MTS 215 User Manual

be certain.

Series 215 Rotary Actuator Product Information

011-199-001 C

Trademark information MTS is a registered trademark of MTS Systems Corporation within the United

States. This trademark may be protected in other countries.

DTE is a registered trademark of Mobil Corporation.

Tellus is a registered trademark of Shell Oil Corporation.

Molykote is a registered trademark of Dow Chemical Corporation.

Publication information

Manual Part Number Publication Date

011-199-001 A

011-199-001 B

011-199-001 C

April 1996

June 2000

March 2008

Manual Template 4.3

Contents

Technical Support 5

How to Get Technical Support 5

Before You Contact MTS 5

If You Contact MTS by Phone 6

Problem Submittal Form in MTS Manuals 7

Preface 9

Before You Begin 9

Conventions 10

Documentation Conventions 10

Introduction 13

Functional Description 13

Optional Equipment 13

Closed-Loop Rotary Actuator Systems 15

Actuator Specifications 16

Options Specifications 19

Reaction Brackets 22

Reaction Bases 23

Diaphragm Flexures 24

Flange Adapters 25

Safety Information 27

Hazard Placard Placement 27

Series 215 Rotary Actuator Product Manual

Installation 31

Actuator Installation 32

Reaction Bracket and Torque Cell Installation 32

Diaphragm Flexure Installation 34

Aligning Force Train Components 34

Component Alignment on an MTS Base Plate 35

Component Centerline Alignment 35

Adjusting Actuator and Torque Cell Centerline Height 35

Adjusting Actuator and Torque Cell Concentricity 36

Adjusting Actuator and Torque Cell Centerline Angularity 37

Operation 39

Thrust and Side Load Characteristics 39

Definition of Useful Mathematical Terms 40

Test Setup Using No Flexures 42

Test Setup Using Standard Flexures 46

Test Setup Using Diaphragm Flexures 50

Summary of Side Load Calculations 54

Rotational Inertial 57

Determining Maximum Rotational Inertia (JT) 57

Rotational Inertia Control Options 60

Maintenance 61

Routine Maintenance 61

Actuator Performance Checks 61

Actuator Inspection 64

Series 215 Rotary Actuator Product Manual

Technical Support

How to Get Technical Support

Start with your

manuals

Technical support

methods

MTS web site

www.mts.com

E-mail techsupport@mts.com

Telephone MTS Call Center 800-328-2255

Fax 952-937-4515

The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes MTS software, look for online help and README files that contain additional product information.

If you cannot find answers to your technical questions from these sources, you can use the internet, e-mail, telephone, or fax to contact MTS for assistance.

MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact MTS in one of the following ways.

The MTS web site gives you access to our technical support staff by means of a Technical Support link:

www.mts.com > Contact Us > Service & Technical Support

Weekdays 7:00 A.M. to 5:00 P.M., Central Time

Please include “Technical Support” in the subject line.

Before You Contact MTS

MTS can help you more efficiently if you have the following information available when you contact us for support.

Know your site

number and system

number

Series 215 Rotary Actuator Product Manual Technical Support

The site number contains your company number and identifies your equipment type (material testing, simulation, and so forth). The number is usually written on a label on your MTS equipment before the system leaves MTS. If you do not have or do not know your MTS site number, contact your MTS sales engineer.

Example site number: 571167

When you have more than one MTS system, the system job number identifies which system you are calling about. You can find your job number in the papers sent to you when you ordered your system.

Example system number: US1.42460

If You Contact MTS by Phone

Know information from

prior technical

If you have contacted MTS about this problem before, we can recall your file. You will need to tell us the:

assistance

• MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem you are experiencing and know the answers to the

following questions:

• How long and how often has the problem been occurring?

• Can you reproduce the problem?

• Were any hardware or software changes made to the system before the

problem started?

• What are the model numbers of the suspect equipment?

• What model controller are you using (if applicable)?

• What test configuration are you using?

Know relevant

computer information

If you are experiencing a computer problem, have the following information available:

• Manufacturer’s name and model number

• Operating software type and service patch information

• Amount of system memory

• Amount of free space on the hard drive in which the application resides

• Current status of hard-drive fragmentation

• Connection status to a corporate network

Know relevant

For software application problems, have the following information available:

software information

• The software application’s name, version number, build number, and if

available, software patch number. This information is displayed briefly when you launch the application, and can typically be found in the “About” selection in the “Help” menu.

• It is also helpful if the names of other non-MTS applications that are

running on your computer, such as anti-virus software, screen savers, keyboard enhancers, print spoolers, and so forth are known and available.

If You Contact MTS by Phone

Your call will be registered by a Call Center agent if you are calling within the United States or Canada. Before connecting you with a technical support specialist, the agent will ask you for your site number, name, company, company address, and the phone number where you can normally be reached.

Technical Support

Series 215 Rotary Actuator Product Manual

Problem Submittal Form in MTS Manuals

If you are calling about an issue that has already been assigned a notification number, please provide that number. You will be assigned a unique notification number about any new issue.

Identify system type To assist the Call Center agent with connecting you to the most qualified

technical support specialist available, identify your system as one of the following types:

• Electromechanical materials test system

• Hydromechanical materials test system

• Vehicle test system

• Vehicle component test system

• Aero test system

Be prepared to

Prepare yourself for troubleshooting while on the phone:

troubleshoot

• Call from a telephone when you are close to the system so that you can try

implementing suggestions made over the phone.

• Have the original operating and application software media available.

• If you are not familiar with all aspects of the equipment operation, have an

experienced user nearby to assist you.

Write down relevant

Prepare yourself in case we need to call you back:

information

• Remember to ask for the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions to be followed, such as data recording

or performance monitoring.

After you call MTS logs and tracks all calls to ensure that you receive assistance and that action

is taken regarding your problem or request. If you have questions about the status of your problem or have additional information to report, please contact MTS again and provide your original notification number.

Problem Submittal Form in MTS Manuals

Use the Problem Submittal Form to communicate problems you are experiencing with your MTS software, hardware, manuals, or service which have not been resolved to your satisfaction through the technical support process. This form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.

The Problem Submittal Form can be accessed:

• In the back of many MTS manuals (postage paid form to be mailed to MTS)

• www.mts.com > Contact Us > Problem Submittal Form (electronic form to

be e-mailed to MTS)

Series 215 Rotary Actuator Product Manual Technical Support

Problem Submittal Form in MTS Manuals

Technical Support

Series 215 Rotary Actuator Product Manual

Before You Begin

Preface

Before You Begin

Safety first! Before you attempt to use your MTS product or system, read and understand the

Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance of MTS equipment in your test facility can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue. It is very important that you remain aware of hazards that apply to your system.

Other MTS manuals In addition to this manual, you may receive additional MTS manuals in paper or

electronic form.

If you have purchased a test system, it may include an MTS System Documentation CD. This CD contains an electronic copy of the MTS manuals that pertain to your test system, including hydraulic and mechanical component manuals, assembly drawings and parts lists, and operation and preventive maintenance manuals. Controller and application software manuals are typically included on the software CD distribution disc(s).

Series 215 Rotary Actuator Product Manual Preface

Conventions

DANGER

WARNING

CAUTION

Conventions

Documentation Conventions

The following paragraphs describe some of the conventions that are used in your MTS manuals.

Hazard conventions As necessary, hazard notices may be embedded in this manual. These notices

contain safety information that is specific to the task to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow the directions that are given. Three different levels of hazard notices may appear in your manuals. Following are examples of all three levels.

Note For general safety information, see the safety information provided with

your system.

Danger notices indicate the presence of a hazard with a high level of risk which, if ignored, will result in death, severe personal injury, or substantial property damage.

Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage.

Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury, equipment damage, or endanger test integrity.

Notes Notes provide additional information about operating your system or highlight

easily overlooked items. For example:

Note Resources that are put back on the hardware lists show up at the end of

the list.

Special terms The first occurrence of special terms is shown in italics.

Illustrations Illustrations appear in this manual to clarify text. It is important for you to be

Electronic manual

conventions

Preface

aware that these illustrations are examples only and do not necessarily represent your actual system configuration, test application, or software.

This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed.

Series 215 Rotary Actuator Product Manual

Documentation Conventions

Hypertext links The electronic document has many hypertext links displayed in a blue font. All

blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.

Series 215 Rotary Actuator Product Manual Preface

Documentation Conventions

Preface

Series 215 Rotary Actuator Product Manual

Introduction

Functional Description

MTS Series 215 Rotary Actuators are heavy-duty, torque-generating actuators that operate under precision servovalve control. When coupled with an appropriate MTS servovalve and transducer, Series 215 Actuators provide the rotational motion and torque required to torsion test materials and components. These actuators receive drive power from a hydraulic power unit via a servovalve which is manifold-mounted to the top of the actuator.

Series 215 Actuators have a maximum static displacement of 100° or ±50°. The maximum dynamic displacement is 90˚ or ±45° with hydraulic cushions in the last 5° of displacement.

Series 215 Rotary Actuator

The preceding figure shows a Series 215 Rotary Actuator with an attached Servovalve/Servovalve manifold, flange adapter, and foot mounting assembly.

Optional Equipment

A variety of options are available for the Series 215 Rotary Actuators. The following figure and table show a test system containing a rotary actuator and the available optional components.

Series 215 Rotary Actuator Product Manual Introduction

Optional Equipment

Rotary Actuator Test System with Optional Equipment

Optional Equipment for Series 215 Rotary Actuators

PTION FUNCTION

Reaction base plate or T-slot table

A reaction base plate or T-slot table is used with the rotary actuator for two purposes; (1) it provides a mounting surface for the actuator and drive train components; (2) it provides a structure which can react the large forces generated by the rotary actuator.

Flange adapter

The flange adapter (located behind the diaphragm flexure in the photograph) is secured to the actuator rotor shaft by a split flange clamp assembly. It provides a coupling surface between the actuator and specimen adapter plate or diaphragm flexure.

Diaphragm flexures

Diaphragm flexures should be used at both ends of the specimen if large axial and angular deflections are generated during testing. If reaction forces exceed stated actuator operating limits, diaphragm flexures help reduce the thrust and side loads experienced by the actuator.

Reaction bracket

The reaction bracket attaches securely to the reaction base plate or T-slot table and provides a mounting surface for the torque cell. Each reaction bracket is designed to restrain a specific model torque cell.

Introduction

Series 215 Rotary Actuator Product Manual

Torque cell

Closed-Loop Rotary Actuator Systems

Optional Equipment for Series 215 Rotary Actuators (Continued)

A torque cell provides a precise electrical feedback signal that is proportional to the torque applied to the specimen. For more information on MTS torque cells, refer to the appropriate MTS product specification.

ADT

An angular displacement transducer (ADT) connected to the rear shaft of the actuator produces a DC electrical signal that is proportional to the angular position of the actuator. Rotation of the actuator will generate a feedback signal (0 V DC to ±10 V DC) from the ADT to the transducer conditioner. Rotation is continuous with no reactive torque induced. The ADT is a precision differential capacitor coupled to a solid state oscillator, demodulator, and amplifier to yield DC input - DC output performance.

RVDT

A rotary variable differential transformer (RVDT) attached to the rear shaft of the actuator provides an AC feedback signal proportional to the angular position of the actuator. As the actuator rotates, a feedback signal is sent to the transducer conditioner. An RVDT converts a mechanical angular displacement into an electrical output by means of an electrical input carrier. It consists of a rotor assembly to which the mechanical input is applied, and a stator assembly in which the windings are contained.

Differential pressure cell

The differential pressure (∆P) cell is a single-unit, dual port, bonded strain gage pressure sensor. Depending on the specific application, the ∆P cell is used to stabilize or control actuator force output. The ∆P cell (located beneath the servovalve) provides a feedback signal to a controller monitoring fluid pressure within the actuator housing. For more information on MTS ∆P cells, refer to the appropriate MTS product specification.

Closed-Loop Rotary Actuator Systems

In a closed-loop control system containing a rotary actuator, a command signal sent to the actuator servovalve is compared to a feedback signal received from an actuator transducer. The following figure shows a block diagram of the major components in a typical rotary actuator closed-loop control system.

Block Diagram of a Testing System Using a Rotary Actuator

Series 215 Rotary Actuator Product Manual Introduction

Actuator Specifications

Series 215 Rotary Actuator Ratings by Model

ODEL RATED

TORQUE*

As the block diagram shows, a program command signal is input to the controller. The command signal is compared to the feedback signal from one of the actuator transducers. If the command signal equals the feedback signal from the transducer conditioner, no DC error is present and the valve driver circuit produces little or no servovalve control signal. If the command signal does not equal the feedback signal, a DC error signal is sent to the valve driver circuit.

The valve driver circuit uses this signal to generate a servovalve control signal. The servovalve control signal causes the servovalve spool to open in a direction and by an amount necessary to direct a regulated flow of hydraulic fluid to the actuator’s pressure or return ports. The actuator moves in response to the flow of hydraulic fluid. The constant feedback of the closed-loop system enables the controller to maintain precise control of actuator torque or movement.

Series 215 Rotary Actuators are available in six models. This section lists specifications for both the Series 215 Actuator and its options.

ISPLACEMENT THRUST LOAD

Q (MAXIMUM)

IDE

S LOAD† P (M

AXIMUM)

ENDING

B M

OMENT

M (MAXIMUM)

lbf·in. N·m in.3/rad cm3/rad lbf kN lbf kN lbf·in. N·m

215.32 2000 226 0.80 13.1 750 3.3 1500 6.67 3600 405

215.35 5000 565 1.9 31.1 750 3.3 3500 15.57 15,400 1732

215.41 10,000 1130 3.7 60.6 750 3.3 3500 15.57 15,400 1732

215.42 20,000 2260 7.2 117.9 750 3.3 3500 15.57 17,300 1946

215.45 50,000 5650 19.0 311.3 1200 5.3 5700 25.36 43,000 4837

215.51 100,000 11,300 38.0 622.7 1200 5.3 6500 28.92 50,000 5625

* Actuator is designed for cyclic use at rated torque: rated at maximum differential pressure at 21 MPa

(3000 psi).

† P and M are interdependent: if P is at maximum, M must be zero; if P = 75% of maximum, M may

be up to 25% of its maximum value.

‡ If these values are to be exceeded, additional internal or external cushions are required; contact

MTS.

§ w = rotational velocity in rad/sec and J or I = rotational inertia in lbm-in. from rotary actuator, flange, flexure, and 1/2 of test specimen (lbm = pounds mass).

¶ Does not include flange adapter.

or kg-m2 including inertias

Introduction

Series 215 Rotary Actuator Product Manual

Series 215 Rotary Actuator Ratings by Model

260

---------=

4.4

-------=

305

---------=

5.2

-------=

385

---------=

6.6

-------=

840

---------=

14.4

----------=

970

---------=

16.6

----------=

1525

------------=

26.1

----------=

ODEL MAX VELOCITY

CUSHION LIMITATION‡

Actuator Specifications

OTARY ACTUATOR ROTATIONAL INERTIA¶

U.S. Customary rad/sec

215.32 11.67 0.00342

215.35 18.54 0.00544

215.41 20.23 0.00594

215.42 29.04 0.00852

215.45 171 0.0500

215.51 284 0.0831

* Actuator is designed for cyclic use at rated torque: rated at maximum differential

pressure at 21 MPa (3000 psi).

† P and M are interdependent: if P is at maximum, M must be zero; if P = 75% of

maximum, M may be up to 25% of its maximum value.

‡ If these values are to be exceeded, additional internal or external cushions are

required, contact MTS.

§ w = rotational velocity in rad/sec and J or I = rotational inertia in lbm-in.2 or kg-m2 including inertias from rotary actuator, flange, flexure, and 1/2 of test specimen (lbm = pounds mass).

¶ Does not include flange adapter.

SI Metric rad/sec

lbm-in. J

kg-m I

Series 215 Rotary Actuator Product Manual Introduction

Actuator Specifications

ABC DE

Actuator Dimensional Drawing

Actuator Dimensions and Weights

ODEL IN. MM IN. MM IN. MM IN. MM IN. MM

215.32 1.50 38.1 7.875 200.0 10.00 254 1.175 29.8 3.130 79.5

215.35 2.251 57.1 7.875 200.0 10.00 254 2.275 57.8 3.130 79.5

215.41 2.251 57.1 7.875 200.0 10.00 254 2.275 57.8 3.130 79.5

215.42 2.251 57.1 7.875 200.0 10.00 254 3.275 83.2 3.130 79.5

215.45 3.751 95.3 9.875 250.8 12.25 311 2.775 74.5 4.137 105.1

215.51 3.751 95.3 9.875 250.8 12.25 311 5.553 141.0 4.137 105.1

FGH KWEIGHT

MODEL IN. MM IN. MM IN. MM IN. MM LB KG

215.32 2.50 63.5 9.000 228.6 1.000 25.4 0.406 10.3 100 45

215.35 2.50 63.5 9.000 228.6 1.000 25.4 0.406 10.3 130 59

215.41 2.50 63.5 9.000 228.6 1.000 25.4 0.406 10.3 130 59

215.42 2.99 75.9 9.000 228.6 1.000 25.4 0.406 10.3 150 70

215.45 3.49* 88.6* 11.000 279.4 1.000 25.4 0.656 16.7 270 125

215.51 5.12* 130.0* 11.000 279.4 1.000† 25.4† 0.656 16.7 365 165

* Contains a 3.0 mm (0.12 in.) shoulder that is 0.25 mm (0.01 in.) larger in diameter than Dimension

'A'.

† 215.51 pattern has more bolt holes, not evenly spaced.

Dimensions and weights are subject to change without notice. Contact MTS for dimensions and weights crit-

ical to your needs.

Introduction

Series 215 Rotary Actuator Product Manual

Options Specifications

Foot Mounting The foot mounting option is used for easy attachment of the actuator to a reaction

Options Specifications

Specifications for the most common options available for use with the Series 215 Rotary Actuators are described below.

base and also provides some flexure capability.

Series 215 Rotary Actuator Product Manual Introduction

Options Specifications

Foot Mounting Dimensions and Ratings

ODEL ABCD

IN. MM IN. MM IN. MM IN. MM

215.32 6.25 158.8 0.75 19 5.00 127 17.00 432

215.35 6.25 158.8 0.75 19 5.00 127 17.00 432

215.41 6.50 166.4 1.00 25 5.00 127 19.50 495

215.42 6.50 166.4 1.00 25 5.00 127 19.50 495

215.45 7.75 196.8 1.50 38 6.00 152 22.00 559

215.51 7.75 196.8 1.50 38 6.00 152 22.00 559

MODEL EFGTHRUST LOAD*

IN. MM IN. MM IN. MM LBF N

215.32 12.00 304.8 3.75 92.3 0.781 19.8 100 445

215.35 12.00 304.8 3.75 92.3 0.781 19.8 100 445

H (M

AXIMUM)

215.41 18.00 457.2 3.50 88.9 0.781 19.8 150 670

215.42 18.00 457.2 3.50 88.9 0.781 19.8 150 670

215.45 18.00 457.2 4.00 101.6 0.781 19.8 500 2200

215.51 18.00 457.2 4.00 101.6 0.781 19.8 500 2200

MODEL THRUST

EFLECTION

I (MAXIMUM)

IN. MM LBF-IN.N-MRAD LBF-IN.N-M RAD

215.32 0.03 0.76 200 22 0.004 4500 508 0.003

215.35 0.03 0.76 200 22 0.004 4500 508 0.003

215.41 0.07 1.8 400 45 0.008 9000 1000 0.003

215.42 0.07 1.8 400 45 0.008 9000 1000 0.003

215.45 0.06 1.5 2000 225 0.006 20,000 2260 0.0008

215.51 0.06 1.5 2000 225 0.006 35,000 3960 0.0004

* Thrust load (H) and bending moments (J and L) are interdependent. H ratings assume J =

0 and L = 0. J and L ratings assume H = 0. Ratings must be decreased in proportion to other loads present, for example, if H = 75% of rating, J and L must not total 25% of rating.

Dimensions and ratings are subject to change without notice. Contact MTS for verification of

critical dimensions and ratings.

ORIZONTAL

H B

ENDING

OMENT*

J (M

AXIMUM)

NGULAR

EFLECTION

ERTICAL*

V M

OMENT L

AXIMUM)

BENDING

NGULAR

DEFLECTION M

Introduction

Series 215 Rotary Actuator Product Manual

Options Specifications

Foot Mounting Specification Drawing

Reaction Bracket Specification Drawing

Series 215 Rotary Actuator Product Manual Introduction

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