THE SPIDER-100 THV Controller

(Integrated Controller for Temperature, Humidity, and Vibration Control)

Spider-100 Diagram - click to enlarge

Click to enlarge diagram.

  Random Vibration Control

Random Vibration Control

  Sine On Random

Sine On Random

  Random on Random

Random on Random

  Swept Sine

Swept Sine

  Resonance Search Track & Dwell (RSTD)

Resonance Search Track & Dwell (RSTD)

  Classical Shock

Classical Shock

  Transient Time History (TTH)

Transient Time History (TTH)

  Shock Response Spectrum (SRS) Synthesis

Shock Response Spectrum (SRS) Synthesis

SPIDER-100 CONTROLLER

The Spider-100 controller by Crystal Instruments is the control engine for environmental test THV chambers. (THV stands for Temperature, Humidity, and Vibration.) Based on the proven platform of Crystal Instruments Spider vibration controller, the Spider-100 precisely controls all aspects of a combined temperature/humidity and vibration test regime to meet testing requirements in various industries, e.g. automobile, aerospace, aviation, electronics, and military.

The Spider-100 is specifically designed to perform all types of tests where the DUT (device under test) is subjected to simultaneous vibration, temperature cycling, and variable humidity, including Highly Accelerated Stress Screening (HASS) and Highly Accelerated Life Testing (HALT). The Spider-100 controls temperature, humidity, and vibration harmoniously in a chamber and shaker system, which includes external heating/cooling and humidification/dehumidification systems. The communication between numerous devices is optimized by the Spider-100 in an integrated design to achieve high control accuracy. The Spider-100 provides eight voltage input channels and two shaker drive outputs for linear shaker control. When a pneumatic hammer table is used, the controller commands the RMS vibration level via its 4-20 mA current-loop output to the table’s pressure control valve. There is a total eight 4-20 mA analog out channels offered on the Spider-100. Additionally, the Spider-100 provides ten 4-20 mA analog input channels for humidity, various types of sensors, and eight temperature input channels for 3-wire RTD or J/K-type thermocouples. Thirty relay control channels control the heaters, compressors, valves, and air circulation system of the chamber. Thirty-two channels of programmable digital I/O serve as communication channels to other instruments and for user-defined applications.

SOFTWARE FEATURES

  • Random Vibration Control
  • Sine-on-Ransom (SoR)
  • Random-on-Random (RoR)
  • Swept Sine Vibration Control
  • Resonance Search Track & Dwell (RSTD)
  • Classical Shock Control
  • Transient Time History (TTH)
  • Shock Response Spectrum (SRS) Synthesis
  • Transient Random Control
  • Sine Oscillator
  • Non-acceleration Control
  • Highly Accelerated Life-Testing/Stress-Screening (HALT/HASS) 
  • Standard FFT Spectral Analysis

PRODUCT SPECIFICATIONS

  • Analog Inputs: 8 BNC connectors per front-end, voltage or IEPE, single-ended or differential, AC or DC coupling, 150 dBFS dynamic range, 24-bit A/D converters, range ±20 volts, up to 102.4 kHz fs per channel
  • Channel Phase Match: Better than ±1.0 degree up to 20 kHz among all channels
  • Analog Outputs: 2 BNC connectors per front-end, 100 dB dynamic range, 24-bit A/D converters. ±10 volts
  • Isolated Digital Inputs: 24 channels (25-pin female D-SUB)
  • Isolated Digital Outputs: 8 channels (25-pin female D-SUB)
  • Temperature Inputs: 8 channels (3-pin screwed terminal), support 3-wire RTD (-200~+850C, ±0.2C) and K type thermocouple (-200~+1250C, ±0.5C)
  • Relay Control: 30 channels (37-pin D-SUB)
  • 4-20mA Analog Inputs: 10 channels (2-pin screwed terminal)
  • 4-20mA Analog Outputs: 8 channels (4-pin screwed terminal)
  • On-Board Memory: 4 GB non-volatile flash memory
  • Dimensions: 440 x 320 x 90 mm
  • Excellent Heat Dissipation: no cooling fan

DOWNLOAD MORE INFORMATION:

TEMPERATURE CHANNEL INTERFACE

Channel ID Definition
1 Temperature Channel
2 Temperature Channel
3 Temperature Channel
4 Temperature Channel
5 Temperature Channel
6 Compressor 1 Output Temperature
7 Compressor 2 Output Temperature
8 Dehumidification Compressor Output Temperature

Channels 1 through 5 can be used as either a control channel or monitor channel. Channels 6 through 8 can only be used for monitoring the output temperature of the three compressors. When the output temperature of the compressor exceeds the maximum allowed temperature in the hidden configuration page, the test will abort.

The sensor type used for the eight temperature channels can be either PT100 RTD sensors or T-type thermocouples. Other types will be supported in the future. The temperature sampling rate can reach 1000 samples per second.

A precise 24-bit ADC was embedded in the temperature control chip which implements two differential and four single-ended inputs - one low noise PGA, two programmable power sources, an internal reference, an oscillator, a low side bridge switch, and a precision temperature sensor.

HUMIDITY CHANNEL INTERFACE

Channel ID Definition
1 Humidity Channel
2 Humidity Channel
3 Humidity Channel
4 Humidity Channel
5 Compressor 1 Intake Air Pressure
6 Compressor 1 Outlet Air Pressure
7 Compressor 2 Intake Air Pressure
8 Compressor 2 Outlet Air Pressure
9 Dehumidification Compressor Intake Air Pressure
10 Dehumidification Compressor Outlet Air Pressure

Channels 1 through 4 can be used as the humidity control or monitor channel. Channels 5 through 10 can be used to monitor the intake and outlet pressure of the three compressors. When the monitored pressure of the compressor exceeds the maximum allowed pressure in the hidden configuration page, the test will abort.

The electric current input range is 4-20 mA corresponding to the 0-100% RH humidity range. The input adopts a 4-20 mA current loop which is an analog communication method. Compared to the various modern digital communication methods, it doesn't require complex coding and decoding and due to the inherent anti-interference ability of the current loop, reliability is very high in the complex and noisy environment of an industrial site. In addition, the 4-20 mA current loop has a more reliable fault diagnosis ability.

As for the 4-20 mA current loop, the zero level is represented by the 4 mA current, and the full level is represented by the 20 mA current.  Current lower than 4 mA is for fault diagnosis with current over 20 mA regarded as overload.

VIBRATION INPUT CHANNEL INTERFACE

The Spider-100 vibration input chain consists of 8 inputs that can be switched in or out of the signal path. There is a calibration circuit for internal calibration and a charge amplifier and IEPE power supply. The Spider-100 adds temperature and humidity control to the Spider-80X and Spider-81 series vibration functions.

The front-end amplifier operates in single-ended or differential mode. In single-ended mode, the shield on the input jack is grounded, and the measured input voltage is referenced to this ground. In differential mode, the shield is not grounded and the measured input voltage is the potential difference between the shield and center terminal. After this initial amplification stage, there is an analog high-pass filter for DC removal that is switched on only in AC input modes. After that, there is the final analog amplification stage, the Analog to Digital Converter, and the DSP processor.

The rest of the signal processing is done by the DSP microprocessor. This processor specializes in floating-point arithmetic and is used to process the input signal and generate an output.

Crystal Instruments achieves a very high dynamic range for all its measurement instruments by using a unique patented technology that uses two A/D converters in each measurement channel.

  A/D Conversion Diagram

A/D Conversion Diagram

During the period of data acquisition, the time streams from both A/D converters are forwarded into the DSP processor allowing the DSP processor to pick the appropriate input.

With such high-dynamic range for each input, the gain settings (voltage range) are all but eliminated.

Crystal Instruments was awarded a United States patent for this and other innovative inventions