Hydraulic Fluid Power System Management

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Hydraulic Fluid Power System Management
Comprehensive hydraulic system monitoring and control
be certain.
W I T H A D VAN CED SOLU TI O N S AND DE CADE S OF RE LE VANT E XP E RIE NCE ,
M T S STA N DS UN I Q U ELY Q U A LIFIE D T O INT E GRAT E AND OP T IMIZ E YOUR
H Y D R A U LI C D I STRI BUTI O N COMP ONE NT S. OUR STAT E -OF-T HE -ART
F L U I D PO WER SY S TEM MA NAGEM ENT SOL UTIONS ALLOW E VE N T HE
LA R G E ST, M OST CO MPLEX TE ST LABORAT ORIE S T O E ASILY MONIT OR AND
C O N T RO L TH EI R OVERALL HYDRAULIC SYST E M STAT E . W E CAN HE LP YOU
C O M BI N E A LL VI TAL FUN CTI ONALIT Y AND SYST E M STAT US INFORMAT ION
I N T O A SI N GLE, SEA MLESS AND HIGHLY INT UIT IVE USE R E XP E RIE NCE .
Manage Your Hydraulic Power From a Single Source
Hydraulic Power Units (HPUs) in most test labs are typically managed as single units
rather than as a whole. The lack of communication between HPUs makes it impossible
to assign specific flow levels to each test station based on need, which then requires the
hydraulic distribution system to maintain far more always-on flow than is necessary
to meet both average and peak demand. This overuse of hydraulic resources increases
electricity consumption and results in the premature component wear that may lead
to unscheduled downtime.
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Test labs also experience lost productivity when operators have to leave their stations
and walk to another part of the facility to request more power or troubleshoot an
HPU-related issue. A similar dip in productivity occurs when an E-stop is activated.
In such an event, test engineers must travel throughout a facility to investigate where
and why hydraulic power was shut down.
MTS Fluid Power System Management Solutions offer a standardized suite of
hardware and software for connecting the control room with hydraulic fluid activity
at each test station across your facility, providing you with visibility to the state of
your entire hydraulic distribution system. You can easily monitor and control your
HPUs as a single system, helping you improve productivity, reduce energy costs and
prolong equipment life.
Productivity
Longevity
With this innovative and visually
intuitive system in place, test engineers
don’t have to leave their stations and visit
a pump room or other remote area of the
test lab to manage their hydraulic power
needs. At the same time, lab and facilities
managers have access to information
they need to intelligently and efficiently
allocate hydraulic power. Early warning
detection and fault identification also
help to protect uptime.
MTS Fluid Power System Management
Solutions are compatible across legacy,
current and future MTS SilentFlo™
HPUs, helping to ensure the longest
functional life from your technology
investments. Distributing hydraulic
pressure only when necessary also
reduces wear on hydraulic distribution
components, helping to further prolong
functional life and reduce total cost of
ownership.
Efficiency
Scalability
Since you have visibility to your facility’s
overall hydraulic fluid demand, you can
control the supply and balance the load
to distribute hydraulic fluid only where it
is needed, instead of reactively and
inefficiently maintaining full pressure to
all stations. This ability to anticipate
future demand and selectively regulate
hydraulic flow helps to minimize
electricity and water consumption,
reducing operating expenses.
These solutions are designed to be easily
upgradeable, so you can purchase what
you need today and expand capabilities
as your testing requirements grow. A
Basic Connection Interface can be
purchased separately and later upgraded
to add multi-pump control capabilities.
Similarly, a Remote HMI can be
field-upgraded to operate as a Station
Flow Manager.
Versatility to Grow with Your Test Program
With MTS Fluid Power System Management Solutions, you can control and monitor
the pump/motor module(s) within a single HPU, or operate up to eight hydraulicallycommoned HPUs as a single system. To manage more than one HPU at a time, you can
start with a Basic Connection Interface (BCI), and from there incorporate multi-pump
control capabilities for consolidated system status and operation. Additional options
are also available for further enhancing the productivity and efficiency of your hydraulic
distribution system.
Fluid Power System Management
Remote Human Machine Interface (RHMI)
Solution for control and
monitoring of the pump/
motor module(s) within a
single HPU
Available for all
MTS SilentFlo 505
Generation 2 Models
Basic Connection Interface (BCI)
Provides basic
connection
interface
Commons safety
chain across all
HPUs in system
Prerequisite
for Multi-Pump
Control
Multi-Pump Control Manager (MPCM)
Solution for
control and
management
of two or more
hydraulicallycommoned HPUs
Available for
up to eight
hydraulicallycommoned
HPUs (standard
product)
Touchscreen
display
included
22” display
(standard for
2-4 HPUs)
Upgrades
available
for SilentFlo
Generation 1
Models (505G1.90
and 505G1.180)
32” display
(standard for 5-8
HPUs, available
as upgrade for
2-4 HPUs)
Multi-Pump Control Manager Options
Station Flow
Manager
System Status
Light Bar
Additional
E-stops
Upgrades
available for
legacy 506.92
MTS Hydraulic Fluid Power System Management Configuration
(A) Remote Human-Machine Interface (RHMI): Emulates the
display panel of an individual HPU and makes it readable and
fully functional from the test station or any other location in
the lab.
(B) Basic Connection Interface: Typically located in the pump
room, and is the starting point for any configuration. Provides
E-stop integration, cooling control and valve control.
(C) Multi-Pump Control Manager: Typically located in the
control room. Builds on BCI functionality to enable remote
system control and monitoring with a user-friendly
touchscreen LCD control panel. Facilitates operation in
equipment-saving load balancing or energy-saving Run-onDemand mode.
(D) Station Flow Manager: Allows operators at test stations to
electronically request flow requirements for their station.
(E) Light Bar: Mounted in a visible location to provide lab
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personnel with at-a-glance notification of hydraulic system status.
(F) Additional E-stops: Provide more locations for stopping the
distribution system.
(C)
( A)
or
( D)
Control Room
(B)
Lab Floor
Pump Room
Hydraulic Fluid Power System Management
Remote HMI
M O N I TO R A N D C O N TRO L A N HPU F ROM A
R E M O TE LO C ATIO N
The Remote Human-Machine Interface
(RHMI) allows you to transfer control
panel operation of a single HPU to
another location of your choice, with
identical screens, functionality and full
E-stop capability. Instead of leaving a test
station and walking to the pump room to
monitor or change HPU settings, test
engineers can now perform such tasks
from a far more convenient location,
improving their productivity. Because
the RHMI uses the same structure as the
Station Flow Manager, it can be easily
field-upgraded to become a Station Flow
Manager when you decide to incorporate
multi-pump control.
Basic Connection Interface
T H E B A SE TECH N O LO G Y ENABL ER
The Basic Connection Interface (BCI) is
a simple box of electronics, typically
mounted on the wall in the pump room
or elsewhere in close proximity to the
HPUs. It serves as the starting point for
any MTS Fluid Power System
Management configuration. The BCI
connects SIL-2 safety relays and E-stop
functionality and offers basic cooling
and dump valve control.
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The RHMI is available in
wall-mount, tabletop or
pedestal configurations for
utmost placement flexibility.
Multi-Pump Control Manager
Easy command of the entire system state
The Multi-Pump Control Manager
(MPCM) allows you to control any HPU
in your system as if you were standing
in front of it, from a centrally-located
touchscreen monitor. In addition to remote
operation and status display of individual
pump modules, the MCPM lets you make
start/stop, pressure and reset decisions as
a system. Other functionality includes
system-level error alarms and faults
including E-stop fault indication, which
identifies the specific user-identified
E-stop location that was tripped.
All of this functionality is literally at
your fingertips in the control room with
a visually intuitive LCD touchscreen
display panel. If you can run a single
HPU, then you’re ready to operate the
MPCM. Touchscreens are available in
two sizes: a 22” touchscreen LCD is
designed for labs with up to four HPUs,
and a 32” touchscreen LCD lets you
control and monitor up to eight HPUs.
Setup View provides
simple, intuitive initial
system configuration.
Station View allows
operators to assign flow
demand thresholds for use
in Auto mode.
Status View replicates
status information from
each HPU and displays
vital system-level status
information.
System View displays
all vital control and
monitoring information
in an easy-to-understand
graphical manner.
Unit View replicates
each HPU’s HMI for
running the system in
Manual mode.
The MPCM facilitates hydraulic fluid
distribution control in any of three modes:
»» Manual
»» Auto
»» Run-on-Demand
Auto mode provides automatic system
load balancing, which equally distributes
pump hours across all available pump
modules rather than those that happen
to come first in the chain. This helps to
improve overall HPU life.
Run-On-Demand mode (see example)
offers tremendous energy-saving
potential for your test lab. In this mode,
the operator inputs information for
module minimum, flow buffer, and next
“on/off ” times for each test station. The
MPCM then uses this data to
automatically start only the number of
modules required to meet demand at
any given time. When more demand is
needed, additional modules are activated
to meet it. Modules automatically shut off
as demand subsides.
Run-On-Demand Example Scenario
60
50 demand<20
50>demand>20
40
demand<20
demand<20
50>demand>20
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30
25
20
15
∆t
10
t<∆ton
5
t<∆toff
∆toff
t (time)
Actual Flow
Available Flow
*Actual buffer value is 6 gpm
greater than entered value to
compensate for circ pump
Module flow = 30
Minimum flow = 10
Flow buffer = 4 (+6*)
Minimum flow + Flow buffer = 20
1. On touchscreen LCD in the control room, the operator sets pump module flow to 30 gpm,
minimum flow to 10 gpm and flow buffer to 4 gpm, based on anticipated demand.
2 One module activates in the pump room to make 30 gpm available.
3. Demand rises to 20 gpm for a designated period of time, exceeding minimum and flow buffer
thresholds. A second module automatically starts to increase available flow.
4. Demand spikes to 60 gpm for a brief period before returning to 20 gpm. No new module is
activated, because the spike was too brief in duration.
5. Flow drops back below 20 gpm for a designated period of time, and the second pump module
automatically shuts down.
Manage system flow demands
With the Multi-Pump Control Manager’s
Station View screen, you can input, view or
change individual station flow requirements
from a single location. Station operators will
no longer need to determine how many or
which pump modules to turn on or off,
reducing the chance of flow calculation
errors that could ruin tests or consume
excessive power. The MPCM combines all
requested flow requirements to manage the
system demands and hydraulic power
distribution in an energy-efficient manner.
For example, if an unattended test has an
interlock, the MPCM can automatically
shutdown HPU demand to save energy
and costs.
With optional Station Flow Managers
placed at the test stations, the station
operator can input flow requirement
requests that can then be combined and
managed from the Multi-Pump Control
Manager.
Flow Requirement Input from Five Independent Test Stations
Station #1
Station #2
Station #3
Station #4
Station #5
Total Flow Requirement
Multi-Pump Control Manager Options
Options
PO WERFU L COM PONENTS TO F URTHER STREAM L INE YO U R H YD RA U L IC D IST RIB U T IO N
The MTS Fluid Power System Management Solution includes several optional
components for optimizing staff productivity and hydraulic distribution system
efficiency. You can choose to integrate only the options you need today, with
flexibility to easily add new capabilities in the future as your needs dictate.
Station Flow Manager
Additional E-stops
O PEN TWO- WAY COM M UNICATION BETWEEN
M O RE O PO RT U NIT IE S T O CO NT RO L
C O N TRO L ROOM AND L AB F L OOR
SYST E M O PE RAT IO N
The Station Flow Manager allows test
engineers at individual test stations to
send an estimate to the control room of
how much power they will need for the
day, based on work in their queue.
Individual flow values can be designated
for up to four channels in manual
operation at each test station.
Adding E-stops at key locations around
the lab allows more operators to stop
the system in case of emergency. With
the Multi-Pump Control Manager’s
E-stop fault indicator, the tripped E-stop
location is easily found, so the issue can
be resolved more quickly, and downtime
is minimized.
Equipped with this depth of information,
lab managers can supply the proper
amount of power to the proper locations
at the proper time, and can proactively
plan for increased demand. They can also
capitalize on advanced MPCM functions
such as Auto Load Balancing and Auto
Run-on-Demand. Up to eight Station
Flow Managers can be integrated into
each hydraulic fluid distribution loop,
for a total of 32 individual flow channels.
System Status Light Bar
AT-A -G LA NCE NOTIF ICATION OF HYDRAUL IC
S Y S TEM S TATUS
The same questions arise whenever
hydraulic pressure slows down or stops.
Is it an issue at the test station? Is it a
problem with an HPU in the pump
room? Or, is it a system-wide issue?
In the past, test engineers have had to
abandon their workstations in their
search for answers. By installing one or
more System Status Light Bars in visible
locations on the test floor, your staff can
get instant answers to vital system status
questions at a glance.
The MTS System Status Light Bar uses
the familiar colors of the stoplight to
impart vital information as clearly and
directly as possible:
»» Solid green – System high pressure
»» Flashing green – System low pressure
»» Yellow with slow buzzing sound – System alarm
»» Red with fast buzzing sound – System fault
The buzzer can be muted, and up to three System
Status Light Bars can be daisy-chained together to
provide multiple locations with system status
information simultaneously.
The Complete Hydromechanical Solutions Offering
MTS is your single resource for the proven technology, unmatched expertise and
responsive support it takes to ensure reliable, efficient hydraulic fluid distribution
across your test facility.
SilentFlo HPUs
Actuators
Global service and support
Test professionals around the world
choose SilentFlo hydraulic power units
(HPUs) for their superior performance,
low-noise operation and energy-efficiency.
Operating at or below sound levels
commonly found in labs and factories,
SilentFlo HPUs deliver exceptionally
clean and quiet hydraulic power. A
variable-volume pump design also
helps to optimize energy-efficiency.
MTS offers a comprehensive family of
fatigue-rated actuators to meet your
testing objectives. MTS actuators deliver
exceptional fidelity over the full range of
motion. Proprietary materials and
processes minimize friction for excellent
reliability, wear-resistance and energyefficiency. You can expect highly reliable
performance over a long functional life,
helping to maximize your uptime and
minimize total cost of ownership.
The MTS global team of service, support
and consulting professionals can offer
complete lifecycle management services for
your test technology and hydromechanical
components. We will help you to achieve
maximum productivity and uptime, as
well as develop and deploy new test
programs rapidly.
HSMs
MTS Hydraulic Service Manifolds
(HSMs) provide independent pressure
regulation for the precise control,
isolation and distribution of hydraulic
fluid to test stations. By installing MTS
HSMs into the hydraulic lines between
the HPU and servovalve, you can turn
each hydraulic circuit on or off and
independently set low-pressure levels.
This allows convenient, efficient test
setup, operation and maintenance
of individual test systems without
disturbing other systems.
Servovalves
Precision-engineered MTS Servovalves
deliver the high-flow, quick-response
and low-distortion performance required
to give you absolute control over your
hydraulic actuation. This helps you
uphold the highest possible levels of test
data fidelity. MTS servovalves deliver
exceptional resolution and low hysteresis
for exacting flow control, and are available
in a wide range of flow ratings. Rugged
designs ensure long operating life, even
in demanding test environments.
ISMs
Hardline design
Easy to set up and maintain, MTS
Isolation Service Manifolds (ISMs)
provide a simple means of regulating
flow and facilitating safe operation
throughout your hydraulic distribution
system. The ISM is placed between the
HPU and HSM to prevent system
over-pressurization, provide full system
pressure discharge, and allow for full
hydraulic power isolation downstream of
the device. This consistent and purposeful
control allows you to meet the most
recent European Norm (EN) machinery
safety standards, including EN 13121,
EN 13849-1, and EN ISO 4413.
MTS has extensive experience helping
test labs implement smart hydraulic
distribution solutions that satisfy both
their functional and budgetary
requirements. We understand the design
and installation challenges involved, and
can help you deploy a versatile solution
that will serve you well over the long
term. Throughout your relationship with
us, we will also provide valuable services
for prolonging equipment life and
keeping your system operating safely,
smoothly and reliably.
There are several service offerings that
are designed specifically for hydraulic
systems. One that is key to maintaining
optimum performance is the MTS Fluid
Care Program which provides fluid
condition assessment specific to hydraulic
test systems.
Another option is our MTS SilentFlo
Pump/Motor Module Exchange Program
that allows the exchange of a pump/motor
module to extend HPU life. We also offer
several upgrade options to allow you to
bring older equipment up to newer
operating standards.
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Corporation in the United States. These trademarks may be protected in other
countries. RTM No. 211177.
©2014 MTS Systems Corporation
100-249-018 HydFluidPower Printed in U.S.A. 10/14