Fatigue Machine Turn on Chiller isolator to machine (Located behind Torque/ Tension Machine) Turn on main isolator to machine Reset Isolator switch and wait for all LEDs to go from red to off LED s Starter Overload - Motor Overload very rare Pressure Line Filter - Filter on top of Reservoir Return Line Filter - Filter on RHS of Reservoir Oil Temperature - Thermocouple in Reservoir attached to water valve Oil Level - Sensor in Reservoir Turn on PC power Supply and monitor ***Before starting : view the Virtual tour located at c:/programs/msoffice/powerpointviewer And carry out the tutorials in the manuals supplied*** Open Virtual Control Panel Reset control panel and check LEDs all green ***Before starting Pump and oil pressure set up machine parameters*** Main Menu 1 Input Zero - If want the stroke zero datum to be offset (default AUTO datum set to current position) Working Range - each Stroke = max +/- 50 mm Strain = extensometer 5 + 2 + 1.25 only colour coded for Load = Load Cell 100 KN capacity. OPERATING INSTRUCTION FATIGUE MACHINE Page 1 of 7 10/09/2002 Chris Crouch
Proportional Gain - Difference set value to measured value (Auto Gain Control) Servo Integrator - errors) Set to ON (applies bias current which reduces servo null Servo Dither - Set to ON (signal 500Hz fed to servo valve to reduce static friction) Cycle Counter - Set number of cycles to run and stop test Input Limits Menu 2 Input Limits should all be OFF Upper and Lower Input Limits - set to Default (max working range) Function Generator Menu 3 Ramp Generator Compressive (-) Tensile (+) Mode - Soft keys bottom of screen (Stroke/Strain/Load) Rate - 5 KN/sec Load 1 mm/sec Stroke (select /h,/min) Hold Level - Value required Hold Time - When Off when ramp reaches the hold level it stops When On Ramp reaches hold level it Holds for time limit set and then starts Ramp2 Generator. (maybe cyclic) Status - Off Highlight and turn ON to start Ramp Generator Oscillator Waveform - Sine (pull down menu of various types) OPERATING INSTRUCTION FATIGUE MACHINE Page 2 of 7 10/09/2002 Chris Crouch
Mode - Highlight to select softkey choice (Stroke/ Strain/ Load) Amplitude - Type in Value (max deviation from starting point ) Highlighted mode allows softkey Adaptive On (More accurate amplitude limit values at machine limits) Frequency - Osc freq set from 1mHz to 99.999Hz Status - Off Highlight and turn ON to start Oscillator cycle Soft Start - 2 sec Prevents shock loads by allowing time set to reach amplitude level and to decay to zero. (0-2 sec) Inner Limit Menu 4 Inner Limits should all be OFF Calibration Menu 5 Use default values Baud Rate - 19200 bps Bias - 0 Servo Drive limit - 100 % Test code - 0 VCP window File - Open controller settings (default machine settings 0 4 ) - 0 - factory default settings - 1 - DCU settings Pull down Hydraulic menu Push Reset Button Turn ON - PUMP A (wait for LED to go green and Pressure button to activate) Turn On - PRESSURE OK window OPERATING INSTRUCTION FATIGUE MACHINE Page 3 of 7 10/09/2002 Chris Crouch
Turn ON Crosshead control using key on front panel LED red Move crosshead up or down Control speed by opening or closing star tap Move Piston to ZERO position using scroll bar Add specimen to top jaws Move crosshead down to locate inside bottom jaws Close speed control tap Clockwise Turn key off Typical starting values Ramp Generator Ramp 1 Stroke Ramp 2 Load 1 mm/ sec 5 KN/ sec 10 mm 10 KN 0 time (OFF if Ramp1only) OFF Status ON OFF Oscillator Waveform Sine Mode ; Stroke Amplitude 5 mm Frequency 1 Hz Status ON To produce graphs and save data use Macro function and / or Block editor Block Editor Block 1 Wait (append) Block 2 Stroke hold for 5 sec no status on block Block 3 Load -20 KN (compression) 1 KN/s yes acquire data OPERATING INSTRUCTION FATIGUE MACHINE Page 4 of 7 10/09/2002 Chris Crouch
Block 4 L 0 KN 2 KN/s No graph/ data acquire Block 5 stroke hold 1 sec No data /graph Enter password Capital ESH save block as XXXX To run Block Program Set up machine settings Stroke 5 mm Load 20 KN Retrieve Block Program XXXX Save to result file XXXX Specimen dia 40 mm with M10 thread at ends Sq XX mm width and depth Run test T/ on pump & pressure Raise/ lower crosshead Fit specimen Start test Results saved into data files (binary bits) and need to convert to ASCII by running Playback program in Macro files To View Data Open ASCII file by using exporter software Click on Exporter Icon Choose file to export XXXX.dat Choose destination : C:/Programfiles/ MicrosoftOffice/Office /Excel.exe Save file XXXX.xls OPERATING INSTRUCTION FATIGUE MACHINE Page 5 of 7 10/09/2002 Chris Crouch
Fatigue Machine Name plate has Machine specification on Pressure and Filters Machine Number - 6080 Working Pressure - 250 bar (Push in knob to read current Pressure) Hydraulic Flow Rate - 23 L / min Pressure Filter - R63013 Return Flow Filter - R6121 Oil Capacity - 205 Litres Oil Type - Shell Tellus 37 (Grade 37) Pressure Gauge on Reservoir set to 9.25 Water Valve set to 2.25 Reservoir piping Draw (return overflow) Pressure Return Frame built for 250 KN Load Cell supplied) Piston only rated for 100 KN (Load Cell and clamping ring Load Cell attached to Machine 29/03/01 hours of running = 1,000 Should Change Oil after 5 years or @1,000 hours or when oil dirty. flat jaws 0-6 mm 6-12 mm Round jaws in toolbox Tensile sprung jaws - tighten and release specimen undo allen head screws M12 2 screws open and close jaws if become stuck OPERATING INSTRUCTION FATIGUE MACHINE Page 6 of 7 10/09/2002 Chris Crouch
Compression test Adaptors to clamp vacuum furnace to head and cylinder also for compression testing large jaw at top Need washers/ slave spacers Tighten lock washer on jaws so there is 1/2 a turn to tighten Slave disc on jaws top and bottom Vacuum Furnace Tensile test 800C under vac Extensometer Add clip to strain gauge before fitting Add clip and gauge to specimen Ceramic extensometer for furnace colour coded cabling LVDT extensometer for furnace colour coded cabling Data acquisition card has a maximum of 10,000 cycles only This is maximum program capacity due to design limits of downloading data to hard drive. OPERATING INSTRUCTION FATIGUE MACHINE Page 7 of 7 10/09/2002 Chris Crouch