Ⅰ. Scope of product usage

Test type: 

tensile test for steel wire ropes and mining chain links;Compression test within a certain range.

Application field: 

construction industry,building materials industry,Metallurgical industry,colleges and universities,Quality Inspection Center,Commodity Inspection Department

This testing machine is an ideal testing equipment for the above fields.

II. Product Introduction

1. Test procedure

The testing machine receives test instructions, sample numbers, sample sizes, and other sample information transmitted from the superior computer. The operator manually confirms the sample number according to the sample sequence transmitted from the superior computer (or manually selects a specific sample), and then clamps the sample for testing.

The testing machine system can automatically switch to different testing conditions according to the testing instructions downloaded from the superior computer. After the test is completed, the test results are automatically transmitted to the superior computer.

2. Introduction to the testing machine:

The testing machine adopts a frame structure, with a single-rod double-acting piston cylinder applying the test force. The entire testing process is controlled by a computer control system. The test data is precisely measured by a load sensor and transmitted to the computer. The software system displays the test force and piston displacement in real time, and is capable of automatically analyzing, processing, and storing the test results. The printer can directly print the required test report.

The frame has high rigidity and strength, with minimal deformation, meeting the requirements of GB/T 8358-2006 "Test Method for Breaking Tension of Steel Wire Rope" and GB/T12718-2001 "High-Strength Round Link Chain for Mining Purposes". The testing space is adjustable, facilitating the testing needs of samples of different lengths. It adopts the proprietary closed-loop coordinated loading electro-hydraulic servo control system independently developed by Maijie, which controls and coordinates multi-level hydraulic loading with microcomputers, ensuring smooth continuous loading, multi-level test force maintenance, automatic load holding, automatic data acquisition and storage, curve drawing, automatic printing of test reports, and timely control of the testing process by computers. It displays the test force and test curve, with simple and reliable operation, making it easy to operate.

3.The overall appearance of the machine is as follows:

(This image is for reference only, subject to the actual product)The structural schematic diagram is as follows:

III. Main Technical Parameters and Performance Indicators

●Maximum load: 1000kN

●Structural form: Single-rod double-acting cylinder frame structure

●Drive control mode: microcomputer-controlled electro-hydraulic servo

●Test type: Tensile test at room temperature

●Overload protection: 105% overload protection (no deformation, no mechanical damage)

●Overall noise level: not exceeding 70dB

●Accuracy of load indication: better than ±1% of the indicated value

●Load resolution: 500,000 yards, with consistent resolution throughout the entire range

●Force measurement range: 2% to 100% F·S (no divisions throughout the range)

●Load control accuracy: better than ±1% of the indicated value

●Stress control accuracy: better than ±1% of the indicated value

●Accuracy of displacement indication: better than ±1% of the indication

●Displacement resolution: 0.001mm

●Displacement control accuracy (speed): better than ±1% of the indicated value

●Piston movement speed range: 0-200mm/min, infinitely adjustable at full load

●Piston stroke: 1000 mm

●Maximum tensile space: 5000 mm

●Tensile space width (internal clear width): 600 mm

IV. Technical Performance Characteristics of the Product

1. Host system

The main unit is primarily composed of components such as the cylinder base, cylinder piston, front moving gripper base, rear gripper base, and load sensor. The cylinder base, steel plate welding frame, and rear moving head base form a force-bearing framework, while the front moving gripper base and rear gripper base connect the two ends of the test sample. The single-rod double-acting low-friction piston cylinder drives the front moving gripper base to move under the action of hydraulic oil, thereby applying the test force to the test sample. The rear moving gripper base is connected to the framework via a pin connection, which is manually inserted and removed. The computer control system achieves automatic control of the test by controlling the servo valve.

1.1 Framework

The frame is constructed using steel plates welded together, featuring full weld seams, high rigidity, and stable structure. It primarily consists of the cylinder base, left and right frames, and rear sealing plate. The left and right frames are shown in the following image:

he frame is equipped with holes for adjusting the distance between the pins, with an adjustment interval of 300mm.

1.2 Oil cylinder base

The simplified diagram is shown below:

1.3 Oil cylinder

The single-rod double-acting piston cylinder is processed by a high-precision machine tool to ensure accuracy, and the final process of the cylinder bore is precision machining by a honing machine, thereby reducing the friction of the cylinder piston and improving the measurement accuracy and service life of the testing machine. Imported seals are used, featuring low friction and long service life. The structural diagram is shown below:

The schematic diagram for installing the oil cylinder is shown below:

1.4 pull rod

The tension rod is made of 45# high-quality structural steel, which not only meets the strength requirements but also enhances its operational reliability. It is processed using high-precision machine tools and undergoes heat treatments such as aging, tempering, and sizing to ensure its accuracy.

1.5 Sensor

This machine adopts a spoke-type load sensor, which has good resistance to lateral forces and accurate force measurement. The installation diagram is shown below:

2. Hydraulic system

Utilizing servo valve control and a differential oil circuit system, the preparation time for the test can be maximally reduced while meeting the test requirements. The pump station is equipped with a precision oil filter not exceeding 5μ; a pressure following system is adopted, ensuring that as the load increases, the pressure of the hydraulic system simultaneously increases, maintaining the stability of the loading speed. The overflow valve controls the maximum pressure of the system and provides safety protection. The entire system is designed based on the principles of energy conservation and simple layout. The oil tank is equipped with an electronic oil temperature and level gauge, a high-pressure oil filter, an air filter, and other components, including oil temperature, level, and oil resistance protection and indication devices. According to the usage requirements of the oil circuit, a water cooling interface is reserved for the oil source.

The appearance of the hydraulic station is shown below:

3. Electrical system

The electrical system adopts an integrated control cabinet, with the strong current system consisting of a low-voltage starter cabinet and an operation console. The low-voltage part is arranged outside the oil source to reduce the impact of system startup on grid voltage. The operation console adopts a desktop structure and is arranged in the test operation area. It is equipped with a built-in remote low-voltage start control device and a specially designed operation panel that makes various test operations clear at a glance. This control cabinet integrates a computer, monitor, keyboard, mouse, printer, and strong current control operating system into one, making it simple, clear, and easy to use. The outline drawing of the control cabinet is as follows:

4. Servo control system

Basic Principles of Electro-Hydraulic Servo Control Technology: The electro-hydraulic servo control system boasts advantages such as high output (torque) and rapid response. It combines the flexibility, speed, and high control accuracy of electrical control with the high-power operation capability of hydraulic control. Furthermore, it can be connected to computers for various complex control and data processing tasks. It is capable of conducting static deformation tests and conventional mechanical property tests. In recent years, test equipment utilizing electro-hydraulic servo control technology has become a leading representative of advanced international test equipment.

The main function of the servo controller is to integrate, compare, correct, and amplify the electrical signals input into the system; the electro-hydraulic servo valve converts the current signal input by the servo controller into hydraulic energy, and is a key component in the electro-hydraulic servo control system; the servo actuator receives the pressure oil output by the electro-hydraulic servo valve, enabling the actuator to move as required.

5. Acquisition system

●Force value acquisition: force measurement with high-precision load sensors;

●Oil cylinder displacement acquisition: automatic acquisition via wired optical encoder;

6. Control system

6.1 Main menu

●Integrating full digital electro-hydraulic servo closed-loop control, data processing, and data analysis

●It possesses complete file operation capabilities, allowing for the storage of test reports, test parameters, and system parameters in a file format.

●Supports various commercial general-purpose printers.

●The control system is supported by a software system, making it easy to upgrade.

●The main interface of the software integrates all functions for daily material testing operations, such as sample information entry, sample selection, curve drawing, data display, data processing, data analysis, and test operation, making the test operation simple and fast.

6.2 Sample information input and selection

The software design is tailored for the speed and convenience of experimental operations, adopting specialized design methods to meet the needs of large-scale process testing. The shape of the test samples can be freely selected

6.3 Curve plotting

The software system provides a rich display of test curves, such as test force-displacement curve, test force-time curve, stress-strain curve, force-deformation curve, displacement-time curve, and deformation-time curve.

6.4 Control operation interface

●The software provides five control modes: open-loop control, speed closed-loop control, single-step closed-loop control, programmed closed-loop control, and full-range strain control.

●The full-range strain control is a test method determined in accordance with GB/T 228.1-2010 "Metallic Materials - Tensile Testing - Part 1: Method of Test at Room Temperature". This software is divided into three modes: beam displacement, extensometer, and beam displacement considering the stiffness of the main machine.

●It possesses a flexible "programming" function for the testing process, enabling the editing of testing procedures of any complexity and any control mode as needed. The test program control scheme can be stored, imported, and further edited.

6.5 Improved data processing function

●Automatic data processing allows for statistical analysis of batch data.

●A variety of internationally recognized units are available, such as the International System of Units (SI), metric units, and traditional Western unit systems.

●It possesses manual data processing capabilities, making it suitable for users to conduct various complex data analyses.

●Experimental data can be stored in text format and can be further processed using any commercially available data processing software.

6.6 Process reproduction function:

It can fully simulate and reproduce the entire testing process, timely display the changes in the test curve during the test, and timely display the current testing speed.

6.7 Process reproduction auxiliary analysis interface:

With powerful auxiliary analysis capabilities, it can display the quantity of any parameter at any point at any time, as well as the real-time speed value at that time, and the position of the parameter point in the entire sampling point. When used together with the mouse following function on the coordinate, it can display the change of the point in real-time as the mouse slides on the curve; it also has a search and positioning function.

6.8 Report printing section:

●Select the print template list to choose a print template. The templates displayed in the list are all placed in the "report" directory under the application directory. When adding a template, simply copy the template to this directory, and the list will automatically update and display it;

7. Safety protection device

●When the test force exceeds 2% to 5% of the maximum test force or the set value, overload protection is activated;

●When the sample breaks, the test will automatically stop;

●When the piston moves to its extreme position, the stroke is protected;

●When the rear moving clamp base reaches its limit position, it triggers travel protection;

●The testing area is equipped with protective covers to ensure the safety of the testing personnel;

●Equipped with oil temperature, liquid level, oil resistance protection and indication devices;

●In case of an emergency, directly press the emergency stop button on the control cabinet for power-off protection.

Ⅴ.System configuration checklist

1. Host system

●One set of single-rod double-acting low-friction piston cylinder (piston stroke 1000mm)    

●Front moving chuck base (hydraulic clamping) - 1 set

●Rear clamping head base (hydraulic clamping) - 1 set

●1 set of rear sealing plate              

●1 set of frame (with steel plate welding structure)          

●One load sensor              

●One set of displacement measurement system (including displacement measurement sensor and installation part)    

●Bolts: 1 set on each side

2. Test accessories

●Hydraulic clamping chucks: 2 sets

●Stretching pliers jaw: 1 set

●Extensometer: 1 set

3. Oil source system: 1 set

4. Electrical part

●Electrical control cabinet:1 set

●1 set of well-known domestic brands of electrical components          

●1 set of wire and cable              

5. control system

●Measurement and control card:1 set

●One   mainstream configuration computer from Lenovo brand    

●Printer: 1 unit

●Test software: 1 set

●Oil source control integrated cabinet:1 set

6. Others

●One set of electrical operation console              

●1 set of safety shield              

●1 set of installation and debugging tools and sealing spare parts          

●One set of accompanying documents including user manual, certificate of quality, packing list, etc      

VI. Installation Conditions

●Power supply: 380V, 50Hz, three-phase five-wire;

●A lifting device, such as a crane or a hoist, must be available at the site to facilitate equipment installation;

●The equipment installation foundation shall be completed by the buyer, and construction shall be carried out in advance according to the foundation drawings provided by the supplier;

●Upon the arrival of the equipment, the buyer shall be responsible for unloading and positioning the equipment;

●Leave at least 1 meter of space around the equipment for installation and routine maintenance;

●The equipment should be placed where there are no high-voltage power lines or other devices that may affect its safe use above it, or the laboratory should be constructed according to the specific height of the testing machine.