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 with our current range of accessories—ready for the next generation.

Even though older testing machines may have given faithful service over many decades thanks to their robust construction, the demands and requirements of today's technology can no longer be met using outdated equipment. Precision and reproducibility are key criteria in materials testing today, as is the observance of current safety regulations. The needs of the markets can best be served with innovative products and sophisticated technology. Based on the modular design of ZwickRoell testing machines, retrofit kits are available for all ZwickRoell machine types—regardless of the nominal force of the machine. Just as with our own machines, modernizing machines from other manufacturers is no problem for ZwickRoell. We have already converted machines from 50 different manufacturers to ZwickRoell technology, gaining a great deal of knowledge and expertise in the process.

Modernisierung elektromechanisch-statischer Prüfmaschinen aller Laststufen

Modernization of Static Testing Machines – Advantages

  • 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 III testing software
  • re-use of expensive components such as extensometers and specimen grips
  • existing load cells converted and re-calibrated

zwickiLine

Modernisierung elektromechanische zwickiLine mit testControl II
In addition to providing modernization packages for large testing machines, ZwickRoell carries out modernizations on machines for low nominal loads between 500 N and 2.5 kN. A new digital high-performance DC servo drive is also installed in very small testing machines. For these machines, the latest version of testXpert III testing software is also the optimal partner for the high-quality testControl II measurement and control electronics. Up-to-date software combined with a new control system ensures use of the testing machine for years to come, and spare part availability is 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 of static testing machines, provided the overall scope of the modernization satisfies the relevant conditions. For any questions regarding this matter please contact us.

Description

Value

Power specifications

Power supply

100 ... 240

V, 1Ph/N/PE

Tolerance range

±10

%

Power consumption (full load), approx.

500

VA

Power frequency

50/60

Hz

AllroundLine

Modernisierung AllroundLine - elektromechanisch-statische Prüfmaschine
Ideally matched modernization packages are available from ZwickRoell for materials testing machines starting at 10 kN. The rugged construction of these testing machines makes modernization a worthwhile alternative. 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 III 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 of static testing machines, provided the overall scope of the modernization satisfies the relevant conditions. For any questions regarding this matter please contact us.

Power input specifications

Version

1

4

9

kW

Power supply

230

400

400

V, 1Ph/N/PE

Phases

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-ZwickRoell testing machines

Modernisierung elektromechanischer Nicht-Zwick Prüfmaschinen
ZwickRoell modernization packages are modular in nature. This system approach allows other manufacturer’s testing machines to be converted to ZwickRoell testing technology without problems. Manufacturer-independent modernizations include the same components as those used on a ZwickRoell testing machine. A new, energy-efficient AC motor powers the high-capacity machine drive. The testControl II measurement and control electronics are mounted on 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. Their modular design allows flexible deployment of additional sensors and measuring devices. We have converted machines from 50 different manufacturers to ZwickRoell 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 of static testing machines, provided the overall scope of the modernization satisfies the relevant conditions. For any questions regarding this matter please contact us.

Power input specifications

Version

1

4

9

kW

Power supply

230

400

400

V, 1Ph/N/PE

Phases

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 ZwickRoell 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 mounted vertically on the side of the load frame. This position protects the electronics from penetration of liquids and conductive particles.

The high-quality surfaces protect testControl II from external influences. In addition, the components used are highly durable.

Machine Compliance Correction

High-quality drive technology plus online correction of machine compliance enable very high travel-measurement and positioning accuracy. The ZwickRoell testing software 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.

Maximum accuracy

The smallest force changes on the specimen are quickly and accurately recorded and displayed. The A/D converter guarantees high measured-value accuracy over a wide measurement range with sampling rates of 400 kHz and 24 bit resolution.

High data transmission rate

Each travel and force peak is acquired with high resolution and recorded synchronously at 500 Hz on all measuring channels. Optionally, the measured value acquisition rate can be expanded to 2,000 Hz. The high data transmission rate enables fast measurement with the highest degree of reproducibility. This is highly advantageous for quick tests, short, brittle fracture events and in tear-growth, adhesion and peel tests.

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.

Adaptive control

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).

Fast, adaptive drive controller

The high drive control frequency of 1,000 Hz delivers fast, precise force and strain control. Benefits include enabling components to be loaded very quickly and accurately with a predetermined force.

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.

Flexibility Through Modularity

testControl II offers six flexible time-synchronized slots. These make it possible to use multiple sensors at the same time, and can be monitored and protected irrespective of use.

  • For 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 plugged-in sensors are automatically protected against overloads.

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 ZwickRoell testing software. 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.

Gigabit Ethernet Interface

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

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.

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).

Eco mode

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

Ergonomic remote control with color display

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

Repeatable Accuracy

The fully automated comparison of the analog measurement signal during each test ensures repeatable and accurate test results, even in varying environmental conditions, by using the ratiometric measurement method. No action is required by the operator.

testXpert III

testXpert III Testing Software

testXpert III is the result of close cooperation with software users in the materials testing industry and the experience of over 35,000 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. Get to know testXpert III and experience how easy it is to use.

Modernization of Static Testing Machines – Video

3:21

Modernization of testing machines with ZwickRoell

Modernizing testing machines with ZwickRoell – RetroLine testControl II

Tensile tests at 3,000kN - ZwickRoell 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 ZwickRoell the testing machine can now perform tensile tests up to 3,000kN.
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