At the Emerson Exchange Americas Virtual Series, Emerson’s Erica Brackman shared ways to improve test bench performance using TESCOM ER5000 series electropneumatic actuator. Here is her presentation’s abstract:
Burst and proof testing are integral methodologies for ensuring the long-term performance of equipment used in pressurized conditions. If a supplier’s radiator hose, pressure vessel, or gauge were to burst prematurely it would jeopardize the safety of the process and the users. The TESCOM ER5000 allows suppliers to mitigate the risk of improperly pressure rating their parts, sending a part not up to snuff out the door, and having to do large recalls. The ER5000 allows manufacturers to optimize the accuracy of their burst and proof testing by automating the testing process, all while ensuring the safety of their employees.
Erica opened with why test benches may behave poorly.
She noted that by automating test bench processes that optimize production conditions, improve quality or conversion, improve decision making about product specifications, and enable safer working conditions for plant personnel.
The ER5000 is an open or closed loop PID pressure controller that brings precise algorithmic pressure control to a wide range of applications. It has an electropneumatic actuator which takes an electronic signal in and provides pneumatic pressure out. This electronic setpoint signal can come from a computer, PLC, DCS or potentiometer. The feedback signal comes from a transducer in the controlled pressure line. This means you don’t necessarily need a dedicated computer, PLC or DCS.
It can be used as a pressure reducing regulator, pilot regulator for pneumatically actuated regulator valves, flow control valve or pressure control valve.
The electronics section of the ER5000 which contains the PID control algorithm compares the setpoint signal to the feedback signal every 25msec. The pneumatics section contains two pulse width modulating solenoid valves.
When setpoint is greater than feedback the inlet valve opens to increase the pressure out. When the setpoint is less than feedback the inlet valve closes, and the exhaust valve opens to decrease the pressure out.
In test bench testing scenarios, the ER500 can be used for burst, leak and strength testing as well as analysis of various components that require pressure or flow control.
These include hoses, fittings, tubing, gauges, catheters, rupture discs, sprinklers, plastic tanks, regulators and valves. The ER5000 can also be used in other applications such as calibration stands, gas supply, filling in food & beverage operations, chemical injection, spray coating/cable coating, laser/plasma cutting, and injection molding.
Erica shared several test stand case studies which applied the ER5000 including burst and proof test benches, automated valve leak check systems for production testing on sprinkler valves, airbag cannister filling, multi-gas selection and control system, and pressure relief valve & vent functionality testing.
Visit the TESCOM ER5000 page on Emerson.com for more on how this technology helps to minimize waste by automating systems, maintain optimum production conditions to improve quality or conversion, provide insight for better product specification decisions, and reduce personnel safety risks.