Dual power supply for hydraulic actuator system

Abstract

To provide a power and signal distribution hub, and a method for distributing a signal and power.SOLUTION: A power and signal distribution hub is provided, which supplies power and an operation signal to a plurality of channels of a test system for operating one or more hydraulic actuators which apply a load to a test object. The power and signal distribution hub includes a first power supply and a second power supply which are connected so as to undergo load sharing of a power to the test system and are configured so as to distribute power to the plurality of channels of the test system. A monitoring circuit for each power supply is configured so as to monitor operation of each power supply and supply a signal showing that the operation of the power supply is outside a normal operation parameter of the power supply.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of priority from U.S. Provisional Patent Application No. 63 / 581,476, filed 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 technology]

[0002] The following discussion is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.

[0003] In a test system, the test objects are very expensive, and under certain conditions, the loading on the test objects must be reduced quickly and effectively to prevent damage to the test objects. If the power supply operation of the test system is outside of normal operating parameters, it may cause unloading that does not normally occur, which may damage the test objects. Summary of the Invention

[0004] This Summary and Abstract herein are provided to introduce selected concepts in a simplified form that are further described below in the Detailed Description. This 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 as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all of the shortcomings discussed in the Background.

[0005] In one aspect, a power and signal distribution hub is provided for supplying power and operating signals to a plurality of channels of a test system for operating one or more hydraulic actuators that apply a load to a test object. 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 and configured to distribute power to the plurality of channels of the test system. A monitoring circuit for each power supply is configured to monitor operation of its respective power supply and, upon detection, provide a signal indicating operation of the power supply is outside normal operating parameters of the power supply.

[0006] Implementations may include one or more of the following features: Each monitoring circuit may include a plurality of relays coupled to its power source. The shared power load may be assumed by the first power source upon failure of the second power source. Both the first power source and the second power source may be used to provide power for inrush current at start-up of the test system, and in normal operation, a single one of the first power source and the second power source may provide power to the test system. Each of the power sources may be electrically coupled to a solenoid for each channel, to a valve for each channel, and to control logic for each channel. The power and signal distribution hub may be configured to provide a signal to an external controller indicative of a failure of the first power source and to receive a command signal from the external controller to perform a controlled load removal of the load at the test object in the test system from each actuator using the second power source. The power and signal distribution hub may be configured to receive a feedback signal regarding a status of the controlled load removal of the load at the test object and to provide a status signal of the controlled load removal to the external controller. The power and signal distribution hub may be configured to receive an interlock load removal signal from the external controller if the controlled load removal fails and to supply interlock load removal power to each valve, solenoid, and control logic for each associated actuator of the test system for interlock load removal of the load in the test object from each actuator.

[0007] In another aspect, a method of distributing signals and power to channels of a test system for operating one or more hydraulic actuators that apply a load to a test object includes supplying power to the channels of the test system using a pair of power supplies connected to load share the power supplied to the test system, the power supplies being monitored for proper operation, and upon detection, a signal being provided indicating operation of one of the pair of power supplies outside of proper operation.

[0008] Implementations of the method may include one or more of the following features: Monitoring is performed by a monitoring circuit for each power supply of the pair of power supplies, each monitoring circuit configured to monitor operation of its respective power supply, and each monitoring circuit may have a plurality of relays coupled to its power supplies. The method may include an operational one of the pair of power supplies taking over the shared load if the other of the pair of power supplies fails. Providing power may further include providing power to a solenoid for each channel, to a valve for each channel, and to a control logic for each channel. Providing the signal indicative of a failure of the other of the pair of power supplies may include providing the signal indicative of a failure of the other of the pair of power supplies to an external controller. The method may include receiving an indication signal from the external controller to initiate a controlled load removal of a load at a test object in the test system. The method may include providing a status signal of the controlled load removal to the external controller. The method may include receiving an interlock load removal signal from the external controller when the controlled load removal fails, and supplying interlock load removal power to valves for actuators of the test system for interlock load removal of the load in the test object from each actuator.

[0009] This summary is not intended to describe each disclosed embodiment or every implementation of the power and signal distribution hub as described herein. Many other novel advantages, features, and relationships will become apparent as this description proceeds. The drawings and description that follow more particularly exemplify illustrative embodiments. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a block diagram of a power and signal distribution hub system according to an embodiment of the present disclosure.

[0011] [Diagram 2] FIG. 1 is a block diagram of an operating environment in which embodiments of the present disclosure can be used.

[0012] [Diagram 3] FIG. 2 is a flow chart diagram of a method according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Embodiments of the present disclosure provide a reliable power source that includes redundant multiple power sources adapted to mitigate failure of a single power source that could otherwise place a control system for a test system in an adverse condition that could cause damage to the test object.

[0014] 1 shows a power and signal distribution hub 150. The power and signal distribution hub 150 is configured to provide power and operating signals to multiple channels of the test system 100 (FIG. 2) for operating one or more, typically multiple, hydraulic actuators to apply a load to a test object. In one embodiment, the power and signal distribution hub 150 includes a first power source 152 and a second power source 154. The power source 152 and the power source 154 are connected to load share the power to the test system 100. The first power source 152 and the second power source 154 are configured to distribute power to the multiple channels of the test system 100. In one embodiment, the power and signal distribution hub 150 provides power to eight channels of the test system, although this should not be considered a limitation.

[0015] In one embodiment, a single one of the two power supplies is sufficient to provide all the power to operate the test system 100 .

[0016] A monitoring circuit 156 for each power supply 152 and power supply 154 is configured to monitor the operation of its respective power supply. Each monitoring circuit 156 provides a signal 158 indicating that operation of its power supply is outside of normal operating parameters for that power supply. In one embodiment, signal 158 indicates a fault in its respective power supply. Each monitoring circuit 156, in one embodiment, includes a number of relays 160 coupled to its power supplies. Relays 160, in one embodiment, are solid-state switching devices. Additionally, visual indicators may be provided to indicate the status of the power supplies.

[0017] In one operating state under normal operation of the test system 100, the total power load used by the test system 100 for controlling one or more actuators is shared between the power supply 152 and the power supply 154, with the output terminals of the power supply 152 and the power supply 154 connected in parallel. When the monitoring circuit 156 detects that the operation of one of the pair of power supplies is outside of its normal operating parameters, the full or total load is taken by the power supply that is not outside of its normal operating parameters. For example, upon failure of the second power supply 154 or other operating conditions that form its predetermined operating state, the load shared by the first power supply 152 is taken, and vice versa. The normal operating parameters of the power supplies may be set or provided in any number of ways without departing from the scope of this disclosure. In one embodiment, the detection by the monitoring circuit 156 is to detect a complete failure of the power supply. This is a likely configuration to be used in a power and signal distribution hub for operation in a test system. However, in another embodiment, the monitoring circuit 156 is capable of detecting a parameter (e.g., without limitation, voltage, current, temperature, etc.) outside of its normal operating condition that may cause it to begin taking over the total power load of the other power supply.

[0018] In one embodiment, each of power supplies 152 and 154 is electrically coupled to multiple channels of test system 100. The number of channels is eight in one embodiment, but it should be understood that a greater or lesser number of channels may be used 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 powered by power and signal distribution hub 150, which derives its power from power supplies 152 and 154. In one embodiment, a single power supply of power supplies 152 and 154 is sufficient to power all of the channels coupled to power and signal distribution hub 150 and all of the solenoids, valves, and control logic for each channel.

[0019] The power and signal distribution hub 150 is configured to provide signals 158 indicative of operation outside of normal operating parameters of the first power source 152 or the second power source 154 to the external controller 130 via communication link 160, and also to receive command signals from the external controller 130 via communication link 160 to perform controlled unloading of a load on a test object in the test system 100 from each actuator of the test system 100 using the second power source 154 or the first power source 152, respectively, in the event of a failure of one of the power sources 152 and 154. The controlled load unloading operating condition is when the controller 130 is capable of providing a command signal to a respective valve of each associated actuator to reduce the load provided by the actuator.

[0020] The power and signal distribution hub 150, in one embodiment, is further configured to receive a number of feedback signals 162 (one of which is shown in FIG. 2) on a number of channels of the test system 100. The feedback signals 162 may be from, for example, but not limited to, load cells, displacement sensors, hydraulic sensors, other contact sensors, and the like. Of particular interest are feedback sensors indicative of the load on the test article, such as load cells that directly measure the load being applied by an actuator, or hydraulic signals indicative of the load being applied by an actuator, and the like. Such feedback signals 162 are indicative of, among other things, the state of controlled unloading of the load on the test article.

[0021] The power and signal distribution hub 150 is further configured in one embodiment to provide controlled load unloading status signals 164 to the external controller 130 on channel communication lines 166 and 168, in one embodiment one channel communication line for four channels. If the controlled load unloading fails, one or more of the status signals 164 trigger the system controller 130 to issue an interlock unloading signal on communication line 160, which in turn results in an interlock command signal being provided to each valve of each actuator. When each valve receives the interlock command signal, the valve controls the associated actuator to reduce the differential load applied by the actuator to the test object. Unlike the controlled load unloading operating state, where the controller 130 continues to provide a command signal to each valve to reduce the differential load applied by each actuator, when the interlock command signal is issued, each valve of each actuator operates the actuator to reduce the differential load without further command signals from the controller 130. In such circumstances, interlock load removal power is provided by an active power supply to each valve, solenoid, and control logic for each associated valve of each actuator of test system 100 for channels connected to power and signal distribution hub 150. The operation of controller 130, and in particular the operation of each valve for an actuator, is described in a co-pending provisional patent application entitled "CONTROLLED LOAD ABORT IN AN ACTUATOR SYSTEM," filed September 8, 2023, numbered 63 / 581465, the contents of which are incorporated herein by reference in their entirety.

[0022] In one embodiment, both the first and second power supplies are used to provide power for the inrush current at startup of the test system 100. During startup operations, the startup or inrush current may exceed the power available from a single power supply 152 or power supply 154. In one embodiment, during normal operation after the initial inrush current is used, a single power supply, either the first power supply 152 or the second power supply 154, can provide full power for all channels of the test system during normal operation, during a controlled load removal state, or during an interlocked load removal state. A failure of one of the power supplies 152 and 154 during startup is detected by its monitoring circuit 156, so that a failure during startup does not adversely affect the test item.

[0023] In one embodiment, the two or more power sources 152 and 154 are coupled to a main power source, such as utility power, line power, mains electric, etc. However, in one embodiment, one or more of power sources 152 and 154 can be batteries or other power sources (batteries, gas engines, etc.) depending on the test system being operated using the power and signal distribution hub.

[0024] Furthermore, where two power sources are mentioned and described, it should be understood to mean two or more. That is, three or more power sources 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 has sufficient power to provide startup and normal operating power for eight channels, if there are two or more. It should be understood that each power and signal distribution hub comprises an output card or module, each card or module having multiple channels, such as eight channels, and that the power and signal distribution hub can have one or more output cards or modules. The power and signal distribution hubs can be further connected to each other, for example, in a daisy chain manner, 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 chained together up to 250 channels or more. In such a chain, one or more power and signal distribution hubs can be powered by a pair of a first power source and a second power source, while in another embodiment, each power and signal distribution hub 150 can have its own pair of a first power source 152 and a second power source 154. In either situation, the system controller 130 operates to receive signals from each power source present and to control each power and signal distribution hub 150. In such a configuration, if a power failure is detected in any of the chained power and signal distribution hubs, this triggers the system controller 130 to perform a controlled unloading of the loads at the test object using the available power sources of the still operational power and signal distribution hubs (or an interlocked load unloading if the controlled load unloading does not work), as well as a controlled unloading of the loads associated with the power and signal distribution hubs, which may typically be powered by two power sources. As the test object may be very valuable, it is important that it is not damaged. It is therefore important to be able to command the actuators that apply the load to the test object to be in an unloaded state, or at least in a reduced load state.This is achieved using the embodiments of the present disclosure because, in the event of a failure of one power supply, a second power supply is provided that is fully capable of manipulating the values ​​of each actuator and supplying power to the power and signal distribution hub(s) 150 to achieve the desired load removal to the test object.

[0025] A representative operating environment for an embodiment of the power and signal distribution hub 150 is shown in more detail in FIG. 2. FIG. 2 illustrates a system 100 for monitoring and unloading a load on a test object, including the power and signal distribution hub 150. The system 100, in one embodiment, includes a hydraulic assembly 110 and a system controller 130. The hydraulic assembly 110, in one embodiment, includes a control valve 112 configured to control a load on a hydraulic actuator 120 coupled to the test object. The hydraulic assembly 110 further includes a pair of pressure transducers 114 configured to detect and communicate pressure on each associated hydraulic actuator 120. For each associated hydraulic actuator 120, an isolation valve 116 is provided that selectively isolates the control valve 112 from a hydraulic source 140 of hydraulic pressure. In such a case, the control valve 112, in an interlock load removal operating state, can locally reduce the load on the actuator 120 on the test object according to instructions executed by a local processor within the control valve without further instructions from the system controller 130.

[0026] The system controller 130, in one embodiment, is configured to determine a load differential between at least one of the calculated loads at the control valves 112 for the hydraulic actuators 120 of the test system 100 and the calculated loads at the load cells 122 coupled to the hydraulic actuators. In a first method of unloading the load at the test object by each actuator connected to the test object, the system controller 130 is further configured to initiate a controlled unloading of the load at the test object via the system controller 130 when the determined load differential reaches a first level. This controlled unloading occurs during a flow mode of the system, i.e., 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. This first level may be referred to as a stop level. If controlled load removal at the stop level does not work, the controller 130 is further configured to perform interlock load removal of the load on the test object via commands sent to each control valve 112 of each actuator 120 required to unload the load on the test object when the determined differential load reaches a second level higher than the first level, at which point valve controlled load removal, i.e. interlock load removal, is used to unload the load on the test object.

[0027] In one embodiment, the control valve 112 further comprises a local valve controller 113 that receives pressure from the pressure transducer 114, and valve firmware 115 operable by the local controller 113 and configured to reduce differential loading on a piston of a hydraulic actuator 120. The unloading of an actuator by execution of the firmware 115 by the local valve controller 113 to control operation of its associated actuator 120 is performed, in one embodiment, without further input from the system controller 130.

[0028] The system controller 130, in one embodiment, is an external controller that executes software to operate the test system 100 based on test procedures in a system computer 131 that provides a user interface to a user for configuring, operating, and monitoring the testing of test objects.

[0029] In the test system 100, a number of control valves 112 may be connected to a number of hydraulic actuators 120 that provide loads to various 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 cell 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, one isolation valve 116 is provided for each control valve 120. The system controller 130 controls the operation of each isolation valve 116 and control valve 112 under a "flow mode" when the test article is being tested according to a desired test procedure, i.e., during normal operation.

[0030] The system 100 , in one embodiment, further includes a power and signal distribution hub 150 coupled between the system controller 130 and the hydraulic assembly 110 .

[0031] A method 300 of distributing signals and power to multiple channels of a test system for operating one or more hydraulic actuators to apply a load to a test object is illustrated in flow chart form in FIG. 3. Method 300 includes, in one embodiment, providing power to multiple channels of a test system using a pair of power supplies connected to load share the power provided by the test system at block 302. At block 304, power supply 152 and power supply 154 are monitored for proper operation and at block 306, a signal is provided indicating operation of one power supply of the pair of power supplies outside of its proper operation. The monitoring is performed in one embodiment by a monitoring circuit for each power supply of the multiple power supplies. Each monitoring circuit is configured to monitor operation of its respective power supply. Each monitoring circuit, in one embodiment, includes a plurality of relays configured to perform the monitoring. In such an embodiment, the current flow from each power supply is monitored and the relay is tripped and turned off when the current flow is interrupted, indicating that the power supply operation is outside of normal operating parameters, which triggers signal 158. Appropriate actions may include operation outside a predetermined set of parameters, total or partial failure of a power source, etc., as described elsewhere.

[0032] In block 308, the operating one of the pair of power supplies assumes the shared load if the other power supply of the pair fails or is operating outside its normal operating parameters.

[0033] The power supply as shown in block 302, in one embodiment, further includes supplying power to eight channels coupled to the power and signal distribution hub 150, including supplying power to the solenoids, valves, and control logic for each channel.

[0034] Providing a signal indicating that operation of the power supply is outside its normal operating parameters includes, in one embodiment, providing a signal to the external controller 130. In one embodiment, the method 300 further includes, in optional block 310, receiving an instruction signal from the external controller 130 to initiate controlled load removal of the load on the test object in the test system 100. The method may also include, in optional block 312, providing a controlled load removal status signal to the external controller 130. The method may also include receiving an interlock load removal signal from the external controller 130 and providing an interlock for load power to valves for the actuators 120 of the test system 100 for interlock load removal of the load on the test object from each actuator 120. Such an interlock load removal signal is provided in one embodiment in response to feedback indicating that controlled load removal of the load on the test object in the test system 100 is not adequately eased. In one embodiment, controlled load removal is commanded by the system controller 130 when the load difference reaches a first, stop level, and interlock load removal is commanded when a second, higher, interlock load difference is reached.

[0035] It should be noted that the same reference numbers are used for the same or similar elements in different drawings. It should also be understood that the terminology used herein is for the purpose of describing the embodiments, and the terminology is not intended to be limiting. Unless otherwise indicated, ordinal numbers (e.g., first, second, third, etc.) are used to distinguish or identify different elements or steps within a group of elements or steps, and do not impose sequential or numerical limitations on the elements or steps of the embodiment. For example, the "first", "second", and "third" elements or steps do not necessarily have to appear in that order, and do not necessarily limit the embodiment to three elements or steps. It should also be understood that unless otherwise indicated, any designations such as "left," "right," "front," "rear," "top," "bottom," "forward," "reverse," "clockwise," "counterclockwise," "up," "down," or other similar terms such as "upper," "lower," "rear," "forward," "vertical," "horizontal," "proximal," "distal," "middle," etc., are used for convenience and are not intended to imply, for example, any particular fixed location, orientation, or direction. Instead, such designations are used, for example, to reflect relative locations, orientations, or directions. It should also be understood that the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0036] Thus, embodiments of the present disclosure provide methods and systems for providing dual power supplies with a shared load that serves to mitigate failure of a single power supply and provide protection to the test object being tested in the test system.

[0037] The above disclosed subject matter is to be regarded as illustrative and not limiting, and the appended claims are intended to cover all such modifications, improvements and other embodiments that fall within the true scope of the present disclosure. Thus, to the maximum extent permitted by law, the scope of the present disclosure should be determined by the broadest permissible interpretation of the appended claims and their equivalents, and should not be limited or restricted by the foregoing detailed description.

Claims

1. a power and signal distribution hub for supplying power and operating signals to a plurality of channels of a test system for operating one or more hydraulic actuators to apply a load to a test object, 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 the multiple channels of the test system; a monitor circuit for each power supply, the monitor circuit being configured to monitor operation of the respective power supply and to provide a signal upon detection that operation of that power supply is outside normal operating parameters of that power supply; 1. A power and signal distribution hub comprising:

2. 10. The power and signal distribution hub of claim 1, wherein each monitoring circuit comprises a plurality of relays coupled to its power source.

3. 3. The power and signal distribution hub of claim 1 or 2, wherein the shared power load is assumed by the first power source upon failure of the second power source.

4. 4. The power and signal distribution hub of claim 1, wherein both the first power supply and the second power supply are used to provide power for inrush current at start-up of the test system, and during normal operation, a single power supply of the first power supply or the second power supply can supply power to the test system.

5. The power and signal distribution hub of any one of claims 1 to 4, wherein each of the power sources is electrically coupled to a solenoid for each channel, a valve for each channel, and control logic for each channel.

6. 6. A power and signal distribution hub as claimed in any one of claims 1 to 5, configured to provide a signal to an external controller indicative of a failure of the first power supply, and to receive a command signal from the external controller to perform controlled unloading of loads on the test object in the test system from each actuator using the second power supply.

7. 7. A power and signal distribution hub as claimed in any preceding claim, configured to receive a feedback signal relating to a status of the controlled load removal of the load on the test object, and to provide a status signal of the controlled load removal to the external controller.

8. 8. The power and signal distribution hub of claim 1, configured to receive an interlock load removal signal from the external controller if the controlled load removal fails, and to supply interlock load removal power to each valve, solenoid, and control logic for each associated actuator of the test system for interlock load removal of the load in the test object from each actuator.

9. 1. A method of distributing signals and power to channels of a test system for operating one or more hydraulic actuators to apply a load to a test object, comprising: powering the channels of the test system with a pair of power supplies connected to load share the power supplied to the test system; Monitoring for proper operation; and providing a signal upon detection indicating that operation of one of the pair of power supplies is outside of proper operation; A method comprising:

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

11. 11. The method of claim 9 or 10, further comprising: if the other of the pair of power sources fails, an operational one of the pair of power sources assumes the shared load.

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

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

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

15. Furthermore, providing a status signal of the controlled unloading to the external controller; and / or receiving an interlock load removal signal from the external controller when the controlled load removal fails; and / or providing interlock load removal power to valves for actuators of the test system for interlock load removal of the loads in the test object from each actuator; The method according to any one of claims 9 to 14, comprising:

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