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Endurance Test System Actuator

The test system is developed to do Characterization and Endurance of E-Park Lock actuators used in automobiles.

Problem Statement

1.Characterization: Programming the position sensor inside the actuator using PTC programmer. The actuator is rotated to the mechanical limits and rotary encoder data is compared. It’s difficult to do the characterization manually.

2.Endurance: The actuator is rotated from 0-45 degree and 45-0 degree. The control law algorithm controls the motor rotation with high accuracy by taking feedback from position sensor in actuator or from rotary encoder. Customer found difficulty in doing Endurance for million cycles with data acquisition, logging and analysis.

Challenge

  • Characterisation of Motor.
  • Automation of position sensor programming in actuator
  • Implementation of high-speed control law algorithm for actuator control.
  • Position Control of actuator through PWM signals.
  • Manage various load profiles for actuator.
  • Actuator safety while mechanical and electrical operation.
  • High speed data acquisition from torque, current and position sensors.
  • Store and Analyse large set of test data.
  • Perform the endurance test for 3 Million cycle.

Solution

  • The LabVIEW test software is developed to perform characterization and endurance test.
  • Automated PTC program to load characterisation data into actuator position sensor.
  • NI cRIO Real Time Controller is used for high performance along with the FPGA layer for high speed control and data acquisition.
  • NI high speed PWM module is used to control the actuator through H Bridge.
  • ABB BLDC motor is coupled with actuator to generate load profiles.
  • Torque, Current, Position sensors are used for mechanical and electrical protection.
  • NI analog module is used to acquire data from sensors through FPGA layer.
  • The acquired set of data is logged in TDMS files.
  • Highly efficient test software in DQMH architecture to do endurance.

Hardware Used

  • NI cRIO
  • NI PWM Module
  • NI DI/DO Module
  • NI AI/AO Module
  • ABB BLDC motor
  • Torque meter
  • Rotary encoder
  • Current sensors

Impact to Customer

  • The test software automates the characterisation of actuator.
  • Endurance test for 3 million cycles with all the test data for each cycle.
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