Real-time measurement, control aids clutch, converter manufacturing

Testing requirements that include control of multiple test stands and real-time data acquisition are integral to manufacturing clutches and torque converters for the automotive and trucking industries at LuK Inc. (Wooster, O.). Clutch materials and designs are evaluated during product research, development, and production, where speed and torque readings are used to calculate friction coe...

06/01/2000


Testing requirements that include control of multiple test stands and real-time data acquisition are integral to manufacturing clutches and torque converters for the automotive and trucking industries at LuK Inc. (Wooster, O.). Clutch materials and designs are evaluated during product research, development, and production, where speed and torque readings are used to calculate friction coefficients.

LuK wanted tighter control of the data acquisition process, but didn't want to devote a PC-based system to each test stand. Using plug-in boards with local microprocessors and memory to offload the PC's processor was the solution. This processor-based strategy yielded the sampling and response rates needed for real-time applications.

LuK's parent company, LuK Group (Buehl, Germany), eventually selected ADwin real-time process control boards from Keithley Instruments (Cleveland, O.). Engineers at LuK's U.S. subsidiary wrote the control software and user-interface software for the test system. Duration and ambient temperatures of these tests are varied to evaluate how hot material can get and still maintain acceptable friction characteristics. The resulting system performs four basic tests on clutch assemblies:

  • Slippage At varying motor speeds, torque and pressure are measured to calculate the friction coefficient of the material;

  • Engagement The motor is brought up to speed and the clutch is engaged with varying pressures;

  • Breakaway This is an inverse engagement test in which a reading is taken of the torque required to slip the clutch, and

  • Flush The fluid system is cleaned and the fluid is analyzed to determine how the clutch material degrades over time.



A block diagram of LuK Inc.'s clutch-slippage test system includes analog outputs for controlling motor speed, analog inputs for taking readings, and digital inputs/outputs for test stand power, low oil indication, and fluid pump activation.

Securing slippage data

LuK Inc.'s clutch slippage test system (see block diagram) includes inputs and outputs connected to a process controller in a 200 MHz, Pentium-based PC. The process controller used in the first two test stands is duplicated in two other stands. The controllers' processor modules contain 32-bit RISC processors and 12-bit analog I/O resolution.

These modules were chosen based partially on their ability to accommodate changes easily. Module variations include 60-500 kHz sampling rates and 1-128 MB memory capacity. The module's I/O board has analog inputs (16 single-ended or eight differential-channel), analog outputs (two- to six-channel), and digital I/O channels (6 or 16 each) and counters.

Using these modules, up to 10 processes for fast control, signal processing, and data acquisition can be calculated in parallel. Processes can run concurrently, exchanging global parameters and data independent of each other and the PC. Data transfers between processor and PC occur in the background, so they don't affect real-time operations.

In addition, LuK uses Keithley's ADbasic with the ADwin processor, which provides a development environment for creating the real-time measurement and control processes. All process parameters, delays, and status indications, as well as watch data arrays in a graphical form are displayed in ADshow, a debugging program.

To satisfy real-time requirements of the current application, LuK decided to locate the processing power close to the signal source, and to dedicate resources for processing the data that do not run into PC timing problems. This architecture provides deterministic responses with acceptable latencies.


Author Information
Jeff Johnson, electircal test engineer, LuK Inc., Wooster, O.




The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me