Hydra-Dyno Transmission Dyno and HTC-S DAQ Control System

Our latest HTC-S controller has the capacity to test and control more than just solenoid and valve body test machines. This controller has a modular architecture allowing the addition of DAQ channels and controls to meet the demands of your system. With our ever-evolving control software we have the capacity to adapt our control system to a variety of valve body test systems, most transmission test stands, chassis dynos and engine dynamometers. Contact us with your application and see how we can get your equipment running like it was intended and results you can be confident in.

HTC-S DAQ and Control System

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The data acquisition and control system (DAQCS) designed on the basis of the HTC-S controller allows receiving and processing of up to 144 input channels of different data types (0-10 V, 4-20 mA, temperature sensors, speed sensors, limit/end switches). Data is read out in high resolution at a frequency from tens to thousands of Hz, depending on the channel type. Intelligent post-processing with flexible user settings ensures a low noise level. DAQCS has up to 52 output channels (PWM, 0-10V, discrete outputs), allowing to arrange the control over different actuating elements: relays, solenoids, stepper motors, DC motors, and air coolers. In addition to classic PID controllers for implementation of closed-loop control circuits, DAQCS allows the use of controllers based on fuzzy logic, as well as proprietary patented solutions.

A simple and at the same time high-speed Ethernet interface, available on most modern computers, is used to communicate DAQCS with a PC for displaying of real-time data controlling different types of actuators. The modular principle of the DAQCS design makes it easy to increase the number of inputs and outputs, allowing to process data from additional pressure sensors, temperature sensors, speed and torque sensors used in the industry. Upon client’s request, it is also possible to develop additional specific expansion modules.

One of the most important features of DAQCS is that it can be configured for work with different types of sensors (pressure, temperature, flow) and devices operating on CANOpen and J1939 protocols, using a can interface for communication.

 

DAQCS can be either installed into the customer’s equipment, or delivered in a rugged industrial case. If necessary all mating connectors, a set of sensors for upgrading the client’s equipment and circuit documentation are supplied with DAQCS.

 

Application. DAQCS can be used for control and modernization of the following systems:

  • IC-engine loading stands

  • brake testing stands

  • transmission dynamometers

  • electric motor test stands

  • test stands for automotive transmissions and solenoids.

HTC-S SOFTWARE PACK

The intuitive and easy-to-learn user interface has flexible settings, allowing the users to customize it according to their requirements and preferences. The user can easily change the number and type of displayed parameters, colors and labels of graphs of currents and pressures, limits and tolerances of measured parameters.

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Gauges Display

- Customizable gauges: Large Numeric, Dial Indicator, Vertical Slider, Horizontal Slider,

- Graph Display, Rev indicator, Customizable Status Indicator

- Customizable color schemes

- Option to mix all gauges on runtime screen

Calibration Screen - screen for periodic calibration and checking of all sensors

Calculated Sensors (Indicators)

- Create new sensors from existing sensors with mathematical functions.

Example 1: Input speed/Output Speed = Ratio

Example 2: Input RPM/Sqrt(torque) = K Factor

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Multiple Display Screens and Tabs

- Create multiple display screens at own convenience

- Switch between any screen and any point in the test script

- Display two screens at the same time on a two monitor setup

Dynamic Gauges Interface

- All gauges and graphs on all screens are independently resizeable, moveable, properties can be edited (mix of metric and US units) as you develop the display screen.

- Drag and drop gauges and indicators, edit the properties of each gauge on the screen as you create each display page.

- Configure graphs for whatever readings wanted per graph (a graph w/just gear ratio, or pressures specific to clutches, or pressures specific to LU).

PDF print generation of test results

7. Notes adding module of performed test - allows to add multiple notes in test graph for operator

Transmission sensor/switch monitoring

- Pressure Switches

- Trans temp sensor

- PRNDL Switch

- Gov Pressure Sensor

- Input/Output Speed Sensors (2 or 3 wire)

- Lever Position sensor (5R110W)

Dyno Control Modes

- Control to a dyno input speed to match a set input speed

- Control to a dyno input speed to match a set dyno output speed (be able to set an input speed limit)

- Control to a dyno output torque to match an output torque

- Control to a dyno output torque to match an input torque (be able to set a torque limit)

PID Controls

- Multiple PIDs for each analog output for each control mode

- Smooth transfer of PID's when switching contol modes while in operation

- PID's are saved and loaded with each test so that different tests can have different

PIDs for the same control (necessary for throttle control on an engine dyno).

Solenoid Control Modes

- Write a table for solenoid control by current

- Set a desired current to hold the solenoid at in each step

- Linearly ramp current from step to step at a programmed rate

User activity data logging add-on

Advanced analytics module and user test result comments add-on

 

HYDRA-TORQUE TRANSMISSION DYNOS

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With over 2 decades of experience in advanced Valve Body testing, Automatic Transmission testing and Torque converter reman equipment manufacturing we have developed our newest modular HTC-S controller system for data acquisition and processing. 

 

We are fully taking on transmission dyno projects with 100% own development. Our team has numbers of successfull integration of HTC-K Controller on transmission test benches produced by 3rd parties. Nowadays, we are taking up custom-built projects to satisfy a wide range of customers' requirements in terms of transmission testing from light to heavy duty industrial transmissions.

The Hydra-Test transmission dyno has been designed with your applications in mind. Weather you are doing strictly automotive units, large on or off highway units, or even high-volume fleet units we can build a test system that meets your needs and give you the result sand performance you need. Contact us today and let us quote a test stand you can rely on for many years. 

 
  • Fully automated test scripts 

  • Allows complete simulation of light, medium and heavy duty load operation modes

  • HTC-S controller unit is used to drive transmission and gather data during the test. 

  • HTC-S Software Package allows to compare gathered data with master data after the test is completed.

  • Includes required number of load cells (500 N/m) and a rotary drive unit with a powerful electric motor (30 kW) as well as separated tanks for standard and specific fluids.

  • For efficient operation, the stand is equipped with a 40-HP engine and a modern VFD (variable frequency drive). This allows for the operator to hear extrinsic sounds as well as identify other problems associated with extrinsic sounds of the gearbox.

  • The design makes it easy to control the motor and load cells in both manual and automatic modes – via the integrated control system 

  • The dynamometer chassis has built-in electronic pressure sensors. This allows the use of standard hoses for connection to the oil ports of the transmission.

  • DST 1.1 is equipped with a electric disk brake. This is an effective locking device, which allows carrying out of tests on the integrity of all components.

  • The stand is equipped with a cantilever-rotary lifting device (jib crane), which greatly facilitates the installation and removal of transmissions.

 Case Study 

HTC-S Controller Upgrade to Mustang Transmission Dyno

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Figure 1: Mustang DAQ Board

CHALLENGE

A customer with an existing Mustang transmission dyno has a need for an easier to use and more capable dyno and transmission control system. Their current system had the following deficiencies:

  1. Difficult and time consuming to program new units.

  2. Did not have the ability to smoothly ramps solenoid current between gears needed for later model clutch to clutch units.

  3. Needed support for the Chrysler 68RFE, Ford 6R140, and Mercedes 722.6.

  4. Existing manufacturer of dyno is phasing out support for the control system and machine in general. This system was built in 2012.

  5. The current transmission shift controller is obsolete and no longer in production.

SOLUTION

Hydra-Test USA proposed the installation of our HTC-S controller with advanced solenoid control and basic dynamometer controls. With the launch of Hydra-Test transmission dynamometer in late 2020, the current software will be undergoing revisions to enable advanced data recording and control capabilities. This customer has also agreed to beta test Hydra-Test’s dyno software and give feedback on the control system as well as gain the ability to develop shift profiles easily that will handle the above listed units.

CONTROLLER IMPLEMENTATION CHALLENGES AND SOLUTIONS

 

Interface with the Mustang DAQ System: Unknown prior to installation.


Mustang uses a custom proprietary DAQ board that uses an RS-232/422 connection to the main computer. Dyno speeds, PAU torque, drive enable/disable, and E-Stop are communicated and controlled through this board with custom signal conditioning. Connection points for dyno signals, signal isolation, and signal converters needed to be implemented on site to bring in the signals to the HTC-S Controller. Calibration to match the Mustang Controller was also performed once all the signals were connected and verified.

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Figure 2: Signal Conditioners

Figure 2: Signal Conditioners

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Figure 3: Connections on the Mustang DAQ board

Figure 3: Connections on Mustang DAQ Board

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Figure 4: Signal Isolators

E-Stop Safety PLC: Implemented as an overall safety monitor.


In order to keep the operator safe, and the machine under control when and E-Stop might be pressed or cleared, a small PLC was used to monitor E-stop. This was tied into the existing E-Stop so that when it was pressed a signal would be detected on the PLC. Upon detecting an E-Stop, the PLC would remove the speed and load signals from the Mustang controls. The PLC would monitor both these signals would only reconnect these signals once E-Stop was cleared and both load and speed were brought back to zero (minimum). This ensured that clearing an E-stop would not allow the system to start spinning up again if the test sequence were still running. The PLC also displayed the state of an E-stop input, the valve of the controller signals (from 0-100%), and if the system was in Dyno Run Mode or E-Stop Mode. By default a loss of power to the PLC would disconnect any control signals from the Hydra-Test Controller.

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Figure 5: E-Stop Monitoring PLC

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Figure 6: E-Stop PLC Controller Signal Monitoring

Pressure Switch Monitoring: Requested per customer.


TransAxle indicated that pressure switch monitoring (especially on the Chrysler 66RFE and 68RFE units) was critical during a dyno test. To accomplish this the unused analog signal channels were repurposed for pressure switches. The needed hardware was placed inside the HTC-S box so that no special hardware was required for the transmission test cables.

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Figure 7: Pressure Switch states showed on-screen

Control System Switch


The Mustang control system had some frequently used features not yet implemented in the Hydra-Test software. To allow TransAxle to continue to use these features on select dyno tests, a switch was added that allowed the controls to switch between the Mustang control system and the Hydra-Test HTC-S. All sensors for the dyno were connected in parallel and no functionality of the original Mustang system was lost.

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Figure 8: Control System selector switch

Hydra-Test Hardware Installation


Hydra-Test installed hardware in the main machine electrical cabinet. Installation was completed in a standard manner consistent with the OEM controls and hardware that was already installed. A control cabinet was provided where the controller, controller power supply, transducer interface box, and computer were installed. An 8-foot adapter cable consistent with some of the more common transmission test cables was wired on site and documented for the customer so that they could reference it for building future transmission test cables.

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Figure 9: Hydra-Test Hardware Installation

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Figure 10: Hydra-Test Controller Cabinet

SUMMARY

Overall, this upgrade proved to be successful. The customer was left with working shift patterns for the Chrysler 68RFE, the Ford 6R140, and the Mercedes 722.6.
1. The customer was now able to easily program new units with the Hydra-Test test sequence editor.
2. The Hydra-Test HTC-S controller is specifically designed to be able to smoothly ramp solenoid current between gears needed for later model clutch to clutch units.
3. Hydra-Test was able to become familiar with the dynamometer and will be able to offer support for this system to keep the customer up and running as needed.
4. The HTC-S is Hydra-Test’s current production controller and is fully supported now and in the future.

 

Hydra-Test is open to develop the dyno specific software features based on Transaxle's valuable feedback. Additionally, the customer is planning on future dyno upgrades and would like to utilize our expertise to help.

VIDEOS AND DOWNLOADABLE MATERIALS