Design and Control of Dynamic Testing Systems

Name: Design and Control of Dynamic Testing Systems
Start: 2015-10-21T08:30:00
Location: Copthorne Tara Hotel London Kensington

Copthorne Tara Hotel London Kensington, London

21 October 2015
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Key Speakers:
• Hans Klaufus, Solution Development Manager Aerospoace Test Systems, MOOG
• Dr Andrew Halfpenny, Chief Technologist, HBM-nCode
• James Cunnane, Principal Engineer, Instron
• George Taylor, Managing Director, Servotest
• Rick Meyers, Senior Application Engineer, MTS Systems Corporation

Overview

Dynamic testing of structures, materials and components in the laboratory to determine their mechanical properties is an essential part of engineering research and development.

Test apparatus of increasing sophistication is being developed to replicate real-world forces and motions within the laboratory environment. Accurate control of actuators is vital to the effectiveness of such apparatus, both the hardware design and the advances in closed and open loop control algorithms which address this need are the subject of this event.

Benefits of attending:
• Enhance your understanding of testing concepts
• Gain insight into test rig design and controller design
• Understand how to analyse test result accuracy
• Recognise cost efficient testing methods
• Network with industry experts and seek their practical advice on testing methods

Day 1

08:30 - REGISTRATION AND REFRESHMENTS

09:30 - CHAIR’S OPENING REMARKS

Andrew Plummer, Professor of Machine Systems, University of Bath

09:40 - DESIGN AND CONTROL OF DYNAMIC TESTING SYSTEMS

Keynote speaker to be announced
• Get an update on hydraulic, electric, electrodynamic and resonant test systems
• Hear the latest industry experience in closed loop control
• Review the current state of Iterative control systems
• Discuss the latest developments in model-in-the-loop systems

10:00 - AUTOMOTIVE STRUCTURAL TESTING

Dr Colin Dodds, Dodds and Associates, Independent Consultants
• Review component fatigue testing: the benefits of random loading or “Betriebsfestigkeit” over the classical sine wave loading
• Understand the advantages of aggregate durability testing, e.g. suspensions, engine mounts and radiators
• Review the objectives of complete vehicle durability testing and manage the cost effectiveness of the number of loading axes
• Discuss how to accelerate structural tests in the laboratory
• Identify current industrial practice and future trends

10:20 - AUTOMOTIVE SUSPENSION TESTING FOR DURABILITY AND CHARACTERISATION

Rick Meyers, Senior Application Engineer, MTS Systems Corporation
• Address the pros and cons of component vs. complete multi-axial suspension testing
• Discuss testing alternatives for testing active suspensions
• Understand the differences between durability and characterisation testing

10:40 - QUESTION AND ANSWER SESSION

An opportunity to put forward any questions to the session presenters

10:50 - NETWORKING REFRESHMENT BREAK

11:20 - HYBRID TESTING

David Wagg, Professor of Nonlinear Dynamics, The University of Sheffield
• Get an update on the development of hybrid testing for mechanical engineering applications
• Know recent developments based on real-time control
• Lean from application examples based on fluid based damper devices

11:40 - VIBRATION CONTROL

Steve Daley, Professor of Industrial Active Control, University of Southampton
• Get an overview of the current state of vibration control research
• Learn about the benefits of using optimal ILC methods for accelerated testing
• Design and development of a novel multi-axis electromechanical actuator for dynamic testing and vibration control

12:00 - CRASH TEST CATAPULTS

Rainer Hoffmann, Managing Director, Carhs GmbH
Michael DeLeeuw, Catapult Business Unit Manager, Instron GmbH
• Why crash catapult testing?
• Compare crash catapult testing and simulation
• Explore the limits of crash catapult testing
• Address the challenges for equipment design and control in closed-loop servocontrolled crash simulators
• Find out the latest about the use of advanced analytical modelling tools to identify system behaviour
• Learn about commercialisation of solutions and results

12:20 - QUESTION AND ANSWER SESSION

An opportunity to ask questions to the session presenters

12:30 - NETWORKING LUNCH

13:30 - AEROSPACE STRUCTURAL TESTING

Dr Andrew Halfpenny, Chief Technologist, HBM-nCode
• Get an update on the new “Test Tailoring” methodology for checking and deriving accelerated vibration tests based on MIL-STD-810G, DEF STAN 00-35, NATO STANAG 4370 and AECP-240
• Understand the relationships between Power Spectral Density (PSD), Shock Response Spectrum (SRS) and Fatigue Damage Spectrum (FDS)
• Discuss the benefits from testing with non-Gaussian vibration signals

13:50 - TRENDS, CHALLENGES AND SOLUTIONS IN PHYSICAL AND VIRTUAL AIRFRAME TESTING. REAL-TIME DATA CORRELATION FOR EARLY DETECTION OF CRACK INITIATION

Hans Klaufus Solution Development Manager Aerospace Test Systems MOOG and Marco Nawijn, Managing Director, Colosso
• Faster testing by smarter testing
• Are current sensors up to the challenge?
• From pre-planned inspection intervals to condition-driven inspection intervals?

14:10 - EARTHQUAKE TESTING

Martin Williams, Professor in Structural Engineering, Fellow of New College, Oxford University
• Get an update on the development of pseudo-dynamic and real-time hybrid testing for earthquake engineering applications
• Understand the basics of distributed hybrid testing for large, complex structures
• Learn from case study tests on seismic energy dissipators

14:30 - EARTHQUAKE TESTING

George Taylor, Managing Director, Servotest Testing Systems Ltd
• Practical design issues in Seismic MAST design.
• Control platform : simplicity of platform v system complexity
• Examples of control issues with difficult requirements
• Scale testing conflicts in requirements: Seismic qualification vs. full scale model vs. scale model

14:50 - QUESTION AND ANSWER SESSION

An opportunity to ask questions to the session presenters

15:10 - NETWORKING REFRESHMENT BREAK

15:40 - CONTROL FOR MATERIALS TESTING

James Cooke, Senior Engineer, Analysis and Control, Instron
James Cunnane, Principal Engineer, Analysis and Control, Instron
• Understand the benefits of simultaneous automated tuning of position, load, and strain control loops for ElectroPuls linear electric motor testing machines, allowing non-expert users to achieve reliably good tuning
• Hear how a similar white-box method has now been applied to tuning of servohydraulic materials testing machines, which improves on common heuristic tuning methods
• Find out how testing of composites can be streamlined using a novel specimen temperature control method which improves test reproducibility and reduces testing time

16:00 - CONTROLLER PLATFORMS

Dr Anton D. Raath, Managing Director, CaTs3 Limited
• Review the practical benefits of digital technology on modern controller platforms
• Discuss the application of real-time adaptive controller strategies to provide practical solutions in industry
• Debate the benefits of time domain based modelling and simulation in controller platforms to replicate in-service loads in the laboratory and some recent developments in this field

16:20 - PLATFORMS FOR THE PRACTICAL IMPLEMENTATION OF YOUR SIMULATION AND CONTROL DESIGNS

Nick Williamson, Staff Systems Engineer, National Instruments
• Learn how to import your existing simulation code into environments that provide physical connectivity for control in the outside world
• Learn about some typical hardware platforms
• Find out how to achieve faster control using reconfigurable hardware
• Learn from real world application case studies

16:40 - QUESTION AND ANSWER SESSION

An opportunity to ask questions to the session presenters

16:50 - CHAIR’S CLOSING REMARKS

17:00 - END OF SEMINAR

ANDREW PLUMMER: PROFESSOR OF MACHINE SYSTEMS & DIRECTOR OF THE CENTRE FOR POWER TRANSMISSION AND MOTION CONTROL, UNIVERSITY OF BATH

Andrew Plummer received his PhD degree from the University of Bath in 1991, for research in the field of adaptive control of electrohydraulic systems. He has worked for Rediffusion Simulation on flight simulator control systems, as a lecturer at the University of Leeds, and as R&D manager for Instron. He is now Professor of Machine Systems at the University of Bath, and Director of the Centre for Power Transmission and Motion Control. Professor Plummer chairs the UK Automatic Control Council, and chaired the institution’s Mechatronics Informatics and Control Group from 2009-14.

Colin Dodds: Dodds and Associates, Independent Consultants UK

Colin Dodds completed his doctorate on the response of vehicle components to random road surface profiles in 1972 and has spent his career in the automotive industry as a supplier of test services. He has designed and built many automotive structural test facilities in the US, India and China and has set up test operations at a new proving ground in Germany. His clients have included GM, Ford, Chrysler, Toyota, Nissan, Fiat and Mercedes-Benz along with numerous OEMs and suppliers in China and India. Prior to becoming an independent consultant he was the General Manager of the largest independent automotive structural test facility in the USA. As an independent consultant, Colin specialises in fatigue life estimation in automotive components, defining and measuring automotive duty cycles and customer correlation.

Rick Meyers: Senior Application Engineer, MTS Systems Corporation

Rick Meyers is a Senior Application Engineer at MTS Systems, a world-wide supplier of advanced test systems. He received a BS - Electrical Engineering and Business Management from St. Cloud State University. Rick has been with MTS Systems for more than 25 years in various roles – all in the Vehicle Dynamics area. From 1995 to 2001 he was responsible for the Ground Vehicle Sales in South East Asia. From 2001 to 2002 he was a worldwide account engineer for one of the major automotive OEMs. In 2002, he began taking on numerous worldwide market-focused areas ranging from multi-axial simulation to rail. He is currently responsible for sales and business development for the Intelligent Vehicles Group.

David Wagg: Professor of Nonlinear Dynamics, University of Sheffield

David Wagg was awarded his BEng degree and PhD from University College London. From 1998 until 2000 he was a postdoctoral researcher at the Earthquake Engineering Research Centre at the University of Bristol. In 2000 he was appointed as a Lecturer in the Department of Mechanical Engineering at the University of Bristol and he became Professor there in 2008. From 2004 to 2009 he was an EPSRC Advanced Research Fellow. In July 2013 he moved to the University of Sheffield to take up a chair in Nonlinear Dynamics. Professor Wagg's research is focused on understanding and controlling nonlinear structural dynamics. He is currently PI for the £4.2M EPSRC funded Engineering Nonlinearity Programme Grant, which is a consortium of five universities and eight industrial partners.

Steve Daley: Professor of Industrial Active Control, University of Southampton

Steve Daley is Professor of Industrial Active Control at the Institute of Sound and Vibration Research and Director of the BAE Systems Centre for Research in Active Control (CRAC). After graduating with a 1st Class Honours Degree in Mechanical Engineering in 1981 he received a PhD in 1984 from the University of Leeds for his thesis on the attitude control of large flexible spacecraft. Following a two-year period working as a researcher at the GEC Engineering Research Centre (ERC) he joined the Department of Electrical Engineering and Electronics at Brunel University as a Lecturer in Control Engineering in 1986. He re-joined ERC in 1990 and following the acquisition of the Centre by ALSTOM in 1996 was promoted to Technology Head for Control and Monitoring. In 2003 he returned to an academic position as Professor of Industrial Control in the Department of Automatic Control and Systems Engineering at the University of Sheffield and moved to the ISVR in 2010.

Andrew Halfpenny: Chief Technologist, HBM-nCode

Andrew Halfpenny is the Chief Technologist for HBM-nCode products. Specialising in vibration, fatigue and fracture he has developed many predictive analysis techniques including: ‘Crack Growth Simulation’, ‘TMF’, ‘Vibration Fatigue’, and ‘Accelerated Vibration Testing’. He has authored many publications and seminars on ‘Fatigue Theory’, ‘Digital Signal Processing’ and ‘Accelerated Testing’. Andrew is heavily involved in consultation with aerospace and automotive companies and developed the new procedures used for vibration qualification of UK military helicopters. Andrew graduated in Civil and Structural Engineering from the University of Sheffield (1992) and subsequently obtained a PhD in Mechanical Engineering from the University College London (1996).

Hans Klaufus: Solution Development Manager Aerospace Test Systems, MOOG

Hans Klaufus holds an MSc degree in Aerospace Dynamics from Cranfield University and has 15 years of experience in Aerospace testing technology working for Moog. In his former roles of Programme Manager and Business Development Manager he was involved in many large scale aerospace test projects for Moog with major aerospace and defence customers around the globe. Having a strong interest in new technology, he now develops new product strategies for Moog by analysing market needs and technology trends.

Marco Nawijn: Managing Director, Colosso

Marco Nawijn holds an MSc in Aerospace Engineering from Delft University of Technology, Netherlands. He has 14 years of experience in the field of aerospace engineering. Marco has a strong focus on applications and innovation in the field of computer simulation, experimental verification and software engineering. He was also actively involved in aerospace certification test programs (for example Gulfstream G650 horizontal stabilizer and elevator test program).

Martin Williams: Professor in Structural Engineering, Fellow of New College, Oxford University

Martin Williams is a Professor in the Department of Engineering Science at Oxford University, and a Fellow of New College, Oxford. He has led numerous research projects in earthquake engineering and structural dynamics, including the development of the real-time hybrid test method, analysis and testing of passive energy dissipation devices, modelling of grandstand vibrations and investigation of dynamic human-structure interaction. He is a Fellow of the ICE and the I.Struct.E and has held visiting academic posts at the University of British Columbia, UNAM Mexico City and the University of Queensland.

George Taylor: Managing Director, Servotest Testing Systems Ltd

George Taylor joined Servotest as Managing Director in 2013. Since joining he has been involved in the bid, and build of Seismic MAST projects but also has been on site in India assisting the commissioning of a 6m x 6m Earthquake Table. George gained his B.Eng (Hons) in Mechanical Engineering from Leeds University and his Chartership with the IMechE in 1995. Prior to joining Servotest, he was Distribution Director at Hartridge and also worked for IST as Asia Sales Manager in the late 90’s. George has an MBA from Imperial College.

Rainer Hoffman: Managing Director, Carhs GmbH

Rainer Hoffman has been involved in automotive safety throughout his career. After graduating from Wayne State University, where he worked at the Bioengineering Centre with Prof. Albert King, he joined a research group on passive safety at Porsche where he was involved in many aspects of automotive safety including accident research, occupant simulation, crash testing and safety engineering. Rainer advanced safety simulation by introducing new techniques like airbag simulation, airbag folding and Finite-Element dummy modelling during his subsequent work with ESI Group. As the head of the simulation department of PARS (now Continental Safety Engineering), he led the R&D efforts for some of the first series production side airbag developments. In 1994 he founded EASi Engineering GmbH, which in 2006 he renamed to carhs GmbH. He has authored numerous technical papers and has been granted German and international patents in the automotive safety field.

Michael DeLeeuw: Catapult Business Unit Manager, Instron GmbH

Michael DeLeeuw has a BSME from Worcester Polytechnic Institute (1986), and has worked for Instron in various capacities for the past 29 years. Located in Ann Arbor, Michigan, he has been working in the automotive industry since 1988, involved in sales of servohydraulic testing equipment. With the formation of Instron Structural Testing Systems in 1997, Mike’s responsibilities included management of the Detroit-based sales and service group. After participating in the effort to develop and commission the first pitching crash sleds in 2002, he took on a worldwide leadership role for IST’s passive safety testing products, including responsibilities for marketing, development, engineering, project management, and sales. His current role is Business Unit Manager, Catapult.

James Cooke: Senior Engineer, Analysis and Control, Instron UK

James Cooke has worked for Instron as a control engineer since he graduated from Bristol University in 2011. At Instron he has worked on projects involving the control of servohydraulic and electromechanical testing systems, and is now responsible for the analysis and control of the ElectroPuls range of electric linear motor materials testing machines.

James Cunnane: Principal Engineer, Analysis and Control, Instron UK

James Cunnane has worked in the fields of structural testing, control, instrumentation, and analysis for over 25 years, including 14 years at Instron. He has experience in identification and characterisation of dynamic systems for customers in the automotive, civil engineering, aerospace, and petrochemical industries, including development of measurement and analysis tools and systems. His initial work at Instron was to provide structural testing consultancy and training to customers with a variety of applications, including dynamic testing of Formula One cars. In later years he has been responsible for specifying and improving the control performance of Instron’s dynamic systems controllers. He is based at Instron’s worldwide centre of excellence for Dynamic Systems at High Wycombe.

Anton D. Raath: Managing Director, CaTs³ Limited

Anton D. Raath was Associate Professor and Head of the Structural Mechanics Laboratories at the Department of Mechanical and Aeronautical Engineering at the University of Pretoria in South Africa. He was active in teaching, research and consulting to industry both nationally and internationally in the fields of Structural Mechanics, Fatigue and Durability for approx 12 years. It is in this laboratory that he developed the time domain based service load simulating technique as part of his PhD studies. In 1998 he was appointed Technical Director to Kelsey Instruments at the University of Warwick Science Park. Following subsequent acquisitions and restructuring by the German based Zwick Roell Group, he has been leading technical development teams for the Zwick Roell Group in development of software products and control systems for the servo-hydraulic test and simulation industry. He is currently co-owner and managing Director of Consultants in Automated Test and Structural-dynamic Simulation Systems or CaTs3. Formed in 2004, CaTs3 is a UK based company in partnership with Zwick Roell and specialises in the development, supply and consulting in the field of test and durability systems in the international market.

Nick Williamson: Staff Systems Engineer, National Instruments

Nick Williamson worked for DERA for eight years, programming instrumentation for research purposes, before joining National Instruments nearly 15 years ago. After several years visiting customers and helping to solve their measurement problems, he moved into the Systems Engineering group. In this role he now provides hardware and software advice as well as creating proof-of-concept examples to demonstrate the capabilities customers ask for. Mostly programming in LabVIEW on Real-Time and FPGA targets, he has also developed with, and taught, VeriStand for MIL, HIL and RCP applications.

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Design and Control of Dynamic Testing Systems

Copthorne Tara Hotel London Kensington, London

Overview

Day 1

08:30 - REGISTRATION AND REFRESHMENTS

09:30 - CHAIR’S OPENING REMARKS

09:40 - DESIGN AND CONTROL OF DYNAMIC TESTING SYSTEMS

10:00 - AUTOMOTIVE STRUCTURAL TESTING

10:20 - AUTOMOTIVE SUSPENSION TESTING FOR DURABILITY AND CHARACTERISATION

10:40 - QUESTION AND ANSWER SESSION

10:50 - NETWORKING REFRESHMENT BREAK

11:20 - HYBRID TESTING

11:40 - VIBRATION CONTROL

12:00 - CRASH TEST CATAPULTS

12:20 - QUESTION AND ANSWER SESSION

12:30 - NETWORKING LUNCH

13:30 - AEROSPACE STRUCTURAL TESTING

13:50 - TRENDS, CHALLENGES AND SOLUTIONS IN PHYSICAL AND VIRTUAL AIRFRAME TESTING. REAL-TIME DATA CORRELATION FOR EARLY DETECTION OF CRACK INITIATION

14:10 - EARTHQUAKE TESTING

14:30 - EARTHQUAKE TESTING

14:50 - QUESTION AND ANSWER SESSION

15:10 - NETWORKING REFRESHMENT BREAK

15:40 - CONTROL FOR MATERIALS TESTING

16:00 - CONTROLLER PLATFORMS

16:20 - PLATFORMS FOR THE PRACTICAL IMPLEMENTATION OF YOUR SIMULATION AND CONTROL DESIGNS

16:40 - QUESTION AND ANSWER SESSION

16:50 - CHAIR’S CLOSING REMARKS

17:00 - END OF SEMINAR

ANDREW PLUMMER: PROFESSOR OF MACHINE SYSTEMS & DIRECTOR OF THE CENTRE FOR POWER TRANSMISSION AND MOTION CONTROL, UNIVERSITY OF BATH

Colin Dodds: Dodds and Associates, Independent Consultants UK

Rick Meyers: Senior Application Engineer, MTS Systems Corporation

David Wagg: Professor of Nonlinear Dynamics, University of Sheffield

Steve Daley: Professor of Industrial Active Control, University of Southampton

Andrew Halfpenny: Chief Technologist, HBM-nCode

Hans Klaufus: Solution Development Manager Aerospace Test Systems, MOOG

Marco Nawijn: Managing Director, Colosso

Martin Williams: Professor in Structural Engineering, Fellow of New College, Oxford University

George Taylor: Managing Director, Servotest Testing Systems Ltd

Rainer Hoffman: Managing Director, Carhs GmbH

Michael DeLeeuw: Catapult Business Unit Manager, Instron GmbH

James Cooke: Senior Engineer, Analysis and Control, Instron UK

James Cunnane: Principal Engineer, Analysis and Control, Instron UK

Anton D. Raath: Managing Director, CaTs³ Limited

Nick Williamson: Staff Systems Engineer, National Instruments

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