HYGETM
Automated Control System
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System Description The system is controlled by
a programmable logic controller (PLC) that provides signals
to various relays which in turn open valves, start compressors,
and more. These relays incorporate logic that allows fail safe
operation by requiring various permissive signals to pressurize
the HYGE Load cylinder. These include signals, as required by
individual system layout, from 
numerous
doors, automatic locks, and area surveillance light curtains.
All permissive signals are required before the cylinder can
be filled with high pressure air and the ram can be fired, simulating
a collision.
The user has the ability to control various doors, compressors,
valves, and other system components while monitoring every pressure
transducer and the state of permissive and control power signals.
System procedure is a major part of the code in this and other
screens. While the relays guarantee that unsafe conditions are
never possible, the system often requires that a process be
carried out in a particular order to have the desired effect.
By incorporating these requirements, a major source of user
error has been eliminated. Reducing the time required to train
personal, while increasing the level of safety
The control system utilizes an intuitive user interface. This
interface provides controls for every automatic function of
the system, from the automatic filling of the system pressure
to the storing of successful test parameters and environmental
data. The tendency for human error is removed by incorporating
proper procedures into the code and providing a live system
schematic on screen.
The first screen a user visits after logging in is dedicated
to data entry of test parameters, as well as to displaying the
output of ambient temperature and humidity sensors. These sensors
and several pressure transducers provide signals to the computer
via communication with PLC input modules. These signals are
calibrated by the LABVIEW engine as determined by tag scaling
settings. Users, based on security privilege, are given access
to the Tag Configuration Editor in the application software
to enter calibration information.
Other screens are accessed as necessary to run the test. They
feature controls and indicators that allow the user to run the
pressure systems and receive appropriate feedback. Pressure
system preparation is accomplished on the screen depicted in
Figure 1.
The system schematic’ design of this screen overcomes the potential
crowding that a complex system requires for numerous controls
and indicators.
Automation features in the system include filling pressures
to target values, an audible ten second countdown over a PA
system, logging of test parameters and environmental data after
a successful test, and the firing process itself.
As in the original system, the user actuates one control to
start the PLC’s ram-firing process. This incorporates control
of various lights, film and video cameras, as well as the arming
and firing of the air bag. This program also provides a ‘T0’
signal to the onboard data acquisition system, signifying exactly
when the ram was fired. Automation is a necessity for this timing,
since the acceleration pulse only lasts on the order of 100
milliseconds.
Summary
The built-in user security and tag configuration components
have shortened development time considerably while allowing
the end user the ability to manage the system. This software
is a well-designed HMI, and provides much more functionality
than a mere graphical “front-end” for the embedded programmable
logic controller.
