Q: What is an EMA system and why did MTS embark upon a next generation redesign?
A: The EMA product line is part of MTS’ portfolio of damper testing products, which we classify by test application (NVH vs performance vs durability), as well as by actuation technology (electric vs servo hydraulic). The EMA (Electro-Magnetic Actuation) product is an electrically actuated test system used for conducting damper performance characterization. It features a highly responsive linear electric actuator that delivers the accuracy and data quality damper manufacturers and OEMs demand; it is energy efficient, and easy to install, operate and maintain. Our next-generation EMA was born of an initiative to develop a new, more cost competitive system design while matching the legacy EMA's proven performance, operational efficiency, and ease-of-use.
Q: How was MTS able to improve upon the cost competitiveness of the EMA design?
A: We achieved a more cost competitive EMA Gen 2, relative to the legacy design, through a variety of approaches. First, we simplified the overall design to reduce the number of machine parts, which makes the EMA Gen 2 easier to manufacture and decreases the labor required for both mechanical and electrical assembly. Second, we reduced material costs and sourced new vendors for numerous critical system components. And third, we made several mechanical improvements to the EMA load frame, most notably, an enhanced actuator bearing design.
Q: What are the advantages of the new actuator bearing design?
A: The configuration of the new design greatly reduces the time and effort required to install and align the actuator bearing properly, making the load frame easier to assemble. The new bearing also streamlines the installation of the motor and magnets, further reducing material and labor costs. The advantages of this new design extend far beyond production, however. The new bearing configuration is far less likely to become unaligned during normal testing, which reduces the need for periodic readjustment – one of the few maintenance issues on legacy EMA systems. In addition, the upper bearing can now be accessed without having to disassemble the load frame, making maintenance and replacement far easier. The new design will also increase bearing life, as there will be less friction from an unaligned bearing, ensuring more consistent performance over the life of the system. Overall, incorporating this new actuator bearing design will yield a higher quality test system that we expect will produce better results.
Q: In addition to improved cost competitiveness, what aspects of the redesign will differentiate these next-generation EMA’s from legacy models?
A: The EMA Gen 2 redesign process afforded us the opportunity to incorporate an array of meaningful improvements to EMA system controls and software, communications, power cabinet and electronics, and load frame. Based on a decade of customer and damper industry feedback, these improvements will differentiate the EMA Gen 2 from the legacy models by enhancing data integrity, expanding utility, increasing operational efficiency, and improving maintainability, longevity, and safety.
Q: How did the redesign improve upon the EMA system controller and application software?
A: We decided to make FlexTest® controllers and MTS Damper software standard on EMA Gen 2 systems, which will help customers in a couple of ways. First, a standard controller for all MTS damper systems simplifies lab maintenance and improves operational efficiency. Our customers field a wide range of test equipment in their labs for which they're hoping to establish a single controller platform and application software. Second, the FlexTest controller offers more advanced capabilities than the Shock 6 systems used in EMA legacy systems. For example, with additional IO and transducer conditioning capabilities, FlexTest can deliver multi-channel control for testing adaptive dampers. FlexTest controllers also enable the playout RPC road profiles and the integration of damper tests into hybrid simulation experiments, greatly expanding EMA testing and simulation utility. MTS Damper software, too, offers more capabilities than the legacy Shock 6 application, especially with respect to custom and arbitrary wave form playout.
Q: How has the redesign enhanced EMA system communications?
A: The EMA Gen 2 is EtherCAT enabled, offering improved digital communication between the controller, power cabinet, and system motor drive. Now the industry standard, EtherCAT communications will reduce noise and improve signal and data integrity. The EtherCAT-enabled motor drive also has a feature that enables redundant safe torque off safety, providing PLD rated safety. In addition, EtherCAT communications features simpler cabling, requiring a single ethernet cable to link the controller and power cabinet.
Q: What improvements to the system power cabinet resulted from the EMA Gen 2 redesign?
A: The EMA Gen 2 power cabinet accommodates a broader range of voltage than the legacy EMA. The legacy EMA required 220 Volt, three phase, which required many customers to acquire a step-down transformer to install and operate the system. Now, with a range of power options, customers can connect the drive and use the system without any transformer. The redesign process also highlighted opportunities for isolating electric noise. This involved ensuring that encoder signal cables were separated from power cables. This will reduce noise, improve grounding, and yield better command and feedback signals, data quality, and data integrity. Additionally, the EMA Gen 2 power cabinet features a front-access design, which allows for free standing or wall mounted installation, making it convenient for both test lab and trailer applications.
Q: What improvements to the mechanical load frame resulted from the decade of customer feedback?
A: Over the years, we've seen a cases where operators have damaged legacy EMA systems by mistakenly driving actuators into the end stops too hard. For these situations, we designed new, larger end stop bumpers capable of absorbing more impact force and reducing the likelihood of actuator damage. While these larger bumpers increase the height of the EMA Gen 2 frame base, it remains a convenient platform for installing and removing specimens. This taller frame base is one of the few noticeable physical differences between the legacy and Gen 2 EMA systems.
Q: Will the redesigned next-generation EMA match the performance capabilities of the legacy EMA?
A:Yes, the EMA Gen 2 will deliver the same - and in some areas better – performance capabilities that the industry has come to expect from our legacy EMA systems. It maintains the core linear electric actuation that our customers prefer for damper performance characterization and delivers the same maximum force, maximum velocity, stroke, and test frequency range as comparable EMA legacy models. In fact, we are seeing better digital encoder accuracy with the new design, which we believe will result in cleaner, more accurate test data. In addition to matching performance, the EMA Gen 2 retains many of the features and the overall size of the legacy EMA frame. The overall footprint and standard column heights remain the same, so a new EMA will fit seamlessly into the same lab space as a legacy EMA. Additionally, the EMA Gen 2 will retain many of the same options as the legacy EMA, including a CE-rated safety enclosure, electric and pneumatic lift locks, pneumatic static support, optional column heights, and a floor isolation assembly.
Q: Will the next-generation EMA product line comprise the same three models as the legacy EMA line?
A: EMA Gen 2 will mirror the three models of the legacy EMA line, but they will have new names based on the metric (kN), as opposed to imperial (kip), force capacities of the system actuator. So, the new EMA 9kN is equivalent to the legacy EMA 2K, the new EMA 18kN is equivalent to the legacy EMA 4K, and the new EMA 27kN is equivalent to the legacy EMA 6K. This naming convention aligns with all other damper test systems in the MTS portfolio, and it will help us clearly differentiate the EMA Gen 2 from legacy EMA systems in the field.
Q: In summary, what should we take away from this discussion about the next-generation EMA Gen 2 systems, when will the new models be available, and how can we learn more?
A: We succeeded in meeting our redesign objectives. EMA Gen 2 systems match - and in some cases exceed – proven legacy EMA performance. While maintaining the convenient EMA geometry, new models leverage versatile FlexTest controller capabilities, EtherCAT communications, and a host of mechanical and electrical innovations to enhance test data integrity, expand system utility, and increase operational efficiency and safety - all in a more cost competitive design. Essentially, we took a great product and made it better.
Production and availability of new EMA 9kN, EMA 18kN, EMA 27kN models will commence in early 2025. Complete information on next-generation EMA performance specifications and capabilities will be communicated in the upcoming formal launch, also in early 2025. In the meantime, I welcome anyone interested in securing an EMA Gen 2 to contact their local MTS sales represenative or submit an online request for more information.
A: The EMA product line is part of MTS’ portfolio of damper testing products, which we classify by test application (NVH vs performance vs durability), as well as by actuation technology (electric vs servo hydraulic). The EMA (Electro-Magnetic Actuation) product is an electrically actuated test system used for conducting damper performance characterization. It features a highly responsive linear electric actuator that delivers the accuracy and data quality damper manufacturers and OEMs demand; it is energy efficient, and easy to install, operate and maintain. Our next-generation EMA was born of an initiative to develop a new, more cost competitive system design while matching the legacy EMA's proven performance, operational efficiency, and ease-of-use.
Q: How was MTS able to improve upon the cost competitiveness of the EMA design?
A: We achieved a more cost competitive EMA Gen 2, relative to the legacy design, through a variety of approaches. First, we simplified the overall design to reduce the number of machine parts, which makes the EMA Gen 2 easier to manufacture and decreases the labor required for both mechanical and electrical assembly. Second, we reduced material costs and sourced new vendors for numerous critical system components. And third, we made several mechanical improvements to the EMA load frame, most notably, an enhanced actuator bearing design.
Q: What are the advantages of the new actuator bearing design?
A: The configuration of the new design greatly reduces the time and effort required to install and align the actuator bearing properly, making the load frame easier to assemble. The new bearing also streamlines the installation of the motor and magnets, further reducing material and labor costs. The advantages of this new design extend far beyond production, however. The new bearing configuration is far less likely to become unaligned during normal testing, which reduces the need for periodic readjustment – one of the few maintenance issues on legacy EMA systems. In addition, the upper bearing can now be accessed without having to disassemble the load frame, making maintenance and replacement far easier. The new design will also increase bearing life, as there will be less friction from an unaligned bearing, ensuring more consistent performance over the life of the system. Overall, incorporating this new actuator bearing design will yield a higher quality test system that we expect will produce better results.
Q: In addition to improved cost competitiveness, what aspects of the redesign will differentiate these next-generation EMA’s from legacy models?
A: The EMA Gen 2 redesign process afforded us the opportunity to incorporate an array of meaningful improvements to EMA system controls and software, communications, power cabinet and electronics, and load frame. Based on a decade of customer and damper industry feedback, these improvements will differentiate the EMA Gen 2 from the legacy models by enhancing data integrity, expanding utility, increasing operational efficiency, and improving maintainability, longevity, and safety.
Q: How did the redesign improve upon the EMA system controller and application software?
A: We decided to make FlexTest® controllers and MTS Damper software standard on EMA Gen 2 systems, which will help customers in a couple of ways. First, a standard controller for all MTS damper systems simplifies lab maintenance and improves operational efficiency. Our customers field a wide range of test equipment in their labs for which they're hoping to establish a single controller platform and application software. Second, the FlexTest controller offers more advanced capabilities than the Shock 6 systems used in EMA legacy systems. For example, with additional IO and transducer conditioning capabilities, FlexTest can deliver multi-channel control for testing adaptive dampers. FlexTest controllers also enable the playout RPC road profiles and the integration of damper tests into hybrid simulation experiments, greatly expanding EMA testing and simulation utility. MTS Damper software, too, offers more capabilities than the legacy Shock 6 application, especially with respect to custom and arbitrary wave form playout.
Q: How has the redesign enhanced EMA system communications?
A: The EMA Gen 2 is EtherCAT enabled, offering improved digital communication between the controller, power cabinet, and system motor drive. Now the industry standard, EtherCAT communications will reduce noise and improve signal and data integrity. The EtherCAT-enabled motor drive also has a feature that enables redundant safe torque off safety, providing PLD rated safety. In addition, EtherCAT communications features simpler cabling, requiring a single ethernet cable to link the controller and power cabinet.
Q: What improvements to the system power cabinet resulted from the EMA Gen 2 redesign?
A: The EMA Gen 2 power cabinet accommodates a broader range of voltage than the legacy EMA. The legacy EMA required 220 Volt, three phase, which required many customers to acquire a step-down transformer to install and operate the system. Now, with a range of power options, customers can connect the drive and use the system without any transformer. The redesign process also highlighted opportunities for isolating electric noise. This involved ensuring that encoder signal cables were separated from power cables. This will reduce noise, improve grounding, and yield better command and feedback signals, data quality, and data integrity. Additionally, the EMA Gen 2 power cabinet features a front-access design, which allows for free standing or wall mounted installation, making it convenient for both test lab and trailer applications.
Q: What improvements to the mechanical load frame resulted from the decade of customer feedback?
A: Over the years, we've seen a cases where operators have damaged legacy EMA systems by mistakenly driving actuators into the end stops too hard. For these situations, we designed new, larger end stop bumpers capable of absorbing more impact force and reducing the likelihood of actuator damage. While these larger bumpers increase the height of the EMA Gen 2 frame base, it remains a convenient platform for installing and removing specimens. This taller frame base is one of the few noticeable physical differences between the legacy and Gen 2 EMA systems.
Q: Will the redesigned next-generation EMA match the performance capabilities of the legacy EMA?
A:Yes, the EMA Gen 2 will deliver the same - and in some areas better – performance capabilities that the industry has come to expect from our legacy EMA systems. It maintains the core linear electric actuation that our customers prefer for damper performance characterization and delivers the same maximum force, maximum velocity, stroke, and test frequency range as comparable EMA legacy models. In fact, we are seeing better digital encoder accuracy with the new design, which we believe will result in cleaner, more accurate test data. In addition to matching performance, the EMA Gen 2 retains many of the features and the overall size of the legacy EMA frame. The overall footprint and standard column heights remain the same, so a new EMA will fit seamlessly into the same lab space as a legacy EMA. Additionally, the EMA Gen 2 will retain many of the same options as the legacy EMA, including a CE-rated safety enclosure, electric and pneumatic lift locks, pneumatic static support, optional column heights, and a floor isolation assembly.
Q: Will the next-generation EMA product line comprise the same three models as the legacy EMA line?
A: EMA Gen 2 will mirror the three models of the legacy EMA line, but they will have new names based on the metric (kN), as opposed to imperial (kip), force capacities of the system actuator. So, the new EMA 9kN is equivalent to the legacy EMA 2K, the new EMA 18kN is equivalent to the legacy EMA 4K, and the new EMA 27kN is equivalent to the legacy EMA 6K. This naming convention aligns with all other damper test systems in the MTS portfolio, and it will help us clearly differentiate the EMA Gen 2 from legacy EMA systems in the field.
Q: In summary, what should we take away from this discussion about the next-generation EMA Gen 2 systems, when will the new models be available, and how can we learn more?
A: We succeeded in meeting our redesign objectives. EMA Gen 2 systems match - and in some cases exceed – proven legacy EMA performance. While maintaining the convenient EMA geometry, new models leverage versatile FlexTest controller capabilities, EtherCAT communications, and a host of mechanical and electrical innovations to enhance test data integrity, expand system utility, and increase operational efficiency and safety - all in a more cost competitive design. Essentially, we took a great product and made it better.
Production and availability of new EMA 9kN, EMA 18kN, EMA 27kN models will commence in early 2025. Complete information on next-generation EMA performance specifications and capabilities will be communicated in the upcoming formal launch, also in early 2025. In the meantime, I welcome anyone interested in securing an EMA Gen 2 to contact their local MTS sales represenative or submit an online request for more information.
