Tenth U.S.

National Conference on Earthquake Engineering

Frontiers of Earthquake Engineering
July 21-25, 2014
10NCEE Anchorage, Alaska

APPLICATIONS OF CALCULATION
CHANNEL FUNCTION IN HYBRID
SIMULATION
Shawn S. You1

ABSTRACT

Hybrid simulation in earthquake simulation has become more and more popular. In this
approach, the overall structure is modeled by analysis software, such as OpenSees, and some
components in the structure are tested by physical tests. Interfacing software, such as
OpenFresco, sends commands from the model to the test systems and sends the response signals
from the test systems to the model. As hybrid simulation develops, more and more functions are
needed for variety of hybrid simulation applications. Regular force and displacement PID control
may not be able to satisfy all of the needs. In some cases, Calculation Channel function in MTS
controller software (Flextest software) may be able to provide an alternative solution.

MTS Calculation Channel function could involve operations on all digital and analog signals
recorded by the controller. The resulting signals from these calculations can be displayed, saved
as data, used in control, and output as valve drive signals. The calculation code is downloaded to
the controller when system is loaded. It runs in real-time according to the system clock rate.
Calculation Channel function may provide an effective way for solving complicated problems.

This paper describes how Calculation Channel function can help hybrid simulation in following
ways: running real-time hybrid testing using the calculation support, conducting delay
compensation with additional valve command input, creating complicated configuration with
calculations, filtering response using digital filter to eliminate sensor noise, and simulating
physical test with virtual testing. The conclusion is that, by proper using of Calculation Channel
function, a lot of hybrid simulation tasks can be simplified significantly.

1
Senior Systems Engineer, MTS Systems Corporation, Eden Prairie, MN 55344

Dr. Shawn S. You. Applications of Calculation Channel function in hybrid simulation. Proceedings of the 10th
National Conference in Earthquake Engineering, Earthquake Engineering Research Institute, Anchorage, AK, 2014.

DOI: 10.4231/D3F18SF8R
 Tenth U.S. National Conference on Earthquake Engineering
Frontiers of Earthquake Engineering
July 21-25, 2014
10NCEE Anchorage, Alaska

Applications of Calculation Channel Function in Hybrid Simulation

Shawn S. You1

ABSTRACT
Hybrid simulation in earthquake simulation has become more and more popular. In this approach,
the overall structure is modeled by analysis software, such as OpenSees, and some components in
the structure are tested by physical tests. Interfacing software, such as OpenFresco, sends
commands from the model to the test systems and sends the response signals from the test systems
to the model. As hybrid simulation develops, more and more functions are needed for variety of
hybrid simulation applications. Regular force and displacement PID control may not be able to
satisfy all of the needs. In some cases, Calculation Channel function in MTS controller software
(Flextest software) may be able to provide an alternative solution.

MTS Calculation Channel function could involve operations on all digital and analog signals
recorded by the controller. The resulting signals from these calculations can be displayed, saved as
data, used in control modes, and output as valve drive signals. The calculation code is downloaded
to the controller when system is loaded. It runs in real-time according to the system clock rate.
Calculation Channel function may provide an effective way for solving complicated problems.

This paper describes how Calculation Channel function can help hybrid simulation in following
ways: running real-time hybrid testing using the calculation support, conducting delay
compensation with additional valve command input, creating complicated configuration with
calculations, filtering response using digital filter to eliminate sensor noise, and simulating
physical test with virtual testing. The conclusion is that, by proper using of Calculation Channel
function, a lot of hybrid simulation tasks can be simplified significantly.

Introduction

A basic servo hydraulic test system for structures includes a hydraulic power supply (a pump), a
controller, actuators with servo valves, feedback sensors, and specimens. The commands are sent
from the controller to the servo valve to move the actuator. The feedback signals are sent back to
the controller for close loop control and data acquisition. The control is typically PID control.
The control modes could be displacement or force for structure tests. Figure 1 shows a diagram
of a basic displacement or force close loop control. This kind of test systems are relatively easy
to setup. However, they may not be able to accomplish complicated tasks.

Calculation Channel function creates control loops that control variables that are calculated from
the existing signals. To show how Calculation Channel works, an example of a beam structure
controlled by two actuators, shown in Figure 2, is used. Translation and rotation are desired
control modes. Basic actuator displacement control will not be able to control the rotation
1
Senior Systems Engineer, MTS Systems Corporation, Eden Prairie, MN 55344

Shawn S. You. Applications of Calculation Channel function in hybrid simulation. Proceedings of the 10th National
Conference in Earthquake Engineering, Earthquake Engineering Research Institute, Anchorage, AK, 2014.
motion. In this case, a configuration as shown in Figure 3 with calculated channels can be used
to achieve the desired motion. To be more specific, the translational and rotational feedback
signals are calculated through actuator displacement signals by following equation:

“Translation Feedback” = “Actuator 1 Displacement” + “Actuator 2 Displacement”

“Rotation Feedback” = “Actuator 1 Displacement” - “Actuator 2 Displacement”

The loop outputs of the translational and rotational control loops can be converted to the servo
valve commands by following equation:

“Actuator 1 Valve Command” = “Translation output” + “Rotation output”

“Actuator 1 Valve Command” = “Translation output” – “Rotation output”

These equations can be entered through Calculation Editor of MTS Flextest controller software.
In this way, translational and rotational motion can be achieved by two linear actuators by using
Calculation Channel function.

Figure 1. A basic displacement or force PID control loop

Figure 2. A diagram for controlling translation and rotation DOF with two linear actuators
Figure 3. A Calculation Channel setup to control translation and rotation DOF

As shown in previous example, MTS Flextest software allows feedback signals to be calculated
from the transducer signals. The loop output signals of the control loop can be converted to
compensated servo valve command. Calculation parameters can be defined so that the
calculation can be modified easily to fit different situations.

Through a Calculation Editor, MTS Flextest software allows calculation to contain regular
mathematical operations and functions as well as complex algorithms, based on C programming
language, containing elements like variables, arrays, loops and conditions. All system signals,
digital and analog, can be used for calculations. Calculations are initialized when loading the test
configuration. They are active from that point on, unless the calculation itself defines a different
behavior, e.g. activation only if high pressure is applied. As a result, proper use of Calculation
Channel function becomes extremely powerful and can significantly extend the capability of a
test system. This paper will explain how Calculation Channel function can be used in different
areas of structure testing, especially in hybrid simulation.

Real-Time Hybrid Simulation Using Calculation Channel Function

A typical Real-Time hybrid simulation setup includes a software tool, such as Simulink, that can
create the analytical model, a code generator, such as Simulink Coder, that can convert the
analytical model into C++ code, a real time computing system, such as a dSpace system or a xPC
Target system, and a special storage device that can store and transfer data fast, such as
SCRAMNET cards with fiber optical cables. All of these hardware and software pieces can
potentially be replaced by Calculation Channel function and a MTS Flextest controller. As a
result, the cost of implementing real-time hybrid simulation can be drastically reduced.

Since Calculation Channel function is able to implement nearly all the functions written in C
language, tasks required by real-time hybrid simulation, such as analytical model generation,
integration algorithm implementation, equation solving, and data recording can all be defined
using Calculation Channel function.
As an example, a real-time hybrid simulation of a single degree of freedom mass connecting to
ground (see Figure 4) with a spring under El Centro earthquake was conducted using both
Calculation Channel approach and traditional Simulink-xPC Target-Scramnet approach. In both
cases, the motion of the mass was solved and applied to a specimen in a physical test. The
measured load information was used for calculation of the displacement command for next step.
Explicit Newmark integration method was used for solving the equations. Table 1 shows the
codes for implementing explicit Newmark method that was entered in Calculation Editor. Figure
5 shows the motion of the mass during the earthquake, which shows excellent match between the
two approaches. For more sophisticated application of this approach please reference Bin Wu’s
work [1].

Figure 4, Real-Time hybrid simulation setup

function int NewmarkExplicitMethod()
{
int idof;
idof=0;
while(idof<ndof)
{
/* Backup displacement commands and get external force */
dcmdz[idof]=dcmd[idof];
F[idof]=-(M[idof]*"file generation Command"*"EQSCALE");
/* Solve for the CURRENT acceleration and velocity responses. */
a[idof]=(F[idof]-R[idof])/M[idof];
if(iPsdStep>0)
v[idof]=vz[idof]+.5*(az[idof]+a[idof])*Dt;
/* Get the NEXT target displacement for the next integratoin step. */
dcmd[idof]=d[idof]+v[idof]*Dt+.5*a[idof]*Dt*Dt;
/* Update responses. */
dz[idof]=d[idof];
vz[idof]=v[idof];
az[idof]=a[idof];
Rz[idof]=R[idof];
idof = idof + 1;
}
Table 1, Code for implementing Newmark integration method in Calculation Editor
 5
D (
i
m
s 0
m 0 2 4 6 8 10 12
p
)

l
‐5
Time (S)

xPC Target Calculated Channel

Figure 5, Displacement comparison of xPC Target approach and Calculation Channel approach

The obvious advantage of real-time hybrid simulation using Calculation Channel function is that
it does not need extra software and hardware besides the basic testing equipment. The
disadvantage of this method is that the analytical models need to be created in C language. For
complicated FEA model, this task is difficult to accomplish. Another disadvantage is that the
calculation is done using the processor in the controller, which also controls the physical test.
Because multiple tasks are running at the same processor, complicated solving cannot be done in
real-time.

Delay Compensation

By nature, servo hydraulic test systems have delays, which are equivalent to negative damping
and could cause the real-time hybrid simulation unstable. Many methods can be used to
compensate for the delay. One of the methods is derivative feedforward compensation by Jung et
al. [2] and Mercan et al. [3]. A block diagram for real-time testing using the derivative
feedforward compensation method is given in Figure 6, where the discrete transfer function
Gff(z) calculates the derivative of the interpolated command displacements from the ramp
generator and adds them to the servo valve of the actuator as a compensation term.

Figure 6. Block diagram representation of real-time testing of an experimental substructure with

derivative feedforward for actuator delay compensation (from [4])

The derivative feedforward delay compensation term in Figure 6 can be added to the valve
through Calculation Channel function. As an example, a one-channel test system was
characterized. The feedforward transfer function was obtained. The compensation was added to
the actuator valve through Calculation Channel function as shown in Figure 7.
Figure 7, Derivative feedforwad delay compensation implemented by Calculation Editor

To verify the effectiveness of the compensator, a sine wave command was played out through
the system with and without the compensation. Figure 8 shows the comparison between
command and feedback for both cases. Without the compensation, the delay was about 10 ms.
With the compensator, the delay was reduced to about 1 ms.

Figure 8, Comparison between command and feedback with and without delay compensation

Signal Filtering

In quasi static hybrid simulation, the overall structure is modeled by analysis software, such as
OpenSees and Abaqus. Some components in the structure are tested by physical tests. Interfacing
software, such as OpenFresco, sends commands from the model to the test system and sends
response signals, such as force and displacement signals, from test systems to the model. Unlike
pure analysis, the response signals from test systems always have certain level of high frequency
noise. This kind of noise can have a significant impact on the accuracy and solving speed of the
hybrid simulation, even cause the simulation fail to converge.

To reduce the noise level, a digital filter can be used to remove the high frequency noise. This
digital filter can be easily implemented through Calculation Channel function.

Figure 9 shows the comparison of same load signal with and without the digital filter. It is quite
obvious that the digital filter removed most of the noise.

Although digital filters can remove high frequency noise, it can create delay as well. The delay
can cause a stability issue for hybrid simulation as mentioned earlier. Therefore, to use the digital
filters effectively in hybrid simulation, the test speed has to be reduced or delay compensation
method has to be implemented. Therefore, the low pass filter is best used for quasi-static hybrid
simulation where test speed can be slowed down significantly.

Figure 9, Filtered (blue) and non-filtered (black) load signal

Test Configuration Creation

In some tests, multiple actuators are needed to apply complicated loading on a specimen. One
example is a Multi-Axial Sub-assemblage Test (MAST) system shown in Figure 10. This MAST
system requires Degree-of-Freedom (DOF) control, which makes the tuning and test much
easier, in addition to direct actuator control. The transformation between local actuator
coordinate and global DOF coordinate can be defined through calculation and the calculation is
done in real-time during test, which enables accurate DOF control. Figure 11 shows the control
diagram of DOF control.

In case of over constrained situations, a special control approach enables the actuators
controlling the over constrained degrees of freedom to achieve equal amount of actuator forces.
This approach enables the system to achieve higher force capacity, better controllability, and
reduced cross coupling effect. This special control algorithm has been implemented by
calculation at the controller.

Sometimes more complicated control modes are desired, such as mixed mode control capability
(For example, vertical in force control, lateral and longitudinal in stroke control in the MAST
system shown in Figure 10); 3rd mode, similar to strain control mode, for local measurement
allowing independent transducers mounted between moment platens; smooth mode switch
between all control modes, particularly between actuator LVDT and local control mode with
external displacement transducers. All these can be implemented through calculation at the
controller.

Figure 10, Multi-Axial Sub-assemblage Test (MAST) system

DOF
DOF control
cmds DOF updates Jacobian servo-
DOF Motion valve
matrix
ACT ACT DOF fbks Ctlrs cmds
fbks Transforms

Figure 11, DOF control diagram

Virtual Testing

Some hybrid tests involve lengthy and expensive test setup, and complicated control algorithm.
More and more researchers start to simulate the tests before investing on the test setup to make
sure that everything will work as expected. Besides simulating the physical test, the virtual
testing approach can pre-tune the control parameters without the potential to damage the
specimen. The virtual test system may be setup through Calculation Channel function.

Specimens are load bearing devices. With loads applied by actuators, the structure deforms and
displacement responses are generated. The relationship between the loads and displacements can
be characterized and calculation channels can be setup to mimic the force and displacement
relationship. In addition to stiffness, inertia and damping of the specimen can be modeled as
well. In this way, a virtual specimen is setup to provide a response with a given command. The
virtual specimen can be as simple as a linear spring or as complicated as a highly non-linear
friction bearing as long as the stiffness, inertia, and damping of the specimen can be described by
C programming language.

When more accurate virtual test result is desired, hydraulic elements, such as servo valves and
actuators, may need to be modeled. In this case, it is more convenient to use software package
such as Simulink to create the plant model and download the model to a target PC or the
controller in order for the model to run in real-time. Figure 12 shows a physical and virtual
system for a Multi Axial Shaker Table.

Figure 12, Physical and virtual test system of a Multi Axial Shaker Table

Other Applications

Calculation Channel function has many other uses. For example, in some of the structure testing,
the desired profile could be a plastic strain signal. Based up on feedback signals of displacement,
force, and specimen geometric information, the plastic strain signal can be calculated and a
calculation channel can be setup to achieve this control mode.

In case of thermo mechanical fatigue test, the thermal strain can be removed through calculation
so that pure mechanical strain is controlled.

Calculation Channel function can be used as an effective tool to monitor a test as well. It can
monitor all feedback signals and calculated variables from these signals. Limits can be set so that
test can be conducted according to different situations. For example, in collapse simulation test,
initial control mode could be force. Once the specimen is damaged, the stiffness of the specimen
becomes much lower. Calculation can be set to monitor the stiffness and switch the control mode
to displacement control after the stiffness change exceeds certain level to prevent the total
collapse of the specimen.
 Conclusions

Calculation Channel function in MTS Flextest control software is a very powerful tool in
structure testing, especially in hybrid simulation. Nearly all algorithms written in C language can
be implemented using this function. This method provides an effective way to build models,
conduct delay and roll-off compensation, filter the response signal, setup complicated test
configuration, and conduct virtual testing without the need of additional real-time operating
hardware and software. Due to the paper length limitation, a lot of the detail information cannot
be covered here.

Calculation Channel function only provides a tool. To use it effectively, the users need to figure
out the mathematic algorithm and enter it through Calculation Editor. Understanding the physics
and come up with correct mathematic calculation is the key for using this method effectively.

References

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