The WS-300 electrohydraulic servo track elastic component fatigue testing machine is composed of a main engine (300kN servo linear actuator), a constant pressure servo pump 11.901 (90L/min), a deformation measuring mechanism, a single channel full digital dynamic servo controller DTC-200s and related test software and other necessary accessories.
1. Product introduction
1. Main use: PWS-300 electro-hydraulic servo track elastic component testing machine is mainly used in the laboratory to test the dynamic stiffness, static stiffness, dynamic and static ratio, fatigue test and other items of the components such as the cushion plate under the railway track. The replacement of accessories is also suitable for the continuous action and static mechanical performance test of the elastic bar and fastener.
2. Project introduction: The testing machine can complete the test project:
2.1 Static stiffness test;
2.2. Dynamic stiffness test;
2.3. Dynamic and static stiffness ratio test;
2.4. Fatigue test.
3. The product meets the standards, test methods and design basis:
4.1, "TB/T2491-1994 fastener assembly fatigue test Method";
4.2, the European standard "EN 13146-4:2002 Railway application - track-fastener system test method";
4.3, "TB/T2326-1992 prestressed concrete simple supported beam bending fatigue test method Fasteners assembly fatigue test method"
4.4 Special Technical Conditions for Fastener System of the Ministry of Railways Passenger Special Line
4.5, "TB/T1878-2002 Prestressed concrete sleeper fatigue test Method";
4.6, "GB/T2611-2007 testing machine general technical requirements";
2. Scheme Description
The WS-300 electrohydraulic servo track elastic component fatigue testing machine is composed of a main engine (300kN servo linear actuator), a constant pressure servo pump 11.901 (90L/min), a deformation measuring mechanism, a single channel full digital dynamic servo controller DTC-200s and related test software and other necessary accessories.
Attached: Photos of similar products (subject to the actual)
Structural unit introduction:
1. The main machine: the main machine is a four-column (electroplated) frame structure, the servo linear actuator is placed above.
1.1. The beam adopts hydraulic lifting, hydraulic clamping and elastic release structure to ensure the stability and reliability of the test, and ensure that the beam remains locked in the non-test state;
1.2. The beam shape has a three-dimensional sense, beautiful and generous. Beam lifting adopts hydraulic lifting, easy to operate;
1.3. The outer surface of the column is treated with hard chromium plating to improve the anti-corrosion ability;
1.4. The beam movement hydraulic module adopts a special manual reversing valve to ensure the stability and reliability of high frequency test;
1.5. The clamping cylinder adopts module design, and the sealing element adopts the special high-speed sealing element imported from Germany to ensure the long-term operation and reliability of the testing machine.
1.6. The front of the main machine design sample clamping, beam movement and emergency stop operation buttons, easy to operate.
2. Electro-hydraulic servo linear actuator: electro-hydraulic servo linear actuator is used for dynamic and static loading test of tensile, compression and other mechanical properties. The actuator uses an advanced closed-loop servo system to precisely control the speed, thrust and position required for the test. The actuator has a built-in position sensor with control accuracy up to 0.05mm. Actuator structure features:
2.1. The actuator adopts double rod, double action structure, which can provide high carrying capacity, high movement speed and ultra-long life. The servo linear actuator has the characteristics of low damping, high response, high life and large gap design. The support of the piston rod is made of non-metal support and has the characteristics of high-speed self-lubrication without knot. The sealing components are all imported from Germany.
2.2. The actuator adopts symmetrical four-way servo valve control pair called actuator principle design. The servo linear actuator amplitude limit position is designed with hydraulic buffer to avoid running out of control and causing damage. Servo linear actuator frequency response is not less than 100Hz.
2.3. Configure HY150 servo valve, flow rate of 56 liters/minute four oil port servo valve.
2.4. The configuration of the United States Wiss - Shiquan axial load sensor, built-in full scale coaxial installation of LVDT displacement sensor.
2.5. The actuator and the sample are connected with the anti-backlash device (three-dimensional ball hinge), the force value is automatically centered, reduce the side force, reduce the impact of high frequency test, and improve the test waveform. To minimize the damage of the actuator from the lateral force of the specimen, the joint support structure adopts a modular design, and the bearing clearance of the joint support can be adjusted after wear to ensure the flexible operation of the test system.
Attached picture: three-dimensional ball hinge
3. Control system: full digital control system hardware composition and function: hardware consists of four parts: microcomputer, full digital controller, manual control panel and accessories.
3.1. The microcomputer provides the basic working environment for the full digital control system software, including providing the operator with a friendly human-machine dialogue interface, managing the full digital controller to control the test process, collect, save and analyze the test data. Industrial control computer is generally selected, which has good anti-interference ability.
3.2. The full digital controller is the core hardware part of the control system, and the real-time control of the testing machine is completed by the full digital controller. The controller controls the number of channels: 1, connected to 2 sensors, is suitable for different types of testing machines, and can be dynamically switched smoothly between various control modes. The controller A/D and D/A conversion accuracy is 16 bits, and the closed-loop control data update rate is 10 thousand times/second. The main components are: CPU unit, sensor regulator unit, servo valve control unit, hydraulic source control unit, analog signal input/output unit and digital signal input/output unit. CPU unit with high performance 32-bit floating point microprocessor as the core, set function generator, feedback selector, comparator and digital PIDF arithmetic in one.
Function generator can output DC voltage, single segment sine wave, single segment triangular wave, sine wave, triangular wave and square wave, as well as any combination of the above waveform waveform (random wave), waveform output frequency range 1×10-5Hz ~ 50Hz. The waveform and amplitude of the output signal of the function generator can be freely changed by software control according to the test needs. Single precision floating-point arithmetic is used to generate waveform of function generator. Digital PIDF arithmetic uses single precision floating point operation, digital PIDF operation update rate of 10 thousand times/second.
Sensor regulator unit can be divided into DC regulator and AC regulator, DC regulator is mainly used for load sensor, strain gauge and oil pressure sensor, AC regulator is mainly used for measuring displacement LVDT. The excitation voltage and amplifier of the regulator are software-programmable, each regulator can be divided into free files, and the switch between each file is all controlled by the software, and the amplified sensor signal is converted to A/D and sent to the CPU unit for use. The A/D conversion accuracy of the regulator is 16 bits, and the conversion speed is 10 thousand times/second.
The valve drive unit is suitable for all kinds of electro-hydraulic servo valves, and the D/A conversion accuracy of the valve drive unit is 16 bits.
The hydraulic source control unit is used to control the working stop of the hydraulic source and the conversion of high and low pressure.
The analog signal input/output unit provides software-programmable analog signal input/output, the signal input/output range is ±10V, the accuracy is 16 bits, each contains 4 channels, providing additional data acquisition and control functions for the controller.
The digital signal input/output unit provides software-programmable TTL digital signal input/output, each containing 16 channels, to provide additional data acquisition and control functions for the controller.
3.3. The manual control panel is mainly used for manual control of hydraulic sources and testing machines, such as switching oil pumps and loading/unloading samples.
3.4 Composition and function of the controller control software: The controller control software is all Chinese interface. Its main function is to provide a friendly human-machine dialogue interface, control the test process, automatically record/analyze the data, print the test results, provide extended programming interface for the test personnel and calibrate the sensor. The working ability and automation degree of the testing machine are mainly reflected by the test software. The running environment of the control software is WindowsXP. The control software is divided into system management software, test software and interface software.
3.5. The controller system management software is the basis of the entire digital control system work, its main function is to manage the hardware resources of the control system, define the sensor range, define the control channel, define the control mode, digital PIDF parameter adjustment, set protection, display the current control mode, hydraulic and function generator status and sensor calibration, The dual trace digital oscilloscope, digital servo valve ammeter and 6 digital voltmeters are provided for real-time display of test data.
Figure: Main interface of test assistant system management software
The system management software can be configured with three types of protection, namely, external protection, internal protection and saturation protection. The above three types of protection can be set up independently for each sensor or control channel. During the test, according to the characteristics of the test, some protection can be set up, and the software can automatically and quickly stop the work of the function generator, servo valve and hydraulic source when the danger is going to occur (such as the specimen fracture), so as to ensure that the test equipment is not hurt.
The dual-trace digital oscilloscope is used to display or print the waveform of sensor feedback, error and command signal in real time during the test. The digital voltmeter is mainly used to display the peak, valley, maximum, minimum and current value of sensor feedback, error and command signal in real time during the test. There are 6 digital voltmeters in total. Figure 7 is the interface diagram of the digital oscilloscope. Figure 8 is the digital voltmeter interface diagram.
Oscilloscope interface diagram
digital voltmeter interface diagram
3.6. The test software is specially designed for the completion of a certain type or a class of tests and designed separately, with the cooperation of the system software, the use of various functions provided by the full digital controller to control the process of the entire test, and automatically record/analyze the test data and print the test results.
The test software is mainly written according to some common functions or standard test methods, which mainly includes: function generator software, static test software, fracture performance test software, low cycle fatigue test software.
Function generator software is mainly used in constant amplitude test. The function generator software automatically tracks and corrects the peak and valley values of the control quantities (such as loads) to ensure error control throughout the test. During the test, the operator can dynamically change the peak value, valley value and frequency, and can also carry out manual or automatic signal holding. If the automatic signal holding cycle interval is set, the software will automatically keep the signal at the set level for each additional cycle interval, so as to facilitate the measurement of some test data (such as visual crack length). The software optional waveforms are sine wave, triangle wave and square wave. Save the important data after the test.
Attached figure: Software interface of dynamic and static stiffness test report
4. Constant pressure servo pump station: mainly by the bottom plate, fuel tank, oil pump electric unit, valve block, pipeline, cooling system and other parts.
4.1. The pump station tank adopts a fully enclosed design, which can effectively prevent external impurities from entering the hydraulic system to pollute the hydraulic oil.
4.2. The oil pump and electric unit are configured with double elastic support in series to further reduce the noise of the pumping station.
4.3. The pump station is equipped with low noise AC motor, low noise linear conjugate internal gear pump.
4.4. The high and low pressure soft switching hydraulic module composed of main relief valve, accumulator, secondary main relief valve, secondary relief valve and reversing valve, and no more than 3u precision oil filter is used to adjust the output system pressure of the pumping station;
4.5. The valve block also has a low pressure start, high pressure switching function, can effectively prevent the impact of the hydraulic system switching machine;
4.6. The pump station is equipped with oil cooler for hydraulic system cooling;
4.7. The pump station is equipped with imported high-pressure hose to ensure that the system has no leakage;
4.8. The pump station is equipped with double electric contact temperature control meter, liquid level control meter, pressure sensor and other necessary sensors; With oil temperature (below 10ºC, higher than 55ºC), liquid level, oil filter blockage alarm, motor overload protection and other safety alarm functions.
4.9. With motor start-stop control circuit, oil source alarm circuit, status display circuit. The motor start-stop control circuit is composed of start, stop, emergency stop and high and low voltage conversion circuit. The oil source alarm circuit is composed of temperature overlimit alarm, oil filter clogging alarm circuit, low liquid level alarm circuit, etc. Configure the remote start and stop function, and arrange the emergency stop button in the hydraulic actuator control room and beside the hydraulic actuator.
Attached: Photo of constant pressure pumping station
5. Displacement measuring mechanism: used to measure the deformation of the sample under the specified load, placed on the surface of the sample, directly and accurately measure the actual deformation of the sample, and display the displacement value and the force value of the testing machine in real time, and draw the corresponding curve through the test software. There are two sets of displacement measuring mechanisms in the test system, which are used in stiffness test and longitudinal resistance test of rail respectively. Each measuring mechanism contains 4 precision displacement sensors, and the measuring position can be moved arbitrarily to meet the requirements of the measuring position in the Test Method. Displacement sensor using magnetostrictive displacement sensor, measuring range: ±5.08mm, frequency range :400Hz to 5KHz, operating temperature :-55℃ ~ 150℃, vibration tolerance :20g/2KHz. The displacement sensor has the characteristics of wide frequency excitation, high output voltage, magnetic stainless steel shell can shield electromagnetic and static electricity, and strong anti-interference ability. The small displacement sensor has high measuring precision and can accurately measure the actual deformation of the sample. The TEST data are directly entered into the MTS FLEX TEST 60 control system, and the test software can form test curves independently or average values of any number of displacement sensors according to the test requirements.
6. Oil cooling unit: used for testing machine hydraulic system cooling, the main features:
6.1. 5-inch HD true color touch screen, sensitive touch, simple operation, dynamic display of unit operating status;
6.2 Weekly timing function can effectively manage the temperature, and the unit start and stop time can be set freely within a week;
6.3. The unit runs for a certain time, automatically remind maintenance, save management worries;
6.4. Dynamic monitoring operation: automatically display compressor operating status, working status at a glance;
6.5. Remote automatic control, according to the temperature of the hydraulic system automatically determine the working state;
6.6. Self-diagnosis function, automatically determine the cause of the fault.
7. Other necessary configurations:
Equipped with a set of calibration tools for calibrating load sensors;
Equipped with 1 set of compression accessories;
Flush accessories for servo actuators and constant pressure servo pump stations;
All hydraulic pipe fittings and high pressure hose are imported products to ensure that the entire system does not leak oil;
Dynamic stiffness test equipment and software
Other necessary accessories.
3. Main technical performance indicators
1. Maximum static test force: ±300kN;
2. Static display accuracy: ±0.5% (2%-100%);
3. Maximum dynamic test force: ±300kN;
4. Dynamic volatility: ±1%FS.
5. The maximum amplitude of the actuator: ±50mm, indicating accuracy of ±0.5%FS.
6. Frequency range: 0.01-30Hz;
7. Control mode: load, displacement, deformation control mode, the main test waveform: supported by the controller (including sine wave, square wave, triangle wave, oblique wave and external input waveform);
8. Maximum test space: 550mm;
9. Test force, displacement, deformation three closed loop control loop. It has control mode smooth switching function without disturbance.
10. Pump station: rated flow 90L/min, motor power: 37kW
11. Amplitude and frequency characteristics: meet the frequency of 4Hz, amplitude ±5mm;
4. Configuration list:
| No. | Configuration Name | Specifications | manufacturers | Number |
| 1 | 300 kN host rack | BeaconAuto | 1 set | |
| 2 | Actuator | 150KN | BeaconAuto | 1 set |
| 3 | Actuator sealing element | Germany Busak+Shamban | 1 set | |
| 4 | Load sensor | 300kN | United States Viss -- Shiquan | 1 set |
| 5 | Servo valves | 63L/min | HY150 | 2 sets |
| 6 | Displacement sensor | ±50 mm | American Schaevitz Sensors | 1 set |
| 7 | Test accessory | BeaconAuto | 1 set | |
| 8 | Deformation measuring device | ±5 mm | AML150 | 4 sets |
| 9 | Hydraulic drive module | BeaconAuto | 1 set | |
| 10 | Single channel servo controller | BeaconAuto | 1 set | |
| 11 | Computer | Advantech industrial computer | 1 set | |
| 12 | Printer | A4 laser printer | HP Company | 1 set |
| 13 | Fluid connector | import | 1 set | |
| 14 | Wash attachment | BeaconAuto | 1 set | |
| 15 | Load calibration tool | BeaconAuto | 1 set | |
| 16 | dynamic stiffness special software | BeaconAuto | 1 set | |
| 17 | UPS power supply | Sante | 1 set |
Pumping station configuration list:
| No. | Configuration Name | Specifications | manufacturers | Number |
| 1 | tank | BeaconAuto | 1 set | |
| 2 | Oil pump | 90L/min | Japan NACHI | 1 set |
| 3 | Motor | 37kW | south Anhui motor | 1 set |
| 4 | Main relief valve | Japan NZCHI | 1 set | |
| 5 | auxiliary main relief valve, auxiliary relief valve and reversing valve | Lixin | 1 set | |
| 6 | oil cooling unit | Shanghai Kangsai | 1 set | |
| 7 | double electric contact temperature control meter | Tianjin Affdi | 1 set | |
| 8 | Accumulator | Wenzhou | 1 set | |
| 9 | Other hydraulic accessories | Wenzhou del | 1 set | |
| 10 | Fluid connector | import | 1 set | |
| 11 | Wash attachment | BeaconAuto | 1 set | |
| 12 | strong electric cabinet | BeaconAuto | 1 set | |
| 13 | Spare filter element | Wenzhou Liming | 3 |
