adapter.

19. The test station according to claim 16, wherein: The adapter includes the enable / disable input terminal and the enable / disable output terminal; and The control valve includes a valve enable / disable input connected to the enable / disable output of the adapter.

20. The test station according to claim 16, wherein, The control output terminal and the first power output terminal are housed in a single connector configured to be attached to the control cable.

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