US-20260126362-A1 - ACTUATOR-BASED TEST MACHINE CALIBRATION INSTRUMENT

US20260126362A1US 20260126362 A1US20260126362 A1US 20260126362A1US-20260126362-A1

Abstract

A testing system calibration instrument includes a plurality of device inputs, a plurality of signal processing units, a display device, a controller and a housing that unifies the components. The plurality of signal processing units includes two or more of a millivolt/volt signal reader configured to produce a first calibration signal based on a millivolt/volt signal received from a first calibration sensor through one of the device inputs, a decoder configured to produce a second calibration signal based on an encoded signal received from a second calibration sensor through one of the device inputs, and a voltmeter configured to produce a third calibration signal based on an analog voltage signal received from a third calibration sensor through one of the device inputs. The controller is configured to control the display device to display information relating to the first calibration signal, the second calibration signal and/or the third calibration signal.

Inventors

Robert George Bowen
Kevin Jay Rust

Assignees

ILLINOIS TOOL WORKS INC.

Dates

Publication Date: 20260507
Application Date: 20251103

Claims (20)

1 . A testing system calibration instrument for use in calibrating actuator-based test machines comprising: a plurality of device inputs; a plurality of signal processing units selected from the group consisting of: a millivolt/volt signal reader configured to produce a first calibration signal based on a millivolt/volt signal received from a first calibration sensor through one of the device inputs; a decoder configured to produce a second calibration signal based on an encoded signal received from a second calibration sensor through one of the device inputs; and a voltmeter configured to produce a third calibration signal based on an analog voltage signal received from a third calibration sensor through one of the device inputs; a display device; a controller configured to control the display device to display information relating to the first calibration signal, the second calibration signal and/or the third calibration signal; and a housing unifying the device inputs, the display device, the signal processing units and the controller.
2 . The testing system calibration instrument according to claim 1 , wherein: the plurality of device inputs includes a millivolt/volt signal input; the plurality of signal processing units includes the millivolt/volt signal reader that produces the first calibration signal based on a millivolt/volt signal received from the first calibration sensor through the millivolt/volt signal input; and the information includes a value corresponding to the first calibration signal.
3 . The testing system calibration instrument according to claim 2 , wherein the first calibration sensor is selected from the group consisting of a force transducer, a load cell, a pressure transducer and a torque transducer.
4 . The testing system calibration instrument according to claim 1 , wherein: the plurality of device inputs includes an encoded signal input; the plurality of signal processing units includes the decoder that produces the second calibration signal based on an encoded signal received from the second calibration sensor through the encoded signal input; and the information includes a value corresponding to the encoded calibration signal.
5 . The testing system calibration instrument according to claim 4 , wherein: the second calibration sensor comprises a linear displacement sensor or an angular displacement sensor; and the encoded signal comprises a linear displacement signal from the linear displacement sensor or an angular displacement signal from the angular displacement sensor.
6 . The testing system calibration instrument according to claim 5 , wherein: the encoded signal comprises a quadrature signal; and the decoder comprises a quadrature signal decoder.
7 . The testing system calibration instrument according to claim 5 , wherein the decoder comprises a synchronous serial interface.
8 . The testing system calibration instrument according to claim 5 , wherein: the encoded signal comprises a sine/cosine signal; and the decoder comprises a sine/cosine signal decoder.
9 . The testing system calibration instrument according to claim 5 , wherein: the instrument comprises a clock configured to output a clock signal; and the controller is configured to: calculate a velocity based on the second calibration signal and the clock signal; and the information includes a value corresponding to the calculated velocity.
10 . The testing system calibration instrument according to claim 1 , wherein: the plurality of device inputs includes an analog voltage signal input; the plurality of signal processing units includes the voltmeter that produces the third calibration signal based on an analog voltage signal received from the third calibration sensor through the analog voltage signal input; and the information includes a value corresponding to the analog voltage signal.
11 . The testing system calibration instrument according to claim 10 , wherein the analog voltage signal corresponds to a sensed force, torque or pressure.
12 . The testing system calibration instrument according to claim 10 , wherein: The third calibration sensor comprises a linear variable differential transformer (LVDT) or a crosshead encoder; and the analog voltage signal comprises an LVDT signal from the LVDT corresponding to a displacement, or a crosshead encoder signal from the crosshead encoder corresponding to a displacement.
13 . The testing system calibration instrument according to claim 10 , wherein the analog voltage signal comprises a calibration sensor excitation signal sent to the calibration sensor.
14 . The testing system calibration instrument according to claim 1 , wherein: the instrument includes a direct current voltage circuit configured to output a direct current voltage based on a command signal from the controller; and the direct current voltage circuit is supported by the housing.
15 . The testing system calibration instrument according to claim 1 , including a plurality of universal serial bus (USB) ports connected to the controller and supported by the housing.
16 . The testing system calibration instrument according to claim 1 , including a plurality of serial ports connected to the controller and supported by the housing.
17 . The testing system calibration instrument according to claim 1 including an ethernet port connected to the controller and supported by the housing.
18 . The testing system calibration instrument according to claim 1 , wherein: the display device includes a touchscreen interface configured to receive a user input; and the controller is configured to control the display device based on the user input.
19 . A testing system calibration instrument for calibrating actuator-based test machines comprising: a plurality of device inputs; a plurality of signal processing units comprising: a millivolt/volt signal reader configured to produce a first calibration signal based on a millivolt/volt signal received from a first calibration sensor through one of the device inputs; a decoder configured to produce a second calibration signal based on an encoded signal received from a second calibration sensor through one of the device inputs; and a voltmeter configured to produce a third calibration signal based on an analog voltage signal received from a third calibration sensor through one of the device inputs; a plurality of communication ports; a display device; a controller configured to control the display device to display information relating to the first calibration signal, the second calibration signal and/or the third calibration signal; and a housing unifying the device inputs, the display device, the signal processing units, the communication ports and the controller.
20 . A method of operating a testing system calibration instrument, which comprises: a plurality of device inputs; a plurality of signal processing units selected from the group consisting of: a millivolt/volt signal reader configured to produce a first calibration signal based on a millivolt/volt signal received through one of the device inputs; a decoder configured to produce a second calibration signal based on an encoded signal received through one of the device inputs; and a voltmeter configured to produce a third calibration signal based on an analog voltage signal received through one of the device inputs; a display device; a controller configured to control the display device to display information relating to the first calibration signal, the second calibration signal and/or the third calibration signal; and a housing unifying the device inputs, the display device, the signal processing units and the controller; the method comprising: connecting each of one or more calibration sensors to one of the device inputs; generating one or more test signals using one or more test sensors of an actuator-based test machine in response to stimulation of the one or more test sensors through the application of a force or a displacement to the one or more test sensors; generating one or more calibration sensor signals using the one or more calibration sensors in response to or in relation to the stimulation of the one or more test sensors, the calibration sensor signals selected from the group consisting of: a millivolt/volt signal; an encoded signal; and an analog voltage signal; producing one or more calibration signals each corresponding to one of the calibration sensor signals received through one of the device inputs comprising: producing a first calibration signal using the millivolt/volt signal reader based on the millivolt/volt signal; producing a second calibration signal using the decoder based on the encoded signal; and/or producing a third calibration signal using the voltmeter based on the analog voltage signal; and controlling the display device to display information relating to the first calibration signal, the second calibration signal and/or the third calibration signal using the controller.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present application is based on and claims the benefit of U.S. provisional patent application Serial No. 63/716,509, filed November 5, 2024, the content of which is hereby incorporated by reference in its entirety. FIELD Embodiments of the present disclosure generally relate to actuator-based test machines of dynamic testing systems and, more particularly, to a calibration instrument that facilitates calibration of test sensors of the test machines. BACKGROUND Dynamic testing systems, such as those developed by MTS Systems Corporation, include test machines that perform various tests on a test specimen through the application of loads and/or displacements to the test specimen using one or more actuators. Test machines may be used to form a vehicle testing station that applies simulated driving conditions to a mobile vehicle or vehicle component, or a building testing station that applies simulated seismic activity to a building, for example. Test machines utilize various test sensors during a test to measure aspects of a response from a specimen under test and/or to provide feedback for controlling the test. Such test sensors may include force transducers (e.g., load cell, torque transducer, pressure transducer, etc.) that may measure a force applied to the specimen, displacement sensors that may measure a displacement associated with an actuation of the specimen, an extensometer that may be used to measure a strain on the specimen, and other test sensors. Such test sensors or sensing devices require periodic calibration to ensure their proper operation using various calibration sensors or devices. For example, a load cell of a test machine is typically calibrated using a calibration sensor in the form of a reference load cell that is placed in series with the load cell of the test machine. A displacement set by the test machine, such as a crosshead position, may be calibrated using a calibration sensor in the form of a displacement sensor (e.g., linear or angular displacement sensor) that measures the set displacement. An extensometer of a test machine may be calibrated using a calibration sensor in the form of an extensometer calibrator that opens the extensometer a known distance or applies a known strain to the extensometer. Conventional calibration operations generally utilize a calibration computing device, that connects to one or more signal processing units (e.g., millivolt/volt signal reader, decoder, voltmeter, etc.) that are used to read the outputs from the calibration sensors, which may be presented on a display of the calibration computing device. The calibration computing device also connects to the test system computing device that is used to control the test machine and process the signals from its test sensors. During a calibration computing device may control a test machine through communications with the test system computing device to stimulate its test sensors and corresponding calibration sensors, possibly along with a specimen. The sensed values from the test sensors and the calibration sensors may be displayed on the calibration computing device and used by the operator to calibrate aspects of the test machine. A conventional setup of a calibration operation on a test machine generally utilizes an intermediary device that facilitates communications between the calibration computing device and a signal processing unit, and between the calibration computing device and the test station computing device through three RS232 serial communication ports. Thus, the calibration computing device receives the output from the processing unit and communicates with the test station computing device through the intermediary device. This conventional setup of the calibration operation may involve numerous connections and cabling including a cable connection between the intermediary device and the calibration computing device, a cable connection between the intermediary device and the test system computing device, a cable between the intermediary device and the signal processing unit, and a cable between the signal processing unit and the calibration sensor, for example. When the operator would like to receive an output from a different calibration sensor, it may be necessary to connect the intermediary device to a different signal processing unit, which in turn must be connected to the calibration sensor. As a result, setting up the conventional calibration operation for an individual test machine can be a cumbersome, complicated and time-consuming task. SUMMARY Embodiments of the present disclosure relate to a testing system calibration instrument that facilitates calibration of test sensors of actuator-based test machines and methods of operating the calibration instrument. One example of the calibration instrument includes a plurality of device inputs, a plurality of signal processing units, a display device, a controller and a housing that unifies the