Programmable Actuator Simulator Card for Controller Testing
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Solution Overview
Problem
Conventional actuator testing procedures are limited by the need for simultaneous availability of actuators and actuator controllers, resulting in delays, and are restricted by analog interface circuits that require specific hardware for each type of actuator, making testing cumbersome and inefficient.
Innovation Solution
An actuator simulation system with a programmable computer, actuator simulator card, and interfaces to communicate with both the computer and actuator controller, allowing for the use of actuator simulation models to generate simulated feedback signals, enabling testing without actual actuators and accommodating various actuator types through digital signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional test procedures using analog interface circuits are used, then testing can be performed with existing hardware, but testing is restricted to specific actuator types and requires different hardware for different actuators
Solution Approach 1:
The patent replaces analog interface circuits with digital signal processing circuits. The digital interface card uses digital filters, modulators, and demodulators instead of analog circuits, allowing software-based configuration for different actuator types. This substitution enables a single hardware platform to test multiple actuator types through programmable digital signal processing.
Solution Approach 2:
The digital interface card is designed with universal functionality to accommodate different actuator types. By implementing digital signal processing with programmable filters and signal generation capabilities, a single interface card can be configured to test various actuator types (electrohydraulic, electro pneumatic, etc.) without requiring different dedicated hardware for each type.
2Reliability
If both actuator and actuator controller must be connected for testing, then adequate testing of both components can be performed, but testing delays occur when components are not concurrently available
Solution Approach 1:
The patent creates a digital model (copy) of the actuator within the simulation module. This virtual actuator model replicates the dynamic characteristics and behavior of the physical actuator, allowing the controller to be tested against the simulation without requiring the actual actuator to be physically present. The simulation model receives controller commands and generates feedback signals that mimic real actuator responses.
Solution Approach 2:
The actuator simulation module serves as an intermediary between the controller under test and the physical actuator. It mediates the interaction by translating controller commands into simulated actuator responses, enabling complete controller testing without direct connection to the physical actuator, thus eliminating waiting delays while maintaining testing validity.
3Productivity
If analog interface circuits are used, then existing hardware can be utilized, but the analog nature restricts testing to specific actuator types with fixed hardware-based filters and modulators
Solution Approach 1:
The patent implements dynamic, reconfigurable digital signal processing instead of fixed analog circuits. The digital filters, modulators, and demodulators can be programmatically adjusted to match different actuator characteristics. This dynamic reconfiguration capability allows the same hardware to adapt to various actuator types by changing software parameters rather than physical circuitry.
Solution Approach 2:
The system enables testing of different actuator types by changing digital parameters (filter coefficients, gain values, frequency settings) rather than changing physical hardware. The digital interface card's parameters can be programmed to match the specific characteristics of different actuators, providing versatility without requiring different hardware configurations.
Data Source
AI summary
An actuator simulator card that is programmable with one or more actuator simulation models is provided. The actuator simulator card may include a first interface configured to communicate with a programmable computer, a second interface configured to communicate with an actuator controller, and a simulation module in communication with each of the first interface and the second interface. The simulation module may be configured to receive at least one actuator simulation model corresponding to at least one actuator from the first interface, receive excitation signals and command signals for operating the actuator from the second interface, and determine simulated feedback signals based on the excitation signals, the command signals, and the actuator simulation model.