Bi-stable Pressure Valve Testing

Challenge

Developing a Zero Leak pressure control system for Bi-stable valve with the accuracy level of 0.01 bar measurement.

Solution

Using LabVIEW and Compact DAQ to develop a pressurized test rig system with interactive HMI control GUI with high precision pressure transducers.

Software Parameters

Initially, dynamic simulations were used to investigate the control system strategy and sensor/hydraulic specifications to meet the target performance defined by customer. We then fully implemented the LabVIEW control software. The prebuilt functions of the LabVIEW Real-Time, LabVIEW DSC Module, LabVIEW Report Generation Toolkit made it easy to work with the different hardware targets and saved countless man-hours compared to building the functionality from scratch.

Before connecting to the real system, the algorithm functionality was tested using a software emulation of the system. We then began factory commissioning and testing the real system and exploring the performance of the control loops under many situations (different pressure, different level and different parts).

Test Panel Software will be built using NI LabVIEW platform with all the test panel options. The software is flexible and having option for future enhancements.

The software development will pass through following stages

1. Software Design
2. Software Coding/Implementation
3. Software Testing

 Test System Description

• Application SoftwareNI LabVIEW software is used to control the following
  • To perform the testing for Sealing Test and functionality testing
• R0 – R6 Solenoid Valves: Is used to electronically control the valve for its turn On and OFF condion as per the test required. The control card that is used to control the solenoid valve is NI 9485 ( 8ch SSR Relay card with 16bit resolution) .
• M1 – M3 Pneumatic Pressure transducers: Is used to monitor the amount of pressure that is been filled inside the reservoir tank and also to provide the difference in value of the pressure during leak test in progress. The sensor that is been used to monitor is Keller 33X for the specification of 0-10bar with the 1% accuracy. The control card that is been used to monitor the Pressure transducer is NI 9237 (4ch AI, 24 Bit Resolution, 50 kS/s/ch, Strain Measurement Card, ±20mV/V).
• V1 – V2 Pneumatic Pressure Control Valve: Is used to set the set the amount of pressure should inlet the reservoir tank. This valve can also the provide the output feedback of amount of pressure released. The control card that is used to control the solenoid valve is NI 9263 (±10V, Analog Output, 100 kS/S, 4ch Module).
• EV1 – EV2 Excitation Pole of Bi-stable valve: Is used to energise the device and able to perform the test under different circumstances. The control card that is used to control the solenoid valve is NI 9482 (SPST Relay, 60 VDC/250 Vrms, 4Ch Module).
• Tower lamp & Switches: Is used to provide the operator an alarm signal in the testing functionality of the device and completion of the sequence. In case of failure can also be get intimated to the operator for their The control card that is used to control the solenoid valve is NI9375 (16 DI/16DO, 30 VDC, 7µs Sinking DI, 500µs Sourcing DO).