ELECTRONIC CONTROLLING

UNIT
INTRODUCTION
The main Electronic unit consists of Controlling and Signal Conditioning unit

CONTROLLING AND SIGNAL CONDITIONING UNIT

HEICO controlling and signal conditioning unit is the main part of system that controls
the operation of the Servo/Stepper motor inturn, which controls the Ram. It consists of
controlling card for the operation of Motor. The system operates on the basis of closed
loop feed back principle. Controlling card receives the signal from the motor movement
and accordingly changes the speed of the motor, in turn Ram.

It also consists of power supply for Electronic unit in it. It is connected to computer
through connecting cables. This unit consists of signal conditioning cards that receive
signals from Load Cell and Displacement Transducer. These cards amplify and process
the signal from sensors and provide an output of 0 - ± 5V. The output of the transducer is
transferred to data acquisition (9111) card inside computer. There are five separate
channels for five transducers.

TABLE NO 1.

CH. NO. NAME OF SENSORS

1 LOAD
2 DISPLACEMENT
3 CONFINING PRESSURE
4 BACK/PORE PRESSURE
5 VOLUME CHANGE
ELECTRONIC LOAD CELL
Load cell is a load-measuring device, which produced an electrical output
proportional to the applied axial load. This output can be displayed on a read out unit
placed at a conventional location. In operation, the elastic deformation of the steel column
(body of the load cell) is sensed by four foil type strain gages connected to form a
balanced whetstone bridge. This bridge is connected to the read out unit through electrical
leads. The sensitivity of the load cell is 0.1% of the total capacity. Safe maximum load is
150% of the rated capacity.

Specification of Load Cell

Foil type strain gauges in full

1 SENSING ELEMENT Bridge configuration.
2 CAPACITY 1100 kg
3 MAXIMUM OVERLOAD 150% of rated capacity
4 DEVICE LINERITY + 1% of rated capacity
5 HYSTERESIS + 0.5% of rated capacity
6 REPEATABILITY + 0.2% of rated capacity
7 TERMINAL RESISTANCE 350 ohms Nominal
8 EXCITATION VOLTAGE 5 Volts DC
9 TERMINAL CONNECTION 5 pin connector
10 FREQUENCY RESPONSE 0 - 50 Hz
11 SAFE TEMPERATURE 0O - 50O C

CALIBRATION OF LOAD CELL

Calibration of load cell is calibrated by proving rings, which is calibrated by

authentic institution. Proving Rings are precision load measuring devices machined from
special forged steel and is properly heat-treated to give maximum sensitivity and
durability. Every proving ring is fitted with a dial gauge of 0.002-mm sensitivity and is
supplied in a wooden case complete with a calibration chart. (Proving ring is not the part
of equipment/ machine)
Circuit Description Strain Gauge Bridge converts the built up pressure to the
proportional voltage signal. This signal is amplified and then applied to ADC. This digital
signal is then applied to channel.

LINEAR VARIABLE DISPLACEMENT TRANSDUCER (L.V.D.T)

(Vertical Displacement)

The variations in strain, deformation, deflection etc can be measured with the help
of displacement transducer, which has linear variable differential transformer type
winding, oscillators, demodulator and filters. The change of the flux due to the movement
of the core inside the transformer is used to monitor the change in linear variation above
parameters.
The ADC acquires signal and stabilise DC voltage output proportional to the
displacement of armature and is directly indicated on the display screen of the read out
unit of the digital form in the term of millimetres. 2KHz oscillator produces 2Vrms
excitation, this voltage is applied to primary coil of LVDT; corresponding voltage is
applied to detector to convert AC into DC. This DC signal is amplified and then
connected to digital signal by ADC.
Specification of Displacement Sensor
Linear variable differential
1 SENSOR Transformer (LVDT) type
2 STROKE ± 20mm
3 LINERITY DEVIATION + 1% of rated capacity
4 REPEATABILITY + 0.1% of rated capacity
5 HYSTERESIS + 0.5% of rated capacity
6 EXCITATION 2-Volt RMS 2 kHz sinusoidal
7 SENSITIVITY 1 mV/v/mm
8 SAFE TEMPERATURE RANGE 0O - 50O C
9 CORE FIXTURE Spring-loaded plunger

Block diagram representation of the circuit for Displacement measurement

2KHz LVDT
Oscillator 2V

O/P

Detector

DC

CHANNEL
ADC Conditioning
Amplifier
PRESSURE TRANSDUCER
(Confining & Back Pressure)
Pressure transducer comprises four precisely matched strain gauge elements
bonded on a diaphragm or a tube and connected in the form of a whetstone bridge.
Pressure transducers are hence used. Under no load condition, the output of the bridge is
zero. Under load, the resistant of the gauge change, thereby producing an output voltage,
which is proportional to the applied pressure.

Circuit Description
Strain Gauge Bridge converts the built up pressure to the proportional voltage
signal. This signal is amplified and then applied to ADC. This digital signal is then
applied to channel.

Circuit diagram for pressure measurement

VOLUME CHANGE TRANSDUCER

The variations in volume can be measured with the help of displacement
transducer (fitted in the Back Pressure Controller), which has linear variable differential
transformer type winding, oscillators, demodulator and filters. The change of the flux due
to the movement of the core inside the transformer is used to monitor the change in linear
variation above parameters.
The ADC acquires signal and stabilise DC voltage output proportional to the
displacement of armature and is directly indicated on the display screen of the read out
unit of the digital form in the term of millimetres. 2KHz oscillator produces 2Vrms
excitation, this voltage is applied to primary coil of LVDT; corresponding voltage is
applied to detector to convert AC into DC. This DC signal is amplified and then
connected to digital signal by ADC.

Specification of Displacement Sensor

Linear variable differential
1 SENSOR Transformer (LVDT) type
2 STROKE 0- 200mm
3 LINERITY DEVIATION + 1% of rated capacity
4 REPEATABILITY + 0.1% of rated capacity
5 HYSTERESIS + 0.5% of rated capacity
6 EXCITATION 2-Volt RMS 2 kHz sinusoidal
7 SENSITIVITY 1 mV/v/mm
8 SAFE TEMPERATURE RANGE 0O - 50O C
9 CORE FIXTURE Spring-loaded plunger

Block diagram representation of the circuit for Displacement measurement

2KHz LVDT
Oscillator 2V

O/P

Detector

DC

CHANNEL
ADC Conditioning
Amplifier
Description of Front and Rear Panel of Electronic Signal Conditioning
Unit
The front and rear view of the Signal Conditioning unit panel contains view of all
buttons and are numbered individually as elaborated below.

1. ON/ OFF- This switch is provided to ON or OFF of the Electronic Box. If the
switch is in OFF position the system will not operate at all.
2. LOAD-This is a potentiometer for fine zero adjustment of the load channel. To
adjust zero, rotate this knob in clockwise/ anticlockwise.
3. DISP-This is a potentiometer for fine zero adjustment of the Displacement
channel. To adjust zero, rotate this knob in clockwise/ anticlockwise.
4. CONFINING PRESSURE- This is a potentiometer for fine zero adjustment of
the Confining Pressure channel. To adjust zero, rotate this knob in clockwise/
anticlockwise.
5. BACK PRESSURE- This is a potentiometer for fine zero adjustment of the Back
/ Pore Pressure channel. To adjust zero, rotate this knob in clockwise/
anticlockwise.
6. VOLUME CHANGE- This is a potentiometer for fine zero adjustment of the
Volume change channel. To adjust zero, rotate this knob in clockwise/
anticlockwise
7. Calibrating Potentiometer: - These are meant for calibration of all five
transducers. Users are requested not to disturb these potentiometers.
8. FUSE- It is a 1 Ampere fuse to provide safety to the Electronic Unit.
9. MAINS- This socket is provided to feed Single Phase (220 VAC) to the
Electronic Unit.
10. CON 1- It is 25-pin D-type connector, which is connected to 25-pin connector of
Controlling Unit through Cable 1.
11. VOLUME CHANGE- It is 5-pin military connector, which connects the Volume
change Transducer to Electronic unit (To provide Excitation to the Volume
change and to receive output) through cable 2.
12. BACK/PORE PRESSURE- It is a 5-pin military connector to connect Back/Pore
Pressure to Electronic unit (To provide Excitation to the Back/Pore Pressure and
to receive output) through cable 4.
13. CONFINING PRESSURE- It is a 5-pin military connector to connect Confining
Pressure to Electronic unit (To provide Excitation to the Back/Pore Pressure and
to receive output) through cable 5.
14. DISPLACEMENT- It is 5-pin military connector, which connects the
Displacement Transducer to Electronic unit (To provide Excitation to the Load
cell and to receive output) through cable 6.
15. LOAD CELL- It is a 5-pin military connector to connect load cell to Electronic
unit (To provide Excitation to the Load cell and to receive output) through cable
7.
16. OUTPUT- These points are provided to check the output voltage of load cell (0-
5V) and Displacement Transducer.
17. GND- This point is the Ground of the system (0 Volt).

Description of Front and Rear Panel of Electronic Controlling Unit

The front and rear view of the Control unit panel contains view of all buttons and are
numbered individually as elaborated below.
1. ON/ OFF- This switch is provided to ON or OFF of the Electronic Box. If the
switch is in OFF position the system will not operate at all.
2. FUSE- It is a 2 Ampere fuse to provide safety to the Electronic Unit.
3. MAINS- This socket is provided to feed Single Phase (220 VAC) to the
Electronic Unit.
4. CON 1- It is 37-pin D-type connector, which is connected to 37-pin D-type
connector of Data Acquisition card inside the computer through Cable 8.
5. CON 2- It is 25-pin D-type connector, which is connected to 25-pin D-Type
connector of Signal conditioning unit through Cable 1.
6. CON 3- It is 25-pin D-type connector, which is connected to 25-pin D-Type
connector of Computer through Cable 9.
7. CON 4- It is 25-pin D-type connector, which is connected to 9-pin connector of
Comport of the computer through Cable 10.
8. PORE/BACK PRESSURE 1- It is a 5-pin military connector to connect
Back/Pore Pressure controller motor to the Controlling Unit through cable 11.
9. PORE/BACK PRESSURE 2- It is a 9-pin D-type connector to connect
Back/Pore Pressure controller limit to the Controlling Unit through cable 12.
10. CONFINING PRESSURE 1- It is a 5-pin military connector to connect
Confining Pressure controller motor to the Controlling Unit through cable 13.
11. CONFINING PRESSURE 2- It is a 9-pin D-type connector to connect
Confining Pressure controller limit to the Controlling Unit through cable 14.
12. LOAD FRAME 1 - It is 5-pin military connector, which is connected to 5-pin
military connector of Load Frame through Cable 15.
13. LOAD FRAME 2 - It is a 9-pin D-type connector to connect Load Frame 9-pin
D-Type to the Controlling Unit through cable 16.