A customer enlisted the LABTECH Services Group to create software to control a high speed hydraulic pump test stand. The application consisted of the measurement and control of the operation of two pressure compensated hydraulic pumps. The test consisted of high speed cyclical events that were to continue for 1000 hours or until the unit failed.
The test stand consisted of two pressure compensated pumps with a load sense that were each connected to a gearbox, suction header, and test manifold. A single 300 HP 1800 RPM electric motor provided power to a gearbox. A charge pump provided cooling flow and charge pressure to the suction header. The apparatus needed to be monitored for flow (Pump 1 and Pump 2), pressure (both pumps monitored for case drain, output, and suction), and temperature (gearbox, suction, and each pump). The proportional relief valves were controlled with analog outputs while discrete outputs provided safety valve operation. In total the test stand required, 8 analog inputs, 4 RTD inputs, 2 Analog outputs and 7 digital outputs.
The operation of the test stand consisted essentially of ramping the pumps to full pressure while monitoring for a proper pressure relief condition and then returning to a non-pressure state and repeating this for the 1000 hour duration of the test. During the test the stand was monitored for failure due to pressure falling outside of a governed range, or excessive temperature anywhere in the apparatus. If a failure occurred, the cause of failure was logged and the test was shut down automatically.
A user interface was also created using LABTECH Realtime Vision which displayed the realtime data of the test stand. All of the analog and temperature measurements were displayed in strip chart style trend graphs in realtime. All alarm/shutdown conditions generated an alarm display which required operator acknowledgment and logged the condition and acknowledgment to disk.
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