Vibration Controller System History

Jan 05, 2018

First generation controller - standalone

The earliest digital vibration controllers in the United States were developed by some HP engineers in the 1970s. They tested a variety of control algorithms on the HP5451, the most successful early signal analyzer. HP5451 is based on a minicomputer HP2100 a device, its memory and computing power is very limited, engineers use a variety of ways to achieve several kilowatts achieve real-time bandwidth of thousands of hertz. Two of Ron Potter and Peter Moseley made a significant contribution to this early controller.


After the HP company successfully tested this algorithm with the HP5451, the HP5427 appeared as a commercial product in the 1980s. It consists of stackable chassis, professional display and control panel. HP5427 is a very successful product, but due to the adjustment of Hewlett-Packard Company and eventually abandoned. In the early 1970s, two other inventors, Edwin Sloane and Charles Heizman, worked on a company called Time Data and took out a patent for random vibration control. Time Data later acquired by GenRad, released their stand-alone control system. The GR25xx is almost the most successful controller of the late 1970s.

GenRad's Vibration Control division later became part of Spectral Dynamics, a division of GenRad Controller. In algorithm development, he focused on replacing the proportional control used by HP with "error" control. Similarly, Tony Keller made a huge contribution to the development of controllers. DEC's PDP series of minicomputers are the vibration controller hardware platform.

In the early 1980s, LMS partnered with HP to provide complete vibration control software for HP's new hardware system (Paragon). The relationship between LMS and HP was related to Microsoft's relationship with IBM's PC. Eventually, compared to IBM and HP, which offer only hardware, LMS and Microsoft proved that software sales are even more important.

Other early vendors such as Ling Electronics, MB Dynamics, Schlumberger and others. Due to the use of dedicated hardware, the early VCS systems cost between $ 80,000 and $ 200,000 and require very careful handling. However, thanks to the tremendous demand for structural testing in the aerospace, automotive and military industries in the 1980s, Vibration control industry was born. Many of the control algorithms used today are generated at the time. It was also during that period that the military standard 810, which dictates most of the complex environmental testing standards (including vibration testing) was established.

Second Generation Vibration Controller - PC-based controller

In the 1990s, IBM PC machines were used in industry. Many companies begin to use PC for data acquisition and dynamic signal analysis. Data Physics was founded by two former Hewlett-Packard experts from Sri Welaratna and Dave Snyder. A project by Lansmont in collaboration with Data Physics to develop a digital PC-based vibration control system culminated in the Lansmont TTVI and DP DP540 controllers. These early DOS-based controllers had a rare graphical user interface in those days. DP540 uses multiple ISA bus plug-in DSP card, each card has multiple DSP processors and A / D, D / A converter chip. This product has achieved great success.


Following the same ideas as the DP540 and DP550 (DP540 for Windows), other manufacturers have also released their PC-based vibration controllers such as Puma from SD, DVC from UniDyn and VWin from Unholtz-Dickie.

The second generation of vibration controllers has benefited from the development of PCs and dedicated DSP processors, greatly improving its performance and ease of use, while reducing costs. The introduction of PC, making the display, reporting capabilities, connectivity and system performance has greatly improved. The continuous decline in price allows the vibration controller system to be used in more commercial applications, such as electronics and packaging testing. While the price of the system drops, the market size of vibration controller products is growing year by year.

The main disadvantage of the second generation vibration controller system is that the system is too dependent on the performance of the PC. This is mainly due to the card whose control loop is to be installed in the PC through the PC CPU. Many controllers use the ISA bus, the control loop time is limited by the PC ISA bus interrupt and transmission bandwidth. In addition to the PC architecture, LMS and M + P rely on HP hardware to build their software systems and use the UNIX operating system, which includes Paragon and VXI systems. They are primarily intended for high-end users who need large amounts of synchronized data acquisition during testing.

The third generation of vibration controller, PC as the peripheral control side of the controller

In the 1990s when Dactron developed a new generation of vibration controllers, Dr. Zhuge said the original system was technically flawed and found an entry point for improvements. Although this generation still uses a PC, the PC's role is already peripherals, since in this new controller the control loop is no longer via a PC. Using this strategy to achieve a more rapid loop control time. At the same time as a floating-point DSP processor, in this controller also achieved a variety of new algorithms.

LASER is a vibration controller that uses multiple floating point DSP processors, 24-bit sigma-delta A / D converter, and PCI, USB bus and other technologies. Application software system using Microsoft MFC development. The new framework and new technologies make the system many functions while still maintaining ease of use. Dactron's LASER family of products has been a huge success, with thousands of Dactron's LASER systems already installed around the world. LDS acquired Dactron in 2001, LDS was then the world's largest manufacturer of electromagnetic vibrating table, LDS has now become part of Danish B & K.


After Dactron released LASER and Comet, many other companies, including VRC and DP, also released third-generation vibration controller systems with control loops that are PC-independent.

Fourth Generation Vibration Controller - Fully Networked Controller

In 2010, Crystal Instruments of the United States released Spider-81, the latest generation of vibration control system. The Spider-81 incorporates the latest hardware design, signal processing algorithms and new software technologies.


The Spider-81 is the first vibration-based control system based on networking and supporting IEEE 1588 time synchronization. The basic module can be set to 4 or 8 channels, and the number of additional channels can be expanded by 1024. It offers a very high degree of flexibility, test accuracy and ease of use. Spider-81 is equipped with a channel, bright LCD display, digital I / O interface, built-in battery backup and front panel controls. Spider-81 uses an Ethernet interface.

As a 4th generation controller Spider-81 has the following features:

Digital signal processor as the main control structure

Unlike traditional controllers that rely heavily on external computers for real-time operation, Spider is the first controller to directly and directly integrate time-synchronized Ethernet connectivity with embedded DSPs. This strategy greatly enhances control performance, system reliability, and exceptional protection, allowing the system to configure extremely large channels without compromising system performance.

The latest hardware design

Equipped with voltage main, charge and IEPE input channels, the Spider-81 module is suitable for shock, vibration and acoustic testing as well as other common voltage signal measurements. Its internal flash memory can store hundreds of channels of test configuration data and real-time analysis of data. Multiple output channels provide various signal waveforms synchronized with the input sampling frequency. Equipped with a liquid crystal display that shows test status information. Each device provides 10 monitoring connections to read analog input and output signals, there are several operating buttons on the front panel. It can be connected to other hardware through the built-in independent digital I / O and RS485 serial ports. There is an emergency stop button to interrupt the test in critical situations.

Simple and convenient internet connection

The Ethernet connection allows the Spider-81 to be physically separated from the PC. This distributed architecture greatly reduces noise and electrical interference in the system. A PC through the network can monitor and control multiple controllers. Since the control process and data logging are performed inside the controller, the network connection does not affect the control performance. Through the wireless network router, PC can also be easily used to connect WiFi remote Spider device.

Multi-module time synchronization between technologies

Spider-81 using IEEE1588 time synchronization technology, Spider module on the same LAN can achieve 100ns time synchronization accuracy, which can ensure that 20KHz analysis bandwidth, channel phase error of not more than ± 1 degree. Using this technology and high-speed Ethernet makes it possible to distribute modules on the network to operate as a centralized device.

Black box mode: work from the PC

The Spider-81 can work in black box mode without a PC. In this mode, the PC configures the device and downloads the configuration parameters to the device before the system starts the test. After the Spider completes the test independently and then connects with the PC, the PC can download the test result data. During the test run, the controller works in a predetermined flow and users can control through front panel keys, remote handles, and WiFi-enabled PDAs such as iPads.

With LCD display

Each Spider-81 front panel is equipped with a bright LCD display to show real-time system status and test information, such as control RMS value, the current frequency sweep and so on.

High reliability design

The Spider-81 is the first vibration control system designed to provide disaster protection, even in the event of a network outage or power outage. The advanced safety control loop can detect sensor dropouts in milliseconds. Spider-81 hardware undergoes rigorous environmental testing including EMI, temperature, drop impact, sinusoidal and random vibration. System design can withstand long-term harsh working environment and reliable operation. The use of floating design also reduces the installation of road grounding problems.

High-precision input design

With its unique technology, the Spider-81 is the first vibration controller to achieve a dynamic range of 150dB input. Each input channel can test a minimum of 6μV and a maximum of 20V at one range, completely eliminating the need to set different input ranges for the input channels during testing, as in traditional controllers.

Excellent control performance

With improved control algorithms and efficient DSP architecture, sinusoidal and stochastic control of the feedback loop time can be greatly reduced. Faster feedback loop times improve search and reside capabilities, and control over high-Q structures. This also provides faster response, better security.

Easy to use

Spider-81 to further improve the user interface level. More graphical guidance, wizards and tools to join, to make setting up quick and easy. New arranged interface to make it more reasonable and easier to use. "Abnormal execution rules", "termination sensitivity" and other new interface features make the operation easier. Database management capabilities make it easier to search by keyword in a large number of test projects.

Combined with modal analysis and signal processing, the Spider-81 integrates modal analysis with versatile signal analysis capabilities including time-history recording, transient acquisition, FFT, self-power spectroscopy and transfer function analysis. Multiple Spider-80 DSA modules can work together as an integrated system with one Spider-81 vibration controller module. The Spider-81 features long-term signal logging to capture time-domain data on each channel for critical testing tasks and save it in the built-in flash memory.

DynaTronic Corporation provides leading edge instrumentation for vibration testing system and measurement, e.g., VENZO 800 vibration controller system can provide you with the most comprehensive vibration control software modules, including: random, sine, classical shock, RSTD, SRS, SoR, SoS, RoR, SRoR, TTH and FDR and other auxiliary applications. Each module provides basic functions and optional functions, so you can customize the desired system. The grateful and characteristics which contain simple operation, rich control function, improved analysis and reporting features, easy-to-upgrade hardware and software, and high reliability and quality contributes the high cost-effective for VENZO 800 series vibration controller system.

DynaTronic Corporation (China) Ltd

Address: Rm. 19C, Lockhart Ctr.,301-307 Lockhart Rd., Wan Chai, Hong Kong.

Contact: Angela Zheng

E-mail: sales@dtc-solutions.com

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