Control Cube Servo Controller and Cubus Software

Fatigue and fatigue strength testing - with maximum flexibility and efficiency.
Control Cube Servo Controller and Cubus Software

Servo-hydraulic testing systems are the preferred option for fatigue and fatigue strength tests. The performance of these systems is determined to a large degree by the measurement and control electronics used, together with the associated testing software. The Control Cube servo controller and Cubus testing software are ideal both for new testing systems and for retrofitting to existing servo-hydraulic testing systems, as well as for multiaxial applications.
This system was developed by Zwick in collaboration with CaTs3 (Consultants in Automated Test & Structural-dynamic Simulation Systems). The company's long-standing experience and expertise are reflected in a highly efficient product capable of handling customers' constantly expanding needs while at the same time meeting Zwick's high safety and quality standards.
During development, special attention was paid to achieving a high degree of testing system flexibility and expandability. Impressive features of the Cubus software platform include outstanding versatility and an extremely user-friendly operating concept, especially when faced with frequently changing testing requirements. From configuration of the test bench to routine cyclic tests to advanced applications - there is a Cubus test program to suit all. For simulation of actual service loads QanTiM iteration® software is optionally available.

Control Cube Servo Controller

Advantages & features

  • A measurement and control system consisting of the Control Cube servo-controller and Cubus testing software includes the following outstanding features:
  • simple, intuitive and well-structured user interface shortens familiarization times
  • flexible, modular design allows straightforward system configuration to accommodate both simple and complex testing requirements
  • easily expanded from 1 to 32 control channels for multi-channel applications
  • flexible and space-saving with compact ½ 19’’ housing with integral signal generator - the world's smallest servo controller
  • safety concept includes integrated safety interface for Emergency STOP
  • basic unit available as 1 or 2-channel version
  • optimized 4 kHz data acquisition and control frequency for cyclic testing requirements
  • 19-bit resolution for reliable, highly accurate test data acquisition
  • reliable PC connection and high data transfer rate via Ethernet
  • Cubuslight basic software and Cubus testing software for wide range of customer-specific testing situations
  • QanTiM® software package for simulation of actual operating loads.

Technical overview

Description

Value

Control frequency

4096

Hz

Measured-value acquisition (max. sampling rate)

4096

Hz

Expansion slots

3

PC interface

Ethernet

Universal measurement-amplifier

2x universal digital signal converter, can be increased to 8 per Control Cube; 19-bit resolution at 64 kHz oversampling and averaging

Analog inputs and outputs

2x analog ±10 V inputs, available for external commands or external measurement amplifiers

2x analog ±10 V outputs, available for synchronized control of external devices; also available for monitor signals, e.g. for an external oscilloscope
expansion option

Digital inputs and outputs

2x optically coupled digital inputs

2x digital outputs; expansion option

Electrical supply

85 to 264 V AC, 47 to 63 Hz / 150 W

Dimensions (H x W x D), approx.

94 x 233 x 315

mm

Approx. weight

8

kg

System graphics

The technical features and integration options of Control Cube

(1)    PC connection via Ethernet interface

(2)    Multi-channel connection up to 32 control channels

(3)    Optional ± 10V set-value preset/monitor channels

(4)    Digital I/O connection

(5)    Remote-control connection

(6)    Hydraulic connection

(7)    System connection, e.g. for safety doors

(8)    Safety connection for integration of emergency-stop circuit

(9)    Channel identification via LED

(10)  Universal measurement amplifier for AC or DC sensors

(11)  Analog I/O module (option)

Cubus Testing Software

Basic software

The basic software CubusLight and its autotune function

Each Control Cube servo controller is supplied with Cubuslight basic software. This contains all functions required to configure the test bench and adapt it to the testing situation involved. Cubuslight also includes a test module which allows simple cyclic tests to be performed.

  • Cubus testing software is arranged in three modules.
  • Setup
    configuration of test bench and set-up of all control parameters and settings
  • Data
    data acquisition, data display and data export
  • Test
    determination and performance of tests

This organized structure simplifies rapid location of all functions.

Test options

Block programs

  • graphical editor for test sequence
  • easy insertion of different block elements into test sequence
  • elements: cyclic, ramps, hold stages, data acquisition, digital I/Os, procedures etc.
  • sub-sequences allow nested and user-specific repeats
  • test position within the sequence can be moved

Dura fatigue tests

  • playback of pre-defined elapsed-time drive files
  • linking multiple drive files together in a test sequence
  • trend monitor.

External tests

  • external control without using the controller’s own function generator
  • command source can be either an external analog drive or PC-controlled drive.

Cyclic Pro

  • specimen management
  • data acquisition
  • peak-value acquisition
  • break detection
  • test-quality monitoring with tolerance bands
  • strain control for LCF
  • inspection interval
  • test parameters, e.g. frequency, amplitude, mean value, can be changed while test is running
  • adaptive peak-value control
  • mixed mode, e.g. displacement-controlled after force peaks
  • graphical failure envelope with limit monitoring
  • signal waveforms: sinusoidal, rectangular, triangular, trapezoidal, sawtooth

Ramps

  • graphical editor for test sequence
  • easy insertion of elements into test sequence
  • ideal for structure tests
  • break detection at force drop
  • elements for extended ramp functions, dwell phases, data acquisition etc.

Customized tests

  • Cubus' plug-in architecture allows development and integration of individual tests
  • examples include seat-belt anchorage test and side intrusion test

Expansion options

General functions

  • event recording
  • virtual channels
  • password protection / user management
  • transducer linearization
  • external analog set-value specification
  • external monitor outputs, e.g. force, displacement
  • Language Swap

Measured value acquisition and display

  • X-Y graph
  • data export / data display
  • time sequence
  • user-configurable digital displays: real time, max, min, amplitude, mean value, peak, trough, cycle counter
  • peak-value acquisition

Control

  • PID auto-tune
  • adaptive, integrated PID control
  • compensation, cascade control

Multi-channel applications

  • hydraulic grouping
  • global and local gain factor
  • automatic synchronized master/slave operation

Procedures

  • action to be performed in response to defined events
  • editor for procedures
  • event-action matrix

TU Chemnitz to use new Zwick testing system for future research

The multiaxial servo-hydraulic testing system is designed for predominantly dynamic loading of components, assemblies and power-transmission mechanisms used in materials handling.
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