Modernization of electromechanical static testing machines

Upgrading to modern technology restores spare-part availability, maintains compatibility with current Windows operating systems and enables the testing machine to be equipped from the current accessory range, making it future-proof in use.
Collage_+FO
  • over 20 years' experience in modernizing materials testing machines
  • warranty for newly installed components, as with new machines
  • renewed long-term service and support
  • rapid assistance via Hotline and in the event of repairs
  • testControl II measurement and control electronics satisfy the most demanding safety requirements
  • enables validation of the testing machine in accordance with the latest quality standards
  • intelligent testXpert II testing software employed
  • re-use of expensive components such as extensometers and specimen grips
  • existing load cells converted and re-calibrated

zwickiLine

Modernization of electromechanical zwickiLine with testControl II
As well as providing modernization packages for large testing machines, Zwick carries out modernizations on machines for low nominal loads between 500 N and 2.5 kN. Even really small testing machines receive a new digital DC servo for optimum performance; these machines too benefit from the ideal combination of the latest version of our testXpert II testing software plus our high-quality testControl II measurement and control electronics Up-to-date software combined with a new control system ensures that the testing machine will give many more years of service, with spare-part availability restored to ensure reliable service and support. Modernization equips the testing machine to handle future innovations and new testing requirements.

Description

Value

Machine electronics

Number of available slots for measurement and control modules:

Synchronized module slots

2 (expandable to 5)[1]

Synchronized PCIe slots

1

Force measurement

Class 0.5/1, depending on load cell, compliant to DIN EN ISO 7500-1, ASTM E4

Measurement range

Up to 165% of Fmax[2]

Calculated resolution (e.g., load cell in tensile/compression direction)

24

bit

Effective resolution in tensile/compression direction:

DCSC module

19 bits (corresponds to ±512,000 points)

USC module

20 bits (corresponds to ±1,000,000 points)

Measured value recording rate

400

kHz

Measurement value transmission rate to PC

500 (optional 2000)

Hz

Zero-point correction

Automatic, at start of measurement

Measurement signal run-time correction for all channels

Yes

Interface to PC

Ethernet

Eco mode

Yes, automatic switch off of power section (time can be set)

CE conformity

Yes, according to Machinery Directive 2006/42/EC

  1. A DCSC module is included in the scope of delivery (occupies one module slot). The drive requires an optional module slot.
  1. For load cells with Fmax 2.5 kN: up to 130% of FN

Note: CE compliance is possible with modernizations provided the overall scope of the modernization satisfies the relevant conditions - please get in touch with us.

Description

Value

Electrical supply data

Electrical connection (Ph, N, PE)

100 to 240

V

Tolerance range

±10

%

Power consumption (full load), approx.

500

VA

Power frequency

50/60

Hz

AllroundLine

Modernization of AllroundLine – electromechanical static testing machine
Available from Zwick for materials testing machines from 10 kN are ideally matched modernization packages. The rugged construction of these testing machines makes modernization a worthwhile alternative, while modern drive technology in the form of a new, energy-efficient AC motor with greatly improved control and positioning accuracy enables the most demanding performance requirements to be met. Other components include the current testControl II measurement and control electronics, featuring high measured-value rates, modularity and high safety standards. The testControl II electronics form a perfect synergy with the latest testXpert II testing software version, providing optimum testing conditions for accurate, repeatable, reproducible and traceable test results.

Description

Value

Machine electronics

Number of available slots for measurement and control modules:

Synchronized module slots

2 (expandable to 5)[1]

Synchronized PCIe slots

1

Force measurement

Class 0.5/1, depending on load cell, compliant to DIN EN ISO 7500-1, ASTM E4

Measurement range

Up to 165% of Fmax[2]

Calculated resolution (e.g., load cell in tensile/compression direction)

24

bit

Effective resolution in tensile/compression direction:

DCSC module

19 bits (corresponds to ±512,000 points)

USC module

20 bits (corresponds to ±1,000,000 points)

Measured value recording rate

400

kHz

Measurement value transmission rate to PC

500 (optional 2000)

Hz

Zero-point correction

Automatic, at start of measurement

Measurement signal run-time correction for all channels

Yes

Interface to PC

Ethernet

Eco mode

Yes, automatic switch off of power section (time can be set)

CE conformity

Yes, according to Machinery Directive 2006/42/EC

  1. A DCSC module is included in the scope of delivery (occupies one module slot). The drive requires an optional module slot.
  1. For load cells with Fmax 2.5 kN: up to 130% of FN

Note: CE compliance is possible with modernizations provided the overall scope of the modernization satisfies the relevant conditions - please get in touch with us.

Power input specifications

Version

1

4

9

kW

Power supply

±230

±400

400

V

Phases

1Ph/N/E

3Ph/N/PE

3Ph/N/PE

Permissible voltage fluctuation

±10

±10

±10

%

Power consumption (full load), approx.

2.3

6

11

kVA

Power frequency

50/60

50/60

50/60

Hz

Non-Zwick testing machines

Modernization of an electromechanical non-Zwick testing machine
Zwick modernization packages are modular in nature. This system approach allows other makes of testing machine to be converted to Zwick testing technology in a straightforward manner. These manufacturer-independent modernizations use the same components as found in a Zwick testing machine, with a new, energy-efficient AC motor to power the high-capacity machine drive. The testControl II measurement and control electronics are mounted at the side of the testing machine. With their high positioning and return speeds they provide an ideal basis for accurate, repeatable, reproducible and traceable test results, while their modular design allows flexible deployment of additional sensors and measuring devices. We have already converted machines from 40 different manufacturers to Zwick technology, gaining a great deal of knowledge and expertise in the process.

Description

Value

Machine electronics

Number of available slots for measurement and control modules:

Synchronized module slots

2 (expandable to 5)[1]

Synchronized PCIe slots

1

Force measurement

Class 0.5/1, depending on load cell, compliant to DIN EN ISO 7500-1, ASTM E4

Measurement range

Up to 165% of Fmax[2]

Calculated resolution (e.g., load cell in tensile/compression direction)

24

bit

Effective resolution in tensile/compression direction:

DCSC module

19 bits (corresponds to ±512,000 points)

USC module

20 bits (corresponds to ±1,000,000 points)

Measured value recording rate

400

kHz

Measurement value transmission rate to PC

500 (optional 2000)

Hz

Zero-point correction

Automatic, at start of measurement

Measurement signal run-time correction for all channels

Yes

Interface to PC

Ethernet

Eco mode

Yes, automatic switch off of power section (time can be set)

CE conformity

Yes, according to Machinery Directive 2006/42/EC

  1. A DCSC module is included in the scope of delivery (occupies one module slot). The drive requires an optional module slot.
  1. For load cells with Fmax 2.5 kN: up to 130% of FN

Note: CE compliance is possible with modernizations provided the overall scope of the modernization satisfies the relevant conditions - please get in touch with us.

Power input specifications

Version

1

4

9

kW

Power supply

±230

±400

400

V

Phases

1Ph/N/E

3Ph/N/PE

3Ph/N/PE

Permissible voltage fluctuation

±10

±10

±10

%

Power consumption (full load), approx.

2.3

6

11

kVA

Power frequency

50/60

50/60

50/60

Hz

Innovative testControl II Machine Electronics

All of Zwick's materials testing machines are equipped with the powerful testControl II measurement and control electronics, offering the ideal basis for precise, reproducible test results.

  • The electronics are installed vertically on the load frame to prevent liquids and from entering the unit and contact with conductive particles.
  • The high-quality finish protects testControl II from external influences. The components used are highly durable.

Maximum Accuracy

High (24-bit) resolution and A/D converter with 400 kHz sampling rate for maximum measured-value accuracy combined with large measurement range. As an example, even the smallest force changes on the specimen can still be recorded and displayed accurately.

System Monitoring

testControl II system monitoring provides the user/laboratory manager with detailed information on the current status and level of utilization of the testing equipment. This enables further increases in testing equipment availability and greatly simplifies maintenance planning and spares/replacement procurement.

Safety for the Entire Testing System

The two-channel safety circuit, including Emergency STOP, crosshead limit stop switch and interlinked accessories, Drive OFF switch and motor brake function, together with the operation mode switch, ensure enhanced safety during setup. The CE-compliant electrically interlocked safety device prevents interference with the machine during the test.

Machine Compliance Correction

High-quality drive technology plus online correction of machine compliance enable very high travel-measurement and positioning accuracy. testXpert II automatically determines the optimum curve, ensuring maximum possible accuracy for travel measurement and positioning via the crosshead displacement transducer.

  • Real-time correction via the corrected channel directly in the testControl II electronics, regardless of test speed and duration!
  • Control and positioning directly to the corrected channel.
  • Ideal for tests for which direct-measurement extensometers cannot be used.

Fast, Adaptive Drive Controller

The high drive control frequency of 1000 Hz delivers fast, precise force and strain control. Benefits include enabling components to be loaded very quickly and accurately with a predetermined force.

In addition, all required control parameters are set automatically, for fast, accurate attainment of target positions. This gives time and cost savings by eliminating the need for expensive, time-consuming pretesting.

Eco Mode

testControl II electronics switch automatically to eco-mode when not in use, saving energy.

Controller Setup

Special controller set-up for testing situations with demanding control requirements. For example, if the force sensor is located on the fixed crosshead in force-controlled tests, the controller can simply be switched in the software.

High Data Transmission Rate

Synchronous 500 Hz measured-value acquisition-rate delivers fast measurement with maximum reproducibility (regardless of number of measurement channels). The measured-value acquisition-rate can optionally be increased to 2000 Hz. The high data transmission rate enables fast measurement with maximum reproducibility. This is highly advantageous for high-speed tests, short brittle-fracture events and in tear-growth, adhesion and peel tests.

Flexibility Through Modularity

testControl II has six flexible time-synchronized slots, allowing multiple sensors to be used simultaneously and monitored and safeguarded regardless of use.

  • As an example, an extensometer and a transverse strain extensometer can be used in addition to the load cell.
  • If the testing system is equipped with several load cells or additional sensors, these can all remain plugged in. All sensors which are plugged in will then automatically be protected against overloads.

Adaptive controller

All required control parameters are set automatically, for fast, accurate approach to target positions.

  • Changes in specimen properties during the test are compensated for online.
  • This brings time and cost savings by eliminating the need for expensive, time-consuming pre-testing.
  • Ideal for strain control to ISO 6892-1 Method A (1).

Gigabit Ethernet Interface

The Gigabit Ethernet interface (a proven industry standard) for the testing machine computer enables very high data throughput.

Powerful Drives

Powerful drives allow cyclic tests to be performed at maximum speed up to nominal load - with no waiting time between tests. AllroundLine and ProLine use maintenance-free AC drives.

Ergonomic Remote Control with Display

Tests can be performed entirely via the remote control, independent of the PC. All important information is shown on the display. Machine operation is therefore more ergonomic and effective. The rocker-switch with integrated dial makes positioning fast yet highly accurate.

Strain Rate Control

The AllroundLine drive technology’s excellent constant-velocity characteristics and interaction with the sensor technology and adaptive control make it ideal for demanding strain-rate control (e.g. ISO 6892-1, Method A1).

Innovative Interfaces

The innovative EtherCat® interface is incorporated as standard. The time-synchronized real-time Ethernet field bus system ensures future-proof integration of sensors and power units.

Time-Synchronous Signal Processing

Time-synchronous acquisition of measured values from all sensors connected to plug-in slots takes place at the fast system-frequency, as does data transmission to testXpert II. This ensures high test-result reproducibility regardless of the sensors in use or the test sequence; for example force and travel signal synchronicity is maintained, even with strongly differing test speeds.

testXpert III testing software

Intuitive and Workflow-Based Right from the Start!

testXpert III is the result of close cooperation with software users in the materials testing industry and the experience of over 30,000 successful testXpert installations. From the very start, testXpert III uses a workflow that is based on your lab processes to guide you step by step through your test.

Getting started is easy!

Our workflow-based software keeps training time to a minimum and makes testing efficient and reliable. The intuitive interface is identical for all Zwick materials testing machines and instruments— enabling efficient testing, from simple standard-based tests to demanding tests in research and development.
The clear, logically structured workflow guides the operator the whole way, through test preparation, execution, and results analysis, establishing a clearly identifiable visual association of all related content, ensuring fast, easy navigation. A newly structured user interface with large, expressive icons helps you navigate through the software easily so you can start testing quickly.

3:21

Modernization of testing machines with Zwick

Modernizing testing machines with Zwick – RetroLine testControl II

Tensile tests at 3,000kN - Zwick modernizes testing machine for steel wire ropes at Redaelli

At its factory in Gardone val Trompia, Italy, Radaelli produces steel wire ropes for a wide range of uses. These include offshore applications, construction machinery, ropeways and cableways and bridge-building. The growing demand for wire ropes with ever-higher load capacity is also placing an increasing burden on quality assurance. After modernization by Zwick the testing machine can now perform tensile tests up to 3,000kN.
022
Top