SHOCKANALYZER V1.7 USER`S MANUAL
Contents
1. 2 5 1 Test Details Name Here the name for a new test has to be entered The program increases the ending number of test name every time a test is done Shock Position The user has to ensure the selected position matches the actual one on the machine sitio ETA i Stroke and an Angle each position number has associated a Stroke and an Angle that the program will use to calculate the dumper movement These values are taken automatically from a table position ini in the program s installation directory 2 5 2 Test Sequence Table This table must be filled for all test types single speed or multi speed When multiple speeds are recorded for a single test this table is used to enter the different speed steps the motor will perform The values entered are e Speed millimetres per second The program provide two methods to calculate the VFD output Printed 21 September 2012 SportDevices com ShockAnalyzer 1 7 Page 13 20 o open loop based on the Max rpm on the configuration which is quite accurate thanks to the internal VFD closed loops o Closed loop based in a PID implemented on the ShockAnalyzer DAQ not all Firmware versions support this mode but it can be updated e Wait number of turns to wait before starting to record data this field is provided to let the motor accelerate up to the desired speed For low speeds the user can enter 1 turn and for high speeds 3 turns e Record number of turns to re2. ease the visual reading Landscape portrait landscape the curves will be printed vertically or horizontally Report Type e Screenshot the program will generate a report with the same format as the current display mode selected on main screen e Detailed the program will generate a report with a fixed format o Summary of Test data forces and speeds o Force vs Displacement graph o Force vs Speed graph Program Settings Language English Spanish and Italian languages are available New translations can easily be done by editing the English lan file with Notepad and saving it as Francaise lan for example COM Port all available COM ports on the computer are displayed here The user can change it manually or he can use the COM Auto function in the Options Menu Autosave active by default the program will automatically save every new test If disabled the program will ask the user to save the test when the user is going to remove it or exit the program Peak Values SportDevices com ShockAnalyzer 1 7 Page 19 20 Peak Values can be configured to detect the maximum value from all testing interval or the maximum value for each turn These peak values are shown at Gauge Window and the Recording Test Window Units International scientific Force is shown in Newtons and speed in meter s Cegesimal common Force is shown in kg and speed is cm s Imperial Force in Pounds and Speed in inches s 2 7 4 Colours Ta
3. of the spring behavior of the shock absorber The resulting line will be displayed over the graphs 2 3 11 Spring compensation The spring coefficients analyzed in the previous point are used to subtract the spring effect from the test 2 3 12 Toggle Load Cell This option is used to toggle compression vs extension sides of the load cell force curves 2 3 13 Push cycle The user can show hide the push cycle of the graph 2 3 14 Pull cycle The user can show hide the pull cycle of the graph 2 3 15 Some Screenshots Force and Velocity vs Time Force is in phase with speed when the machine pushes the shockabsorber the Force is approximately constant the shock does not absorb too much power When the machine pulls from the shock the force is proportional to speed the shock is converting energy to heat SportDevices com ShockAnalyzer 1 7 Page 10 20 Force vs Position Position is related with speed at central position speed is maximum at upper and bottom position speed is zero Force vs Velocity For positive speed push force is close constant flat for negative speed force is proportional to speed 2 4 Test Columns Spig Constant Kamm noreg HARIA MEIA x aL gi 20200633 14H 10 MD 0 oe 3222 153 1003 Connect Song fet See Name Comments mai m s Tension Kal Compresion Kal n Date Time Time s Stoke Ange Teeth Pr offset Ko Type Samples Channel Mulltes Drecton STD FOST FREDDO The fol
4. option saves a CSV file Comma Separated Values that can be loaded by Excel This file includes the test header and the pre processed data for all recorded turns of the test This data consists of tooth Angle RPM Speed selected units mm s m s or inches s Force selected units Kg N or Lb and temperature Export Speed Report This option saves a text file with the maximum and minimum speeds for the speed values configured at the speed_data ini file in the installation folder This configuration file consists of a sorted list of soeeds in mm s Preview lt shows a preview in the screen of the tests in the same way as they will appear in the printer Print It prints the selected tests It shows a window so the user can first choose and configure the printer Exit It exits from the program Test Menu se Options He Run FS Remove Delete Run F5 It shows the Input Data window In this window will enter the data for the test Then the user can start the test by clicking over the Ok button Remove It removes the selected test from the program not from the disk Delete It deletes the test run from the program and from the DISK Be careful Options Options Help COM Auto Ctrl Configuration Load Cell Wizard COM Auto It will open the Automatic COM Port Selection window The process will search a data transmission from ShockAnalyzer unit at every port When it is received it will be s
5. SportDevices com ShockAnalyzer 1 7 Page 1 20 SportDevices Dynamometers and DAQ systems SHOCKANALYZER V1 7 USER S MANUAL Copyright 2012 SportDevices com ShockAnalyzer 1 7 Page 2 20 TABLE OF CONTENTS RIT AGI SUA ATIO Mad ao ne 3 Veh Data Acquisition las asia 3 12 UNIECONNSCUON SS ai 4 LS WS TAM AMON anat 4 ON I EN OR ne D a ed ta ee 5 o Losa Celada Miseria dada 6 2 ShockAnalyZer Software ocooonnnonocononccnoncncnonanononanononanonananonannononanonananonananonanass 6 Zalk A A A A 6 2 1 1 HIS MIO dada 6 21122 Test Men said J A E ONU oa E E E A O TTA 7 2 MEDM N Ususin eto das 8 a ANS ON at tal os 8 a DAWN Sado 8 2 3 1 EN O POSON eren GE on 8 2 3 2 FAV Force absolute vs Velocity 8 2 3 3 F Vac ONCE VS VOIOCILV ai 8 2 34 FPT Force and Position VS TIMO ini 8 2 3 9 FVT Force and Velocity VS Time 8 20 0 Average ON OFF aioin ita 8 al AVerage LOS ONO asados atole litio 8 208 EXET ON OB ada 9 2393 Temperaire ON ORE iia da 9 23 10 PIN analysis tia 9 23 11 ODINO COMPDEN SAUNON sesane aE E EA E 9 29 12 Tooge Load 67e RER 9 Peeler PUSH CV ClO 9 2191 A aired nace eee ee O in 9 2 0 10 SOMME erecta id 9 2A MESEOOIUMAS arta add oia 10 20 Vest Dala WINGOW si 12 2 5 1 Testi ia 12 252 Testoequ nce Table nica iia 12 2 9 3 A aadenelease ase abenec means 13 E A 6 Gene RU ae ee ee re ee 13 210 AECA ed due 14 27 Program CC OM MIC UN ATOM ts 15 2 7 1 MECHANISM Type Tab an
6. b Configuration M ShockAnalpzerT WTZ gt SportDevices Dynamometers and DAQ systems Each channel for each test can have a different colour The user can edit them on this window After editing the write button has to be pressed to save the changes By default the program uses thick lines width 2 for Average mode but this can be configured in this window Printed 21 September 2012 SportDevices com ShockAnalyzer 1 7 Page 20 20 3 LOAD CELL WIZARD This window eases the Load Cell calibration process It is divided into two steps 3 1 Load Cell Zero Load Cell Wizard Seles Step 1 Step 2 Step 1 Please set your load cell without load And press button set to zero 0 Zero Load Cell ero 32000 Next 320 0 LoadCell kKo With the load cell free press the set to zero button and check the load cell zero value is between 30000 and 35000 otherwise there may be some problem on the wiring or ShockAnalyzer DAQ 3 2 Load Cell Scale VENA AE Step 2 Put Calibration Weight at the end of the Load Cell Press Button to Calibrate Calibration eight 10 Eg Calibrate Reference Load Cell Factor 0 01 320 0 Load Cel Kg With the calibration weight pulling the load cell enter the calibration weight value on the white box and press the calibrate button Check that the load cell reading blue number Kg matches the reference load number Fina
7. cess which will take a few tenths of seconds to stop the machine during this process a small error in the teeth position is done so this value is used to compensate that error The slower the braking speed Min PWM parameter the smaller the error Shock Position this value informs to the program about the drum position in which the connecting rod is mounted in order to do the stop tests This is not a configuration value only a test value The program will use the current test shock position at gauge window every time a new test is finished to calculate the stop position Pos to begin to stop this is an informative box with the result from using the previous values stop position teeth to slowdown and shock position Test button press this button to start the shockdyno and press it again to stop it and test the stop position SportDevices com ShockAnalyzer 1 7 Page 18 20 2 3 Options Tab Configuration ShockAnalpzer T 41 72 SportDevices Dynamometers and DAQ systems Print Program M Colour printer Language English if Landscape COM Part COMI Auto Save M Print Temperature Report Type y Peak Values Screenshot le Masiraum f Detailed C Eyer Turn gt Units INTERNATIONAL Force Newtons Speed ms f CEGESIMAL Force Kg Speed cms f IMPERIAL Force Pounds Speed inches Printer Settings Colour Printer when printing in a non colour printer all curves will use the same colour to
8. cord the minimum is 1 2 5 3 Peak Values The program will show in these four boxes the peak values for RPM Speed Extension Force and Compression Force during the tests with this window Peak Values can be configured to detect the maximum value from all testing interval or the maximum value for each turn at Configuration Window see section 2 7 2 5 4 Speed Check Prior to the recording of the test the selected speeds for the Test Sequence Table can be tested to see if the motor is able to reach that speed if the max Speed setting is correct and the open loop option is working correctly or the closed loop settings are correct to reach the desired speed depending on the method selected for speed control Test method consists of e Enter the desired speed in mm s e Press Test button e Look at the RPM gauge and verify the current soeed according to the calculated target rom at the box under speed in mm s Speed box in the Peak Values area can also be used to verify the linear speed e Press Stop button Open Closed loop setting can also be changed in this window but for changing their internal settings max Speed for open loop or PID settings for closed loop it is necessary to use the Configuration Window SportDevices com ShockAnalyzer 1 7 Page 14 20 2 6 Recording Data Recording Data Peak Values Step 1 Speed 100 Stauts Wait 1 Laps Errors O Teeth 1 This screen will show the recording pr
9. e Offset Adjust Dyno Name name for the reports print Connecting rod length of the bar used to connect the drum with the sliding bar in which the shockabsorber is mounted not the drum diameter Test Length maximum number of turns of test recording Pickup offset pickup hall sensor should be mounted at position 3 o clock of the drum 0 degrees horizontally This parameter lets the user compensate its real position Piston Crank by default in this machine the mechanism is like into an engine the created motion is not completely sinusoidal but the program has the mathematical model to calculate it Scotch Yoke Slider this machine creates a perfect sinusoidal motion but it is more complex to build Number of Teeth number of teeth for the gear tooth including the missing tooth by default 120 Scales Thermocouple this value should be kept to 1 It will let the user to setup a different type of temperature sensor Thermocouple offset this value allows to compensate small offset errors in thermocouple It allows to add o subtract some degrees to the readings SportDevices com ShockAnalyzer 1 7 Page 16 20 2 7 2 VFD Tab Configuration Shock nalyzer1 1 7 2 yportDevices Dynamometers and DAQ systems PID Closed Loop Kp Joso Ki fe gt Test BPM Wanable Speed Drive Open Loop Mas Output RPM 401 Min Paw Stop Position Top Teeth to Slowdown 1 Left E C Righ
10. er oscillations Test RPM this value is used to observe the closed loop behaviour SportDevices com ShockAnalyzer 1 7 Page 17 20 Test Button press this button to start the speed test And press it again to stop the test During the test a RPM box is displayed on the right bottom corner to show the current RPM value 2 2 2 Open Loop Control Max Output RPM this value is used on the calculation of the linear speed for multi speed tests It is the maximum speed of reduction gearbox with VFD set to 100 Press the Test Button to see the actual max speed when the output is set to 100 During the test a RPM box is displayed on the right bottom corner to show the current RPM value Min PWM this value is used by the program when a slow movement has to be performed for instance for the Stop Position Feature It should be a value low enough to create a slow movement but high enough to move the machine A very small value ex 1 will create some output but the motor will not move The allowed range is 1 to 1023 1023 100 output 2 2 3 Stop Position some ShockAnalyzer DAQ Firmware Versions include the Stop Position feature to control the position to stop the machine Firmware can be upgraded with a program Positions There are four possible positions to stop the machine after a test Top Left Right or Bottom see figure above Teeth to slowdown when the output is removed from VFD it normally performs a deceleration pro
11. hown in green If none receives data the user should check if there is another program using the COM port and repeat the process lt is very useful when used with USB adaptors where the COM id is a pseudo random number Configuration It shows a window with the program configuration it is explained below Load Cell Wizard lt opens the Load Cell Wizard window See section 3 SportDevices com ShockAnalyzer 1 7 Page 8 20 2 1 4 Help Menu About Ctrl About lt shows information about SportDevices developer of the software and manufacturer of the unit 2 2 The Button Bar s c e 2 gt ol6 2 sE ARCE By clicking over these buttons the user can do more quickly the same actions that using the menu Options are Shinning sheet New File new menu Open Folder Open File open menu Disk Save as lt saves the test with another name or in another directory Two folders Change directory File change directory menu Play Run Test run menu F5 key Sheet amp glass Preview File oreview menu F11 key Printer Print File print menu F12 key Tools Configuration lt opens program configuration window Load Cell Load Cell Wizard see section 3 SportDevices icon About Help about menu Draw Modes Buttons See below 2 3 Draw Modes 2 3 1 FD Force vs Position It draws the force versus the direct position reading It shows a smile type graph 2 3 2 FAV Force absolute vs Velocity It draws all f
12. ins connector Default voltage is 230 volt 50 60 Hz It can be requested for 115 volt too 2 VFD Output PWM output for the Variable Frequency Drive From 0 to 5 Volt PWM Output 0 to 5 volt 8 volt unregulated 3 Speed Sensor Hall Effect Sensor 5 volt digital 5 volt Signal active high 4 Load cell direct connection to load cell amplifier inside the unit White Cell IN Black GND Red 5 volt Green Cell IN 5 RS232 Serial RS232 connector 115200 baud no parity An USB to serial adapter can be used with computers without serial port Sportdevices strongly recommend FTDI based adapters 6 Thermocouple type K At front Input for temperature up to 1000 C Installation Very important when using a Variable Frequency Drive we strongly recommended using a VFD to power the motor high electric noise pulses are generated and they will strongly affect the old inductive soeed sensor This problem is completely solved by using the new Hall effect sensor and the provided ground cable yellow which connects the machine frame to the yellow plug in the back of the data acquisition unit and the The speed sensor has to be placed near the provided gear tooth 120 1 teeth at a distance of less than 1 mm aprox This sensor is connected directly to the data acquisition unit SportDevices com ShockAnalyzer 1 7 Page 5 20 The sensor is thought to be placed horizontally in the machine 3 o clock O degree
13. kabsorber position when using the Piston Crank type machine Offset is the position of the hall effect sensor Default position is 3 o clock 0 degrees K not used Type type of machine 0 for Piston Crank default 1 for Scotch Yoke Slider Samples number of samples read by the unit cycles teeth 1 Channels number of channels stored default 3 Multi test number of turns of each sub test Example 2 2 2 is 3 sub tests of 2 turns each Direction direction of the rotation 1 Clock Wise 1 CounterClockWise Spring Offset when using the Spring Compensations this offset is the force of shockabsorber at middle position approximately 3 o clock and 6 o clock drum positions Spring Constant when using the Spring Compensations this coefficient shows how the spring effect force increases as the shock is compressed Theoretically at low speeds the force measurements should be only caused by the spring effect gas not to the hydraulic effect which is related with speed SportDevices com ShockAnalyzer 1 7 Page 12 20 2 5 Test Data Window This window is used to enter data when a new test is going to be recorded Enter Data For New Test Vest d tails gg gt Peak Values Mare TEST_054 Shock Position 5 dl gt APH Stroke 100 Angle 120 Comments a C Remove last tests E Temp 0 0 ar 2 Test sequence O Speed Check O y o Speed DO mms
14. lly press OK button to finish the calibration process
15. lowing data is shown for every loaded test by double clicking over the row the data window will by displayed and the user can change some of these data Show the user can check uncheck this column to show hide the test Name name of the test Comments commentaries for the test V max maximum speed detected during the test km h or mph it supports the sub test format example 47 134 277 mm s each value corresponds to each sub test 3 sub tests in the example Tension maximum force pulling the shockabsorber detected during the test it supports the sub test format example 77 133 226 Kg the program can be configured to Newton Kg or Pound SportDevices com ShockAnalyzer 1 7 Page 11 20 Compression maximum force pushing the shockabsorber detected during the test It has the same format as Tension column T Max Maximum temperature detected during the test it does not support sub test format Date Time date and time when the test was done Time duration of the test Stroke distance that the drum fixing point moves from upper point to the lower point for the current selected position The drum in our plans has 10 positions see below each one with one angle and stroke Angle angle for the drum position used for the test Teeth number of teeth of the gear tooth default is 120 1 Connecting Rod is the part that connects the shockabsorber to the drum it size affects to the calculation formula for shoc
16. ocess each new turn is numbered in the right area If the recording of a new turn fails the program moves the cursor back and overwrites the data for the existing turn with the incoming data When all the specified turns and sub tests have been recorded then the program automatically exits this window and the Stop Process is started see section 2 7 2 3 Peak Values The program will show in these four boxes the peak values for RPM Speed Extension Force and Compression Force during the tests with this window Status bar bottom The program shows several data on the status bar Step from the Test Sequence List for multi speed tests Speed Current target soeed mm s Status Wait Record Laps Number of recorded turns Errors Number of laps that raised an error maximum is 3 Teeth total number of teeth detected in the last turn It should match the configured value if not then the Errors field is increased and the latest turn data is discarded Printed 21 September 20 SportDevices com ShockAnalyzer 1 7 Page 15 20 2 7 Program Configuration Configuration is distributed in four tabs 2 7 1 Mechanism Type Tab Configuration ShockAnalpzer T Wie SportDevices Dynamometers and DAQ systema Dynamometer data Dino name ShockAnalyzer 1 Connectina Rod 50 mm Test Lenght 50 turns Pickup Offset 0 deg MHechani n type Teeth fe Piston Crank Teeth pe Scales scotch Yoke Slider i i Thermocoupl
17. orce curves versus the absolute function of speed lt shows a C type graph 2 3 3 FV Force vs Velocity lt draws all force curves versus direct speed lt shows a bended 8 type graph 2 3 4 FPT Force and Position vs Time lt draws force and position channels and temperature versus time It shows oscilloscope type graphs 2 3 5 FVT Force and Velocity vs Time lt draws force and velocity channels and temperature vs time Force is in phase with the speed when the machine pulls from dumper and uses to be constant when the machine pushes the dumper 2 3 6 Average ON OFF This option enables or disables the average calculation When enabled all turns of the same test are averaged to create a single graphs lt increases accuracy and the clearness of the drawing 2 3 7 Average Loops ON OFF SportDevices com ShockAnalyzer 1 7 Page 9 20 2 3 8 Extend ON OFF When multiple speeds are recorded for a single test this option expands the speed axis to fit all the curves in the same range in order to ease the comparation When expanding the speeds the X axis is no longer referenced to speed since each sub test is using a different speed reference 2 3 9 Temperature ON OFF lt draws hides the temperature curves from the tests if recorded 2 3 10 Spring analysis When multiple speeds are recorded for a single test the first speed sub test has to be recorded at low speed This sub test is used to perform an analysis
18. s but if its position is different it can be configured in the software sensor offset The rotation should be clockwise lf can be done by swapping the cables from three phase motor The load cell has to be placed at the upper side of the machine When adjusting the upper bar the user must ensure that the shock absorber can move along all its displacement and it doesn t reach its boundaries because in such case the force applied to load cell will be very high and it could be damaged 1 4 How it works The device senses all pulses from the speed sensor and does an analog conversion from the Load Cell channel and the Thermocouple channel for every tooth pulse and transmits all these data to the computer Thus the data acquisition frequency is variable with the drum speed The elapsed time between pulses is also transmitted to the computer to know the speed and the position for the machine at every moment When the missing tooth is detected the elapsed time between teeth is greater than 50 from the last one N 1 pulses have to been received if other number of pulses Printed 21 September 2012 SportDevices com ShockAnalyzer 1 7 Page 6 20 have been read this is consider as an error and the computer software discards all the cycle and starts it again this ensures the data integrity for every cycle 1 5 Load Cell Calibration The value shown in the screen is the converted reading from Load Cell in Newtons Calibration sho
19. sn iss 15 AS A TR NN RE DS 16 2 1 2 11 Closed Loop COMO ads 16 2 1 22 OPEN ECO ON o lee bios a 17 2 ION ROS A 17 Bhs OPUS MA aos 18 2A COOU AN da Daes DUE A A 19 3 LOAD GEEL WIZARD osa iia 20 Sy WAG C OZO te ARAU Po OO 20 92 AS Reed 20 SportDevices com ShockAnalyzer 1 7 Page 3 20 1 Kit and Installation The Shock Analyzer Kit consists of a Data Acquisition Unit Speed Sensor Gear Tooth 120 1T Load Cell sensor to acquire data from a Shock Dynamometer machine Computer Load Cell ShockAbsorver Variable Reduction box Frequency Drive l output 250 400 rpm 3 phase Hall effect sensor Parts included ShockAnalyzer DAC Hall effect sensor Gear Tooth 120 1 Load Cell 1500 Kg Shock Analyzer Connections 1 1 Data Acquisition Unit e Display 16x2 char LCD display RMP current speed of the machine CELL Load Cell channel converted to Newtons it depends on the calibration of the unit STOP RUN Current data transmission mode It will be on run when acquiring data T Temperature for the thermocouple type K input usually tied to the shock absorber Temperature can be in range from O to 999 degrees If there is no sensor connected the reading will be Printed 21 September 2012 SportDevices com ShockAnalyzer 1 7 Page 4 20 1 2 1 3 Unit connections Back VFO Out Speed Load Cell 1 Mains Computer type ma
20. t Shock Position Bottom Pos to Begin to Stop 113 This window is used to configure the VFD Variable Frequency Drive output which powers the 3 phase motor Two control methods are allowed e Closed Loop e Open Loop 2 2 1 Closed Loop Control Some ShockAnalyzer DAQ Firmware Versions include a PID controller to perform the closed loop actually it is a P I type Firmware can be upgraded with a program Kp value controls the amount of power applied to the motor according to the difference between the desired speed target and the current speed This difference is called error and Kp multiples the error so KP 1 means that error is multiplied by 1 to create the output The higher the Kp the faster the approximation but a high Kp value could lead to over oscillations the target speed is over passed during the stabilisation and then the PID removes some power to complete the stabilisation process It is recommended to test several values until a good speed response is found but without oscillations Anyway the ShockDyno is a relatively slow machine high load due to the shockabsorber effect and does not create high oscillations Ki value controls the final phase of stabilisation If only using Kp the final speed will be close to the target speed but it will not completely reach it thus Ki performs a final approach by accumulating the error The higher the Ki the faster the approach but high Ki values could lead to ov
21. uld be checked for zero load display 0 and calibration weight known weight without the shockabsorber It is recommended to use a mass as heavy as possible for each load cell although it may be difficult to handle When using lower weights for example 50 kg for the 450 kg load cell this may introduce a scale error and the error at end of scale 450 kg will be unknown See section 3 Load Cell Wizard 2 ShockAnalyzer Software ShockAnalyzer V1 1 C TMP H 10 x File Type Options Help seul gt ale 2 5 Name Comments Max max Date Time Max Diam Angle Teeth lever Type Samp chan v TEST_022 632 0 094 16 03 2006 19 09 51 3 58 20 0 60 50 0 302 2 1 tests Disconnected 2 1 The Menu 2 1 1 File Menu Test Options Help Remove all Cbrl h Open Chile Change Directory Cir Save as Export to Excel Export Speed Report Preview Fil Print Piz Exit Ctrl Q Remove All It removes all tests from the memory but not from the disk SportDevices com ShockAnalyzer 1 7 Page 7 20 Open lt shows a window to choose the tests to be loaded in memory It is possible to load them one by one or several at once Change directory lt allows changing the directory where tests are automatically saved Current directory is shown in the title of the window upper text Save as It allows saving the test with a different name or in a different place Export to Excel This
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