Endurance Tester for Mission-Critical Mechanical Component using NI cRIO

Endurance Tester for Mission-Critical Mechanical Component using NI cRIO

Ability to run tests unattended and overnight reduces operator labor and compresses test schedules

Client – Major Aerospace Component Supplier / Manufacturer

Challenge

The client had an older VB & PLC-based test system in place already, but it was obsolete. A new endurance test system needed to be developed to validate prototyped components (in this case, aircraft & aerospace bearings). Many of the prototypes are one-off, so it was important that the test system not destroy the component.

Solution

A new endurance test system was developed to validate prototyped components. The test system can be configured for automatic shutdowns so as not to destroy the component under test in the event of unexpected performance of electro-mechanical subsystem components. The updated endurance tester supports product validation by allowing the product to run under various test conditions (e.g. speed, load, oil flow, temperature) and collecting data for analysis.

Viewpoint developed the software and selected the NI hardware (other hardware was selected by the client).

Benefits

  • Ability to run tests unattended and overnight eases operator labor and compresses test schedules

  • Data collection allows for offline engineering analysis

  • Automatic shutdowns reduce destruction of the prototype component under test

System Overview

The updated cRIO-based endurance tester incorporates configurable profiles, data logging, and automatic shutdown to allow for safer extended validation testing.  LabVIEW FPGA and LabVIEW RT were used together to interface with the test hardware sensors and controls.  LabVIEW as used create the HMI for the test system.

SOFTWARE FUNCTIONS
Closed loop control of bearing test oil flow
Axial load control
Driver for Emerson VFD
E-Stop and safety management (shutdowns based on alarm limits)
Data collection – temperature, pressure, flow, vibration, frequency
Operator/Diagnostic GUI for control of system
HARDWARE USED
NI CompactRIO (cRIO)
NI C Series Current Input Module
NI C Series Voltage Input Module
NI C Series Temperature Input Module
NI C Series Current Output Module
NI C Series Analog Input Module
NI C Series Sound and Vibration Input Module
NI C Series Digital Module
Emerson VFD (Variable Frequency Drive)
INTERFACES / PROTOCOLS
TCP/IP
TCP Modbus
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2018-06-26T15:42:21-05:00