MTS TestStar 490.01 & Bionix 858 Control Using Labview/Matlab-Simulink

I believe these were all run with proprietary software....

https://smiadm2.hst.aau.dk/smiold/manuals/techman/mts/doc/790_Inst.pdf

I found a link referencing this load cell use of a TestStar:https://forums.ni.com/t5/Academic-Hardware-Products-myDAQ/How-to-connect-a-extra-load-cell-on-MTS-Mini-Bionix-858-Test/m-p/424919?profile.language=en

What is it you want to do with this system? I am in the business of automating test and calibration of cutting edge sensors and their interfaces. I program with Labview almost exclusively. This looks like an older piece of equipment due to the program installation via floppy drive. This is not a show stopper, but it is indicative of a level of difficulty in obtaining drivers and how to communicate with the instrument. The manual references example programs in other programming languages:

Do you want to install the programming environment plus example programs? Four sets of example programs are included: BASIC examples and C language examples. These text files can be complied with the appropriate compiler. These files are installed in following locations: ✦ Microsoft C6.0 examples are installed at C:\TS2\examples\msc ✦ Borland C++ examples are installed at C:\TS2\examples\borc ✦ Microsoft 7.0 BASIC examples are installed at C:\TS2\examples\msbasic ✦ IBM Set++ examples are installed at C:\TS2\examples\ibmc A ReadMe.ex file located in the examples directory explains the examples. An optional Programming Reference manual is available.

Most equipment with serial communications ports will have a table of commands and responses that you can use to create your own Labview driver/program to automate this equipment. I've submitted a couple of these to the National Instruments community myself, here is the code I use to detect and count bubbles in water with a sonar device for a very accurate depth measuring system: https://forums.ni.com/t5/Community-Documents/Sonotec-Bubble-detector-code/ta-p/3539468?profile.language=en

Originally, the machine was controlled via a computer running on OS/2.

I would like to use either Matlab or Labview to control the machine. The interface should allow both force and position control, and be able to record in realtime data from the sensors (position, force).

Ideally, I would like simulink blocs: [output: position] [output: force] [input: servo valve].

The Bionix is equipped with a load cell that is connected to the controller. The controller is connect to hydraulic servo valves and to a computer via a serial connection.

Wow! ...now that's what I call a delayed response....haha, and still doesn't provide critical information....

Please, only reply if you have something useful to say. Thank you.

Please only ask valid questions, and respond to mikemack

A retired guy's view:

The manual at the on-line link dates from the 1990's, IBM DOS era, maybe Win 3, if not some proprietary control system. The manual is a user manual, not factory documentation containing detailed control algorithms or comm protocols.

In the late 1980's, I dabbled in data acquisition for analytical instruments and ran into Instron impact testers; MTS might have made them, too. Same deal; old, out-dated control and data acquisition systems, and while the data acquisition could be tackled with signal conditioning modules; the control system was a different ball game. No manufacturer for that type and level of instrumentation back then provided documentation containing parts lists, control algorithms, or source code in the detail needed to reverswe engineer a product. Consequently, there were one or two small businesses that specialized in updates for old Instrons.

My take - unless a) this is an academic environment where a grad student can be assigned the task of reverse engineering the MTS operation and performance for purposes of upgrading the tester, or b) there's a garage shop operation that targets this line for upgrade, the tester is a boat anchor.

You are not likely to find a commercial systems integrator who can afford to tackle undocumented controls, especially involving serial comm protocols, because of the time involved.

Thanks for your insight Iris.

The machine is located in university premises. We could replace the old controller with an Arduino*. However, we are not allowed to do so for safety reasons. We might be in possession of the most expensive boat anchor ...

*FPGA or microcontroller + additional soft and hard safety measures (e-stops) + servo valves + ...

>we are not allowed to do so for safety reasons.

Who is the safety authority?

Machine safety is not a new topic or new set of regs; it's been around for awhile. Not my particular field, but those doing controls on the PLC fora bring up the safety topic all the time. Although the Arduino is not likely to be on the safety certified list, there are agency approved dedictated safety rated controls and control modules.

If you have the manpower that can do the engineering and programming of an Arduino (the hard part of the upgrade task), why not get safety certified hardware/software and update the tester?

Fair point!

We will look into that.