Micro Dyne System User`s Manual
Contents
1. Rm H Su NS e 209 Weight 1 5kg 32 1 Ja 788 ati c 6 Neem Due to the continual development of our products we reserve the right to modify specifications without forewarning 2 Installation Configuration 2 1 DYNAMOMETER SETUP Shipping bolt knob Motor electrical connection Bubble level Leveling knobs Figure 2 1 Micro Dyne Dynamometer UNLOCKING THE SHIPPING RESTRAINING BoLT Before dynamometer operation the shipping restraining bolt must be unlocked A knob attached to the bolt is located on the top of the dynamometer housing as shown in Figure 2 1 To unlock lift up on the knob and turn it clockwise 90 to the Unlock position DvNAMOMETER LEVELING Simply level the dynamometer with the two leveling knobs at the front of the base plate using the embedded bubble level as a guide Mogtrol Micro Dyne System Chapter 2 Installation Configuration 2 2 ELECTRICAL CONNECTIONS The Micro Dyne is shipped with the dynamometer and the electronics unit already connected to one another by a set of cables These four cables are bundled together at the dynamometer end and branch out into the following for connection to the electronics unit Connection Cable Attaches To De2. 8 WM ANE 8 g NE 8V 5 3 amp 2 Lp Lo Lp a mH b E kota MESS 4 5 T E z z 8 2 B ad a amp gt gt 5 z 4 E By woh 8 4 3 az 18 2 GNDAA 0 0 10 gNDA GNDAV PORE D GNDA A DCDCNKE MOTOR POWER OUT Lai en 1 NPN MOTOR POWER IN n gt m 2 Oo m RELAY 45 Appendix C Calibration Record DATE DYNAMOMETER MODEL SERIAL APPLIED TORQUE INDICATED TORQUE ERROR TESTER 46 gt 2 m Magtrol Limited Warranty Magtrol Inc warrants its products to be free from defects in material and workmanship under normal use and service for a pe
3. 2 2 222222 00 0 0000000000 tren rennen etre tren enne 30 6 2 CALIBRATION PREPARATION LE 30 6 2 1 DYNAMOMETER REAR PANEL REMOVAL ene 090090 30 6 227 CALIBRATION WEIGHTS te t eee ed iet t m at Ee ee f 31 6 3 CALIBRATION PROCEDURE petet e i o ee Pe TER EC E a de PRO Pet de 31 TROUBLESHOOTING 37 APPENDIX A HARDWARE COMMANDS cessent eene nennen tenant natns natn annuas 38 AAIEO RM 38 A CODES FOR CR EEE 7 38 A2 MICRO DYNE COMMAND SE 38 A 2 1 COMMUNICATION COMMANDS nennen nennen a trennen teen 39 2 2 RAMP COMMANDS t 39 2 3 SETUP COMMANDS rr eti m re i ede rte e cei e ada t re Re R 40 AZA SPEED COMMANDS iie aee dte RR ed EE EU EC E IR END SERERE CR eere ren BERE ent 40 4 25 TORQUE COMMANDS 5 41 A 2 6 POWER ANALYZER AND RELAY 5 41 A2 7 MISCELLANEOUS COMMANDS 41 A 2 8 lt CALIBRATION COMMANDS et ee dne 42 Mogtrol Hysteresis Dynamometers Table of Contents APPENDIX B SCHEMATICS ioni nid brides Dri 43 CORE BLOCK DIAGRAM 11 43 BZ MAIN SCHEMA TIO eaque ea ate Mae aes 44 B3 pep t e e e e ET Pe EE Rer Ene beue Feet Est etian 45 APPENDIX C CALIBRATION RECORD EE 46 MAGTROL LIMITED WA
4. LED Color Indicates USB Yellow Flashing USB communication is taking place 24V Green The 24 volt power is OK CPU Yellow The power up sequence has been initiated 5V Green The 5 volt power is OK 2 6 INITIAL CALIBRATION After communication is verified it is highly recommended to calibrate the dynamometer before performing any tests Refer to Chapter 6 Calibration for a detailed procedure 3 Testing Considerations 3 1 3 2 BS A number of factors must be taken into consideration before running a test including safety power dissipation and influences that affect the apparent accuracy of the torque readout such as shaft alignment windage friction vibration dynamometer leveling cogging Eddy currents and temperature rise The following sections describe these factors and their effects in further detail Note If you have not already done so please take a moment to familiarize yourself with the Micro Dyne System s technical specifications See Section 1 2 Data Sheet SAFETY FOLLOW THESE FEW COMMON SENSE RULES STOP WARNING FOR GENERAL SAFETY CONSIDERATIONS PLEASE sure all wiring and connections have been properly made e Secure all grounding wires to the appropriate locations to reduce the chance of shock and damage to the equipment e Always wear safety glasses when working around Micro Dyne equipment e Do not wear loose clothing or tie
5. 25 Eo ER e sveaocuaeesneducuossesaeens 14 2 5 COMMUNICATION CHECK ertet io rt ty gu tenes e Ht e eye eda eie 15 26 INITIAL CALIBRATION 15 3 TESTING CONSIDERATIONS LER nU 16 SUE Lidia H 16 3 2 POWER DISSIPATION 5 enimse etae er Ro Eee eg ovt on Ente ee bee Eee 16 221 POWER ABSORPTION CURVE iecit i tiep p ge teer rape oe dne 17 5 3 SHARTALIGTNMENE au a D RIA ee 17 34 WINDAGE ste t eter ee ls eh deae Fe a ee Ee ve Eres ved on e He beets 17 3 90 JBERIGTIQNNC sid ttr het e das eves e etre te hu ec e m ete eee caves t ig 18 3 6 VIBRATION tee p OH e e p te erp 18 34 DYNAMOMETER EEVELING 2 o OR et eet to estes 18 9 8 et e m e e e ett ue ete lo a ee rtt e o tet 18 Table of Contents Magftrol Hysteresis Dynamometers 33831 AVOIDING COGGING ete A e hte t ee orta tu eet 19 3 8 2 REMOVING COGGIN Gi LEO 19 3 0 EDDY CURRENTS rer sate cove 19 3 10 TEMPERATURE RISE 1 19 TEST SETUP mat ied putt dise 20
6. Z i m z gt z Ie m Appendix Hardware Commands A 1 A 1 1 2 Although most motor tests can be performed with M TEST the following command reference tables are included for users who wish to write their own application DATA FORMAT Speed torque data is a fixed length string in ASCII format with a floating point decimal Use the following string format SdddddTdddd R cr 1f Or SdddddTdddd L cr If Where S 1 Speed in No leading zeroes used Decimal digit 0 through 9 Torque in mN m The torque value always contains a decimal point Counterclockwise dynamometer shaft rotation left Clockwise dynamometer shaft rotation right Decimal point The decimal point location depends on the specific dynamometer and torque range in use Note The cr and If characters will not display EXAMPLE If a motor is running at 1725 rpm clockwise with the dynamometer loading the motor to 22 6 oz in the Micro Dyne will return 1725T22 60R By manipulating the string the speed torque and shaft direction 1f required can be extracted Then separate numerical variables can be assigned to them for data processing Copes ron CR LF BASIC HEX DEC CR CHR 13 00 13 LF CHRS 10 0 10 MICRO DYNE COMMAND SET When entering a command code 1 all characters in uppercase ASCII format 2 End all
7. CAL Sets current output to Displays CALCOMPLETE FSA X XXX Takes the full scale amps reading X XXX is the applied current Displays FSA X XXX prompting the user to apply zero full scale amps FSV X XXX Takes the full scale volts reading X XXX is the applied voltage Displays FSV X XXX prompting the user to apply zero full scale volts ZERO Takes zero reading for both volts and amps Displays ZERO prompting the user to apply zero volts and zero amps GL xxxx Sets average gain after calibration on left side Input floating point GR xxxx ZL XXXX Sets average gain after calibration on right side Sets average of Zero calibration reading on left side Input floating point Input floating point ZR XXXX Sets average of Zero calibration reading on right side Input floating point 42 gt m 2 Oo m Appendix Schematics B 1 CORE BLOCK DIAGRAM CORE BLOCK RAM 128K x 24 FLASH RS232 1 8 DRIVER GSI GS73024AB SST SST39LF080 3 3V 3 3V EEPROM 48 FBGA 93C66A 4 119
8. 32 Mogtrol Micro System Chapter 6 Calibration 6 Tozero the pendulum at its current rest state without weights click Send Zero After the dialog box displays a value of 0 consistently for a few seconds click Continue 7 The next prompt asks the user to hang the calibration weight starting with the right side Carefully hang the appropriate calibration weight from the calibration peg as show in Figure 6 5 Tweezers have been included in the accessory tool bag for your convenience Calibration peg Calibration weight Pendulum Figure 6 5 Dynamometer Calibration 8 Continue to follow the prompts on the screen alternating between hanging the weight on opposite sides of the pendulum and removing the weight This entire cycle will be performed a total of five times After each cycle the message instruction bar will display the status of the calibration routine The blue progress bar will also update Note After clicking Continue the Continue button is grayed out purposely in order to prevent accidental double button pressing which would result in a skipped step 33 Z i m 2 gt 2 m Chapter 6 Calibration Magtrol Micro Dyne System gt Micro Dyne Calibration Software rev 1 1 MD 1 8 FP2 I MAGTROL T NAA CN Micro Dyne 5 00100 Mass of Calibration Weight g cilia oleae rev 1 1 271 Calibration routine steps 1 5 Completed
9. MAGTROL Micro Dyne System User s Manual Purchase Record Please record all model numbers and serial numbers of your Magtrol equipment along with the general purchase information The model number and serial number can be found on either a silver identification plate or white label affixed to each unit Refer to these numbers whenever you communicate with a Magtrol representative about this equipment Model Number Serial Number Purchase Date Purchased From While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents Magtrol assumes no responsibility for errors or omissions Additionally no liability is assumed for any damages that may result from the use of the information contained within this publication COPYRIGHT Copyright 02007 Magtrol Inc All rights reserved Copying or reproduction of all or any part of the contents of this manual without the express permission of Magtrol is strictly prohibited TRADEMARKS National Instruments is a trademark of the National Instruments Corporation First Edition revision A October 2007 Fa MASTROL Safety Precautions Secure all grounding wires to the appropriate locations to reduce the chance of shock and damage to the equipment Make sure all wiring and connections have been properly made Always wear safety glasses when working around Micro Dyne equipment D
10. Fuse 5 x 20 mm IEC 315mA 250V T Current Input isolated 5 Power Requirements 14 VA Voltage Input isolated 30 VDC Voltage Requirements 85 264 V AC 60 50 Hz Conversion Rate 15 second input Accuracy Up to 0 02 Operating Temperature 0 C to 70 C Isolation to earth 50 VDC Relative Humidity lt 60 without condensation Isolation channel to channel 100 VDC MOTOR FIXTURE MOTOR ACCOMMODATION Motor Diameter 5 mm 30 mm ADJUSTABILITY X Y Z Adjustable Range 5 mm all axes Motor Length 5 mm 50 mm Controllable Motion 0 005 mm Motor Shaft Diameter 0 75 mm 3 mm Travel per Knob Revolution 0 318 mm Maximum Load 1009 z T 2 O Z 0 m 2 m 2 gt r Mogtrol Micro System Chapter 1 Introduction Dimensions mm Micro Dyne DYNAMOMETER Weight m Z m 2 gt r z T O O Z 229 gt 1i 8 U 8 ELECTRONIC UNIT 816 264 245 3DIMENSIONAL FRONT VIEW 27 cro ome
11. H MONA np 7 x Ast z Gemwouog UP ia nogaz lt summe amai e ADS ano arg z T HDV AU d 4 A T 951 1 yusenaves mhl 45 ante d Ao gy E m rss ag AE Nrigwo 10 zun E EE mitted D in ol aen ote 1 ange sin n ors ET o uw q vuserasesa Ast Que o NV WadoONa iv Yiqvno BARRE o Hr 2 a 5 1 HN Yi AL oH TONI gt t wow Na to i i IDOI xou ave my m 1 318884 zo Ww Le n MEE 1 Hx ADS 13090 44 Mogtrol Micro System Appenidix B Schematics B 3 DC WATTMETER p
12. If using a third party measurement device not found on the list by selecting None M TEST will no longer be responsible for measuring the input power 23 Chapter 4 Test Setup Magtrol Micro System 4 3 1 Motor REVERSAL If it is desired to perform a motor test in both clockwise and counter clockwise directions a relay card is required Motor direction is configured in M TEST and requires a power supply supported by M TEST Supported power supplies are found in the Device text box under the Power Supply options in the Configure Hardware window See Figure 4 5 4 3 1 1 Reversing Motor Direction Before Test is Run To reverse the motor direction and keep the direction of rotation constant throughout the entire test use the Configure Hardware window for motor reversal setup 1 Open the Configure Hardware window 2 Under Power Supply click on the Device text box and scroll through for a list of supported power supplies 3 After selecting a power supply set the voltage and current output for that voltage supply If a negative voltage is entered M TEST switches relays to change the polarity of the motor voltage and in turn reverses the direction of rotation for a DC motor Sorensen DHP GPIBO 6 INSTR 7 24 00 O m gt O 2 J 1 00 0 Disabled Disabled Figure 4 5 M TEST Power Supply Configuration 4 3 1 2 Automatic Reversal of Motor Direction During Test
13. operating systems for PC based data acquisition The software measures and calculates a motor s performance characteristics by employing these user configurable testing methods Ramp Select from average ramp down up or ramp down with inertia correction factor Also allows extrapolation of free run and locked rotor data plus interpolation of specific speed or torque data points Curve Test speed torque amps watts input watts output and open loop parameters and compares actual values to user defined limits Capable of adjusting sampling rate and using step or ramp from one load point to the next Pass Fail Checks amps input watts speed torque and output watts against user defined values The data generated can then be stored displayed and printed in tabular or graphic formats and is easily imported into a spreadsheet Torque Measurement The Micro Dyne contains a reflective fiber optic speed pickup Each rotor slot that passes by the sensing end of the fiber optic generates an electronic pulse which is then converted to a speed reading in rpm A hysteresis brake is used to develop a resistance to rotation of a mechanical shaft A torsional force is produced by the test motor and applied to the brake s rotor shaft assembly Reaction torque is measured by the angle of the brake pendulum assembly and is interpreted by the Micro Dyne system software M TEST 5 0 z on 2 2 a gt or Z Chapter
14. CONTINUE STOP Figure 6 6 Calibration Routine Status 9 After the message instruction bar displays Calibration routine steps 5 5 Completed one of two dialog boxes will appear dependent upon whether or not the calibration was successful gt Micro Dyne Calibration Software rev 1 1 MD 1 8 FP2 TIME TO COMPLETION MAGTROL i SESE S A Micro Dyne 75 00100 Mass of Calibration Weight 4 Calibration Software 1 1 271 Calibration Sequence Successful PASS CONTINUE STOP Figure 6 7 Calibration Sequence Successful z m m z gt z m 34 Mogtrol Micro Dyne System Chapter 6 Calibration Micro Dyne Calibration Software rev 1 1 MD 1 8 FP2 TIME TO COMPLETION MAGTROL AAC F s TT Micro Dyne 5 00100 Mass of Calibration Weight Pe ueniet or TR 1 1 271 Calibration Error Calibration did not pass specification Please try recalibrating the unit CONTINUE STOP Figure 6 8 Calibration Error 10 If calibration was successful click Continue and proceed to step 11 If a calibration error occurs it is most likely due to the pendulum not fully returning to zero after the weight is removed Make sure that the dynamometer is level and then click Continue to restart the calibration sequence If the Calibration Error message is displayed after repeated calibrations contact Magtrol Technical Support 11 A dialog box will appear asking the u
15. Curve tests and Pass Fail tests allow for reversing the motor direction during a test Note Because Ramp tests do not allow motor voltage control the motor must ramp up and down in the same direction for the entire test To reverse the direction of rotation for a ramp test after running the first test enter a negative power supply voltage in the Configuration Hardware window as described in Section 4 3 1 1 and then run the test a second time 1 Ifnotalready done so select a power supply supported by M TEST in the Configure Hardware window 2 Openthe Configure Test window If Curve Test or Pass Fail Test is selected an extra column in the Control Data table under Test Parameters labeled Volts should appear 24 Mogtrol Micro Dyne System Chapter 4 Test Setup M TEST 5 0 Motor Test Software 5 5 O OL Final mes 6 FINAL TEST msf Rev 2 15 Beta Adjust PID 1 Reports Security Select Test Curve i Control Parameter Torque Speed Range 99999 00 2 2 Timebase Sampling Rate sec Seconds 1 00 Number of Cycles 1 Max Brake Current 9o Max Temp Max Current Negative Values will reverse motor polarity tmport From Spreadsheet Save Data Include Equipment List Print Report save Report Operator Code Data Folder Report Folder Auto Increment Pass Filename Serial Number Fail Filename
16. Figure 4 6 Curve Test Parameters with Motor Reversal O m gt O 2 3 To have the motor direction reversed during a test simply enter a negative voltage as shown in Figure 4 6 25 5 Operating Principles TORQUE MEASUREMENT An innovative approach to measuring small torques is implemented in the Micro Dyne The design employs a very small pendulum and brake assembly hung in a precision machined carrier The basic concept a textbook physics problem is described below Torque L mg sin Pendulum g Cos 0 m 8 sin 0 8 29 m Symbol Represents 5 2 L the length to the center of mass of the pendulum m the force applied by the mass and gravity o m8 Sin 0 the force in the radial direction Figure 5 1 Illustrated Torque Principle TORQUE CALCULATION At calibration time a known mass at a known distance is applied to the pendulum system and a precise calibration is accomplished L m 8 sin L m g cos Symbol Represents Le the length from the center to the calibration weight 8 the force applied by the known mass and gravity The coefficient is calculated and stored Torque data is calculated using this coefficient along with position data 26 Mogtrol Micro System Chapter 5 Operating Principles 5 2 SPEED MEASUREMENT The Micro Dyne contains a
17. Magtrol Micro Dyne System ics Schemat Appenidix B MAIN SCHEMATIC B 2 Se vni G35n SHOIWNOIs3d LVI wsvzasn da ES ss 9 3 DADO EN xL x DADA 923 P OOA 2 EYE z ess Hg a E EN T i n 2 AR amo E lt Qm HE Bs FE aiawos H aoad ais anise 3 SG Wa E asn Lou rm _ iavno 4 8 two Vous Viano 9 EJ 4 AnBWHSSY 91248 OL 8 M S INANI dBHBWLIVA gt YOGS 2 Pu 5 98 TES n t lt gt EZ AOS 36 6 E sa L senen 5p 595 2 Je sspe 25 5 ney Ez a ac 5 Im t E WS Ep E ye AS TXDH NC 3NNd Wa ds 43093805 n 103 9195 EI fud 8451 1241 SWHO EE 5 Ao sor 10 T i 20 1000258 g T oma m MOTA pem a np mu Le Me f 1InOHD
18. 1 Introduction Magtrol Micro Dyne System Specifications DYNAMOMETER The Micro Dyne offers two different torque configurations in one unit Depending on the motor s maximum torque rating the user can easily switch between the 2 0 mN m and 4 0 mN m torque settings via the dynamometer s rear access panel The ratings are the same for either configuration Micro Dyne Maximum Nominal Maximum Kinetic Power Maximum Akou Torque Input Inertia 5 minute continuous Speed mN m kg cm wW W rpm Torque Speed E lt 1 of lt 0 02 of 4 0 or 2 0 5 48 x 10 4 4 100 000 full seale reading Maximum Rated Torque 4 0 Power Absorption Curve C 30 Based on maximum kinetic power ratings E the curve below represents the maximum power t heat that the dynamometer can dissipate over 20 time The area under the curve equals the maximum speed torque combinations for both 5 a motor test of less than 5 minutes intermittent F 10 duty and a continuous duty motor test 0 0 20000 40000 60000 80000 100000 Maximum Rated Speed SPEED rpm DYNAMOMETER ENVIRONMENTAL REQUIREMENTS Operating Temperature 0 to 70 Relative Humidity 6096 without condensation EMC In accordance with IEC 61326 2002 ELECTRONIC UNIT GENERAL ELECTRICAL CHARACTERISTICS POWER MEASUREMENT DC
19. 4 2 4 STAGE ADJUSTMENT For precise motor alignment the stage of the motor fixture may be axially adjusted using the three colored adjustment knobs Knob Color Axis Adjustment Direction Red X Horizontal side to side positioning Yellow Y Vertical shaft height Green 2 of motor to input shaft of dynamometer Note The entire motor fixture can also move as one unit along the length of the dynamometer base plate in line with the bolt pattern The fixture is locked in place by screwing into the tapped holes with the provide hex key screws 22 Mogtrol Micro System Chapter 4 Test Setup 4 3 SOFTWARE CONFIGURATION This section only provides very basic instructions for setting up M TEST to run with the Micro Dyne For detailed information about selecting configuring and running a test refer to Magtrol s M TEST 5 0 User s Manual 1 Power up the Micro Dyne 2 Start M TEST 3 Open the Configure Hardware window M TEST 5 0 Motor Test Software DHR IMAGTROL Current Setup E ITT RULEVTT Industries 24VDC Motor msf Rev 7 3 27 Configure Hardware Configure Test Adjust PID 5 Axis Graph 1 Axis Graph Compare Reports Model 9 Micro Instrument Type HD Instrument Type Auxiliary Display Torque mN m Brake Type WB Model Interface k COMI HD 825 6 Encoder 30 bit Acquire Aux TSC2 No Tandem Disable Torque
20. 41 TORQUE CONFIGURATION ge PE eR ERU duels e HT Ede dt 20 42 MOTOR MOUNTING a ertt ret o ete e UD pet E e UU e ot reduce ien 21 42 4 2 21 4 22 ADAPTERS e etus oen CEA I RR mint det 21 4 223 CLAMPING STRAP iu ettet ente Ea Lee EU ea beoe Ee tede eoa cheer 22 42 4 SYEAGEPADJUS TMENT eget eet esee re tee enr 22 4 3 SOFTWARE CONFIGURATION 235 2 p rhe e ede Pepe et o e RE E e E Rr p e 23 434 MOTOR REVERSAL ungue Rem RU needed de 24 MEeld PqxIckuri el Nc 26 CTORQUEMEASUREMSENTJT ii tek e tet e t EE P o tert e t p i re e eet een 26 TORQUE CALCULATION 2 intret th onte teens 26 5 4 SPEED MEASUREMENT ep eoe era ep t ive es 27 5 3 CONTROLLER AND THE PID EOOP dettes tee tte t rt petro ete det eder e en 27 53 2 P PROPORTIONAL tee ten t tite e et p E Rep ti ERE 27 5 3 2 E ENTEGR ATP eee pta amen ende eam ta etel EE t 27 5 22 DDBRIVATTVB 0 27 5 324 sADDITIONAL SCALE FACTOR OO 28 5 35 HOW THE PID LOOP WORKS 28 53 6 PIDPEQUATIONS fi 28 23 4 WATTMEBTPER t tt a e PR Ee E EHE AR EE Ee ep Hb EI edet e GE SEE Ret a 29 Be CALIBRATION T 30 6 1 CALIBRATION SOFTWARE
21. at time of manufacture The 10 gram weight is used for the 4 mN m torque configuration and the 5 gram weight is used for the 2 mN m torque configuration 6 3 CALIBRATION PROCEDURE The Micro Dyne Calibration Software walks the user through every step in the calibration process Simply follow the instructions and prompts that appear on the screen 1 Start the Micro Dyne Calibration Software by opening the MD CAL exe application file mentioned in Section 6 1 The COM Port Selection dialog box will appear COM Port Selection Please select COM port you wish tn communicate with COM3 2 i m 2 gt z m Figure 6 2 COM Port Selection 2 Selectthe COM port to which the USB interface is connected as previously determined in Section 2 5 2 Verify Communication with M TEST and click OK 3 The main window of the Calibration Software will appear displaying the version of your Micro Dyne System at the top 31 Chapter 6 Calibration Magtrol Micro System MAGTROL 515 000 Mass of Calibration Weight rev 1 1 271 Enter Mass of Calibration Weight CONTINUE STOP Figure 6 3 Enter Mass of Calibration Weight 4 Enter the exact weight as labeled on the weight s tag Refer to Section 6 2 2 Calibration Weights for more information 5 Click Continue The Reset ZERO dialog box will appear 2 i m z gt Z m Figure 6 4 Reset ZERO
22. commands with CR LF hex 0D 0A 3 Do not string multiple commands together in one line 38 gt m 2 Oo m Mogtrol Micro System Appendix A Hardware Commands A 2 1 A 2 2 The character represents a floating point numerical value following the command Leading zeroes are not required Communication COMMANDS Function Explanation Returns Magtrol Identification Example MD 1 4 2 and software revision Micro Dyne REV 1 4 and FPGA REV 2 BO Brake Off 1 Brake OD Returns speed torque value Output Data prompt to return data string with this format SxxxxxTxxxxxRcrlf Or SxxxxxTxxxxxLcrlf RorLis the shaft direction indicator as viewed looking at the dynamometer shaft where R right clockwise CW L left counterclockwise CCW Ramp COMMANDS ramp to RPM Command Function Explanation Code DILXX XX Sets dynamic scale coefficient When using dynamic scaling XX XX is multiplied by the term to give the end value DPLXX XX Sets dynamic scale coefficient When using dynamic scaling XX XX is multiplied by the P term to give the end P value DS Enable or disables dynamic Values for are scaling 0 disable 1 enable PD Program Down Sets ramp Specify speed range F AND a stop down rate to rpm per second speed S before using this command This an
23. connect the speed pickup to the dynamometer 1 Lift up the plastic cover 2 Slide the fiber connection mechanism up 3 Locatethe two openings in the sliding mechanism and insert the bifurcated ends of the fiber optic cable inserting as far as the mechanism will allow Note It does not matter which fiber optic sensing end goes into which opening 4 Slide the fiber connection mechanism down in order to lock Mogtrol Micro System Chapter 2 Installation Configuration 2 2 3 REAR PANEL CONNECTORS 14VA 50 60Hz 85 264VAC INPUT ENCODER MAGTROL Figure 2 4 Electronics Unit Rear Panel The rear panel connectors from left to right are Connector Attaches To Connection Cable POWER Input Power source Main power cord BRAKE Output Dynamometer Dynamometer brake cable SPEED Output External speed sensor 6 pin sensor cable USB Port Personal computer USB cable ENCODER Input Dynamometer 15 pin instrument cable Using the table above make the necessary connections with the cables provided As noted in Section 2 2 Electrical Connections some of the cables have been installed prior to shipping 2 3 MOTOR POWER Note For detailed instructions on motor mounting refer to Section 4 2 Using the three power supply cables provided make the following basic connections Other power configuration options are shown in Section 2 2 1 CAUTION PAY ATTENTION TO WH
24. design and torque measurement Magtrol has revolutionized the industry Magtrol s NEW Micro Dyne capable of measuring extremely low torques 2 0 mN m can be Motor resolved to 0 0004 mN m is designed Characteristics EXCLUSIVELY for testing miniature Measured and micro low torque motors Calculated For the utmost convenience the Micro Torque Dyne is packaged as a COMPLETE Speed MOTOR TESTING SYSTEM Amps Everything that is needed to accurately evoke and efficiently test miniature motors and micro motors is included with the Horsepower purchase of a Magtrol Micro Dyne Efficiency The only component that needs to be Input Watts supplied by the customer is a laptop or desktop personal computer and motor Output Watts power supply APPLICATIONS Magtrol motor test systems can be found in test labs at inspection stations and on the manufacturing floors of most of the world s leading motor manufacturers The Micro Dyne system is used exclusively for closed loop testing of miniature motors and micro motors used in low torque high speed applications Motor sub types include but are not limited to the following Brushed and brushless DC motors e Miniature stepper motors Gearmotors Brushless DC servomotors e Vibrator motors Miniature air motors These mini micro motors are used in a diverse range of industries and products including Medical and laboratory equipment e Robotics and automat
25. it Some information has been deliberately repeated in different sections of the document to minimize cross referencing and to facilitate understanding through reiteration The structure of the manual is as follows Chapter 1 INTRODUCTION Contains the technical data sheet for Magtrol s Micro Dyne System which describes the system and all of its components and provides detailed technical characteristics complete parts list along with unpacking instructions is also included in this section Chapter 2 INSTALLATION CONFIGURATION Provides information needed for setup of the Micro Dyne System primarily electrical connections and power configuration Chapter 3 TESTING CONSIDERATIONS Provides information on a number of factors that must be taken into consideration before running a test including safety power dissipation and influences that affect the apparent accuracy of the torque readout Chapter 4 TEST SETUP Provides instructions on how to set up a motor test including dynamometer setup motor mounting and software configuration Chapter 5 OPERATING PRINCIPLES Information pertaining to the theory of operation including torque measurement speed measurement and the PID control loop Chapter 6 CALIBRATION Step by step instructions for the calibration procedure Chapter 7 TROUBLESHOOTING Solutions to common problems encountered during setup testing and calibration Appendix HARDWARE COMMANDS Provides comm
26. its own hard sided carrying case with shock resistant packing foam The packaging is designed to protect the instruments during normal handling Inspect the contents for any evidence of damage in shipping In the event of shipping damage immediately notify the carrier and Magtrol s Customer Service Department Note Save all shipping cartons and packaging material for reuse when returning the instrument for calibration or servicing 1 1 2 Parts List Make sure the case contains all the following A Dynamometer with attached motor fixture B Electronics unit CAUTION THE DYNAMOMETER AND ELECTRONICS UNIT ARE SHIPPED ALREADY CONNECTED TO ONE ANOTHER BY A SERIES OF CABLES BUNDLED TOGETHER USE CAUTION WHEN LIFTING OUT OF THE CASE C CD ROMs 1 M TEST 5 0 CD ROM 2 Micro Dyne Supplemental Programs and Utilities CD ROM 3 Magtrol User Manual CD ROM D Bag of cables USB cable 2 Three power supply cables with dual banana plugs on both ends 3 Main IEC power cord E second bag of parts contains the following 1 Circular weight and fastening hex key screw for torque configuration 2 Hardware for motor fixturing a Two motor fixture adapters b Small Allen wrench hex key c Two small hex screws 3 Three bags of rubber couplings a Ten pieces of 0 5 mm inside diameter tubing each 25 mm in length b Ten pieces of 0 8 mm inside diameter tubing each 25 mm in length c Ten pieces of 1 6 mm inside diameter tubing each 25
27. 75 O to 6826 counts Finer k Position Figure 5 3 Control Loop and PID System Block Diagram D 2 Q m SI E 6 5 3 6 PID Equations Where Skp Ski and Skd factory determined system coefficients Yd e t e t 3 3 e t 1 e t 2 10 Skd D DS Yp t e t Yd t 10 Skp P PS Yi t Yi t 1 e t Yd t 10 Ski I IS Yt t Yp t Yi t Ys t Scale Yt t 28 Magtrol Micro System Chapter 5 Operating Principles 5 4 DC WATTMETER The data acquisition stage in the hardware of this DC power measurement instrument is very simple The input voltage is divided by an amplifier circuit and applied directly to a LTC2515 A D converter The input is differential and isolated from the amps circuitry The input current is applied to a shunt resistor and the resulting voltage is amplified and applied directly to a LTC2515 A D converter The input is differential and isolated from the voltage circuitry The wattage presented is a multiplication of the amps and voltage See Section B 3 DC Wattmeter Schematic 29 D z Q m ONILVYAdO 6 Calibration 6 1 CALIBRATION SOFTWARE INSTALLATION l Insert the Micro Dyne Supplemental Programs and Utilities CD into your CD ROM drive The USB Driver Utility will auto start Just press EXIT Start Windows Explorer Locate th
28. Filter 10Hz Active Channel 1 Encoder 60 bit Nominal Speed 955 Airflow Alarm Disable Quadrature Input Disable Max Speed 8000 Waterflow Alarm Disable Torque Filter 10 Hz Speed Excited 4000 Apply Settings External Alarm Disable Nominal Speed 0 Max Power kW 0 500 IPre Load 0 00 Speed 25000 Max Torque 5 000 SaveSetup Max Power kW 10 000 Scale Factor 5 000 100 000 Torque Ratio 1 000 Scale Factor 55 000 Speed Ratio 1 000 Torque Ratio 1 000 Speed Ratio 1000 21 O m gt O 2 Micro Dyne i Jj Device Jj GPIBO 14 INSTR X ace 6 GPIBO 6 INSTR Thermocouple Type Watts Elements 24 00 Units External Shunt Yes 0 ent Sel 1 00 TCO Shunt 1 Scaling 8 0000 Volts 0 Shunt 2 Scaling 0 0000 RMS Disabled Shunt Scaling 0 0000 Jj Disabled TC3 Figure 4 4 M TEST Configure Hardware Window 4 Enter the following settings a Under Dynamometer Controller select Micro Dyne for the Model b For the Interface select the COM port where the USB interface is connected as determined in Section 2 4 2 M TEST Communication c Under Power Measurement select Micro Dyne as the Device Note For increased power measurement capabilities other power analyzers such as Magtrol s 6510e or 6530 may be used in conjunction with the Micro Dyne If applicable the supplemental power analyzer should be selected as the Device
29. ICH PIN ON THE BANANA PLUG IS POSITIVE AND WHICH ONE IS NEGATIVE CONNECT TO THE RED AND BLACK TERMINALS ACCORDINGLY Chapter 2 Installation Configuration Magtrol Micro System Terminal on Electronics Unit Motor Power In User s power supply Allows power measurement and on off switching from electronics unit Motor Power Out Motor connection point on Outputs power to the motor Connected To Description dynamometer Controlled by relay inside electronics unit which turns motor power on off Voltage Sense Motor connection point on Measures voltage directly from the motor thus dynamometer eliminating voltage drop Results in increased power measurement accuracy and efficiency MOTOR MOTOR MAGTROL POWER POWER MICRO DYNE Figure 2 5 Electronics Unit Front Panel Figure 2 6 illustrates the internal wattmeter and relay layout showing the complete basic power circuit from power supply to motor Banana plugs on dynamometer power terminal Current Meter VOLTAGE SENSE POWER Inside Micro Dyne Electronics Box Figure 2 6 Basic Motor Power Circuit 12 Mogtrol Micro Dyne System Chapter 2 Installation Configuration 2 3 1 2 3 1 1 2 3 1 2 Power CONFIGURATION OPTIONS Basic Configuration This standard Micro Dyne setup shows a customer provided motor power supply wired to the M
30. NUAL 2 OO VI WHO SHOULD USE THIS MANUAL heo e eene ei vetet twee etui VI MANUAL ORGANIZATION re et et E RE eee et P Pe E A RAE VI CONVENTIONS USED IN THIS 2 ttt or ree rt n Er Seat a bet tees ER ted VII INTRODUCTION puse 1 1 7 UNPACKING THE MICRO et e Pete ee tegere ee e erg 1 PACKAGING ecnin RED ERU RECEN ote e EE ERR ere eee pan 1 1 12 PARTS EIST hose a REOR p noe ei 1 1 2 DATASHEET etant censui 3 2 nennen nnne nnn ranas 8 2 1 DY NAMOMETER SETUP d ete nat dett e ui dete 8 2 1 1 UNLOCKING THE SHIPPING RESTRAINING BOT 8 2 1 2 DYNAMOMETER LEVELING 5 piene e e thor EH eR EC RED EUM ERE ere 8 222 ELECTRICAL CONNECTIONS rette teen rr HR e er ter tea Pe e SERE eR 9 22 ARTE GROUND d e e UE ONE et RR 9 2222 SPEED PICKUP rrt trt pret epe HER ree Etpe bene 10 2 23 REAR PANEL CONNECTORS enne i eeu tated ed aene 11 2 3 MOTORPOWERL2L eS 11 2 3 1 POWER CONFIGURATION OPTIONS 13 2 44 MOTOR TESTING SOFTWARE th ceti i e ab e he o e CHE E pr ed pp ep pedo 14 24 1 SOFTWARE INS TALLATION ES 14 24 22
31. OT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE MAGTROL SHALL NOT BE LIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSS WHETHER IN CONTRACT TORT OR OTHERWISE CLAIMS Immediately upon arrival purchaser shall check the packing container against the enclosed packing list and shall within thirty 30 days of arrival give Magtrol notice of shortages or any nonconformity with the terms of the order If purchaser fails to give notice the delivery shall be deemed to conform with the terms of the order The purchaser assumes all risk of loss or damage to products upon delivery by Magtrol to the carrier If a product is damaged in transit PURCHASER MUST FILE ALL CLAIMS FOR DAMAGE WITH THE CARRIER to obtain compensation Upon request by purchaser Magtrol will submit an estimate of the cost to repair shipment damage 45 Service Information RETURNING MAGTROL EQUIPMENT FOR REPAIR AND OR CALIBRATION Before returning equipment to Magtrol for repair and or calibration please visit Magtrol s Web site at http www magtrol com support rma htm to begin the Return Material Authorization RMA process Depending on where the equipment is located and which unit s will be returned you will be directed to either ship your equipment back to Magtrol Inc in the United States or Magtrol SA in Switzerland Returning Equipment to Magtrol Inc United States When r
32. PBGA JP2 DSP FPGA RESET MOTOROLA DSP56303GC100 APA075 2 5 REG 33V 2 5V XTAL 8 MEG 144 BGA 196 JTAG 1 JTAG 2 Ul 78B212 CORE DSP REVB 33V COREV 3 33 EM 4 ml 2 5 i 2 1 82 4 3 3 5 6 5 6 D DO D23 88 us lt D D0 D23 ur 77 1 92 12 lt WR 17 14 MODB 3 944 RD 15 16 lt 5 96 16 RESET T TS MODD 2 7 98 18 DIS 19 20 MODA gt 9 1002 Di4 21 22 101 102 22 DB 23 24 103 104 D12 25 26 105 106 DII 27 28 107 108 DIO 29 50 109 1101 29 D 3T 52 12 9 DE 35 34 H3 114 7 55 56 115 1161 46 De 37 38 117 118 Ds 37 20 91200 D4 En 42 121 12 25 24 123 124144 lt A A0 AT9 gt D 4s 26 125 12649 19 DI 47 45 127 128 50 Do 79 50 129 130 52 We om EI A2 53 54 AL 55 56 PB6 135 136 6 57 38 137 138 38 59 50 1 139 14060 5 m s d 63 64 65 66 te 145 146 L 86 67 68 RSRXD 2 147 148 77 67 70 850 149 192 1 72 STXD gt ls1 I2 L2 75 74 153 154 x 75 76 135 128 TR 77 78 TPie 79 30 TPIT 159 16080 CONN 80PIN 080 CONN 80PIN 080 SAMTEC BSE 040 01 F D A SAMTEC BSE 040 01 F D A MTI MT2 MOUNT HOLE 128 DIA 43 gt 2 m APPENDICES
33. RRANTY Ear 47 EAT 47 SERVICE INFORMATION pA 48 RETURNING MAGTROL EQUIPMENT FOR REPAIR AND OR CALIBRATION eee 48 RETURNING EQUIPMENT TO MAGTROL INC UNITED 5 5 200 48 RETURNING EQUIPMENT TO MAGTROL SA SWITZERLAND eee emen ene enne 48 TABLE OF FIGURES 2 INSTALLATION CONFIGURATION Figure 2 1 Micro ye 8 Figure 2 2 Dynamometer Earth 7o777 7 9 7 7 2 SDee 7 70 Figure 2 4 Electronics Unit Rear Panel As wll Figure 2 5 Electronics Unit Front Panel aes 22412 Figure 2 6 Basic Motor Power Circuit Ps 2 12 Figure 2 7 Basic System Configuration 13 Figure 2 8 Relay Configuration xe 13 Figure 2 9 Motor Drive Co 7 14 3 TESTING CONSIDERATIONS Figure 3 1 Micro Power Absorption Ce 17 Figure 3 2 Hysteresis Brake 18 4 TEST SETUP Figure 4 1 Dynamometer Inside View 20 Figure 4 2 Micro Dyne Motor Fixture ds us Figure 4 3 Motor Fixture 4 22 Figure 4 4 M TEST Configure Hardware MO Figure 4 5 M TEST Power Supply Configuration Figure 4 6 Curve Test Parameters with Motor Reversal 5 OPERATING PRINCIPLES Figure 5 1 Illustrated Torque 26 Figure 5 2 Micro Dyne Rotor sits Figure 5 3 Control Loop and PID System Block 77 7 28 6 CALIBRATION Figure 6 1 Dynamometer Rear Pane
34. ameters Maximum brake temperature 100 212 F Ambient temperature 25 5 C 77 9 F Maximum Rated Torque 20 30 2 2 0 2 c 10 0 0 20000 40000 60000 80000 100000 Maximum Rated Speed SPEED rpm Figure 3 1 Micro Dyne Power Absorption Curve SHAFT ALIGNMENT In motor testing shaft alignment is one of the most important factors to consider An improper coupling and or shaft alignment can lead to unwanted side loads and vibration damaging both the test equipment and motor To accommodate micro motor sizes while preventing side loading on the dynamometer shaft a coupling of small flexible rubber tubing should be used The friction of the rubber tube on the shaft alone suffices as a clamping agent Several pieces of rubber tubing in various diameters are included with the Micro Dyne for this purpose Refer to Section 4 2 1 Shaft Coupling for detailed coupling instructions WINDAGE Windage is proportional to the square of speed The air friction is tangential to the surface and impinges upon the stationary field assembly This acts as viscous drag and becomes part of the motor load and torque reading There is also a small amount of air dissipated as pumping loss Since this appears as a load on the motor not measured by the dynamometer it becomes a source of error Considering the size of the parts affected by windage in the Micro Dyne
35. and reference tables for users who wish to write their own application Appendix B SCHEMATICS Contains a core block diagram main schematic and wattmeter schematic Appendix C CALIBRATION RECORD Data record for tracking calibration results vi Mogtrol Micro System Preface CONVENTIONS USED IN THIS MANUAL The following symbols and type styles may be used in this manual to highlight certain parts of the text BS o Note This is intended to draw the operator s attention to complementary information or advice relating to the subject being treated It introduces information enabling the correct and optimal function of the product CAUTION THIS IS USED TO DRAW THE OPERATOR S ATTENTION TO INFORMATION DIRECTIVES PROCEDURES ETC WHICH IF IGNORED MAY RESULT IN DAMAGE TO THE MATERIAL BEING USED THE ASSOCIATED TEXT DESCRIBES THE NECESSARY PRECAUTIONS TO TAKE AND THE CONSEQUENCES THAT MAY ARISE IF THESE PRECAUTIONS ARE IGNORED WARNING THIS INTRODUCES DIRECTIVES PROCEDURES PRECAUTIONARY MEASURES ETC WHICH MUST BE EXECUTED OR FOLLOWED WITH THE UTMOST CARE AND ATTENTION OTHERWISE THE PERSONAL SAFETY OF THE OPERATOR OR THIRD PARTY MAY BE AT RISK THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT AND ACT UPON IT BEFORE PROCEEDING FURTHER vii 1 Introduction 1 1 UNPACKING THE MICRO DYNE 1 1 1 PACKAGING Your Micro Dyne System was shipped in
36. d starts ramp command programs a decreasing shaft speed at a rate of rpm per second PR Resets ramp up or down This command resets the ramp function halting Sets speed to maximum the ramp s progress and returns the motor to speed free run e Turns brake off PU Program Up Sets ramp up rate Specify speed range F AND a start to rpm per second and starts speed S before using this command This ramp command increases the shaft speed at a rate of rpm per second S Sets start or stop speed for When this command is used with the PD command the controller will ramp down to this speed and halt When this command is used with the PU command the controller will load immediately to this speed and ramp up to free run 39 gt m z m Appendix Hardware Commands Magtrol Micro Dyne System A 2 3 A 2 4 Setup COMMANDS Command Code Function Explanation R Resets as follows Use this command to cancel any previous Brake OFF commands RQ1 Resets quadrature counter Use this command to reset torque count to Zero SPEED COMMANDS Command Code Function Explanation Sets maximum speed to rpm Sets a speed range for the controller Must be specified before using the speed or ramp mode Sets the range of the PID calculation N Resets speed point to Use this command sent alone to reset maxim
37. e directory where M TEST 5 0 is installed Copy the entire Calibration Sequence rev 1 0 folder into the same folder as the M TEST program If the default directory was used the location is C Program Files M Test 5 0 6 Once copied onto the hard drive locate the MD CAL exe application file This is the executable file for the Micro Dyne Calibration Software Note Create a shortcut to the calibration program by clicking the MD CAL exe file and dragging it to the desktop 6 2 CALIBRATION PREPARATION 1 Disconnect motor 2 Remove coupling 3 Disconnect all wiring and power supply cables from motor connection point 4 Remove the rear panel of the dynamometer as described in Section 6 2 I 5 Levelthe dynamometer as described in Section 2 1 2 Dynamometer Leveling 6 2 1 DYNAMOMETER REAR PANEL REMOVAL Z i m 2 gt 2 m Rear panel screws Ground lug Figure 6 1 Dynamometer Rear Panel Removal 30 Mogtrol Micro Dyne System Chapter 6 Calibration 1 Remove the three rear panel screws with the smaller of the two Allen wrenches provided in the accessory tool bag 2 Remove the ground lug with the larger Allen wrench 3 Using a small flathead screwdriver for leverage GENTLY pry open the dynamometer rear panel and remove 6 2 2 CALIBRATION WEIGHTS Two calibration weights are included with the Micro Dyne System They are tagged and labeled with their exact weight
38. eturning equipment to Magtrol Inc s factory in the United States for repair and or calibration a completed Return Material Authorization RMA form is required 1 Visit Magtrol s Web site at http www magtrol com support rma htm to begin the RMA process 2 Complete the RMA form online and submit 3 An RMA number will be issued to you via e mail Include this number on all return documentation 4 Ship your equipment to MAGTROL INC 70 Gardenville Parkway Buffalo NY 14224 Attn Repair Department After Magtrol s Repair Department receives and analyzes your equipment a quotation listing all the necessary parts and labor costs if any will be faxed or e mailed to you 6 After receiving your repair estimate provide Magtrol with a P O number as soon as possible A purchase order confirming the cost quoted is required before your equipment can be returned Returning Equipment to Magtrol SA Switzerland If you are directed to ship your equipment to Switzerland no RMA form number is required Just send your equipment directly to Magtrol SA in Switzerland and follow these shipment instructions 1 Ship your equipment to MAGTROL SA After Sales Service Centre technologique Montena 1728 Rossens Fribourg Switzerland VAT No 485 572 2 Please use our forwarder TNT 1 800 558 5555 Account No 154033 Only ship ECONOMIC way 3 days max within Europe 3 Include the following documents with your equipment Delivery n
39. figured to either a 4 mN m or 2 mN m torque scale The Micro Dyne is shipped with the 2 mN m configuration To convert it to 4 mN m follow the procedures below 1 Remove the rear panel of the dynamometer as described in Section 6 2 1 Dynamometer Rear Panel Removal 2 Locate the small parts bag that contains a single circular weight and fastening screw 3 Once the inside of the dynamometer is accessed move the pendulum in either direction in order to expose the threaded hole located at the center of the pendulum Pendulum Circular weight for 4 mN m torque scale O m P O 2 Figure 4 1 Dynamometer Inside View 4 Attach the circular weight with the provided hex screw using the smaller of the two Allen wrenches included in the accessory tool bag 5 Calibrate the dynamometer with the 10 gram calibration weight Refer to Chapter 6 for complete calibration instructions Note Re calibration is necessary after every conversion between the 2 mN m and 4 mN m torque configurations 20 Mogtrol Micro System Chapter 4 Test Setup 4 2 4 2 1 4 2 2 MOTOR MOUNTING Clamping strap Vertical adjustment knob Knurled cam grip Horizontal adjustment Depth knob adjustment knob Figure 4 2 Micro Dyne Motor Fixture SHAFT CouPLING Ifthe motor shaft diameter is 0 5 mm to 1 6 mm itis highly recommended to use one of the provided rubber couplings to adapt the motor s
40. haft to the 2 0 mm Micro Dyne Dynamometer shaft 1 Trim the tubing to allow about 2 mm of tubing over the dynamometer shaft and 3 mm of tubing over the motor shaft 2 Place the tubing snugly around the dynamometer shaft being careful not to bend the shaft 3 After the motor is mounted as described in Sections 4 2 2 4 2 3 and 4 2 4 place the other end of the rubber tubing around the motor shaft ADAPTERS When testing motors with diameters less than 20 mm the appropriately sized adapter must be used Motor Diameter Adapter 5 mm 10 mm V Adapter 10 mm 20 mm V Adapter Il 20 mm 30 mm No adapter necessary Attach the adapters to the fixture using the provided hex screws and Allen wrench The threaded holes are found in the groove of the V adapters Note The adapter should be secured in place but be careful not to overtighten 21 O m gt O 2 Chapter 4 Test Setup Magtrol Micro System Motor Fixture Motor Fixture Motor Fixture with with without V Adapter V Adapter 1 adapter Figure 4 3 Motor Fixture Adapters 4 2 3 CLAMPING STRAP 1 Place the motor under the rubber strap fe 2 Tighten by pulling on the strap A knurled cam will lock the strap in place when the strap m is let go 3 release the motor rotate the cam upward and the strap will loosen Oo Note Ideally the clamping strap should be secured at the middle of the motor
41. icro Dyne Electronics Unit This setup allows the Micro Dyne s electronics to control on off power to the motor under test and to monitor input power Micro Dyne Electronics Unit SENSE POWER Voltage Sense Leads Customer Micro Dyne Motor Power Supply Dynamometer Figure 2 7 Basic System Configuration Relay Configuration To run a motor in both clockwise and counter clockwise directions without having to rewire during the middle of a test a relay card is required A National Instruments PCI relay card available for purchase from Magtrol allows for the automatic reversing of motor leads when the motor power supply is connected to the relay card Like the basic system configuration the Micro Dyne controls on off power to the motor under test and monitors motor input power For more information regarding motor reversal refer to Section 4 3 1 Micro Dyne Electronics Unit POWER Voltage Sense Leads Customer Micro Dyne Motor Power Supply Dynamometer Figure 2 8 Relay Configuration 13 Chapter 2 Installation Configuration Magtrol Micro System 2 3 1 3 2 4 2 4 1 2 4 2 Motor Drive Configuration This setup allows for the addition of a motor drive unit The advantage to this is that the Micro Dyne is now measuring the drive motor efficiencies instead of the just the motor alone This is especially beneficial when the motor is depende
42. igh as possible without causing the loop to become unstable 5 3 2 INTEGRAL With integral the controller output is proportional to the amount of time the error is present Increasing the integral value eliminates the offset from the set point If the response becomes oscillatory increase the derivative value 5 3 3 D Derivative With derivative the controller output is proportional to the rate of change of measurement or error Derivative can compensate for a changing measurement Derivative takes action to inhibit more rapid changes of the measurement than proportional gain 27 Chapter 5 Operating Principles Magtrol Micro System 5 3 4 ADDITIONAL SCALE Factor The Additional Scale Factor PS IS and DS is a multiplier of the P I or D term Due to the fact there are so many different motor combinations this multiplier is needed to extend the range of the PID The letters represent the following values A 0 001 D 0 05 The default multipliers and B 0 005 E 0 10 5 C 20 010 F 0 50 10 Using the multiplier PID values from 0 001 0 001 x 1 to 990 10 0 x 99 may be inputted 5 3 5 How rHE PID LooP Wonks The following diagram demonstrates the correlation between the variables in the PID Loop Ys t Set Point 010 120 000 rpm 0 to 20 kHz SPEED rpm v Power Brake Filter Speed Coil lt to
43. ion e Toys e Handheld communication devices e Audio video equipment e Optics and photonics e Aerospace and defense e Security and instrumentation Industrial machinery z Tl fe 2 z e 2 TVd N 5 Chapter 1 Introduction Magtrol Micro Dyne System System Configuration Micro Dyne SYSTEM MODEL z on 2 2 a gt or Z shipping bolt 4 Electronic Unit knob functions as Dynamometer Controller DC Wattmeter Power Relay USB Interface Dynamometer motor power IN terminals motor power OUT motor clamping strap temm erminals with knurled cam grip voltage sense motor fiber optic speed picku terminals electrical connection Motor Fixture motor fixture adjustment knobs height width and depth leveling knobs BLOCK DIAGRAM motor power PC with M TEST 5 0 Slotted Disc speed signal via fiber optic speed pickup USB cable and calibration software Firmware torque signal brake power i Power Supply Mains IEC 80 240 VAC 60 50 Hz Mogtrol Micro System Chapter 1 Introduction System Information SYSTEM COMPONENTS Dynamometer Micro Dyne Motor Fixture The Micro Dyne dynamometer absorbs power with Magtrol s unique Hysteresis Braking System Because it does not require speed to create torque the dynamometer can conduc
44. l e7 oy 30 Figure 6 2 Port Selection T n Figure 6 3 Enter Mass of Calibration Ve 32 Pigre 0 4 ReSCt ZERO ss M 32 Figure 6 5 Dynamometer Calibration sss Figure 6 6 Calibration Routine Status eee ns 2 34 Figure 6 7 Calibration Sequence Successful ees 34 Figure 6 8 Calibration Error eee 239 Figure 6 9 Calibration Data Results Prompt sss nt 5039 Figure 6 10 Additional Report 36 PURPOSE OF THIS MANUAL This manual contains all the information required for the setup and general use of Magtrol s Micro Dyne System To achieve maximum capability and ensure proper use of the system please read this manual in its entirety before operating Keep the manual in a safe place for quick reference whenever a question should arise WHO SHOULD USE THIS MANUAL This manual is intended for bench test operators who are going to use the Micro Dyne System in order to determine the torque and power of a miniature micro motor in relation to its speed It is assumed that the user has sufficient knowledge in mechanics and electronics to be able to install operate the dynamometer and its corresponding electronics unit without risk MANUAL ORGANIZATION This section gives an overview of the structure of the manual and the information contained within
45. lations in proportion to the deviation from a true level surface The base plate of the Micro Dyne is equipped with two leveling knobs and an embedded bubble level for easy leveling 3 8 COGGING Rotor Poles Figure 3 2 Hysteresis Brake Cross Section Mogtrol Micro System Chapter 3 Testing Considerations 3 8 1 3 8 2 3 9 3 10 This cross section shows by one tooth the magnetic relationship of the hysteresis brake elements If the dynamometer shaft is at rest with the torque applied and if the torque control is then reduced to zero a magnetic salient pole will be temporarily imposed on the rotor of the brake If the shaft is then rotated slowly the magnetic poles on the rotor will attempt to align with the adjacent case pole tooth form This is often referred to as cogging The action is sinusoidal First it tries to resist rotation and then as the rotor passes through the tooth form it subsequently supports rotation The most obvious results of cogging are uncontrolled oscillations within the torque speed curve It will become difficult for the motor under test to tune in the PID loop along with a possible increase in resonant noise from the dynamometer and motor AvopiNe COGGING To avoid magnetic cogging before the shaft comes to rest slowly reduce the torque control to Zero REMoviNe CoGGING To most effectively remove cogging once established reapply current on the dynamometer Then sl
46. mm in length 4 Two calibration weights one 5 g and one 10 g tagged and labeled z 2 z e z 0 m 2 m 2 gt Chapter 1 Introduction Magtrol Micro Dyne System Calibration documentation a b c Calibration certificate for Micro Dyne Calibration test report for wattmeter Calibration test report for dynamometer Accessory tools a b Tweezers Medium Allen wrench Large Allen wrench Five cable ties z om 2 2 5 gt or Z Mogtrol Micro System Chapter 1 Introduction 1 2 DATA SHEET Micro Dyne Motor Testing System FEATURES e DESIGNED SPECIFICALLY for miniature and micro motors Torque Easily convertible from 2 0 mN m to 4 0 mN m 0 28 oz in to 0 57 oz in e Speed up to 100 000 rpm Power 4W e Low inertia e Sold as a complete out of the box motor testing system Components include e Hysteresis Dynamometer provides precise torque loading independent of shaft speed Motor Fixture accommodates motors from 5 mm to 30 mm in diameter e Dedicated Electronics all in one dynamometer controller DC wattmeter power relay and USB interface Comprehensive Motor Testing Software new version of Magtrol s M TEST 5 0 updated for the Micro Dyne e Easy to use calibration software e necessary connection cables Calibration weights 5 g and 10 g DESCRIPTION With over 50 years experience in dynamometer
47. nt on the motor drive for operation With the power supply unit attached to the Micro Dyne relay the power to the motor drive can be controlled through M TEST Micro Dyne Electronics Unit Voltage Sense Customer Micro Dyne Motor Power Supply Dynamometer Figure 2 9 Motor Drive Configuration MOTOR TESTING SOFTWARE SOFTWARE INSTALLATION For detailed installation instructions refer to Magtrol s M TEST 5 0 User s Manual M TEST Communication In order to use M TEST with the Micro Dyne the COM port to which the USB interface is connected must first be determined 1 Power up the Micro Dyne 2 Find the COM port For Windows 95 98 2000 Go to Start menu gt Settings gt Control Panel gt System gt Hardware gt Device Manager gt Ports Look for the USB Serial Port and note the COM port number in parenthesis For Windows XP Go to Start menu gt Control Panel gt Switch to classic view gt System gt Hardware gt Device Manager gt Ports Look for the USB Serial Port and note the COM port number in parenthesis Note To configure M TEST for the Micro Dyne refer to Section 4 3 Software Configuration Mogtrol Micro System Chapter 2 Installation Configuration 2 5 COMMUNICATION CHECK When powering up the Micro Dyne check to make sure that all four LEDs on the rear panel of the electronics unit see Figure 2 4 are illuminated according to the table below
48. o not wear loose clothing or ties when operating the Micro Dyne equipment Ensure motor under test is properly mounted to the motor fixture Revisions This Manual The contents of this manual are subject to change without prior notice Should revisions be necessary updates to all Magtrol User s Manuals can be found at Magtrol s web site at www magtrol com support manuals htm Please compare the date of this manual with the revision date on the web site then refer to the manual s Table of Revisions for any changes updates that have been made since this edition REVISION DATE First Edition revision A October 2007 TABLE OF REVISIONS Date Edition Change Section s 10 21 07 1st Edition Added option to print calibration data results at end of 6 3 calibration procedure 06 13 07 1st Edition Finalized version of preliminary manual various Table of Contents SAFETY PRECAUTIONS REVISIONS TO THIS MANUAL EEE ll REVISION DATE sche teet eter a imet o OP ere iUe Ue Re REN Ee II TABLE OF REVISIONS rrt rtt ER inre I II TABLE OF CONTENTS aci hu cxi centes credet p rino re DN Ek aa EDI cun DUE TABLE OF FIGURES LE V PREFACE niia a ood IIa CAN dr aW anni aida d PO DU Rp Ge RE eK px P GR CONES VI PURPOSE OF THIS MA
49. ote with Magtrol SA s address as listed above Three pro forma invoices with e Your VAT number e Value for customs purposes only e Description of returned goods Origin of the goods in general Switzerland e Noticed failures 4 A cost estimate for repair will be sent to you as soon as the goods have been analyzed If the repair charges do not exceed 25 the price of a new unit the repair or calibration will be completed without requiring prior customer authorization 46 MAGTROL INC 70 Gardenville Parkway Buffalo New York 14224 USA Phone 1 716 668 5555 Fax 1 716 668 8705 E mail magtrol 9 magtrol com Testing Measurement and Control of Torque Speed Power Load Force Weight Tension Displacement MAGTROL SA Centre technologique Montena 1728 Rossens Fribourg Switzerland Phone 41 0 26 407 3000 Fax 41 0 26 407 3001 E mail magtrol 9 magtrol ch Subsidiaries in Germany France Great Britain China Worldwide Network of Sales Agents ISO 9001 2000 BUREAU VERITAS Certification www maogtrol com
50. owly ramp the current to zero while maintaining a very low speed only a few rpms The current ramp to zero can be increased slightly in speed when the dynamometer rotation is sped up during this process EDDY CURRENTS There is some Eddy current generation within the brake rotor These magnetically induced currents cause an increase in braking torque proportional to speed While more pronounced in larger dynamometers which exhibit higher rotor surface velocities in a pure loading system it becomes a benefit of the dynamometer Since the Eddy currents effect the rotor surface this torque is measured by the torque pendulum and becomes another load source and not a source of error TEMPERATURE RISE Temperature rise has a more complex effect on hysteresis brake load torque and is difficult to quantify As the temperature of the brake increases differential expansions cause dimensional changes that tend to increase torque Conversely electrical resistance in the rotor increases with temperature resulting in decreased Eddy current generation and load all in a variable frame CAUTION UNDER NO CIRCUMSTANCES SHOULD THE MAXIMUM WATTAGE RATINGS FOR THE DYNAMOMETER BE EXCEEDED THE RESULTING RISE IN TEMPERATURE CAN CAUSE PERMANENT DAMAGE TO THE ROTATING ASSEMBLY INCLUDING ALTERING THE MAGNETIC PROPERTIES OF THE ROTOR ITSELF 19 m gt O 2 4 Test Setup 4 1 TORQUE CONFIGURATION The Micro Dyne be con
51. reflective fiber optic speed pickup As each rotor slot passes by the sensing end of the fiber optic an electronic pulse is generated which is then converted to a speed reading in rpm The incoming pulses from the speed pickup can be resolved down to 5 Hz or 5 pulses per second With 6 slots on the rotor this results in a minimum speed setting of 50 rpm The speed reading will drop to zero at 50 rpm Note The rotor speed measuring mechanism of the Micro Dyne has been optimized for motors running from 10 000 rpm to 100 000 rpm Figure 5 2 Micro Dyne Rotor 5 3 CONTROLLER AND THE PID LOOP The Micro Dyne has PID adjustment capability for both the speed and torque modes to provide the best system response The PID Loop comprises the following three variables P proportional gain I integral D derivative Other important variables include e Set point desired load or speed Error difference between the set point and the actual measurement Additional scaling used to broaden the range of the control loop D 2 Q m ONILVYAdO 5 3 1 P PROPORTIONAL GAIN With proportional gain the controller output is proportional to the error or to a change in measurement Deviation from the set point is usually present Increasing the proportional gain will make the PID loop unstable Increasing the integral value will eliminate this instability For best loop control set the proportional gain as h
52. riod of twenty four 24 months from the date of shipment Software is warranted to operate in accordance with its programmed instructions on appropriate Magtrol instruments This warranty extends only to the original purchaser and shall not apply to fuses computer media or any other product which in Magtrol s sole opinion has been subject to misuse alteration abuse or abnormal conditions of operation or shipping Magtrol s obligation under this warranty is limited to repair or replacement of a product which is returned to the factory within the warranty period and is determined upon examination by Magtrol to be defective If Magtrol determines that the defect or malfunction has been caused by misuse alteration abuse or abnormal conditions of operation or shipping Magtrol will repair the product and bill the purchaser for the reasonable cost of repair If the product is not covered by this warranty Magtrol will if requested by purchaser submit an estimate of the repair costs before work is started To obtain repair service under this warranty purchaser must forward the product transportation prepaid and a description of the malfunction to the factory The instrument shall be repaired at the factory and returned to purchaser transportation prepaid MAGTROL ASSUMES NO RISK FOR IN TRANSIT DAMAGE THE FOREGOING WARRANTY IS PURCHASER S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT N
53. s when operating the Micro Dyne equipment e Ensure motor under test is properly mounted to the motor fixture POWER DISSIPATION All Magtrol dynamometers are power absorption instruments As a dynamometer loads a test motor it is absorbing power from the motor into the hysteresis brake The brake is converting this mechanical energy into heat There are finite limits to the amount of energy and resulting temperature rise that any absorption brake can withstand Excessive power over extended periods of time may result in more obscure damage including breakdown of bearing lubricants and degradation of magnetic coil insulation Extreme temperatures due to inappropriate operation can not only warp the rotor and surrounding housings but also alter the magnetic characteristics Absolute best case scenario under such circumstances would be a reduced torque output from the brake assembly if complete dynamometer failure were not realized 16 O m gt O 2 Mogtrol Micro Dyne System Chapter 3 Testing Considerations 3 2 1 3 3 3 4 Power ABSORPTION CURVE Based on the maximum kinetic power ratings the curve represented in Figure 3 illustrates the maximum power heat that the dynamometer can dissipate over time The area under the curve equals the maximum speed torque combinations for both a motor test of less than 5 minutes intermittent duty and a continuous duty motor test Conditional Environmental Par
54. scription Earth ground Mounting plate of speed Provides safety against electric shock pickup Bifurcated fiber optic cable Speed pickup Reads speed measurement Dynamometer brake cable BRAKE Output Delivers power from electronics unit to dynamometer brake 15 pin instrument cable ENCODER Input Quadrature encoder reads torque measurement 2 2 1 EARTH GROUND For your safety the dynamometer has been earth grounded and shipped with the ground strap already in place This protective wire provides an alternate path to ground in case of short circuits or heavy electrical currents The dynamometer connection point is located on the rear of the base plate and is clearly marked with the earth ground symbol Ground lug Figure 2 2 Dynamometer Earth Ground The other end of the ground strap should be connected to the metal tab attached to the speed pickup mounting plate located on the Micro Dyne Electronics Unit See Figure 2 3 Speed Pickup The complete earth ground path is as follows Dynamometer gt Electronics unit gt Main power cord gt Earth Chapter 2 Installation Configuration Magtrol Micro Dyne System 2 2 2 SPEED Pickup CONNECTION speed pickup Plasti cables here astic cover Fiber connection mechanism shown in up unlocked position Partial side view of electronics unit Insert fiber optic cable ends here Earth ground connection Figure 2 3 Speed Pickup To
55. ser whether or not they would like to print a copy of the calibration data results TIME TO COMPLETION Z i m 2 gt z m CONTINUE STOP Figure 6 9 Calibration Data Results Prompt 35 Chapter 6 Calibration Magtrol Micro Dyne System To print a calibration report click Yes and proceed to step 12 Click No to quit the Calibration Software without printing the results 12 The Additional Report Information dialog box will appear Figure 6 10 Additional Report Information Enter any additional information concerning the calibration routine and click Print The Calibration Data Report will print to the default printer and the Calibration Software will quit Z m m z gt 2 36 7 Troubleshooting Problem Speed Measurement Speed is eratic or there is no speed reading Micro Dyne revision is not displayed in the calibration software window Reason Speed pickup is in incorrect mode Lost communication with electronics unit Solution Switch speed pickup to SHS Mode Calibration Check USB connections Calibration Error message appears at completion of calibration procedure Pendulum not fully returning to zero after the weight is removed Make sure the dynamometer is level and restart calibration procedure If you require additional assistance please contact Magtrol Customer Service at 1 716 668 5555
56. t a full motor ramp from free run to locked rotor In addition to a dedicated motor fixture the dynamometer base plate also includes leveling knobs and motor power terminals The housing of the dynamometer protects all the moving parts of the brake Electronic Unit At the hub of the Micro Dyne system is a multifunctional electronic unit The unit employs DSP technology for high speed data acquisition and complete PC control of the dynamometer A USB receptacle enables easy connection to a personal computer An integrated DC wattmeter reads volts and amps and calculates watts and a built in power relay controls motor power on off The front panel includes the terminals for motor power in out and voltage sensing LED power and communication indicators are located on the rear panel of the unit OPERATING PRINCIPLES Speed Measurement Attached to the dynamometer base plate is a motor fixture designed expressly for micro miniature motors The base of the fixture features an XYZ stage with 3 axis positioning for excellent adjustability and motor centering With the included adapters motors from 5 mm to 30 mm in diameter can be easily mounted The fixture is keyed to help secure the motor under test and a rubber strap with knurled cam grip provides motor clamping Motor Testing Software Magtrol s M TEST 5 0 is a state of the art comprehensive motor testing program designed for use with Windows
57. this source of error will be less pronounced then if similar speeds were seen on larger dynamometers 17 O m gt O 2 Chapter 3 Testing Considerations Magtrol Micro System 3 5 FRICTION Friction of the carrier bearings is a measurable load When correctly loaded and lubricated the friction is insignificant During actual motor testing there is usually enough system vibration to settle negating frictional effects If excessive drag is present mechanical realignment may be required In the design of the Micro Dyne careful attention was paid to carrier bearing friction for the proper operation of the pendulum assembly mainly in ensuring the pendulum returned to the Zero position within the published error bands Note Friction is the largest source of error in the Micro Dyne but it is relatively small in comparison to the overall range and accuracy lt 1 of the dynamometer 3 6 VIBRATION rotating dynamometer assemblies are precision balanced At high speeds some vibration and noise are inevitable but not necessarily harmful However excessive resonant vibrations caused by bent shafts and poor alignment will produce data errors and are a safety hazard 9 D CAUTION SEVERE VIBRATION LEFT UNATTENDED COULD ULTIMATELY LEAD TO gt PERMANENT DAMAGE TO THE TEST EQUIPMENT OR THE MOTOR UNDER 9 TEST 3 7 DYNAMOMETER LEVELING An improperly leveled dynamometer will alter the torque calcu
58. to free run Turns brake OFF Qs Sets torque point to Closed loop command with its own set of PID Turns brake ON parameters Units are in mN m QD Sets torque derivative to Derivative value can be any number from 0 to 99 QDS Sets scaling factor Values for are A 0 001 D 0 05 G 1 B 0 005 E 0 10 H 5 C 0 01 F 0 50 10 Q Sets torque integral to Integral value can be any number from 0 to 99 QIS Sets scaling factor Values for are A 0 001 D 0 05 G 1 B 0 005 E 0 10 H 5 C 0 01 F 0 50 10 QP Sets torque proportional gain Proportional gain value can be any number to from 0 to 99 QPS Sets scaling factor Values for are A 0 001 D 0 05 G 1 B 0 005 E 0 10 H 5 C 0 01 F 0 50 10 Power ANALYZER AND RELAY COMMANDS oe ee Function Explanation OA1 0 Reads amps 1 0 Reads volts OW1 0 Reads watts PWRO Switches off the power relay PWR1 Switches on the power relay MiscELLANEOUS COMMANDS us Function Explanation Sets current output to The Micro Dyne power supply outputs a fixed value of current Use any value between 0 and 99 99 99 99 FS SAVE Saves present configuration of unit to non volatile memory 41 gt 2 Oo m Appendix Hardware Commands Magtrol Micro Dyne System A 2 8 CALIBRATION COMMANDS Command Code Function Explanation
59. um speed any previous speed stabilized setting to the Sets speed mode OFF maximum speed range Sets brake OFF N Sets speed point to Use this command to load the motor under Sets brake ON test to a specific speed value Issue a speed range command first for best dynamic response The controller is functioning with the dynamometer as a closed loop system Adjust the speed PID values to tune the response ND Sets speed derivative to Derivative value can be any number from 0 to 99 NDS Sets scaling factor Values for are A 0 001 D 0 05 G 1 B 0 005 E 0 10 H 5 C 0 01 F 0 50 10 Sets speed integral to Integral value can be any number from 0 to 99 NIS Sets scaling factor Values for are A 0 001 D 0 05 G 1 B 0 005 E 0 10 H 5 C 0 01 F 0 50 10 NP Sets speed proportional to Proportional gain value can be any number gain from 0 to 99 NPS Sets scaling factor Values for are A 0 001 D 0 05 G 1 B 0 005 E 0 10 H 5 C 0 01 F 0 50 10 40 gt m z m Magtrol Micro System Appendix A Hardware Commands A 2 5 A 2 6 A 2 7 Torque COMMANDS Command Code Function Explanation Q Resets torque to 0 0 Resets any previous torque stabilized Turns torque mode OFF command and returns the motor
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