Highly Advanced, Fully Integrated Dynamic Testing Software
Vsync is RedViking’s 4th generation powertrain dynamic testing software, based on over 100 fielded dynamic component test benches. Our customers in aerospace, automotive and off-highway powertrain testing rely on Vsync for comprehensive test control, remote monitoring and advanced data analysis. Your lab or end-of-line test stand won’t have to rely on multiple stand-alone systems with limited data acquisition and analysis capabilities. Vsync provides an integrated, user-friendly platform for indisputable test data with superior repeatability and traceability.
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The Vsync Platform
The Vsync platform includes all of the fundamentals you need to run your RedViking dynamic testing software system. The system includes manual and automatic control, an overview of the unit under test, trend screens, basic user management, active alarm views and basic calibration.
Vsync Plug-in Software Modules and Editing Tools
Every RedViking powertrain test bench will include the Vsync hardware and software platform configured for your test requirements, such as engines, helicopter dynamic components, helicopter whirl towers, and automotive or off-highway vehicle drivetrains. Plug-in modules and editors will be recommended to customize your turn-key solution.
The vibration analysis module displays selected accelerometer data in real-time, either by FFT or order spectrum. All machine and test article vibration sensors can be viewed for detailed analysis. We’ll work with you to define exactly the elements you want to analyze and determine limits so you can identify flaws prior to failure. You’ll also be able to give users the ability to configure the spectrum resolution with resolution and filtering parameters.
The maintenance manager captures runtime on all critical machine components to create a preventative maintenance schedule. Tasks can be easily created with specific tag names and predefined runtimes. System downtime is mitigated by creating and following a maintenance work order during scheduled downtime. Machine components can be separated into weekly, monthly and yearly events.
Equipment Health Monitor
The Equipment Health Monitor uses real-time data to prioritize and optimize maintenance. The CBM+ manager will monitor the test machine’s health and notify system personnel when service items are needed. This plug-in module allows online prognostics and diagnostics to reduce system downtime and spare parts inventory.
This module enables remote control and screen view for approved users to diagnose system behavior, advise remote operators or technicians, and provide remote access to any other plug-in modules or editing tools. It integrates seamlessly with your IT security standards and protocols and facilitates quick and effective remote system support. The Remote Access module can be configured to instantly notify your maintenance center of service requirements, either by text or email, in order to reduce system downtime.
While the machine is active, all alarms will be captured and displayed on the test-in-process screen. After the test is complete and active alarms have been cleared from the list, a historical log will be captured for traceability and troubleshooting. Alarms will be logged by a data/time stamp with a detailed description of the fault that caused the alarm. You’ll be able to perform trend analysis, filtering by date, time and Error type.
Systems Schematic Display
The System Schematic Display module allows your operator to quickly assess the test system’s state and health through an intuitive schematic view of the test article, facility gearbox sensors, drive system, fluid power, test cell status and more. The schematic views are simple one-line and render diagrams with go/no-go indication of system health. These features can be customized to optimize operator and engineering needs.
Work Instruction Viewer
The Work Instruction Viewer creates an intuitive, user-friendly method of communicating test process requirements to your operators. This paperless method ensures the most up-to-date test stand operation documents are always used. The Viewer can also quickly display electrical and fluid power schematics of the system for quick diagnostics, as well as mechanical exploded views for service and maintenance. Our customers using automated work instructions see reduced training time, better process consistency, and less downtime.
Dynamic Configuration Manager
The Dynamic Configuration module allows a user to disable or override programmable limits for each sensor. Programmable limits, set with the configuration tool, are evaluated by the PLC whenever a test is running. The “hard-coded” machine safety limits and automatic test sequence limits can’t be overridden by this module. Programmable limits may be changed at “run time” by users who’ve been given access.
Advanced User Interface
Our dynamics testing software includes an Advanced User Interface module that is used to set up a customized interface for operator, maintenance, engineering and supervisor profiles and access rights. User access and security level will limit users from restricted projects, customers, screens, screen edits, manual test profile overrides and more. Smart card, bar code or type-in password will be integrated according to your requirements.
Vsync’s Camera Interface Module creates a comprehensive physical view of tests in process, either from the control room nearby, or with Remote Access, from any approved location. All cameras are high resolution pan-tilt-zoom and have an industrial housing with heaters and fans to eliminate fogging. The camera controller has a dedicated PC for video recording and archiving. The cameras can be controlled with a joystick with predefined zoom location or using direct mouse control. All Vsync cameras are configured for PoE to enable easy and seamless integration.
Vsync Editing Tools
Test Sequence Set Editor
The Test Sequence Set Editor allows approved users to create and manage test profiles for all the units under test. Test profiles can be copied and modified to create new testing procedures for new test articles. Date/time stamped logs are automatically created to track who has accessed, modified or created a new test profile.
Configuration Management Editor
Vsync’s Configuration Management Editor allows approved users to create and manage system configuration elements such as overall system limits, mechanical configuration and hardware IP addresses. This Editor allows users to change, modify or delete low level system items without requiring expensive software development licenses. The editor tracks each change with a revision log for traceability of the overall system configuration.
Every RedViking Powertrain Test System Includes Vsync Hardware
Vsync requires a host system, safety PLC and cRIO for data acquisition, test control and test monitoring. These components are designed into every powertrain test system that we build. The degree of sensor installation will depend on your specific test requirements and software modules selected.
The host system console consists of three (3) high resolution monitors. The primary monitor displays test article information, such as speed and torque. The secondary monitor displays details on the test in process as well as equipment health monitoring. The third monitor displays views of the test stand and test article captured with pan-tilt-zoom cameras.
The Safety PLC is the heart of the test system controller, as it manages all critical motion and safety tasks. The specific PLC chosen to execute test sequences will be designed to fit your controls standards.
The cRIO is a high speed data acquisition device used to digitize analog sensor data at a high rate, improve the noise-to-signal ratio and eliminate the need for large cables running to a remote control room. They include a customizable FPGA backplane and a rugged real-time controller. They also share a common code base across multiple cRIO models to facilitate customization.
Motors and Drives
RedViking designs both mechanical and electrical energy regeneration dynamic testing systems. The common bus solution paired with the active front end (AFE) has the ability for power factor correction, further increasing the overall savings of a common bus system. AFE drives allow for unity power factor and low total harmonic distortion (THD) that meets IEEE 519 harmonic standards, which allows the drive systems to improve the present power factor displacement in the end users facility.