Wholesale of 100 ton electro-hydraulic servo hydraulic material testing machine

1. Main Overview

100 ton electro-hydraulic servo hydraulic material testing machineAdopting microcomputer control for loading, body and control of electro-hydraulic servo valvecabinetThe separated design has the characteristics of easy operation, stable and reliable work, high test accuracy, and smooth force application. It is suitable for tensile, compressive, bending, and shear tests of materials such as metal, cement, concrete, and plastic.

It is recommended to install and use this device in an environment that meets the following conditions:

a. Clean, dry, and vibration free, with a surrounding space for testing and maintenance (≥ 0.7m);

b. The room temperature is between 10 ℃ and 35 ℃.

The product specifications and main technical indicators are shown in the attached table.

2. Host structure principle

2.1 Mechanical Structure Principle

100 ton electro-hydraulic servo hydraulic material testing machineThe main body is composed of a height adjustable support frame (consisting of a machine base, screw rod, and moving crossbeam (lower jaw seat)) and a working frame (consisting of a working oil cylinder, piston, table, bracket, and upper crossbeam (upper jaw seat)). Its working principle is: the high-pressure oil pump supplies oil to the working cylinder, and through the movement of the piston, the worktable and upper crossbeam (upper jaw seat) are pushed upward to perform tensile or compression tests on the sample. The tensile test is conducted between the upper crossbeam and the moving crossbeam of the host, and the compression test is conducted between the platform of the host and the moving crossbeam. The adjustment of the experimental space is achieved by driving the double screw synchronous rotation through the driving mechanism (lifting motor, sprocket, chain, etc.) to lift the moving crossbeam.

2.2 Electrical Principles

This equipment adopts three-phase 380VTwo phase 220V50Hz AC power supply. The main circuit includes the oil pump motor and the lifting motor. Fuses are connected to the main circuit and the control circuit respectively to prevent excessive current. A thermal relay is also connected in series before the oil pump motor and the lifting motor to prevent motor overload.

3. Installation

3.1 Open box inspection

After you open the box, please check the quantity of equipment and accessories according to the order contract and packing list to ensure completeness. If any shortage or damage is found, please notify our company as soon as possible for timely handling.

3.2 Preparation before installation

The testing machine should be installed in a clean, dry, vibration free room with a room temperature of 10 ℃ -35 ℃. Sufficient space (≥ 0.7m) should be left around the testing machine for testing and maintenance purposes.

The main body and control cabinet of the testing machine should be installed on a concrete foundation. The basic dimensions shall be based on the shape and foundation drawings, leaving room for anchor screws and other devices such as electrical wires and pipelines. The upper plane of the foundation shall be horizontally aligned.

3.3 Preliminary calibration of installation accuracy of testing machine

Preliminary calibration of the main body: Use a frame level or borrow a plumb bob from the attachment to calibrate the verticality of the column in two perpendicular directions, and adjust it by inserting a small iron piece at the bottom of the main body. Hang the anchor screws securely.

Use cement mortar to solidify the screws at each foot, and fill the gaps between the testing machine and the ground. Maintain for one week.

3.4 Connection of Hydraulic System

a. Remove all binding materials and clean the inside of the oil pipe with clean kerosene.

b. Check if the gasket at the joint is intact. If it is damaged due to transportation, it should be replaced with a new gasket that comes with the machine to prevent oil leakage under high pressure.

c. Use a suitable wrench to connect each oil pipe.

d. This equipment usually uses N68 anti-wear hydraulic oil. When the ambient temperature is too high, N100 hydraulic oil can be added as needed to increase viscosity.

3.5 Electrical Installation

The power supply voltage of this device is three-phase 380VTwo phase 220VThe equipment must be grounded. The electrical connection between the main body and the control cabinet is made using plugs. Before powering on, the iron door of the control cabinet should be opened to check for any loose connections, loose fuses, and to remove dust and debris from the electrical box. After confirming that the device has been connected to the power supply line, press the "Power" button on the control panel to check if the lifting action of the clamp seat matches the text on the button. If it is opposite, switch the position of any two phase wires.

3.6 Debugging

3.6.1 Start the oil pump and repeatedly lift the piston to exhaust the air in the oil cylinder and oil pipe. It can be observed that the return oil is continuous and stable.

If the pointer is found to be stagnant in a certain interval during the pressure test, the following operations should be performed:

a. Adjust the work pressure to half of the range and stabilize it.

b. Open the iron door of the control cabinet and unscrew itstress reliefThe exhaust plug on the right side of the outer circle of the valve should be turned back after clearing the air.

*c. When performing the above operations, attention must be paid to: ① The work pressure should not be too high; ② When turning the exhaust plug, use gentle force to prevent it from twisting and breaking.

3.6.2 Test Drive

a. Pull the cold-formed support evenly apart on both sides, ensuring that it does not touch when moving the crossbeam up and down;

b. Install a spherical lower pressure plate on the platform, and move the crossbeam up and down to make the distance between the upper and lower pressure plates about 20mm;

c. Start the oil pump,Activate the software control systemRaise the table and slowly increase the pressure to 80% of the measuring range;

d. Check for oil leakage at each oil pipe joint;

e. If there is oil leakage, tighten the joint after unloading the force.

4. Operation

4.1 The operation of the whole machine must be coordinated with the control cabinet measurement and control system, as detailed in 6

4.2 Daily Maintenance

4.2.1 All parts of the testing machine should be wiped clean regularly. After wiping the unpainted surface clean, cotton yarn dipped in a small amount of engine oil should be wiped again to prevent rusting. During the rainy season, attention should be paid to wiping, and a dust cover should be used to cover it when not in use to prevent soil from entering.

4.2.2 All valves on the control cabinet should not be opened and placed to prevent dust from entering the interior and affecting the sensitivity of the measuring mechanism.

Long term and frequent use may lead to a decrease or deterioration of the oil level, and the oil level should be checked every 1-3 months based on usage. After the equipment stops running for 15 minutes, observe the left oil window of the control cabinet. If the oil level is lower than the oil window, add the same type of hydraulic oil to the middle position of the oil window; If the oil has deteriorated, it is necessary to replace it with new hydraulic oil.

Frequent use of this equipment for tensile fracture testing may result in some fasteners becoming loose. The fastening of the following parts should be checked regularly:

a. There are two (a total of 8) L-shaped pressure plates in front and behind the upper crossbeam and the moving crossbeam, which serve as guide plates for clamping jaws. Each pressure plate is used for2Only fix with screws;

b. Move 6 screws at each end of the crossbeam;

c. Check the tightness of the screw drive chain every 6 months and adjust the position of the tensioning wheel accordingly (after removing the lower body panel of the main body);

4.2.5 Lubricate the following parts every 3-6 months according to environmental conditions and frequency of use:

a. Lubricate the joint between the screw and the machine base with 100 oil;

b. The screw drive chain is lubricated with butter;

c. Keep the screw part of the screw clean and lubricate it with butter or molybdenum disulfide;

Lubrication at both locations A and B needs to be carried out after removing the lower panel of the main body.

4.2.6 There are two clamp plates for clamping on the upper crossbeam and the moving crossbeam, which are important parts of this machine. The debris on the contact surface between the clamp plates and the crossbeam should be regularly removed according to usage to avoid scratching the contact surface. The method is to remove the pressure plate on one side of the moving crossbeam, take out the clamp plate, clean the contact surfaces between the clamp plate and the crossbeam with an oil cloth, apply a suitable amount of mixed grease of butter and graphite, and then tighten the fixing screws of the pressure plate after reinstalling the clamp plate.

4.3 Use of hydraulic clamping mechanism

a. Connect the rubber hose according to Figure 7,(A1-A1'，B1-B1'，A2-A2'，B2-B2'Hydraulic jaw type，C-C'，D-D'，E-E'。

b.WE-300B/100B downward typeelectro-hydraulic servoThe machine adopts a hydraulic clamp clamping mechanism, and the magnetic mobile control box consists of six buttons including upper clamping, upper releasing, lower clamping, lower releasing, and jaw lifting and lowering.

c. The working pressure adjustment of the overflow valve is located below the integrated block of the force measuring machine. The adjustment handle can be adjusted so that the upper and lower clamping pistons can move, and the smaller the pressure, the better.

d. High pressure rubber hose size:

Additional: O-ring 5 × 1.8 Quantity: 6

Additional: O-ring 8 × 1.8 Quantity: 8(Hydraulic jaw type)

5. Fault handling

I Fault phenomenon: The oil delivery valve has abnormal noise and vibration.

Possible reasons: Due to high temperature or prolonged continuous operation, the oil temperature is too high, causing the viscosity of the oil to decrease.

Corresponding elimination method: Add a suitable amount of hydraulic oil with high viscosity (such as N100 oil), temporarily stop the machine and wait for the oil temperature to drop before continuing to work.

II Fault phenomenon: The testing machine cannot reach the rated test force.

Possible reasons:

a. The oil delivery valve is blocked by foreign objects;

b. The hydraulic system is leaking.

Corresponding exclusion methods:

a. Disassemble and clean the oil delivery valve. If the valve core has burrs, it can be ground with seed paste until smooth.

b. Tighten or replace the gasket at the oil leakage point.

III Fault phenomenon: The jaws slip during the stretching process.

Possible reasons: Oxidation scales or iron filings on the sample may fall into the sliding surface between the clamp plate and the crossbeam, causing biting or increased resistance.

Exclusion method: Remove the clamp plate and use a file to polish the scratched area on the sliding surface, and apply a mixture of graphite and butter.

Fault phenomenon IV: The lifting of the moving crossbeam is not smooth.

Possible causes after eliminating electrical faults:

a. Insufficient lubrication or foreign object blockage between the screw and the machine seat hole;

b. The locking screw of the lower nut of the screw is loose.

Corresponding exclusion methods:

a. Remove the lower nut of the screw rod, start the oil pump, use the piston to push the screw rod out by about 150 millimeters, clean, lubricate, and install it;

b. Check and reinstall the screw lock.

6. System composition

6.1.1WE-B-type microcomputerControl electro-hydraulic servo materialsIntroduction to testing machine:

This system adopts high-precision digital electro-hydraulic servo voltage and speed regulation technology. It has functions such as electronic measurement, collection of experimental data, automatic analysis, printing of reports and curves. Suitable for tensile and compression tests of metals, as well as compression tests of non-metallic materials such as cement and concrete, it is an ideal testing system for industrial and mining enterprises, commercial inspection and arbitration, scientific research institutions, colleges and universities, engineering quality supervision stations and other departments.

6.1.2 System composition: (The system consists of hardware and software)

6.1.2.1 Hardware composition and characteristics:

6.1.2.1.1WAW-B-type digital electro-hydraulic measurement and control box;

a) Built in microcomputer control card, throughnetCommunication between mouth and PC;

b) All use BB, AD, Atmel, etcIntegrated devices, fully digital design;

c) Adopting integrated precision instrumentation amplifiers;

d) 18 bit high-precision analog-to-digital conversion;

6.1.2.1.2 Sensors;

a)loadPressure sensor;

6.1.2.1.3 Digital servo valve;

Stepper motor driven by fully digital control, with * anti pollution capability;

6.1.2.1.4 Measurement and Control Software:

a) Automatic constant speed loading, constant speed displacement, and constant speed deformation closed-loop control;

b) Automatic constant load, constant displacement, and constant deformation closed-loop control;

c) Automatic switching of control mode during stretching process;

d) Adopting PID and excellent fuzzy control algorithms;

6.1.3 System requirements:

6.1.3.1 Requirements of the measurement and control system for the testing machine:

① The test oil source must be stable;

② There is no oil leakage in the oil system;

③ For testing machines with manual and automatic loading functions, the oil supply valve and return valve should be confirmed to be functioning properly.

6.1.3.2 Requirements of Measurement and Control System for Computer System

The system configuration is as follows:

IBM/PC machines with Pentium mmx200/32M or more memory

■ One serial port

Microsoft operating systems Windows 9x, Windows ME, Windows NT, Windows 2000/XP

Color graphics adapter and monitor (supporting display resolution of 1024 * 768 or higher)

6.1.4 System technical performance indicators:

a)、 Indication accuracy:

b)、 Measurement accuracy range: 4% -99%

c)、 Force rate control range: 1kN/s-50kN/s

d)、 Displacement speed control range: 0.5mm/min -50mm/min

e)、 Deformation rate control range: 0.01mm/s1mm/s

f)、 Speed control accuracy: ≤± 5%

6.1.5 Control principle diagram:

6.1.6 Hydraulic oil circuit schematic:

6.2 Hardware Installation and Introduction

6.2.1 Digital servo valve and hydraulic integrated block

1. Digital servo valve: fixed on the hydraulic manifold block with M5 internal six legged screws. (Note: Before installing the digital servo valve, it is necessary to confirm whether the three O-rings on the valve body are intact.). ）

2. The oil outlet of the oil pump is connected to the P0 port of the hydraulic manifold block, the P1 port of the hydraulic manifold block is connected to the cylinder piston, and the return oil channel (T) of the hydraulic manifold block is directly connected to the oil tank.

6.2.2 Sensors

a) Pressure sensor: installed in the oil cylinderBetween platforms.

6.2.3 Measurement and Control Box

6.2.3.1 Place on a stable workbench to avoid collisions (the measurement and control box is the control center of the measurement and control system, belonging to precision equipment, please handle with care when moving);

6.2.3.2 According to the interface markings on the back panel of the measurement and control box, fasten the connecting wires to each interface to prevent poor contact caused by looseness.

6.3 Introduction to Measurement and Control System Software

6.3.1 Installation of Measurement and Control Software

seeWAW-B electro-hydraulic servo testing machine measurement and control software, user manual andWAW-B electro-hydraulic servo testing machine measurement and control software control steps, user manual.

6.4 Precautions and common fault diagnosis

6.4.1 Precautions:

6.4.1.1 The microcomputer system must be separately connected to a single-phase AC 220V ± 10% 500W power supply;

6.4.1.2 The laboratory where the testing machine is placed must have a good grounding wire;

6.4.1.3 The casing of the testing machine host must be reliably grounded;

6.4.1.4 When using a computer, please do not read, write (or copy) floppy disks of unknown origin or unrelated to this machine to prevent computer virus infection, otherwise it may cause system paralysis.

6.4.1.5 Before starting up, it is necessary to check whether the connection wires, plugs, sockets, and power plugs between the computer and the host, as well as the electrical control box, are correct. When the computer exits, it must exit normally according to the operating system rules;

6.4.1.6 During the test process, if there is a sudden power outage: ① First, unplug the power lead of the testing machine host, and turn off the power of the measurement and control box and computer; ② For testing machines with manual/automatic testing functions, open the return valve to make the oil cylinder fall back. For fully automatic pressure testing machines, wait until the power supply is restored to normal before clicking the valve port reset button on the main interface to make the oil cylinder fall back; ③ After the power supply is restored to normal, first turn on the power switch of the measurement and control box, then start the computer, enter the main interface of the control software, click on the "Valve Port Reset" button on the main interface until you hear a creaking sound. For the fully automatic pressure testing machine, the oil cylinder slowly falls back. After the oil cylinder completely falls back, connect the power cord of the testing machine host, start the oil pump, and start the test;

Before opening the casing of the testing machine, the main power switch should be turned off first;

6.4.1.8 If there is a malfunction, please contact the manufacturer or distributor.

6.4.2 Analysis of Software Prompt Information

6.4.3 Common faults and their solutions