DOLI's STANDARD COMPRESSION FLEXOMETER (GOODRICH FLEXOMETER)
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- Veronica Moore
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1 Qualitest USA LC, Toll-Free: TEST, Fax: , DOLI's STANDARD COMPRESSION FLEXOMETER (GOODRICH FLEXOMETER) Basic System The measurement is based on ISO 4666 (DIN ) Part 3, or ASTM D 623 Specimen size: Height 25,4 mm (1 inch) diam. 17,8 mm (0,7 inch) Stroke variation: 4,45 mm up to 6,4 mm Cyclic Compression: 30 Hz, controlled motor Mechanical Construction 1. Basic body with complete stroke system, controlled electric motor, toothed belt, bearing unit and stroke adjustment. 2. The shaft bearing for the stroke of work is delivered as a ball bearing and the shafts are tempered. 3. The balance beam is complete with all adjustments and can be fixed with a bolt, if not active. A compensation weight is connected to both ends. The entire mechanics is maintenance free. compr_flexo_long_en.doc/
2 Technique of Measurement The contact temperature of the specimen is measured at the lower holder. The deformation of the specimen is measured and controlled with the lower holder also, via rotary incremental transducer. Basic Electronics The basic electronics drives and controls all systems of the Flexometer. The basic electronics is inside the Measuring Computer. Functions: Microprocessor controlled Test run and measurements Temperature measurements: Holder and room temperature, (Puncture Needle) (Chamber Temperature) Balance control and displacement-motor control Power amplifier Designed for extensions Puncture Needle The puncture needle is used to measure the temperature in the centre of the specimen. The needle can only be used, when the motor is at "STOP". Measurement can be triggered manually via the keyboard. In the automatic test, the needle is driven by the computer. If the needle temperature measurement is active, the temperature output is switched from mould temperature (minus environment temperature ET) to needle temperature (minus ET). Temperature Chamber The manual temperature chamber is controlled from room temperature up to 110 C. The medium is air. Specimens can be loaded manually through the front door. The automatic chamber has an air actuator, plus electronics and software to open a door in the rear for the handling arm. The software also supports the pre-heating place with timing and handling. Testing and pre-heating place are served by the handling arm through the rear door. 2 compr_flexo_long_en.doc/
3 Automatic Handling Arm The handling arm is constructed as a linear and radial axis, with a driving distance of 100 mm (linear) and 120 (radial). The linear movement is carried out by a pneumatic actuator, the radial movement by a DC motor with incremental transducer. The grip itself is driven pneumatically. ready tested specimens silo 2 10 specimen silo 1 10 specimen cooling station 1 height measurement cooling station 2 cooling station 3 cooling station 4 cooling station 5 test preheating place The sketch shows all possible positions of the handling arm. With the fully automated version, the complete action is controlled by the basic electronics and the computer. 10 specimen can be loaded into a silo. A further silo for another 10 specimen is offered optionally. The maximum staple of specimen in a silo can't exceed 10, because the specimen like to stick together. Extensions can be realised by the handling arm, such as: height-measurement and cooling stations, to get values as the final set etc. compr_flexo_long_en.doc/
4 Automatic Height Measurement Incremental height measurement station for a measurement of 30mm. Accuracy is ±0,001mm. Pneumatic actuator for the movement of the gauge. Measurement before and after the test. Digital display of the measured value on the screen is printed and plotted in mm and %. The handling arm moves the specimen to the station. Two cooling stations will keep the specimen in place for the selected cooling time. The cooling time is programmable. Measurement of the final-set: F.S. = (H1-H2) *H100/H1. specimen cooling down one cooling station not in action one specimen in height measuring position one specimen cooling down incremental height measurement 30 mm pneumatic actuator actuator is released during measurement The possible test and cooling time has to be considered. In order to reach other test- and cooling-times, another cooling station, including three cooling-places, is offered. Therefore, it is possible to reach, e.g. a test time of 15 min. per specimen and cooling times of 1,5 hrs. with 5 cooling stations. Dead-Centre Motor Some specimens may cause the eccentric to stop in a position other than top dead centre, preventing the correct insertion of the temperature probe to measure the internal sample temperature. To ensure correct sample positioning a second drive motor is applied via a pneumatic actuator to move the lower holder into the top dead centre position. This is acknowledged by an indicator and the temperature probe sequence is commenced. 4 compr_flexo_long_en.doc/
5 Measuring Computer MC The MC is a personal computer (industrial standard). Standard VGA monitor, keyboard, RAM, floppy disc and CD drive, Hard disk, 2xRS232 and parallel printer port. The communication interface between the MC and the frame control is the standard RS232 interface. Therefore, the MC could be a standard PC or just a notebook. The frame control is a DOLI EDC System (External Digital Controller) with an event controlled operating system kernel DORTOS (DOLI-Real-Time-Operating-System) for fast microprocessors, designed for parallel processing of data. Data Measuring Measured signals: Calculations:! Time t via the internal clock! Holder temp.! Temperature t-holder (before, after test) = delta t! Room-Temp. - Chamber Temp.! Static deformation! Deformation Options: Calculations:! Puncture needle temperature! Specimen temp.! Specimen height (Temp.inside - environment temp.) (before, after test)! Permanent set = deformation! Final set Blow-out detection The blow-out detection is realised via the control of the adjustable gradient in the temperature-deformation curve. compr_flexo_long_en.doc/
6 Specifications! Compressed-air supply: 6 bar, 1l/min! inner diameter of the hose of the instrument: 6mm! electric power supply: 230V AC, 50Hz, 1kW Power Supply / Stromversorgung TN-S Standard Flexometer 230V AC, 50Hz, 1,0kW U N 230V AC, 50Hz, 16A L1 N PE bn/sw brown/black bl blue ge/gn yellow/green Power Supply / Stromversorgung Canada, USA TN-S Standard Flexometer VAC, 60Hz, 1,0kW VAC, 60Hz, 16A UN VAC, 60Hz, 16A L3 L2 L1 N PE sw black bn brown bl blue ge/gn yellow/green! Dimensions: Flexometer recommended space recommended height approx. 2000mm front PC front compr_flexo_long_en.doc/
7 MC Software The Flexometer Software runs with the Windows NT operating system and enables the user to see the real curve on-line. One of the other good features is the recall of an already tested specimen. The curve can be displayed on the monitor again. The MC is constructed in menus, just as a state of the art windows driven modern software. Selections are made via mouse clicks and function icons. All actions and data can be seen and controlled via the screen. compr_flexo_long_en.doc/
8 The following inputs are possible during the automatic test. The data name is entered directly. 1. Program-number 2. Test procedure 3. Test-time 4. Climate chamber-temperature 5. Pre-heat duration 6. Cooling duration 7. Maximum deformation 8. Blow-out factor 9. Operator 10. Supplier 11. Test stroke 12. Loading 13. Filename 14. Test number 15. Compound 16. Vulcanisation 17. Ageing conditions Comment 1-4 Test parameters and display help texts can be stored and recalled with the function keys. During the test, no test adjustments are possible. The difference between the automatic and the manual test is, that no specimen quantity will be asked for, because there is only one specimen to be tested. Test run The first result is Static Deformation. The eccentric is steady and the beam in balance. The measured value is the static deformation. The result is the specimen height in % referred to 1 inch = 100% During the test, the measured results are shown as numerical values and as an on-line curve on the screen. The deformation and temperature scale stay constant. The time-axis will be scaled in accordance with the selected test time. Actions of the Flexometer are displayed in the status line. That gives information and offers a constant monitoring e.g. during waiting time when the holder has to cool down etc. 8 compr_flexo_long_en.doc/
9 The second result is Dynamic Deformation. The value is stored after start of the eccentric and the beam to be in balance the first time. The result is the specimen height in % referred to 1 inch = 100% During the test, the measurement data file is closed and opened at 5 minute intervals. Due to this procedure, all measured results older than 5 minutes are saved in case of a power failure. The results can be plotted or printed, if a printer is in use. The deformation at test end is stored as Final Deformation. It is the last value under dynamic conditions. The result is the specimen height in % referred to 1 inch = 100% If a height-measurement station is integrated, the constant deformation will be calculated and stored as Final Set. The height before test (H1), after test (H3) and after cooling (H2) will be measured. (Formula: H1 - H3 : H1 x 100% = final set) compr_flexo_long_en.doc/
10 Test types are in general "FLEX TEST" and "BLOW OUT": 1. Flex Test Test end can be caused by a) test time exceeded, b) maximum deformation exceeded c) the loss of specimen. 2. Blow Out a) check on a temperature curve b) check on a deformation curve In both cases, the turning point of the curve has to be found to check the raising factor. The test will be stopped if the adjustable raising factor is exceeded. Blow out can be seen at the temperature curve or deformation curve. A "STOP" will always be given, if the deformation is smaller than -50% or the defined value. If height-measurement is used, the actual measured height is 100%. Regular Test end: Emergency switch, eccentric-motor error, climate chamber temperature error, PC shut down key, blow-out on the deformation curve is realised, end switch of balance beam, testspecific maximum deformation is achieved, hardware specific maximum deformation is achieved, end switch deformation reached, end of test time reached, error input from the eccentric-motor, voltage error. 10 compr_flexo_long_en.doc/
11 Temperature Measurement inside the Specimen First the actual deformation is checked to see, if it is possible to puncture into the specimen. The needle measurement point is not positioned in the middle, between top and bottom, of the specimen: It is always positioned at the same distance from the specimen top. While the needle is in the specimen the temperature is sampled. The temperature measurement in the specimen is completed, as soon as the maximum temperature is found (app.30 sec.) or if the temperature is constant (up to 1 min). Temp. max. needle Temperature detection app. 30 sec compr_flexo_long_en.doc/
12 Data Output Data is available on the hard disk drive. With a copy command it is possible to transfer data from the hard disk to the floppy disk. If a printer is connected, a hard copy is possible. In case of a full automatic test with a plotter, the data is sent to the plotter automatically. To be sure that a plot of a certain specimen is really made, its data is kept until the user has the plot in his hands, then the data can be deleted manually. This prevents data from getting lost during a pen-crash. Also data output to the ECLIPSE Laboratory Management System is possible. Automatic Test Software run-off points: 1. Fix zero point of height-measurement 2. Get specimen out of the silo 3. Insert specimen into the height measurement station 4. Open the grip 5. Measure specimen height 6. Insert specimen into the preheat station 7. Drive the arm into the park position 8. Pre-heat the specimen with the set time and temperature 9. Drive the deformation-motor up to the limit switch "deformation open" 10. Return puncture needle (Check) 11. Activate balance beam fixing 12. Check if eccentric is on top, if it isn't, position it with the OT motor (Check) 13. Insert the specimen into the test area for testing 14. Drive deformation motor to -2% deformation 15. Drive arm into park position 16. Ascertain Initial Static 17. Drive deformation motor up to 10% deformation 18. Check environment- and room-temperature before test 19. Start eccentric motor 20. Detach balance beam fixing after 2 seconds 21. Activate balance beam Controller 22. Start test time 23. Measure deformation at the beginning of the dynamic stress as soon as the balance beam is in balance (earliest after 5 seconds) 12 compr_flexo_long_en.doc/
13 24. Test is running: Register measurement results and control test end On-line display of the measurement results On-line drawing of the curve Functions for data set processing are activated Close and open the measurement result file every 5 min. 25. After test end, stop balance beam Controller 26. Measure deformation at the end of the dynamic stress 27. Measure environment- and room temperature after test end 28. Activate balance beam fixing 29. Stop eccentric motor and wait until the motor is standing still. If the eccentric isn't in the top position, use the dead-centre motor to adjust. 30. Activate the pneumatic actuator for the puncture needle 31. Ascertain the max. temperature within the puncture time and return the needle after the peak has been detected. Report result to needle temperature 32. Switch temperature measurement back to holder temperature 33. If there is a great deformation drive the platen back to -40% 34. Drive handling arm to the test area close the grip 35. Drive deformation motor to the limit switch "deformation open" 36. Move specimen into a free cooling station or measure the height and cool then 37. Start cooling time for the cooling station 38. Start cooling time for the test area 39. Arm in park position 40. Cool down the specimen for the set time 41. Fix zero point of height measurement 42. Insert specimen from cooling station into heightmeasurement station with handling arm. 43. Measure specimen height 44. Insert specimen into the specimen waist-basket 45. Arm in park position 46. Output of the curve to the plotter 47. Output of the result protocol to the printer 48. Wait for the end of the test area cooling time It is possible to preheat, check and cool specimen simultaneously. compr_flexo_long_en.doc/
14 Manual Test The only difference between automatic and manual test is, that the specimen is inserted manually between the holders, and that it bis taken out manually after the test At the start of the test, the holders are controlled immediatelly, pre-heating, cooling and height-measurements are not considered. Software run-off points: 1. Drive deformation motor up to limit switch "deformation open" 2. Return puncture needle 3. Activate balance beam fixing 4. Insert specimen between holders 5. Drive deformation motor to -2% deformation 6. Ascertain Initial Static 7. Drive deformation motor up to 10% deformation 8. Check environment and room temperature before test 9. Start eccentric motor 10. Detach balance beam fixing after 2 seconds 11. Activate balance beam controller 12. Start test time 13. Measure deformation at the beginning of the dynamic stress, as soon as the balance beam is in balance (earliest after 5 seconds) 14. Test is running: Register measurement results and control test end On-line display of the measurement results On-line drawing of the curve Functions for data file processing are activated. Close the measurement results data file every 5 minutes. 15. After test end stop balance beam Controller 16. Measure deformation at the end of dynamic stress 17. Measure environment and room temperature after test end 18. Activate balance beam fixing 19. Stop eccentric motor and wait until the motor is standing still. If the eccentric isn't in the top position, use the dead-centre motor to adjust 20. Activate the pneumatic actuator for the puncture needle 14 compr_flexo_long_en.doc/
15 21. Ascertain the max. temperature within the puncture time and return the needle after the peak has been detected. Report result to needle temperature 22. Switch temperature measurement back to holder temperature 23. Drive deformation motor to the limit switch "deformation open" 24. Start cooling time for the test area 25. Output of the curve to the plotter 26. Output of the result protocol to the printer 27. Wait for the end of the holder cooling time compr_flexo_long_en.doc/
16 The Advantages for you, using DOLI's COMPRESSION FLEXOMETER 1. Results are available directly and without staff influence. 2. The Flexometer works all day, at night and on Sundays also. 3. Unpopular handling and adjusting are eliminated. 4. Personal can do other control work, which requires real human control. 5. Temperature measurements are done with the puncture needle immediately, temperature loss is eliminated. 6. The Flexometer will fit into a CAQ system, by reporting data to a Host computer, e.g. DAISY from ECLIPSE, to suit your needs. 7. The advantage can be calculated in money. Qualitest USA LC (USA) Tel: TEST (8378) Fax: Internet : Qualitest International Inc. (Canada) Tel.: Fax: Canada info@qualitest-inc.com 16 compr_flexo_long_en.doc/
17 Series of four Fully Automated DOLI Flexometers at DEGUSSA AG in Hürth, Germany. compr_flexo_long_en.doc/
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