Vortex-dV Motorised Torque Testing System. Operating Manual

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1 Vortex-dV Motorised Torque Testing System Operating Manual July 2016

2 Important It is essential that you familiarise yourself with the contents of this Manual and the separate Guide to Safe Use of Mains Powered Test Systems (part no ) before attempting to operate your Vortex-dV Test System. Scope This reference manual covers operation of Vortex-dV torque test stands, intended for use with the Mecmesin Advanced Force and Torque Indicator (AFTI). Operation of the AFTI is covered in a separate manual. For operating in conjunction with VectorPro Lite, see the manual , VectorPro Lite for dv Test Stands and Instruments Mecmesin Ltd, supplied with Mecmesin test systems and not for redistribution Part no ii Mecmesin Vortex-dV Operating Manual

3 Contents 1. Items Supplied with your Test Stand 1 Available accessories 1 2. Installation Unpacking the stand Lifting the test stand Locating the stand Mains power supply 2 3. Assembly and Operation Attaching the torque sensor Fitting the AFTI torque indicator Connecting the AFTI and the Vortex-dV 5 Connect the test stand to a PC (VectorPro Lite users only) 5 Cable management Attaching grips and fixtures Test stand states Front panel controls 7 Emergency stop button 7 Dial control 7 The display 8 The multi-function selector buttons Settings Understanding angular position Understanding direction of rotation Understanding cyclic movement Jog settings Units settings Test settings 12 Cycle (by angular displacement) 12 AFTI Control 12 Half Cycle Language settings Specification 16 Declaration of Conformity 17 Vortex-dV Operating Manual Mecmesin iii

4 iv Mecmesin Vortex-dV Operating Manual

5 1. Items Supplied with your Test Stand Vortex-dV test stand (you will have also purchased a torque transducer rated at 1.5, 3, 6, or 10 N.m) AFTI gauge bracket (for fitting an AFTI torque indicator to the column) Allen key for tightening crosshead to gauge bracket Mains cable Document: A Guide to Safe Use of Mecmesin Mains Powered Test Systems Document: Vortex-dV Motorised Torque Testing System, Operating Manual Available accessories For a full range of digital force gauges and accessories, please go to the Mecmesin website or your local distributor, as listed on the back cover. Use communications cable part no to connect the Mecmesin Advanced Force and Torque Indicator (AFTI) to the Vortex-dV. When using Mecmesin VectorPro Lite software, use communications cable part no to connect the stand to MS-Windows computer. Vortex-dV Operating Manual Mecmesin 1

6 2. Installation 2.1 Unpacking the stand When you first receive the stand, please check that there is no obvious damage to the packaging. If there is any sign that the packaging or the test stand itself has been damaged, please contact Mecmesin or your authorised distributor immediately. Do not use the stand until you have done so. We strongly recommend that the packaging is retained, as this can be useful if the machine needs to be returned for calibration. Section 1 lists items that should be included with your test stand. Please contact Mecmesin or your authorised distributor if any items are missing or damaged. 2.2 Lifting the test stand The unpackaged weight of the test stand is given in the Specification table at the back of this manual. Do not try to lift heavy loads unaided. Use suitable lifting equipment if necessary. 2.3 Locating the stand The test stand should be positioned on a suitable, level, stable work surface. 2.4 Mains power supply Vortex-dV test stands can be used on or V ac Hz supplies. The rear fuse carrier will be set for your local requirement, but is reversible, so should you replace a fuse, the correct local voltage must be selected. The voltage that is selected is the one where the arrows meet: Fuse carrier Carrier removal 2 Mecmesin Vortex-dV Operating Manual

7 3. Assembly and Operation Top-load tray Crosshead Static torque transducer Upper fixing plate (optional) AFTI torque indicator Lower fixing plate (optional) shown with saddle plate AFTI bracket Control panel Vortex-dV Operating Manual Mecmesin 3

Insert each bolt and tighten lightly, make sure the transducer is seated centrally and then tighten the bolts. 3.

8 3.1 Attaching the torque sensor Attach the torque sensor to the crosshead using the four M6 caphead bolts supplied. Make sure the cable exit is towards the side you will fix the AFTI. Insert each bolt and tighten lightly, make sure the transducer is seated centrally and then tighten the bolts. 3.2 Fitting the AFTI torque indicator The Vortex-dV is suitable for left or right-handed operation. The fixing bracket is easily adjusted or removed and transferred to the opposite column. Use an 4 mm Allen key for tightening. Adjusting the AFTI fixing bracket 4 Mecmesin Vortex-dV Operating Manual

Attaching the AFTI Adjusting the bracket angle 3.

Connect the top port of the AFTI to the RJ45 port marked gauge in the back of the Vortex-dV, using supplied cable 351-092.

RJ45 AFTI / gauge port USB B connector for PC (VectorPro Lite only) Connect the test stand to a PC (VectorPro Lite users only) If

9 Attaching the AFTI Adjusting the bracket angle 3.3 Connecting the AFTI and the Vortex-dV Connect the transducer to the side port of the AFTI, using the cable from the transducer. Connect the top port of the AFTI to the RJ45 port marked gauge in the back of the Vortex-dV, using supplied cable This cable enables AFTI torque control testing, and passes the torque readings to the Vortex-dV for display. RJ45 AFTI / gauge port USB B connector for PC (VectorPro Lite only) Connect the test stand to a PC (VectorPro Lite users only) If you are using VectorPro Lite software, connect the USB B port to a PC using cable part no Cable management It is essential that no cables are permitted to interfere with the controls or any moving parts. Vortex-dV Operating Manual Mecmesin 5

3.4 Attaching grips and fixtures The most commonly-used upper fixture used is the 100 mm upper fixing plate with a diameter capacity of 10 mm to 78 mm.

10 3.4 Attaching grips and fixtures The most commonly-used upper fixture used is the 100 mm upper fixing plate with a diameter capacity of 10 mm to 78 mm. This is fixed to the adaptor on the torque transducer using the four countersunk screws supplied, using a 2.5 mm Allen key. The fixture can also be more quickly removed by means of the two grub screws in the adapter, accessed through slots in the sides of the fixing plate, as shown below. The most commonly-used lower fixture is the 188 mm diameter lower fixing plate with a diameter capacity of 10 mm to 190 mm. This is fixed to the Vortex-dV spindle using the four countersunk screws supplied, using a 2.5 mm Allen key. A range of other torque testing fixtures is available, including saddle plates that help support samples in the fixing plates, longer grip fingers, mandrels, and chucks. 3.5 Test stand states The test stand can be in one of five states: A. test readiness (ready to start, or complete) B. testing (platen rotating) C. stopped (interrupted, or emergency stop) D. manual control (for jogging, or positioning the lower platen) E. settings menu In each state, the selector buttons have functions described by icons. 6 Mecmesin Vortex-dV Operating Manual

3.6 Front panel controls status messages button functions multi-function selector buttons dial wheel dial button emergency stop display dial lights Emergency stop button Push to immediately

If cycling between torque loads, reset the AFTI indicator before resuming testing.

11 3.6 Front panel controls status messages button functions multi-function selector buttons dial wheel dial button emergency stop display dial lights Emergency stop button Push to immediately stop movement in the platen. Rotate the button to release it and resume motor control. Do not simply restart a test. Rectify the situation and/or any residual torque. If cycling between torque loads, reset the AFTI indicator before resuming testing. Dial control The lights The lights surrounding the wheel show in three colours, and three states, indicating the status of the test stand: Green: pulsing, ready to test; Amber: static, test complete Red: static, test stopped rotating: scrolling a menu rotating: platen moving or interrupted Vortex-dV Operating Manual Mecmesin 7

The wheel When in jogging mode (by selecting the double-ended arrow button in test status) the wheel drives the spindle directly clockwise or anticlockwise.

enable crosshead jogging The wheel is also a speed controller.

12 The wheel When in jogging mode (by selecting the double-ended arrow button in test status) the wheel drives the spindle directly clockwise or anticlockwise. This is an alternative to using the jog buttons, which move the drive spindle at the clockwise (CW) and anticlockwise (ACW) speeds as set in Settings > Jog Settings. enable crosshead jogging The wheel is also a speed controller. The jog buttons move the drive spindle at the set speeds, but rotating the wheel clockwise whilst holding a jog button will increase the speed, and rotating the wheel anticlockwise will decrease the speed. The set speed is restored when the jog button is released. The wheel is also turned to navigate the menus. When in a selection menu, the wheel cycles through the selections and their values. This is an alternative to navigation using the up and down arrow buttons (see E: Settings buttons below). Menu: use buttons or wheel The button The central button is used to confirm a menu selection. It is equivalent to the tick button. The display The display indicates the stand status and mode (ready, stopped, test type, speed, cycle count, settings menu), and when ready: angular displacement, speed and torque. An icon shows when an AFTI is not detected. The functions of the four buttons at any time are indicated by a series of icons. 8 Mecmesin Vortex-dV Operating Manual

13 The multi-function selector buttons A: Test readiness No AFTI connected Start test sequence (B) Go to jog mode (manual motor control) (D) Go to settings (E) B: Testing Interrupt test. This stops drive spindle movement, leaving the stand in a state of test readiness, with Interrupted: User displayed. The start button will restart, not resume, the test sequence. C: Stopped Emergency stop button pushed. Message: Emergency Stop. Release the emergency stop to regain control and remedy the situation before resuming testing. D: Motor control If this button is pressed, the message is Interrupted: User, and the test readiness buttons (A) are displayed. The Start test button resumes testing. Cyclic testing returns to the first cycle action. Important! Under torque load control, the AFTI MUST be reset first. Shows clockwise and anticlockwise speeds as set Zero (tare) angular displacement of the drive spindle Vortex-dV Operating Manual Mecmesin 9

14 Jog the drive spindle clockwise at speed as set (or turn wheel clockwise) Jog the drive spindle anticlockwise at speed as set (or turn wheel anticlockwise) Go back to test readiness (A) E: Settings Confirm selection (or press dial button) Navigate up a menu selection or value (or turn wheel clockwise) Navigate down a menu selection or value (or turn wheel anticlockwise) Go back to previous menu item, or from Settings (E) to test readiness (A) 3.7 Settings All settings are made by moving the selection marker to the required menu item or digit, and confirming with the tick button or using the central dial button. 3.8 Understanding angular position An angular position of xº means rotation by xº from tared zero, in the direction of travel according to the sign. A set position of +270º means rotated 270º from tared zero in a clockwise direction. An angular position greater than 360º will always produce movement of greater than one complete rotation in relation to tared zero. The drive spindle will therefore never take the quickest route to a position, even to a start test position. 10 Mecmesin Vortex-dV Operating Manual

15 3.9 Understanding direction of rotation All icons for rotation represent the movement of the spindle as viewed. However, when performing a closure unscrewing test (for example), even though this is an anticlockwise test it is performed by a clockwise rotation of the drive spindle. Angles clockwise from tared zero are positive and angles anticlockwise from tared zero are negative Understanding cyclic movement Any cycle to a position (i.e. rather than to a torque limit), is between two angular limits: anticlockwise and clockwise. A complete cyclic rotation must be between the two angles, so a clockwise-starting cycle must begin at the anticlockwise angle, and vice versa. If not at this angle, the spindle will rotate initially to this position. Any cycle then starts in a direction towards the angle of its sign, for example starting clockwise to +60º. Tared zero angle Anticlockwise direction: applies clockwise torque Clockwise direction: applies anticlockwise torque Anticlockwise (ACW, ve) angle: start of CW cycle, end of ACW cycle Clockwise (CW, +ve) angle: start of ACW cycle, end of CW cycle drive spindle 3.11 Jog settings On a Vortex-dV, jogging means manual rotation, using the control panel buttons. These speeds are set by the user and take effect whenever the jog buttons are used, for example in a non-cyclic or manual test. Remember that the wheel in jog mode can give more precise direct drive positioning. Clockwise (CW) / Anticlockwise (ACW) speed 0.1 to 30.0 rpm Vortex-dV Operating Manual Mecmesin 11

16 3.12 Units settings Angle Speed rev, deg rev/min, rev/s, deg/min, deg/s 3.13 Test settings Cycle (by angular displacement) In a cyclic test, the spindle will move between two reference angles that are relative to tared zero. A cycle only starts when the drive spindle is at the furthest displacement position from the angle set in the initial direction of rotation. Cycle Count Clockwise (CW) Speed Anticlockwise (ACW) Speed Speed is always positive units (range as jog speeds, above) CW Angle ACW Angle Sets clockwise and anticlockwise limits for a cyclic test. Up to 9999 revolutions from tared zero are allowed. A +ve value is a clockwise relative angle of the drive spindle, and a ve value is an anticlockwise relative angle. Start Direction Select in which direction the drive spindle should move to start the test cycle. Note that depending on the angle at which the spindle has been left, it may need to first move in the opposite direction through the tared zero angle, to reach the starting angle. AFTI Control The AFTI can be used to set torque limits to control drive spindle movement during a cycle. In the AFTI Comms menu Port, set the gauge baud rate to 115,200, and TX Units and TX sign, both to On. Loads, action (reverse/stop/cycle) and cycle count are all set on the gauge. The stand can then be made to: move to a set torque or break condition and stop cycle between two torque values 12 Mecmesin Vortex-dV Operating Manual

17 cycle to a maximum torque or break condition then reverse Note: Although the AFTI can be set to reverse on break or at a torque value, there is no other trigger to stop the spindle rotating, so it must be stopped manually. Examples Rotate the gripped sample at a given speed until the applied torque is 50 N, then stop. Rotate the gripped sample at a given speed until the sample breaks (a drop in applied torque by a percentage of sensor capacity), detected by the AFTI, and stop. Rotate the gripped sample at a given speed until the applied load is 3 N.m, then reverse to 0.5 N.m, reapply the torque, and continue this cycle for as many times as set by the AFTI. Clockwise (CW) Speed Anticlockwise (ACW) Speed Speed is always positive. Start Direction Select in which direction the drive spindle should move to start the test cycle. Note that depending on the angle at which the spindle has been left, it may need to first move in the opposite direction through the tared zero angle to reach the starting angle. Performing a torque-controlled test 1. Adjust the AFTI for upper and lower load limits, and cycle count, or to stop at a torque limit or break. Note that: on the AFTI, torque applied clockwise to the transducer (applied through anticlockwise spindle rotation) is +ve. Clockwise spindle rotation applies anticlockwise torque to the transducer, which is -ve. the cycle counter in the gauge decrements, whereas the stand cycle counter increments 2. Set up the test stand for AFTI control, with speed and initial direction of rotation. 3. Secure the test sample, set the angular position of the lower grip, and zero this. 4. Always ensure Reset is pressed on the AFTI before commencing a test. 5. Start the test At the end of a test, or in a stopped condition, you may need to move the crosshead to clear a sample, or the drive spindle to remove a torque. Never restart a test from a stopped condition with a residual torque, and always Reset the gauge before a subsequent test. If the AFTI is switched off or loses power during an active test in AFTI Control mode, the drive spindle will stop. Vortex-dV Operating Manual Mecmesin 13

18 Half Cycle A half-cycle test is to an angular displacement relative to tared zero. Movement always ends at the angle set in the starting direction, shown in red below. A half-cycle only starts when the drive spindle is at the furthest displacement position, relative to tared zero, from the end position. This can appear confusing. The conditions in the shaded rows of the table below provide a true half-cycle test. Familiarise yourself with why the others effectively result in a full-cycle movement. A single cycle test is usually a better choice. Note that row conditions 3 and 4 under a full cycle test (any number of counts) will also result in a half-cycle action. Half-cycle tests will always end with the display reading the final angle that was set. To re-run, the drive spindle must be returned to zero, or the displayed angle tared to zero. CW angle ACW angle Start direction Action from tared zero Press run button again without taring angle +30º zero CW Go CW to +30º and stop Go to ACW angle (zero), then CW to +30º (becomes a full cycle) zero 30º ACW Go ACW to 30º and stop Go to CW angle (zero), then ACW to 30º (becomes a full cycle) +30º +30º CW or ACW Go to CW angle of +30º and stop No action 30º 30º CW or ACW Go to ACW angle of 30º and stop +30º zero ACW Go to CW angle of +30º and return ACW to zero zero 30º CW Go to ACW angle of 30º and return CW to zero +30º -30º CW Go ACW to -30º, then through tared zero to +30º and stop +30º -30º ACW Go CW to +30º, then through tared zero to -30º and stop No action Repeat action Repeat action Go ACW through tared zero to - 30º, then through tared zero to +30º and stop. Go CW through tared zero to +30º, then through tared zero to 30º and stop. 14 Mecmesin Vortex-dV Operating Manual

19 CW Speed ACW Speed Speed is always positive. Clockwise (CW) angle Anticlockwise (ACW) angle Often more clearly set in degrees rather than revolutions, this is relative to the tared zero angle. CW angles are normally positive and ACW angles negative, though if within the range of the opposite angle set, an opposite sign may not be disallowed (see table above). Start direction Select in which direction the drive spindle should move to start the test cycle. Note that depending on the angle at which the spindle has been left, it may need to first move in the opposite direction through the tared zero angle to reach the starting angle Language settings Select the appropriate language. This returns you to the Settings menu in the language chosen. Vortex-dV Operating Manual Mecmesin 15

20 4. Specification Vortex-dV 1.5 N.m 3 N.m 6 N.m 10 N.m Measurement range N.m kgf.cm lbf.in Dimensions Maximum travel of adjustable transducer carriage mm (7.2 ) Maximum headroom 505 mm (19.9 ) [448 mm (17.6 )]* Width between columns 280 mm (11.02 ) Weight 19.5 kg (48 lb) Capacity of lower mounting table mm ( ) Capacity of upper mounting table mm ( ) Power requirements Voltage Max power drain Torque measurement Torque accuracy Torque units Speed Speed range Speed accuracy Speed resolution Position Maximum rotation 230 V AC 50 Hz or 110 V AC 60 Hz 100 W 0.5% of full scale mn.m, N.m, kgf.cm, lbf.in, ozf.in (as per AFTI) rev/min to 30 rev/min (clockwise and anticlockwise) ±1% of indicated speed 0.01 rev/min (0.1º/s) 9999 revs Positional accuracy 0.2 per 36,000 Positional resolution * with upper and lower mounting tables fitted 0.1º (0.001 rev) 16 Mecmesin Vortex-dV Operating Manual

21 Declaration of Conformity Vortex-dV Operating Manual Mecmesin 17

22 18 Mecmesin Vortex-dV Operating Manual

23 Vortex-dV Operating Manual Mecmesin 19

Mecmesin : a world leader in affordable force and torque testing solutions Since 1977, Mecmesin has assisted thousands of companies achieve enhanced quality control in design and production.

24 Mecmesin : a world leader in affordable force and torque testing solutions Since 1977, Mecmesin has assisted thousands of companies achieve enhanced quality control in design and production. The Mecmesin brand represents excellence in accuracy, build, service, and value. In production centres and research labs worldwide, designers, engineers, operators, and quality managers endorse Mecmesin force and torque testing systems for their high performance across countless applications. Algeria Argentina Australia Austria Bangladesh Belgium Brazil Bulgaria Cambodia Canada Chile China Colombia Costa Rica Croatia Czech Republic Denmark Ecuador Egypt Estonia Finland France Germany Greece Hungary India Indonesia Iran Ireland Israel Italy Japan Korea Kuwait Laos Latvia Lebanon Lithuania Malaysia Mexico Morocco Myanmar Netherlands New Zealand Norway Peru Philippines Poland Portugal Romania Russia Saudi Arabia Serbia Singapore Slovakia Slovenia South Africa Spain Sri Lanka Sweden Switzerland Taiwan Thailand Tunisia Turkey UAE UK USA Vietnam The Mecmesin global distribution network guarantees your testing solution is rapidly delivered and efficiently serviced, wherever you are. Head Office UK Mecmesin Limited w: e: sales@mecmesin.com North America Mecmesin Corporation w: e: info@mecmesincorp.com France Mecmesin France w : e: contact@mecmesin.fr Asia Mecmesin Asia Co. Ltd w: e: sales@mecmesinasia.com Germany Mecmesin GmbH w: e: info@mecmesin.de China Mecmesin (Shanghai) Pte Ltd w: e: sales@mecmesin.cn

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