MTS 215 User Manual

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Series 215 Rotary Actuator Product Information

011-199-001 C

Page 2

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

Page 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

Page 4

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

Page 5

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

Page 6

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

Page 7

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

Page 8

Problem Submittal Form in MTS Manuals

Technical Support

Series 215 Rotary Actuator Product Manual

Page 9

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

Page 10

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

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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

Page 12

Documentation Conventions

Preface

Series 215 Rotary Actuator Product Manual

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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

Page 19

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

Page 20

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

Page 21

Options Specifications

Foot Mounting Specification Drawing

Reaction Bracket Specification Drawing

Series 215 Rotary Actuator Product Manual Introduction

Page 22

Reaction Brackets

Reaction brackets provide a torsionally rigid connection between the torque cell and the reaction base. Brackets provide some flexural capability and readily accept MTS torque cells.

Reaction Bracket Dimensions and Ratings

ODEL ABCD E F

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

215.32 6.25 158.8 0.75 19 5.00 127 17.00 432 12.00 304.8 3.75 92.3

215.35 6.25 158.8 0.75 19 5.00 127 17.00 432 12.00 304.8 3.75 92.3

215.41 6.50 166.4 1.00 25 5.00 127 19.50 495 18.00 457.2 3.50 88.9

215.42 6.50 166.4 1.00 25 5.00 127 19.50 495 18.00 457.2 3.50 88.9

215.45 7.75 196.8 1.50 38 6.00 152 22.00 559 18.00 457.2 4.00 101.6

215.51 7.75 196.8 1.50 38 6.00 152 22.00 559 18.00 457.2 4.00 101.6

MODEL GTHRUST LOAD*

H (M

AXIMUM)

IN. MM LBF N IN. MM LBF·IN

HRUST

T D

EFLECTION

I (MAXIMUM)

ORIZONTAL

H B

ENDING

OMENT*

J (M

AXIMUM)

NGULAR

EFLECTION

ERTICAL*

V B M (M

M RAD LBF·IN.N·M RAD

N·

ENDING OMENT L

AXIMUM)

NGULAR

EFLECTI

215.32 0.781 19.8 100 445 0.03 0.76 200 22 0.004 3500 395 0.003

215.35 0.781 19.8 100 445 0.03 0.76 200 22 0.004 3500 395 0.003

215.41 0.781 19.8 150 670 0.07 1.8 400 45 0.008 9000 1000 0.003

215.42 0.781 19.8 150 670 0.07 1.8 400 45 0.008 9000 1000 0.003

215.45 0.781 19.8 500 2200 0.06 1.5 2000 225 0.006 20,0002260 0.0012

215.51 0.781 19.8 500 2200 0.06 1.5 2000 225 0.006 35,0003960 0.0012

* 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 dimensions

and ratings critical to your needs.

Introduction

Series 215 Rotary Actuator Product Manual

Page 23

Reaction Bases

Reaction bases are constructed of heavy-duty steel and designed for high torsional stiffness. They readily accept MTS rotary actuators and reaction brackets. When used with MTS reaction brackets and foot mounting options, the stiffness/flexural capability is adequate to prevent excessive actuator side loads. (However, a review of thrust loads should be made.) When purchased as a system, the specimen length is fully adjustable (within the specified limits) without requiring realignment of the actuator and reaction bracket. If required, legs are available to raise the bases to any specified height.

Reaction Base Dimensions and Ratings

ODEL LENGTH§WIDTH HEIGHT*MAXIMUM SPACE†

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

Reaction Bases

215.32

215.35

215.41

215.42

215.45

215.51

ODEL WEIGHT TORSIONAL STIFFNESS‡

215.32

215.35

215.41

215.42

215.45

215.51

45 1143 15 380 4.7 120 28.50 724

45 1143 15 380 4.7 120 28.00 711

54 1370 22 560 5.7 144 33.50 851

54 1370 22 560 5.7 144 29.75 756

60 1525 22 560 20 508 34.50 876

60 1525 22 560 20 508 30.25 768

LB KG LBF·IN./RAD N·M/RAD

375 170

800 363

1125 510

55 x 10

122 x 10

742 x 10

6.2 x 10

13.7 x 10

83.8 x 10

* Without legs.

§ Longer bases available on request. † Maximum space between mounting surfaces of actuator output flange and torque cell (with the

MTS reaction bracket supporting the torque cell).

‡ Torsional stiffness over entire length. Stiffness increases proportionately as the actuator and

reaction bracket are moved toward each other.

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

dimensions and ratings critical to your needs.

Series 215 Rotary Actuator Product Manual Introduction

Page 24

Diaphragm Flexures

As described in the “Test Setup Considerations” section, one or two diaphragm flexures are used when large thrust and side loads are encountered on test setups having both the rotary actuator and the reaction bracket rigidly mounted to the reaction base. The flange adapter option is required to attach the diaphragm flexure to the actuator. The flexure attaches readily to torque cells. The rotational inertia of the diaphragm flexure must be included when determining the actuator performance.

Diaphragm Flexure Dimensions and Ratings

ODEL AB C DE F G

IN. MM IN. MM IN. MM THREAD

IZE

215.32 4.00 101 9.75 248 2.00 51 5/16-18 0.88 22 0.344 8.7 0.41 10

215.35 5.00 127 9.75 248 2.00 51 3/8-16 0.86 22 0.406 10.3 0.40 10

215.41 5.00 127 12.25 311 2.03 52 3/8-16 0.89 23 0.406 10.3 0.42 11

215.42 8.00 203 12.25 311 2.93 74 5/8-11 1.33 34 0.656 16.6 0.39 10

215.45 8.00 203 15.25 387 2.99 76 5/8-11 1.36 35 0.656 16.6 0.42 11

215.51 9.75 248 15.25 387 3.49 89 3/4-10 1.62 41 0.781 19.8 0.42 11

MODEL HTHRUST LOAD

J (MAXIMUM)

. MM LBF N IN. MM LBF·IN.N·M RAD

215.32 3.25 82.55 100 450 0.15 3.81 100 11.3 0.028 85 0.0249

215.35 4.25 107.95 100 450 0.15 3.81 100 11.3 0.025 95 0.0278

215.41 4.25 107.95 150 670 0.15 3.81 100 11.3 0.025 210 0.0614

EFLECTION

D K (MAXIMUM)

. MM IN. MM IN. MM

ENDING

B M

OMENT

L (MAXIMUM)

NGULAR

A DEFLECT M

OTATIONAL

R INERTIA

·IN.

LBM

KG·M

215.42 6.50 165.10 150 670 0.17 4.32 300 33.9 0.015 460 0.135

215.45 6.50 165.10 500 2200 0.25 3.81 400 45.2 0.015 960 0.281

215.51 8.00 203.20 500 2200 0.15 3.81 400 45.2 0.015 1400 0.410

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

dimensions and ratings critical to your needs.

Introduction

Series 215 Rotary Actuator Product Manual

Page 25

Flange Adapters

Diaphragm Flexure Specification Drawing

A flange adapter may be used to mount the specimen to the actuator. Adapter mounting position is adjustable. The actuator shaft may extend beyond the adapter, be flush with it, or be recessed into it. Diameter A may be used as a shallow pilot.

Flange Adapter Dimensions and Inertia

ODEL ABCD

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

215.32 2.2511 57.2 4.00 102 2.25 57 2.99 75.9

215.32 2.2511 57.2 5.00 127 2.25 57 2.99 75.9

215.41 2.2511 57.2 5.00 127 2.00 51 2.99 75.9

215.42 2.2511 57.2 8.00 203 2.00 51 2.99 75.9

215.45 3.7400 95.0 8.00 203 3.25 83 3.68 93.5

215.51 3.7400 95.0 9.75 248 4.88 124 5.31 134.9

Series 215 Rotary Actuator Product Manual Introduction

Page 26

Flange Adapters

ODEL EF G ROTATIONAL INERTIA

THREAD

. MM IN. MM LBM·IN.

KG·M

SIZE

215.32 5/16-18 0.63 16.0 3.25 82.5 14.4 0.00421

215.32 3/8-16 0.75 19.1 4.25 107.9 21.8 0.00639

215.41 3/8-16 0.75 19.1 4.25 107.9 21.8 0.00639

215.42 5/8-11 0.75 19.1 6.50 165.1 208 0.0608

215.45 5/8-11 1.25 31.8 6.50 165.1 273 0.0799

215.51 3/4-10 1.50 38.1 8.00 203.2 737 0.216

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

dimensions critical to your needs.

Introduction

Flange Adapter Dimension Drawing

Series 215 Rotary Actuator Product Manual

Page 27

Safety Information

(27.6 MPa).

Hazard Placard Placement

Hazard placards contain specific safety information and are affixed directly to the system so they are plainly visible.

Each placard describes a system-related hazard. When possible, international symbols (icons) are used to graphically indicate the type of hazard and the placard label indicates its severity. In some instances, the placard may contain text that describes the hazard, the potential result if the hazard is ignored, and general instructions about how to avoid the hazard.

The following labels and icons may be found on an actuator.

ABEL DESCRIPTION

Hazard Placard Placement

Part #46-140-101

Part #46-140-201

WA RN I NG

Hydraulic pressure above 3000 psi can rupture components. Can cause severe personal injury or damage to equipment.

Do not exceed 3000 psi (20.7 MPa).

Read instructions before operating or servicing.

WA RN I NG

Hydraulic pressure above 4000 psi can rupture components. Can cause severe personal injury or damage to equipment.

Do not exceed 4000 psi (27.6 MPa).

Read instructions before operating or servicing.

Series 215 Rotary Actuator Product Manual Safety Information

Page 28

Hazard Placard Placement

ABEL DESCRIPTION

CAUTION

High drain pressure can cause rod seal damage and hydraulic oil leakage.

Remove drain line shipping cap and connect drain hose before operating.

Part # 045-283-501

Attached mass warning.

Do not exceed maximum attached mass.

Part # 057-230-041

Part # 700-004-198

Hydraulic Actuator ID tag lists the following:

• Model number

• Serial number

• Assembly number/Rev

• Force

• Effective Area

• Static Stroke

• Dynamic Stroke

• Hydrostatic/Non-Hydrostatic

• Maximum attached mass

Safety Information

Series 215 Rotary Actuator Product Manual

Page 29

ABEL DESCRIPTION

Hydraulic Actuator ID tag lists the following:

• Model number

• Serial number

• Assembly number/Rev

• Force

• Effective Area

• Static Stroke

Hazard Placard Placement

Part # 037-588-801

Part # 57-237-711

Part # 57-238-5xx

• Dynamic Stroke

• Hydrostatic/Non-Hydrostatic

Pressure icon.

Can be used alone, or in conjunction with pressure rating label (Part # 57-238-5xx).

Pressure rating. Actual rating listed on this label will vary. This label is used in conjunction with the Pressure icon (Part #

57237711). Located directly beneath pressure icon on actuator.

Series 215 Rotary Actuator Product Manual Safety Information

Page 30

Hazard Placard Placement

Safety Information

Series 215 Rotary Actuator Product Manual

Page 31

Installation

This section describes the procedures for installing the Series 215 Rotary Actuator and optional equipment onto a base plate or T-slot table. It also includes instructions for aligning the components of the rotary actuator test system after they have been installed or moved.

Though the Series 215 Rotary Actuator can be installed onto any suitable base plate or T-slot table that conforms to the specifications listed in the Diaphragm Flexure Dimensions and Ratings table, these instructions assume that an MTS supplied base plate or T-slot table will be used.

Typical Test System Configuration (Using T-slot Table)

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Page 32

Actuator Installation

Typically, the Series 215 Rotary Actuator is first bolted to a foot mounting assembly, then positioned on a base plate or T-slot table and secured with lightly lubricated mounting bolts. The foot mounting dimensions and ratings must match the actuator in use. After completing the alignment of force train components, torque the bolts to the correct values.

Actuator Mounting Bolt Torque Values

ODEL ACTUATOR ASSEMBLY TO FOOT

OUNTING

·FT N·MLBF·FT N·M

LBF

215.32, 215.35 35 47 150 204

FOOT MOUNTING TO BASE PLATE OR T-SLOT T

ABLE

215.41, 215.42

215.45, 215.51

80 110 150 204

Reaction Bracket and Torque Cell Installation

The reaction bracket should be positioned at the opposite end of the base plate or T-slot table from the actuator. Ensure that it is oriented with the smooth vertical surface facing the actuator.

Lightly lubricate the reaction bracket mounting bolts and hand-tighten them to secure the position of the reaction bracket. The reaction bracket mounting bolts should not be fully tightened until the force train components are aligned. Refer to the appropriate table for the reaction bracket force ratings and the torque values used when installing the reaction bracket and torque cell.

In most cases the selected torque cell bolts directly to the surface of the reaction bracket. When possible, the side of the torque cell that attaches to the center collar should be bolted to the reaction bracket. This configuration will cause the least movement of the torque cell electrical cable. The torque cell and reaction bracket should be bolted together with the correct torque value. It may be necessary to temporarily tighten the reaction bracket mounting bolts to keep it from moving while the torque cell is bolted in place.

Installation

Series 215 Rotary Actuator Product Manual

Page 33

Reaction Bracket and Torque Cell Installation

MTS Base Plate and Reaction Bracket

Reaction Bracket Ratings and Mounting Bolt Torque Value

ODEL REACTION BRACKET RATING TORQUE CELL TO REACTION

RACKET TORQUE VALUE

·FT.N·MLBF·FT.N·MLBF·FT.N·M

LBF

215.32 2000 0.226 18 24.0 150 204

215.35 5000 0.560 35 47.0 150 204

215.41 10,000 1.130 35 47.0 150 204

215.42 20,000 2.260 170 230.0 150 204

215.45 50,000 5.650 170 230.0 150 204

215.51 100,000 11.300 280 380.0 150 204

REACTION BRACKET TO BASE OR TS

LOT TABLE TORQUE VALUE

Series 215 Rotary Actuator Product Manual Installation

Page 34

Diaphragm Flexure Installation

Depending upon user requirements, the end of the actuator rotor shaft can extend beyond the flange, be flush with it, or be recessed into the flange adapter to allow the use of the inside diameter as a pilot diameter.

Diaphragm flexures are used to reduce the potentially damaging effects of large axial and lateral deflections of the actuator rotor shaft. Perform the necessary calculations for determining whether or not diaphragm flexures are required by the specific test system.

Mount the flexure(s) to either the flange adapter or the torque cell.

The following table lists the flexure ratings and mounting bolt torques for the available flexure diaphragms.

Flange Adapter and Diaphragm Flexure Rating

FLANGE AND DIAPHRAGM FLEXURE RATING MOUNTING BOLT TORQUE

ODEL

·N.N·MLBF·IN.N·M

LBF

215.32 2000 226 18 24

215.35 5000 565 35 47

215.41 10,000 1130 35 47

215.42 20,000 2260 170 230

215.45 50,000 5650 170 230

215.51 100,000 11,300 280 380

Aligning Force Train Components

After the actuator, reaction bracket, and torque cell have been positioned on the base plate or T-slot table, they must be aligned. The goal of the alignment process is to ensure that the actuator and torque cell share the same centerline.

If the test system utilizes a base plate supplied by MTS, the actuator and reaction bracket will have been pre-aligned at the factory. The combination of an MTS base plate and reaction bracket enables the operator to easily move the reaction bracket/torque cell assembly and simplifies the alignment procedure.

If the test system does not utilize an MTS base plate or T-slot table, the torque cell has been separated from the reaction bracket, or the actuator has been moved, then the “Component Centerline Alignment Procedure” must be performed in order to ensure proper alignment of the components of the test system. If the reaction bracket, torque cell, and actuator have not been moved and were properly aligned when installed, then it is not necessary to perform the alignment procedures.

Installation

The diaphragm flexure assemblies are self-centering.

Series 215 Rotary Actuator Product Manual

Page 35

Note In each of the following procedures the base plate or T-slot table must be

flat to within 0.015 mm/m (0.002 in./ft).

Component Alignment on an MTS Base Plate

Rotary actuator testing systems equipped with an MTS base plate and reaction bracket combination are pre-aligned. The following procedure describes the alignment process used when you wish to increase or decrease the distance between the actuator and the torque cell.

Note If the actuator has been moved or the torque cell has been separated

from the reaction bracket, the “Component Centerline Alignment Procedure” must be completed before attempting this procedure.

1. To move the reaction bracket and torque cell assembly, loosen the lateral clamping bolts located on the left side of the reaction bracket.

2. Loosen the vertical clamping bolts on the reaction bracket.

3. Slide the reaction bracket and torque cell assembly to the desired position.

4. Tighten the lateral clamping bolts on the left side of the reaction bracket to assure alignment.

Component Alignment on an MTS Base Plate

5. To secure the reaction bracket and torque cell assembly, lubricate and tighten each of the lateral clamping bolts to 3.9 N·m (35 lbf·in.).

6. Lubricate and tighten each of the vertical clamping bolts to 84.7 N·m (750 lbf·in.). Alignment is complete.

Component Centerline Alignment

If the test system does not utilize an MTS base plate or T-slot table, or the torque cell has been separated from the reaction bracket, or the actuator has been moved, then this procedure must be performed in order to ensure proper alignment of the components of the test system. In each of the steps, it is assumed that the bolts used to install the actuator and reaction bracket to the base plate or T-slot table are hand tight unless otherwise specified.

The purpose of this procedure is to ensure that the actuator and torque cell share the same centerline. The procedure is composed of three groups of steps covering the following operations:

• Adjusting actuator and torque cell centerline height,

• Adjusting actuator and torque cell concentricity, and

• Adjusting for actuator and torque cell centerline angularity.

Adjusting Actuator and Torque Cell Centerline Height

This procedure describes the steps necessary to adjust the centerline height of the torque cell with respect to the actuator. The procedure requires a dial indicator, magnetic V-block, extension rod, and clamps.

1. Attach a dial indicator to the actuator rotor shaft using a magnetic V-block as the base.

Series 215 Rotary Actuator Product Manual Installation

Page 36

Adjusting Actuator and Torque Cell Concentricity

2. Rotate the V-block around the rotor shaft circumference while simultaneously reading the pilot diameter runout on the face of the torque cell flange. Check the reading at top and bottom positions.

A. Variation between the actuator reading and the torque cell flange face

must differ by less than 0.0508 mm (0.002 in.).

B. Height adjustments are made by loosening and repositioning the torque

cell. When the proper position has been achieved, re-tighten the torque cell mounting bolts to the appropriate torque values.

3. Repeat Steps 1 and 2 to ensure that the adjustment was not altered when the torque cell was re-torqued.

Adjusting Actuator and Torque Cell Concentricity

While centerline heights may be identical and parallel to the base plate or T-slot table mounting surface, the actuator and torque cell can be eccentric in a lateral direction. There are two ways to correct for actuator/torque cell eccentricity. The most appropriate method depends on the type of specimen to be tested. Both methods are listed below.

Rigid specimen If the current test application makes use of a rigid specimen, then the specimen

itself can be used to facilitate the alignment process. Because the presumed goal of the alignment process is to mount the specimen without exerting any unintentional forces upon it, it may be simplest to loosen the bolts securing the reaction bracket to the table and then place the specimen in position.

Flexible or fragile

specimen

When installing the mounting bolts, ensure that there are no gaps between the specimen, flexures, and torque cell. Only after checking that both ends of the specimen contact the mounting surfaces should the mounting bolts be torqued. This technique allows the specimen configuration to control the “at rest” position of the reaction bracket. Once the specimen is securely positioned, the reaction bracket bolts may be torqued to the proper value. Do not use the mounting bolts

to pull

the reaction bracket into position.

If the current test application uses a flexible or fragile specimen, then the following procedure must be used to correct for actuator/torque cell eccentricity.

1. Attach a dial indicator to the actuator rotor shaft using a magnetic V-block for the base.

2. Rotate the V-block around the rotor shaft circumference while simultaneously reading the pilot diameter runout on the torque cell flange.

3. Adjust the torque cell position for an acceptable level of eccentricity by loosening the reaction bracket. The acceptable level of eccentricity is determined by the test requirements.

4. After positioning the torque cell, re-tighten the mounting bolts to the appropriate torque values.

5. Recheck the centerline height and adjust as required.

Installation

Series 215 Rotary Actuator Product Manual

Page 37

Adjusting Actuator and Torque Cell Centerline

Adjusting Actuator and Torque Cell Centerline Angularity

The final alignment procedure adjusts for centerline angularity deviations between the actuator rotor shaft and the torque cell flange face.

Do not apply hydraulic pressure to the system unless the servovalve command (DC error) has been zeroed.

If the servovalve command (DC error) does not equal zero when hydraulic pressure is applied to the system, equipment damage or personal injury can result.

Always ensure that the DC error is zero before applying hydraulic pressure to the system.

1. Adjust the system controller for zero DC error and apply system hydraulic pressure according to applicable system procedures.

2. Attach a dial indicator to the actuator rotor shaft using a magnetic V-block for the base. Set the dial indicator to read the runout of the torque cell flange face, outside the bolt circle area.

3. Use the Set Point control on the controller to rotate the actuator rotor shaft while simultaneously reading the indication from the face of the torque cell flange.

4. To obtain a reading over a wider range of motion, reposition the V-block on the opposite side of the actuator rotor shaft and repeat Step 3.

5. Adjust the torque cell position for an acceptable level of angularity by loosening and moving the reaction bracket. The acceptable level of angularity is determined by the test requirements.

6. After positioning the torque cell, re-tighten the reaction bracket mounting bolts to the appropriate torque.

7. Turn off system hydraulic pressure.

8. Repeat the “Actuator and Torque Cell Centerline Height” and “Actuator and Torque Cell Concentricity” procedures to ensure that all measurements conform to the requirements of the test.

Series 215 Rotary Actuator Product Manual Installation

Page 38

Adjusting Actuator and Torque Cell Centerline

Installation

Series 215 Rotary Actuator Product Manual

Page 39

Operation

CAUTION

Thrust and Side Load Characteristics

This section discusses the calculations and precautions that must be considered in order to produce accurate test results and help protect equipment and personnel. Though some of the calculations included in this section may not be required by specific test situations, it is recommended that you read each section and ensure that the actuator will be operated within the limits of its thrust load, side load, and rotational inertia ratings.

Do not exceed the thrust load, side load, or rotational inertia ratings of the actuator.

Exceeding the thrust load, side load, or rotational inertia ratings of the actuator can damage equipment, injure personnel, and void any warranty in effect on the Series 215 Rotary Actuator.

Ensure that the thrust load, side load, and rotational inertia ratings for the actuator exceed the anticipated test forces. This section contains calculations for deriving the anticipated test forces.

Thrust and Side Load Characteristics

The thrust and side loads that may be encountered during testing are generally the result of the following factors:

• Specimen shortening or lengthening due to torsional force

• Specimen shortening or lengthening due to temperature

• Misalignment of the test specimen when initially mounted

• Base plate or T-slot table twisting

• Permanent deformation of the specimen due to torsional force

Thrust loads The following table lists the maximum allowable thrust load (Q) that can be

applied to the actuator rotor shaft. Because thrust loads can be induced by a wide variety of experimental conditions, this manual will not attempt to define or predict the forces that can result from specific testing situations. If there is a possibility that the maximum thrust load rating of the actuator will be exceeded during testing, steps should be taken to minimize the load. One way of reducing the effect of thrust loads on the actuator bearings is to install diaphragm flexures.

Thrust loads can have a significant effect on actuator bearings. These effects are a function of specimen geometry, material, and temperature as shown in the following example:

Increase the temperature of a steel shaft 25.4 mm (1 in.) in diameter and 1,270 mm (50 in.) in length by 22˚C (40˚F). The increase in specimen temperature causes the shaft to expand by approximately 0.305 mm (0.012 in.). If the shaft is

Series 215 Rotary Actuator Product Manual Operation

Page 40

Definition of Useful Mathematical Terms

mounted in a force train using a 215 Rotary Actuator, the shaft expansion would exert a resultant force of 6,000 lbs. on the actuator bearings.

To confine the resultant force to an acceptable maximum requires the addition of diaphragm flexures to the force train. Multiplying the stiffness of the diaphragm flexure by the amount of specimen expansion will give the thrust load imposed on the actuator bearings.

Use the following formula to calculate the maximum thrust load applied to the actuator bearings when using diaphragm flexures:

Flexure Stiffness (Flexure’s Maximum Thrust Deflection) = Maximum Thrust Load

Side loads Side loads, which are normally induced by specimen misalignment or base plate

or T-slot table compliance, may be active at the same time thrust loads are active. If the specimen is soft, such as a length of rubber hose, side loads on the actuator are relatively small. This is because the specimen bends easily and exerts little resistance to the deflection caused by base plate twisting. However, if the specimen is stiffer (steel for example), the increased resistance of the specimen to bending exerts substantial side loads on the actuator bearings and torque cell due to the restraining characteristics of the test setup. As in the test setup for thrust loads, diaphragm flexures can be used to reduce the side loads to a practical limit.

Note The service life of the actuator is normally reduced by significant thrust

and side loads. For this reason, the use of flexure diaphragms and a rigid base plate is recommended even when the actuator’s thrust and side load ratings are sufficient for the test situation.

Definition of Useful Mathematical Terms

The following terms are listed in alphabetical order and defined in both U.S. Customary and SI Metric units of measure.

Mathematical Terms (part 1 of 3)

ERM DEFINITION TERM DEFINITION

a Distance from actuator's center line to

center of reaction base plate’s solid height (mm) (in.).

β 0.333 - 0.21 (d/b) k

b Width of reaction base plate (mm) (in.). k

k2 Lateral stiffness of a solid cylindrical

specimen (kN/mm) (lbf/in.)

12 ET IL2 3

Angular horizontal stiffness of actuator and reaction bracket flexures (N·m/rad) (lbf·in./ rad).

F1/θF1

Lateral stiffness of diaphragm flexures (lbfin./rad).

d Thickness of reaction base plate (mm)

(in.). Measurement of solid metal only. Do not include T-slot depth.

Operation

=MF2/θ

Length of base plate or T-slot table subjected to twisting (mm) (in.).

Series 215 Rotary Actuator Product Manual

Page 41

Mathematical Terms (part 2 of 3)

ERM DEFINITION TERM DEFINITION

Definition of Useful Mathematical Terms

Modulus of elasticity of the base plate or

T-slot table, shear (N/m2) (lb/in.2)

Length of test specimen (mm) (in.). Do not include specimen adapter plates unless their compliance is equal to or greater than that of the specimen.

Modulus of elasticity of the specimen,

tension (N/m2) (lb/in.2).

Moment of inertia for a round solid (mm

(in.

)

πr4/4

Torsional stiffness of a thin flat plate (Nm./rad) (lbf-in./rad)

Distance between flexing points of diaphragm flexures.

M Bending moment on test specimen with no

)

flexures (N·m) (lbf·in.).

PL 22

Bending moment on actuator and reaction bracket with standard flexures installed (Nm) (lbf-in.).

Es (β)bd3 /L

Bending moment on test specimen with

T Applied torque (N-m) (lbf-in.) standard flexures or diaphragm flexures installed (N-m) (lbf-in.).

(Standard Flexures)

(Diaphragm Flexures)

Maximum lateral bending capacity of standard flexures (N-m) (lbf-in.)

u Distance from front bearing to specimen

(mm) (in.). Include specimen adapter plates if they are less compliant than the specimen.

Maximum horizontal bending capacity of

W Load on front actuator bearing (kN) (lbf) diaphragm flexures (N-m) (lbf-in.)

P Side load imposed on test specimen and

actuator.

∆ Centerline offset between actuator and

reaction bracket mountings due to twisting of base plate or T-slot table (mm) (in.).

=k2k1aT1 + k2k1a2

∆ =

r Radius of test specimen (mm) (in.) q Angle of flex imposed on flexures (rad).

(Standard Flexures)

(Diaphragm Flexures)

Series 215 Rotary Actuator Product Manual Operation

Page 42

Test Setup Using No Flexures

Mathematical Terms (part 3 of 3)

ERM DEFINITION TERM DEFINITION

s Distance between front and rear

bearings (mm) (in.).

Bending stress on test specimen due to

base plate twisting (N/m2) (psi).

MrI Without Flexures

M2rI With Flexures

Maximum horizontal angular deflection of standard flexures (rad).

Maximum angular deflection of diaphragm flexures (rad).

Test Setup Using No Flexures

The following figure illustrates an example of a test setup having no flexures. If diaphragm flexures will not be used in the rotary actuator test system, special attention should be paid to the side loads that will be imposed on the specimen and actuator by twisting of the base plate or T-slot table.

Side load calculations The following side load calculation procedure is used to determine side loads due

to the base plate or T-slot table torsional compliance. When side loads are unacceptable as determined from these calculations, optional components are required in the force train to reduce the load imposed on the actuator and torque sensor.

Loads on an Actuator and Specimen due to base plate twist (excludes thrust loads)

Operation

Series 215 Rotary Actuator Product Manual

Page 43

Test Setup Using No Flexures

Sample calculation The previous figure illustrates the forces and measurements pertinent to the

calculations. Refer to the appropriate tables for ratings and dimensions of the Model 215.45 Rotary Actuator used in the example.

The following procedure uses sample values. When performing the calculations to determine the anticipated test forces, the values appropriate to your specific test should be substituted for the sample values. In addition, the example uses U.S. Customary units of measure.

Calculate the side load (P) and compare P to the actuator's side load rating in the actuator ratings table. If P exceeds or approaches the side load rating, two flexures must be used in the test setup.

Also calculate SB, the bending stress on the specimen under test. If SB is above the determined maximum tolerable value, two flexures must be used in the test setup.

Example

: Suppose a Model 215.45 Rotary Actuator is mounted to a T-slotted

steel reaction base, resulting in the following parameters:

Base: 48 in. x 24 in. x 6 in.

T-slot depth: 2 in.

Height (A from Table 1-4): 7.75 in. (Actuator centerline to base of foot mounting)

Actuator torque capacity (T): 50,000 lbf-in.

Length of base subjected to twisting (L

Specimen material: Steel (E

Specimen length (L

): 10 in.

= 12 x 106, ET = 29 x 106)

): 37 in.

Specimen radius (r): 1 in.

Calculate side load Calculate the side load (P) imposed on the test specimen and actuator bearing as

a result of base plate twist using the following formula:

A. To calculate P, it is first necessary to calculate k

, d, β, k2, I, a, and T as

follows:

Series 215 Rotary Actuator Product Manual Operation

Page 44

Test Setup Using No Flexures

Then:

B. Calculate the value of k

, the lateral stiffness of a solid cylindrical

specimen, by using the formula:

C. Substitute the calculated values for k

, k2, and the example values into

the original equation to compute the side load (P).

Operation

Series 215 Rotary Actuator Product Manual

Page 45

Test Setup Using No Flexures

The value of 862 lbf is the side load (P) imposed on the test specimen and actuator by base plate twist.

Calculate bending

moment

Calculate specimen

stress

Calculate the bending moment (M) on the test specimen with no flexures installed by using the following formula:

The value of 4310 lbf-in. is the bending moment exerted on the actuator shaft and specimen.

For this example, P = 862 or 12% of side load capacity, and M = 4310 or 10% of bending moment capacity. The sum is less than 100% at capacity, so flexures are not necessary.

Calculate SB as the final step:

The value 5488 psi represents the amount of stress experienced by the specimen under test. Typically, in a torsion test, stress caused by reaction base or T-slot table twist should be zero or as close to zero as possible. In the sample calculation, the excessive specimen stress loading introduces unfavorable loads

Series 215 Rotary Actuator Product Manual Operation

Page 46

Test Setup Using Standard Flexures

on the test specimen which can invalidate the test results or cause premature failure of the specimen. To reduce these loads requires the use of flexure options or a stiffer mounting surface.

Test Setup Using Standard Flexures

The following figure shows an example of a test setup in which flexures are integral on both the actuator foot mounting and the reaction bracket. Flexures are used to reduce excessive side load forces applied to an actuator or specimen.

It is important to determine if standard flexures are adequate for your test setup or if diaphragm flexures need to be used. This subsection describes calculations that help make this determination.

Operation

Forces Resulting from Base Plate Twisting (Integral Flexures)

∆ = Center line offset between actuator and reaction bracket mountings due to base plate twisting or T-slot table (in.) (mm):

θ = Angle of flex imposed on actuator and reaction bracket flexures (rad):

= Maximum horizontal angular deflection of standard flexures (rad).

Series 215 Rotary Actuator Product Manual

Page 47

Test Setup Using Standard Flexures

= Angular horizontal stiffness of actuator and reaction bracket (N·m/rad)

(lbf·in./rad):

= Bending moment on actuator and reaction bracket with standard flexures

installed (N·m) (lbf·in.):

= Maximum horizontal bending capacity of standard flexures (N·m)

(lbf·in.).

= Bending moment on specimen with standard flexures installed (lbf·in.)

(N·m):

Calculate centerline

offset

SB = Bending stress on test specimen due to base plate twisting (N/m

) (psi):

The previous figure illustrates the forces and measurements pertinent to the calculations. Refer to the appropriate tables for ratings and dimensions of the Model 215.45 Rotary Actuator used in the example.

Use the following values and formulas to calculate Δ (centerline offset) and then θ (angle of flex on flexures). If θ is not greater than θ

, the standard flexures are

adequate.

Also calculate SB, the bending stress on the specimen under test. If SB is above the determined maximum tolerable value, diaphragm flexures must be used in the test setup.

Calculate the centerline offset (D) between the actuator and reaction bracket mountings due to base plate twist by using the following formula:

Series 215 Rotary Actuator Product Manual Operation

Page 48

Test Setup Using Standard Flexures

Calculate angle of flex Calculate the angle of flex (q) imposed on foot mounting and reaction bracket

flexures by using the following formula:

Compare angular

deflection

Calculate lateral

stiffness

Compare the maximum horizontal angular deflection of the standard flexures value (K = qF1= 0.006 rad.) with the calculated angle of flex imposed on foot mounting and reaction bracket flexures (q=0.000107 rad.) to determine if the flexures are adequate.

θ < θ

In the case of the sample calculation, the flexures are adequate. If the flexures are not adequate, additional flexural capability is required or base plate stiffness must be increased. Consult MTS Systems for assistance.

Calculate the lateral stiffness (k

) of the foot mounting and reaction bracket

flexures by using the following formula:

Operation

Series 215 Rotary Actuator Product Manual

Page 49

Test Setup Using Standard Flexures

Calculate bending

moment (M1)

Calculate bending

moment (M2)

Calculate specimen

stress

Calculate the bending moment (M1) that is applied to the actuator and reaction bracket when equipped with standard flexures.

Calculate the bending moment (M2) induced in the test specimen with standard flexures installed by using the following formula:

Calculate the additional stress (SB) induced in the specimen due to base plate twist by using the following formula:

The value 12.2 psi represents the amount of stress experienced by the specimen under test and is an acceptable stress level. Typically, in a torsion test, stress caused by reaction base or T-slot table twist should be zero or as close to zero as possible. Specimen stress loading introduces unfavorable loads on the test

Series 215 Rotary Actuator Product Manual Operation

Page 50

Test Setup Using Diaphragm Flexures

specimen which can invalidate the test results or cause premature failure of the specimen.

Test Setup Using Diaphragm Flexures

If the values derived from the calculations in “Test Setup Using Standard Flexures” section indicate that diaphragm flexures must be used to reduce side loads to acceptable levels, then the following calculations should be performed to ensure that the selected diaphragm flexures are adequate. In addition, this subsection contains the equations necessary for calculating the stress experienced by the specimen when diaphragm flexures are installed in the test system.

The following figure shows an example of a test setup in which diaphragm flexures are mounted at both ends of the test specimen. These would be required on test setups where both the rotary actuator and the reaction bracket are rigidly mounted to the reaction base.

Operation

Forces Resulting from Base Plate Twisting (Diaphragm Flexures)

Series 215 Rotary Actuator Product Manual

Page 51

Test Setup Using Diaphragm Flexures

Sample calculation The previous figure illustrates the forces and measurements pertinent to the

calculations. Refer to the appropriate tables for ratings and dimensions of the Model 215.45 Rotary Actuator used in the example. The following calculations use values derived from the sample calculations performed previously.

Using the preceding formulas and following values calculate Δ (centerline offset) and then θ (angle of flex on flexures). If θ is not greater than θ adequate (from Table 1-7, θ

Calculate S

and determine if it is within acceptable limits for the specific

= M).

test.

a = 11.75 in. (Distance from actuator center line to base plate center)

= 148.5 x 106 lbf-in./rad. (Torsional stiffness of thin flat plate)

= 43 in. (Length of base plate subjected to twisting)

Note Length of base plate subject twist has been changed from 37 in. to 43 in.

This was necessary because using diaphragm flexures at the ends of a specimen increases the distance between the foot mounting and reaction bracket. Refer to “Diaphragm Flexure Dimensions and Ratings”, dimension C.

F =

13 in. (

Distance between flexing points of the diaphragm

flexures) (from Diaphragm Flexure Dimensions and Ratings, rating L)

, the flexures are

= 400 lbf·in (Maximum lateral bending capacity of the diaphragm

flexure) (from Diaphragm Flexure Dimensions and Ratings, rating M)

= 0.015 rad (Maximum angular deflection of the diaphragm

flexure)

T = 50,000 lbf·in. (Applied torque)

Series 215 Rotary Actuator Product Manual Operation

Page 52

Test Setup Using Diaphragm Flexures

Calculate centerline

offset

Calculate the center line offset (∆) between actuator and reaction bracket due to base plate twist by using the following formula:

Calculate flex angle Calculate the angle of flex (q) imposed on each diaphragm flexure by using the

following formula:

Compare angular

Calculate lateral

Operation

deflection

stiffness

Compare the maximum horizontal angular deflection of the diaphragm flexures (qF2=0.015 rad.) with the calculated angle of flex imposed on foot mounting and reaction bracket flexures (q=0.000305rad.) to determine if the flexures are adequate.

θ < θ

Calculate the lateral stiffness (k

) of the diaphragm flexures by using the

following formula:

Series 215 Rotary Actuator Product Manual

Page 53

Test Setup Using Diaphragm Flexures

Calculate bending

moment (M2)

Calculate specimen

stress

Calculate the bending moment (M2) that is induced in the test specimen with diaphragm flexures installed by using the following formula:

Calculate the additional stress (SB) induced in the specimen due to base plate twist by using the following formula:

The value 10.4 psi represents the amount of stress experienced by the specimen under test and is an acceptable stress level. Typically, in a torsion test, stress caused by reaction base or T-slot table twist should be zero or as close to zero as possible. Specimen stress loading introduces unfavorable loads on the test specimen which can invalidate the test results or cause premature failure of the specimen.

Series 215 Rotary Actuator Product Manual Operation

Page 54

Summary of Side Load Calculations

This section contains a brief summary of side load calculations made before beginning a test.

Side load calculations

excluding flexures

The following formulas are used in preliminary calculations to determine if forces generated exceed the actuator rating, thus requiring the addition of flexures.

1. Calculate the side load (P) imposed on the test specimen and actuator bearing as a result of base plate twist using the following formula:

A. Calculate the value of k

, the torsional stiffness of a thin flat plate, by

using the formula:

Note In the above formula, is used in place of J (polar

momentary inertia) due to warpage that occurs in thin flat plates under torque.

B. Calculate the value of ks, the lateral stiffness of a solid cylindrical

specimen, by using the formula:

2. Calculate the bending moment (M) on the test specimen by using the following formula:

3. Calculate the stress (S

) induced in the specimen due to base plate twist by

using the following formula:

Operation

Series 215 Rotary Actuator Product Manual

Page 55

Summary of Side Load Calculations

Side load calculations

when using standard

flexures

The following calculations are used when flexures are installed on the foot mounting and reaction bracket.

1. Calculate the center line offset (∆) between the actuator and reaction bracket due to base plate twist by using the following formula:

2. Calculate the angle of flex (θ) imposed on standard flexure by using the following formula:

3. Compare the maximum horizontal angular deflection of the standard flexures in use with the calculated angle of flex imposed on the flexures. This will determine if the flexures are adequate. The relationship should be:

4. Calculate the lateral stiffness (k

) of the diaphragm flexures by using the

following formula:

5. Calculate the bending moment (M

) that is applied to the actuator and

reaction bracket with standard flexures installed.

6. Calculate the bending moment (M2) that is applied to the test specimen with standard flexures installed.

Series 215 Rotary Actuator Product Manual Operation

Page 56

Summary of Side Load Calculations

7. Calculate the stress (SB) induced in the specimen due to base plate twist by using the following formula:

Side load calculations

using diaphragm

flexures

The following calculations are used when diaphragm flexures are coupled to the ends of a specimen.

1. Calculate the center line offset (∆) between actuator and reaction bracket due to base plate twist by using the following formula:

2. Calculate the angle of flex (θ) imposed on each diaphragm flexure by using the following formula:

3. Compare the maximum horizontal angular deflection of the diaphragm flexures in use with the calculated angle of flex imposed on one diaphragm flexure. This will determine if the flexures are adequate. The relationship should be:

Operation

4. Calculate the lateral stiffness (k

following formula:

5. Calculate the bending moment (M when equipped with diaphragm flexures.

6. Calculate the stress (S

) induced in the specimen due to base plate twist by

using the following formula:

) of the diaphragm flexures by using the

) that is applied to the test specimen

Series 215 Rotary Actuator Product Manual

Page 57

Rotational Inertial

CAUTION

Rotational Inertial

This subsection describes how to calculate the total rotational inertia of the Series 215 Rotary Actuator, specimen, and optional equipment. High rotational speeds or large-diameter flexures and specimens can cause large torques even though the masses involved are quite small. If the total rotational inertia exceeds recommended levels and the actuator is allowed to rotate until the rotor vane makes contact with the rotor vane stops at high rotational speeds, then the flange adapter may rotate on the actuator shaft or the actuator may be damaged.

Do not depend on the internal actuator rotor vane stops to protect equipment and personnel from damage and injury.

The internal actuator rotor vane stops can break if the rotor vane strikes them with a rotational inertia greater than the maximum value. The internal actuator rotor vane stops can also fail in fatigue if subjected to repeated lesser impacts.

Ensure that the internal actuator rotor vane does not repeatedly impact with the actuator rotor vane stops. Do not rely on the internal actuator rotor vane stops to protect equipment and personnel from injury.

Determining Maximum Rotational Inertia (JT)

To determine if the internal actuator rotor vane stops are adequate, the total

ODEL ROTARY ACTUATOR (J

LBM-IN.

rotational inertia (J of the calculated J, for the specimen, plus known J for the actuator, flange, and flexures.

The following table provides the rotational inertia values for the actuator and optional components.

Rotational Inertia for Actuator Components

)FLANGE ADAPTER (JF)DIAPHRAGM FLEXURE (JD)

·M

) must be determined for the rotating mass. JT equals the sum

LBM·IN.

·M

LBM·IN.

·M

215.32 11.67 0.00342 14.4 0.00421 85 0.0249

215.35 18.54 0.00544 21.8 0.00639 95 0.0278

215.41 20.23 0.00594 21.8 0.00639 210 0.0614

215.42 29.04 0.00852 208 0.0608 460 0.135

Series 215 Rotary Actuator Product Manual Operation

Page 58

Determining Maximum Rotational Inertia (JT)

Rotational Inertia for Actuator Components

215.45 171 0.0500 273 0.0799 960 0.281

215.51 284 0.0831 737 0.216 1400 0.410

1. Calculate the total rotational inertia by using the following formula:

= JR + JF + JD + J

Where:

= rotational inertia for actuator (“Rotational Inertia for Actuator

Components”)

JF = rotational inertia for flange adapter options (“Rotational Inertia for Actuator Components”)

JD = rotational inertia for diaphragm flexure (“Rotational Inertia for Actuator Components”)

= rotational inertia value for specimen configurations (Step 2)

2. To determine J

refer to Substeps A, B, and C and select the formula

appropriate to the specimen configuration. Refer to the “Rotational Inertia Calculations” figure and note that in each formula, m is equal to the mass of the specimen.

Rotational Inertia Calculations

A. If the specimen is a regular solid

calculate J

mass, use the following formula to

Operation

B. If the specimen is a regular hollow

calculate J

C. If the specimen is an offset

mass, use the following formula to calculate

Series 215 Rotary Actuator Product Manual

mass, use the following formula to

Page 59

Determining Maximum Rotational Inertia (JT)

ΔP

1000

------------

3. After calculating the total rotational inertia (J maximum allowable J

for the specific actuator and servovalve combination

indicated in the following. If the maximum allowable J

), compare the value to the

is exceeded, the

test setup must be altered to reduce the total rotational inertia or an additional restraint must be provided to keep the actuator rotor vane from impacting the internal actuator rotor vane stops at full velocity.

Maximum Allowable Rotational Inertia (J) When Using Only Internal Actuator Rotor Vane Stops

U.S. C

USTOMARY

SERVOVALVE FLOW MAX J FOR ACTUATOR MODEL (LBM·IN.2)

ODEL RATED

(

GPM)

252.23 5.00 9 39 302 1825 32905 305558 3020992

252.24 10.00 17 -- 76 456 8226 76389 755248

252.25 15.00 26 -- 34 203 3656 33951 335666

252.31 25.00 43 -- -- 73 1316 12222 120840

256.04 40.00 70 -- -- -- 514 4774 47203

256.09 90.00 156 -- -- -- -- 943 9324

EAK*

P (

GPM)

215.32 215.35 215.41 215.42 215.45 215.51

SI METRIC

SERVOVALVE FLOW MAX J FOR ACTUATOR MODEL (KG·M2)

ODEL RATED (L/

MIN)

252.23 19.00 33 0.01 0.09 0.54 9.67 89.49 884.89

252.24 37.00 64 -- 0.02 0.13 2.42 22.37 221.22

252.25 56.00 97 -- 0.01 0.06 1.07 9.94 98.32

252.31 93.00 161 -- -- 0.02 0.39 3.58 35.40

256.04 151.00 262 -- -- -- 0.15 1.40 13.83

256.09 340.50589--------0.282.73

* Flow through the valve at 3,000 psi (∆P). Using reduced system pressures (∆P) will

decrease peak flow Q peak = Q rated

Decreasing peak flow will allow an increase in acceptable inertia (J). Refer to “Series 215 Rotary Actuator Ratings by Model” for the maximum velocity into vane stops where W= Q peak x 3.85 in.3/sec Displacement in.3/rad.

EAK* (L/

MIN)

215.32 215.35 215.41 215.42 215.45 215.51

Series 215 Rotary Actuator Product Manual Operation

Page 60

Rotational Inertia Control Options

If the anticipated rotational inertia (JT) exceeds the maximum levels, then steps must be taken to control actuator motion and limit servovalve pressure. Contact MTS Systems Corporation for information on available actuator cushions and cross port relief valves.

Operation

Series 215 Rotary Actuator Product Manual

Page 61

Maintenance

Routine Maintenance

Weekly Clean exposed areas of the actuator rotor with a clean, dry, lint-free rag. If the

Routine Maintenance

This section contains information regarding routine maintenance, problem diagnosis, actuator seal replacement, and actuator disassembly.

Procedures in this section assume that the operator is familiar with all operating aspects of the system electronic console and all interlock restrictions that apply to the hydromechanical equipment.

Series 215 Rotary Actuators are designed for extended periods of operation without extensive maintenance requirements. A summary of the routine maintenance procedures is listed below. The following subsections describe the recommended procedures.

actuator is continually exposed to a dirty operating environment, clean the rotor on a daily basis.

Monthly Inspect actuator rotor and seals for excessive wear or leakage. Small scratches in

the torsional direction of the rotor or polishing of the rotor surface is considered normal operating wear.

Yearly Change actuator seals if necessary. Actuator assemblies may require more or less

frequent seal changes depending on usage. External oil leakage or decreased performance are indicators of seal wear.

Actuator Performance Checks

The following procedure is designed to help determine the cause of abnormal actuator operation by checking specific actuator performance benchmarks. The previous figure shows the components of the Series 215 Rotary Actuator.

1. Perform the servovalve mechanical null procedure. (Refer to the appropriate servovalve product manual for this procedure.)

2. Turn off system hydraulic pressure and ensure that all residual pressure (including service manifold accumulator pressure) has bled off.

3. Attach a flow meter to the return line (from the servovalve).

4. Run actuator hard over clockwise (viewed from shaft end) and increase pressure to 21MPa (3000 psi).

5. Measured cross vane flow values should not exceed:

• 1 gpm for 215.32/35 actuators

• 2 gpm for 215.41/42 actuators

• 3 gpm for 215.45/51 actuators

6. Repeat Steps 4 and 5 in the counterclockwise direction.

Series 215 Rotary Actuator Product Manual Maintenance

Page 62

Actuator Performance Checks

WARNING

If measured cross vane flow exceeds recommended values in either direction, refer to the “Excessive Cross Vane Flow” section.

Do not apply hydraulic pressure to the system unless the servovalve command (DC error) has been zeroed.

If the servovalve command (DC error) does not equal zero when hydraulic pressure is applied to the system, equipment damage and/or personal injury can result.

Always ensure that the DC error is zero before applying hydraulic pressure to the system.

7. Disconnect the hydraulic power supply drainback hose from the actuator drainback port plumbing. Connect a hose or tubing to the drainback ports on both the front and rear end caps. Direct the free end of each hose into an empty pail capable of holding at least 18.9 liters (5 gallons) of fluid.

8. Position the actuator at mid-stroke.

9. Adjust the system controller for zero DC error and apply system hydraulic pressure according to applicable system procedures.

10. Time the flow of hydraulic fluid coming from each drainback port for one minute. At the end of one minute, turn off electrical and hydraulic power to the system and measure the amount of fluid in each pail.

11. If the amount of fluid in each pail is between 0.38–1.9 liters (0.1 gal–0.5 gal), actuator fluid flow is normal.

Note If measured drainback port flow exceeds recommended values, refer

to”Abnormal Drainback Port Flow” section.

12. If fluid flow is normal, reconnect the hydraulic power supply drainback hose to the actuator drainback port and tighten the coupling.

Note If fluid flow is normal but actuator performance is not, abnormal

performance may be caused by improper servovalve balance or other related system components.

13. If your actuator has a ∆P cell, perform the following procedure to measure maximum stiction:

A. Rotate the actuator clockwise at system hydraulic pressure.

B. Measure both maximum stiction and variation over stroke.

C. Repeat Steps A and B while rotating the actuator counterclockwise.

Maintenance

D. Check to ensure that maximum stiction did not exceed 50 psi.

Note If maximum stiction exceeds 50 psi, refer to the ”Maximum Stiction

Exceeded” section.

Series 215 Rotary Actuator Product Manual

Page 63

Actuator Performance Checks

Excessive cross vane

flow

Abnormal drainback

port flow

Maximum stiction

exceeded

Low pressure seal

leaks

Excessive cross vane flow, as measured during actuator performance checks, may indicate actuator component damage or excessive wear.

Above normal cross vane flow typically indicates that the actuator rotor or cylinder has been damaged. Actuator disassembly to inspect actuator components and wear surfaces may be required.

Contact MTS for assistance.

Abnormal drainback port fluid flow, as measured during actuator performance checks, may indicate actuator component damage or excessive wear. Actuator disassembly to inspect actuator components and wear surfaces may be required.

Contact MTS for assistance.

Exceeding maximum stiction, as measured during actuator performance checks, can indicate abnormal internal friction at high torque values. This condition can prevent the actuator from reaching its full torque output.

Actuator disassembly to inspect actuator components and wear surfaces may be required. Thrust bearing wear surfaces should receive particular attention.

Contact MTS for assistance.

Fluid leakage noted on either actuator rotor shaft end may indicate a low pressure seal leak.

After removing the ADT/RVDT, flange adapter, and seal retainer, inspect the low pressure seals for wear and replace if needed.

The following table provides the seal kit part numbers necessary to replace the seals for each rotary actuator model.

Contact MTS for assistance.

Model 215 Rotary Actuator Internal Seal Kits

CTUATOR MODEL SEAL KIT NUMBER

215.32C 479171-01

215.35C 363716-01

215.41C 363716-01

215.42C 363716-01

215.45C 445272-01

215.51C 445272-01

Series 215 Rotary Actuator Product Manual Maintenance

Page 64

Actuator Inspection

When the actuator is disassembled, it is recommended that the individual parts of the actuator be examined for excessive wear and scratches or pitting. Give particular attention to the actuator rotor shaft and radial bearings.

Rotor shaft inspection Examination of the actuator rotor shaft should include the following:

1. Check the rotor shaft for surface wear. If the metal surfaces are pitted, scratched, or damaged in any way, the rotor shaft may need to be replaced or rebuilt. Contact MTS Systems for assistance.

Note Excessive rotor shaft wear may be indicated if fluid leakage reappears

after recent replacement of the low pressure seals.

2. Check the surface dimensions of the rotor shaft with a micrometer. The following figure indicates the locations of pertinent measurements.

3. Compare these measurements against the specifications given in the “Actuator Rotor Dimensions” table.

If the rotor shaft dimensions are less than the minimum dimensions in the “Actuator Rotor Dimensions” table, contact MTS Systems for assistance.

Maintenance

Rotor Shaft Measuring Points

Series 215 Rotary Actuator Product Manual

Page 65

Actuator Rotor Dimensions

IMENSION A

ODEL MAXIMUM MINIMUM

. MM IN. MM

215.32, 215.35 1.5010 38.125 1.5007 38.118

215.41, 215.42 2.2511 57.178 2.2508 57.170

215.45 3.7512 95.280 3.7509 95.273

215.51 3.7512 95.280 3.7509 95.273

DIMENSION B

ODEL MAXIMUM MINIMUM

. MM IN. MM

Actuator Inspection

215.32,215.35,

215.41, 215.42

215.45,215.51 0.0012 0.03 0.0009 0.023

0.0010 0.025 0.0007 0.018

DIMENSION C

ODEL NOMINAL

IN. MM

215.32 1.175 29.845

215.35, 215.41, 2.275 57.785

215.42 3.275 83.185

215.45 2.775 70.485

215.51 5.553 141.046

Series 215 Rotary Actuator Product Manual Maintenance

Page 66

Actuator Inspection

Maintenance

Series 215 Rotary Actuator Product Manual

Page 67

Page 68

MTS Systems Corporation

14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255

(within the U.S. or Canada)

Phone: 952-937-4000

(outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com Internet: www.mts.com

ISO 9001 Certified QMS

MTS 215 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Technical Support

How to Get Technical Support

Before You Contact MTS

If You Contact MTS by Phone

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

Problem Submittal Form in MTS Manuals

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

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

Before You Begin

Preface

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

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

Conventions

Documentation Conventions

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

Notes Notes provide additional information about operating your system or highlight

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

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

Introduction

Functional Description

Optional Equipment

Closed-Loop Rotary Actuator Systems

Actuator Specifications

Options Specifications

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

Reaction Brackets

Reaction Bases

Diaphragm Flexures

Flange Adapters

Safety Information

Hazard Placard Placement

Installation

Actuator Installation

Reaction Bracket and Torque Cell Installation

Diaphragm Flexure Installation

Aligning Force Train Components

Component Alignment on an MTS Base Plate

Component Centerline Alignment

Adjusting Actuator and Torque Cell Centerline Height

Adjusting Actuator and Torque Cell Concentricity

Rigid specimen If the current test application makes use of a rigid specimen, then the specimen

Adjusting Actuator and Torque Cell Centerline Angularity

Operation

Thrust and Side Load Characteristics

Thrust loads The following table lists the maximum allowable thrust load (Q) that can be

Definition of Useful Mathematical Terms

Side loads Side loads, which are normally induced by specimen misalignment or base plate

Test Setup Using No Flexures

Side load calculations The following side load calculation procedure is used to determine side loads due

Test Setup Using Standard Flexures

Test Setup Using Diaphragm Flexures

Sample calculation The previous figure illustrates the forces and measurements pertinent to the

Calculate flex angle Calculate the angle of flex (q) imposed on each diaphragm flexure by using the

Summary of Side Load Calculations

Rotational Inertial

Determining Maximum Rotational Inertia (JT)

Rotational Inertia Control Options

Maintenance

Routine Maintenance

Weekly Clean exposed areas of the actuator rotor with a clean, dry, lint-free rag. If the

Monthly Inspect actuator rotor and seals for excessive wear or leakage. Small scratches in

Yearly Change actuator seals if necessary. Actuator assemblies may require more or less

Actuator Performance Checks

Actuator Inspection

Rotor shaft inspection Examination of the actuator rotor shaft should include the following: