Mecmesin Vortex-dV 1.5 N.m, Vortex-dV 3 N.m, Vortex-dV 10 N.m, Vortex-dV 6 N.m Operating Manual

Vortex-dV
Motorised Torque
Testing System

Operating Manual

431-468-02

May 2018

ii  Mecmesin Vortex-dV Operating Manual

Important

It is essential that you familiarise yourself with the contents of this Manual and the
separate Guide to Safe Use of Mains Powered Test Systems (part no. 431-398) before
attempting to operate your Vortex-dV Test System.

Scope

This reference manual covers operation of Vortex-dV torque test stands, intended for use
with the Mecmesin Advanced Force and Torque Indicator (AFTI). Operation of the AFTI
is covered in a separate manual.

For operating in conjunction with VectorPro™ Lite, see the manual 431-464, VectorPro Lite
for dV Test Stands and Instruments.

2018 © Mecmesin Ltd, supplied with Mecmesin test systems and not for redistribution

Part no. 431-468-02

Vortex-dV Operating Manual Mecmesin  iii

Contents

1. Items Supplied with your Test Stand 1

1.1 Available accessories 1

1.2 Environment Conditions 1

2. Installation 2

2.1 Unpacking the stand 2

2.2 Lifting the test stand 2

2.3 Locating the stand 2

2.4 Mains power supply 2

3. Assembly and Operation 3

3.1 Attaching the torque sensor 4

3.2 Fitting the AFTI torque indicator 4

3.3 Connecting the AFTI and the Vortex-dV 5

Connect the test stand to a PC (VectorPro Lite users only) 5
Cable management 5

3.4 Attaching grips and fixtures 6

3.5 Test stand states 6

3.6 Front panel controls 7

Emergency stop button 7
Dial control 7
The display 8
The multi-function selector buttons 9

3.7 Settings 10

3.8 Understanding angular position 10

3.9 Understanding direction of rotation 11

3.10 Understanding cyclic movement 11

3.11 Jog settings 11

3.12 Units settings 12

3.13 Test settings 12

Cycle (by angular displacement) 12
AFTI Control 12
Half Cycle 14

3.14 Language settings 15

4. Specification 16

Declaration of Conformity 17

iv  Mecmesin Vortex-dV Operating Manual

Vortex-dV Operating Manual Mecmesin  1

1. Items Supplied with your Test Stand

Vortex-dV test stand (you will have also purchased a torque transducer rated at 1.5, 3, 6,
or 10 N.m)

AFTI gauge bracket (for fitting an AFTI torque indicator to the column)

Allen key for tightening crosshead to gauge bracket

Mains cable

Document: A Guide to Safe Use of Mecmesin Mains Powered Test Systems

Document: Vortex-dV Motorised Torque Testing System, Operating Manual

1.1 Available accessories

For a full range of digital force gauges and accessories, please go to the Mecmesin website
www.mecmesin.com, or your local distributor, as listed on the back cover.

Use communications cable part no. 351-092 to connect the Mecmesin Advanced Force and
Torque Indicator (AFTI) to the Vortex-dV.

When using Mecmesin VectorPro™ Lite software, use communications cable part no.
351-093 to connect the stand to MS-Windows computer.

1.2 Environment Conditions

In line with BS EN 61010-1 it is recommended that your Mecmesin Vortex-dV test stand is
operated in an environment that matches the following conditions:

 Indoor use only, recommended to be operated in a lab environment.
 Altitude up to 2 000 m,
 Temperature range between 10 °C to 35 °C. Please note that the instrument should not

be used for long durations at higher temperatures.

 The maximum relative humidity is 80 % for temperatures up to 31 °C decreasing

linearly to 50 % at 40 °C. It is crucial that the surrounding environment does not cause
water to form on the device.

 Mains supply voltage fluctuations up to a maximum of ±10 % of the nominal voltage.
 The environments should also take considerations of excessive dust or metal

particulates as ingress of these into the device can cause damage to the system.

2  Mecmesin Vortex-dV Operating Manual

2. Installation

2.1 Unpacking the stand

When you first receive the stand, please check that there is no obvious damage to the
packaging. If there is any sign that the packaging or the test stand itself has been
damaged, please contact Mecmesin or your authorised distributor immediately. Do not
use the stand until you have done so.

We strongly recommend that the packaging is retained, as this can be useful if the
machine needs to be returned for calibration.

Section 1 lists items that should be included with your test stand. Please contact
Mecmesin or your authorised distributor if any items are missing or damaged.

2.2 Lifting the test stand

The unpackaged weight of the test stand is given in the Specification table at the back of
this manual. Do not try to lift heavy loads unaided. Use suitable lifting equipment if
necessary.

2.3 Locating the stand

The test stand should be positioned on a suitable, level, stable work surface.

2.4 Mains power supply

Vortex-dV test stands can be used on 110–120 or 220–240 V ac 50-60 Hz supplies. The rear
fuse carrier will be set for your local requirement, but is reversible, so should you replace
a fuse, the correct local voltage must be selected. The voltage that is selected is the one
where the arrows meet:

Fuse carrier Carrier removal

Vortex-dV Operating Manual Mecmesin  3

3. Assembly and Operation

Top-load tray

Crosshead

Static torque

transducer

Upper fixing plate

(optional)

Lower fixing plate

(optional) shown

with saddle plate

AFTI torque indicator

AFTI bracket

Control panel

4  Mecmesin Vortex-dV Operating Manual

3.1 Attaching the torque sensor

Attach the torque sensor to the crosshead using the four M6 caphead bolts supplied.
Make sure the cable exit is towards the side you will fix the AFTI. Insert each bolt and
tighten lightly, make sure the transducer is seated centrally and then tighten the bolts.

3.2 Fitting the AFTI torque indicator

The Vortex-dV is suitable for left or right-handed operation. The fixing bracket is easily
adjusted or removed and transferred to the opposite column. Use an 4 mm Allen key for
tightening.

Adjusting the AFTI fixing bracket

Vortex-dV Operating Manual Mecmesin  5

Attaching the AFTI Adjusting the bracket angle

3.3 Connecting the AFTI and the Vortex-dV

Connect the transducer to the side port of the AFTI, using the cable from the transducer.

Connect the top port of the AFTI to the RJ45 port marked ‘gauge’ in the back of the
Vortex-dV, using supplied cable 351-092. This cable enables AFTI torque control testing,
and passes the torque readings to the Vortex-dV for display.

Connect the test stand to a PC (VectorPro Lite users only)

If you are using VectorPro™ Lite software, connect the USB B port to a PC using cable
part no. 351-093

Cable management

It is essential that no cables are permitted to interfere with the controls or any moving
parts.

RJ45 AFTI /

gauge port

USB B connector for PC

(VectorPro Lite only)

6  Mecmesin Vortex-dV Operating Manual

3.4 Attaching grips and fixtures

The most commonly-used upper fixture used is the 100 mm upper fixing plate with a
diameter capacity of 10 mm to 78 mm. This is fixed to the adaptor on the torque
transducer using the four countersunk screws supplied, using a 2.5 mm Allen key.

The fixture can also be more quickly removed by means of the two grub screws in the
adapter, accessed through slots in the sides of the fixing plate, as shown below.

The most commonly-used lower fixture is the 188 mm diameter lower fixing plate with a
diameter capacity of 10 mm to 190 mm. This is fixed to the Vortex-dV spindle using the
four countersunk screws supplied, using a 2.5 mm Allen key.

A range of other torque testing fixtures is available, including saddle plates that help
support samples in the fixing plates, longer grip fingers, mandrels, and chucks.

3.5 Test stand states

The test stand can be in one of five states:

A. test readiness (ready to start, or complete)
B. testing (platen rotating)
C. stopped (interrupted, or emergency stop)
D. manual control (for jogging, or positioning the lower platen)
E. settings menu

In each state, the selector buttons have functions described by icons.

Vortex-dV Operating Manual Mecmesin  7

3.6 Front panel controls

Emergency stop button

Push to immediately stop movement in the platen. Rotate the button to release
it and resume motor control. Do not simply restart a test. Rectify the situation
and/or any residual torque. If cycling between torque loads, reset the AFTI
indicator before resuming testing.

Dial control

The lights

The lights surrounding the wheel show in three colours, and three states, indicating the
status of the test stand:

Green: pulsing, ready to test; Amber: static, test complete Red: static, test stopped
rotating: scrolling a menu rotating: platen moving or interrupted

dial lights

dial button

dial wheel

emergency

stop

display

button

functions

status

messages

multi-function
selector buttons

8  Mecmesin Vortex-dV Operating Manual

The wheel

When in jogging mode (by selecting the double-ended arrow button in test status) the
wheel drives the spindle directly clockwise or anticlockwise. This is an alternative to
using the jog buttons, which move the drive spindle at the clockwise (CW) and
anticlockwise (ACW) speeds as set in Settings > Jog Settings.

The wheel is also a speed controller. The jog buttons move the drive spindle at the set
speeds, but rotating the wheel clockwise whilst holding a jog button will increase the speed,
and rotating the wheel anticlockwise will decrease the speed. The set speed is restored
when the jog button is released.

The wheel is also turned to navigate the menus. When in a selection menu, the wheel
cycles through the selections and their values. This is an alternative to navigation using
the up and down arrow buttons (see E: Settings buttons below).

The button

The central button is used to confirm a menu selection. It is equivalent to the tick button.

The display

The display indicates the stand status and mode (ready, stopped, test type , speed, cycle
count, settings menu), and when ready: angular displacement, speed and torque.

An icon shows when an AFTI is not detected.

The functions of the four buttons at any time are indicated by a series of icons.

enable crosshead jogging

Menu: use buttons or wheel

Vortex-dV Operating Manual Mecmesin  9

The multi-function selector buttons

A: Test readiness

No AFTI connected

Start test sequence (B)

Go to jog mode (manual motor control) (D)

Go to settings (E)

B: Testing

Interrupt test. This stops drive spindle movement, leaving the stand in a
state of test readiness, with ‘Interrupted: User’ displayed. The start button
will restart, not resume, the test sequence.

C: Stopped

Emergency stop button pushed. Message: ‘Emergency Stop’. Release the

emergency stop to regain control and remedy the situation before resuming
testing.

If this button is pressed, the message is ‘Interrupted: User’, and the test

readiness buttons (A) are displayed.

The Start test button resumes testing. Cyclic testing returns to the first cycle
action. Important! Under torque load control, the AFTI MUST be reset
first.

D: Motor control

Shows clockwise and anticlockwise speeds as set

Zero (tare) angular displacement of the drive spindle

10  Mecmesin Vortex-dV Operating Manual

Jog the drive spindle clockwise at speed as set (or turn wheel clockwise)

Jog the drive spindle anticlockwise at speed as set (or turn wheel
anticlockwise)

Go back to test readiness (A)

E: Settings

Confirm selection (or press dial button)

Navigate up a menu selection or value (or turn wheel clockwise)

Navigate down a menu selection or value (or turn wheel anticlockwise)

Go back to previous menu item, or from Settings (E) to test readiness (A)

3.7 Settings

All settings are made by moving the selection marker to the required menu item or digit,
and confirming with the tick button or using the central dial button.

3.8 Understanding angular position

An angular position of xº means ‘rotation by xº from tared zero, in the direction of travel
according to the sign’. A set position of +270º means ‘rotated 270º from tared zero in a
clockwise direction’. An angular position greater than 360º will always produce

movement of greater than one complete rotation in relation to tared zero. The drive
spindle will therefore never take the quickest route to a position, even to a start test
position.

Vortex-dV Operating Manual Mecmesin  11

3.9 Understanding direction of rotation

All icons for rotation represent the movement of the spindle as viewed. However, when
performing a closure unscrewing test (for example), even though this is an anticlockwise
test it is performed by a clockwise rotation of the drive spindle. Angles clockwise from
tared zero are positive and angles anticlockwise from tared zero are negative.

3.10 Understanding cyclic movement

Any cycle to a position (i.e. rather than to a torque limit), is between two angular limits:
anticlockwise and clockwise.

A complete cyclic rotation must be between the two angles, so a clockwise-starting cycle
must begin at the anticlockwise angle, and vice versa. If not at this angle, the spindle will
rotate initially to this position.

Any cycle then starts in a direction towards the angle of its sign, for example starting
clockwise to +60º.

3.11 Jog settings

On a Vortex-dV, ‘jogging’ means manual rotation, using the control panel buttons. These
speeds are set by the user and take effect whenever the jog buttons are used, for example
in a non-cyclic or manual test. Remember that the wheel in jog mode can give more
precise ‘direct drive’ positioning.

Clockwise (CW) /
Anticlockwise (ACW) speed

0.1 to 30.0 rpm

Tared zero angle

Clockwise
(CW, +ve) angle:

start of ACW cycle,
end of CW cycle

Anticlockwise

(ACW, –ve) angle:

start of CW cycle,

end of ACW cycle

Clockwise direction:
applies anticlockwise torque

Anticlockwise direction:

applies clockwise torque

drive spindle

12  Mecmesin Vortex-dV Operating Manual

3.12 Units settings

Angle

rev, deg

Speed

rev/min, rev/s, deg/min, deg/s

3.13 Test settings

Cycle (by angular displacement)

 In a cyclic test, the spindle will move between two reference angles that are relative to

tared zero.

 A cycle only starts when the drive spindle is at the furthest displacement position from

the angle set in the initial direction of rotation.

Cycle Count

1-8000

Clockwise (CW) Speed
Anticlockwise (ACW) Speed

Speed is always positive units (range as jog speeds, above)

CW Angle
ACW Angle

Sets clockwise and anticlockwise limits for a cyclic test. Up
to 8000 revolutions from tared zero are allowed.

A +ve value is a clockwise relative angle of the drive
spindle, and a –ve value is an anticlockwise relative angle.

Start Direction

Select in which direction the drive spindle should move to
start the test cycle. Note that depending on the angle at
which the spindle has been left, it may need to first move in
the opposite direction through the tared zero angle, to reach
the starting angle.

AFTI Control

The AFTI can be used to set torque limits to control drive spindle movement during a
cycle. In the AFTI Comms menu ‘Port’, set the gauge baud rate to 115,200, and TX Units
and TX sign, both to On.

Loads, action (reverse/stop/cycle) and cycle count are all set on the gauge. The stand can
then be made to:

 move to a set torque or break condition and stop
 cycle between two torque values

Vortex-dV Operating Manual Mecmesin  13

 cycle to a maximum torque or break condition then reverse

Note: Although the AFTI can be set to reverse on break or at a torque value, there is no

other trigger to stop the spindle rotating, so it must be stopped manually.

Examples

 Rotate the gripped sample at a given speed until the applied torque is 50 N, then stop.
 Rotate the gripped sample at a given speed until the sample breaks (a drop in applied

torque by a percentage of sensor capacity), detected by the AFTI, and stop.

 Rotate the gripped sample at a given speed until the applied load is 3 N.m, then reverse

to 0.5 N.m, reapply the torque, and continue this cycle for as many times as set by the
AFTI.

Clockwise (CW) Speed
Anticlockwise (ACW) Speed

Speed is always positive.

Start Direction

Select in which direction the drive spindle should move to
start the test cycle. Note that depending on the angle at
which the spindle has been left, it may need to first move in
the opposite direction through the tared zero angle to reach
the starting angle.

Performing a torque-controlled test

1. Adjust the AFTI for upper and lower load limits, and cycle count, or to stop at a

torque limit or break. Note that:

 on the AFTI, torque applied clockwise to the transducer (applied through

anticlockwise spindle rotation) is +ve. Clockwise spindle rotation applies
anticlockwise torque to the transducer, which is -ve.

 the cycle counter in the gauge decrements, whereas the stand cycle counter

increments

2. Set up the test stand for AFTI control, with speed and initial direction of rotation.

3. Secure the test sample, set the angular position of the lower grip, and zero this.

4. Always ensure Reset is pressed on the AFTI before commencing a test.

5. Start the test

At the end of a test, or in a stopped condition, you may need to move the
crosshead to clear a sample, or the drive spindle to remove a torque.

Never restart a test from a stopped condition with a residual torque, and
always Reset the gauge before a subsequent test.

If the AFTI is switched off or loses power during an active test in AFTI Control mode, the
drive spindle will stop.

14  Mecmesin Vortex-dV Operating Manual

Half Cycle

 A half-cycle test is to an angular displacement relative to tared zero.
 Movement always ends at the angle set in the starting direction, shown in red below.
 A half-cycle only starts when the drive spindle is at the furthest displacement position,

relative to tared zero, from the end position.

This can appear confusing. The conditions in the shaded rows of the table below provide
a true half-cycle test.

Familiarise yourself with why the others effectively result in a full-cycle movement. A
single cycle test is usually a better choice. Note that row conditions 3 and 4 under a full
cycle test (any number of counts) will also result in a half-cycle action.

Half-cycle tests will always end with the display reading the final angle that was set. To
re-run, the drive spindle must be returned to zero, or the displayed angle tared to zero.

CW

angle

ACW

angle

Start

direction

Action from tared zero

Press run button again –
without taring angle

+30º

zero

CW

Go CW to +30º and stop

Go to ACW angle (zero), then
CW to +30º (becomes a full
cycle)

zero

–30º

ACW

Go ACW to –30º and stop

Go to CW angle (zero), then
ACW to –30º (becomes a full
cycle)

+30º

+30º

CW or ACW

Go to CW angle of +30º and stop

No action

–30º

–30º

CW or ACW

Go to ACW angle of –30º and
stop

No action

+30º

zero

ACW

Go to CW angle of +30º and
return ACW to zero

Repeat action

zero

–30º

CW

Go to ACW angle of –30º and
return CW to zero

Repeat action

+30º

-30º

CW

Go ACW to -30º, then through
tared zero to +30º and stop

Go ACW through tared zero to ­30º, then through tared zero to
+30º and stop.

+30º

-30º

ACW

Go CW to +30º, then through
tared zero to -30º and stop

Go CW through tared zero to
+30º, then through tared zero
to –30º and stop.

Vortex-dV Operating Manual Mecmesin  15

CW Speed
ACW Speed

Speed is always positive.

Clockwise (CW) angle
Anticlockwise (ACW) angle

Often more clearly set in degrees rather than revolutions,
this is relative to the tared zero angle.

CW angles are normally positive and ACW angles
negative, though if within the range of the opposite angle
set, an opposite sign may not be disallowed (see table
above).

Start direction

Select in which direction the drive spindle should move to
start the test cycle. Note that depending on the angle at
which the spindle has been left, it may need to first move
in the opposite direction through the tared zero angle to
reach the starting angle.

3.14 Language settings

Select the appropriate language. This returns you to the Settings menu in the language
chosen.

16  Mecmesin Vortex-dV Operating Manual

4. Specification

Vortex-dV

1.5 N.m

3 N.m

6 N.m

10 N.m

Measurement range N.m
kgf.cm
lbf.in

0–1.5
0–15
0–13

0–3.0
0–30
0–26

0–6.0
0–60
0–52

0–10.0
0–100
0–90

Front Panel Function

Digital display of Load/Position/Speed

USB Function

Output of test results to printer/PC (Software required)

Dimensions

Maximum travel of adjustable transducer
carriage

182 mm (7.2”)
Maximum headroom

505 mm (19.9”) [448 mm (17.6”)]*

Width between columns

280 mm (11.02”)

Weight

19.5 kg (48 lb)

Capacity of lower mounting table

10 - 190 mm (0.39 - 7.5”)

Capacity of upper mounting table

10 - 78 mm (0.39 - 3.07”)

Power requirements

Voltage

230 V AC 50 Hz or 110 V AC 60 Hz

Max power drain

100 W

Torque measurement

Torque accuracy

0.5% of full scale

Torque units

mN.m, N.m, kgf.cm, lbf.in, ozf.in (as per AFTI)

Speed

Speed range

0.1 rev/min to 30 rev/min (clockwise and anticlockwise)

Speed accuracy

±1% of indicated speed

Speed resolution

0.01 rev/min (0.1º/s)

Position

Maximum rotation

8000 revs

Positional accuracy

0.2° per 36,000°

Positional resolution

0.1º (0.001 rev)

* with upper and lower mounting tables fitted

Vortex-dV Operating Manual Mecmesin  17

Declaration of Conformity

18  Mecmesin Vortex-dV Operating Manual

Vortex-dV Operating Manual Mecmesin  19

Mecmesin : a world leader in affordable force and torque testing solutions

Since 1977, Mecmesin has assisted thousands of companies achieve enhanced quality control in design and production.

The Mecmesin brand represents excellence in accuracy, build, service, and value. In production centres and

research labs worldwide, designers, engineers, operators, and quality managers endorse Mecmesin force and torque

testing systems for their high performance across countless applications.

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