Controllers
RC4 controllers are industrial electronic appliances designed to control any hydraulic, electric or pneumatic testing machines.
Its high performance CPU platform allows implementation of latest control algorithms and advanced, state of the art, features available in today testing industry.
RC4 is suitable to control wide range of dynamic or static tests with high flexibility and customizability.
Applications covers all between single axis static tests up to complex multiaxis dynamic tests with heavy cross-coupling, inertia masses and non-linearities.
Test frequencies can reach 1000Hz or more while the test duration may last from milliseconds up to weeks or months.
RC4 has great support for testing process automation including automatic manipulation with test specimen so the test rig can be easily integrated in to production lines or in environments having tight timing requirements. See possible testing applications.
RC4 software covers all stages of typical test cases from data pre-processing through performing test to evaluation of recorded data.
Look at software features for details. Beside this it can easily integrate third party software
either to extend real-time functionality or to add custom data evaluation and presentation.
That makes RC4 Controllers perfectly suitable for OEM manufacturers.
Models
RC4 Express ™
Desktop controller for single to four axis machines.
Lightweight, compact appliance intended for installation in control rooms or labs with IP20 protection. Desktop case contains real-time controller, signal conditioners while a client computer and UPS is placed individually outside.
RC4 Flex ™
Free-standing 19'rack controller for multi-axis machines.
Standalone controller for mid to big size test appliances. Heavy-duty cabinet resist to harsh environment according IP54. Suitable for installations in production, open space labs or other places with higher protection demands. Cabinet accommodates all equipment including a client computer and backup power supply.
Hardware Specification *
RC4 controllers are built on powerful CPU platform running real-time system.
- CPU Platform
- 3GHz Quadcore CPU, 8GB RAM, 128GB SSD, Gigabit Ethernet
- Control channels
- 1 - 64 axis
- Control loop rate
- 1 - 10 kHz
- Data acquisition
- 24bit, 1-128* kHz, up to hundreds of signals
- Ultra low noise
- SNR 110dB
- Transducer support
- AC/DC bridges, IEPE/ICP, LVDT, Load cells, Strain gauges, Accelerometers, IRC - Optical incremental sensors and many others. See signal conditioners section.
- Outputs
- Voltage +/-10V, Current +/-160mA (servovalves), Power digital outputs 24V/1.5A (solenoids)
- Communication
- Gigabit, Ethernet, EtherCat, CAN-Bus, RS-485 (modbus), SSI
- -
- RCS can develop any customized or special hardware modules according customer's specification.
Capabilities *
RC4 controllers bring many outstanding features allowing easy coping with the most complex test tasks while keeping user friendliness and intuitive approach.
Advanced Regulation
Standard PID(FA) regulator may be switched to FlexReg ™ which allows configuring custom closed loop regulators with flexibility outperforming most of today's systems:
- MIMO regulators, cascade or parallel
- Nonlinear or Fuzzy terms
- Variable regulation structures
- User defined tunable parameters supporting gain profiling
All types with bump-less operation and anti windup protection.
Real-time Computing
Ability to insert custom computing code in to real-time loop allows realization of highly sophisticated functions like:
- Kinematic transformations
- Computed signals
- Full Modal Control, incl. Hexapod platform
- Inertia (mass) compensation
- HIL - connecting external DSP in to regulation loop
- SIL/MIL - inserting custom code (model) in to regulation loop
Multi-station
One RC4 unit can control up to 8 independent single or multi-axis testing machines simultaneously.
Definition of test rig is purely virtual and can exploit any available input and output signals.
Configuring of machines is stored at disk and can be reloaded according actual test tasks in the lab.
Automation
Automation saves time and avoids routine work or mistakes while operating the test rig. Manipulation with specimen between and after the test can be predefined in Sequence Editor and launched by press of single button.
Multi-axis test rigs often require several steps to install specimen or to move test rig in to operation position and back. That all can be fully automated preserving maximum level of security of specimen, test rig and operator.
Automation also allows integration of test rig in to production line.
Response Optimization
REWO - Iterations
Model based iterative optimization
MIMO, non-square models
Frequency and time domain profiling
Amplitude-Offset-Phase correction
Automatic correction in real-time
Usable for all periodic signals
Master span
Interactive tuning of offset and amplitude
Test Sequencer
Ability to define and perform arbitrary test sequence including complex conditions and branching is a strong feature of RC4.
- Single and Multi-axis synchronized sequences
- Generation of dynamic loading signals
- Subroutines, Jumps, Repetitions, Conditional branching
- Triggers - Global or block based conditional actions
- Smooth transitions between blocks is guaranteed
A use of Variables allows parameterization of testing signals like amplitudes, speeds etc. at one place influencing the whole sequence.
Signal Generators
RC4 implements all common periodic and static function generators plus advanced user defined types.
- Ramps and periodic functions: sine, square triangle...
- Sine sweeps of amplitude, frequency and offset
- Signal from dataset (various data formats accepted)
- Noise with PSD shaping
- User defined functional generator
Parameters of generators can be modified during the test e.g. on triggering specific condition.
Emergency recorder
Sometimes something extraordinary happens without operator presence like during long term unattended tests.
Emergency recorder stores all signals for recent 60s in circular buffer regardless of active data acquisition mode.Thus it helps quickly identify the origin of problem looking at complete history just before the incident.
Integration with third-party programs
Web based SOAP protocol allows straightforward integration with third party software running locally or remotely.
API covers most of RC4 functionality:
- Remote configuration and control of tests
- Receiving signals from test rig
- Monitoring test rig events
External program can serve as another user interface with specific definition of test and processing of data.