WAW-1000D Computer-Controlled Electro-Hydraulic Servo Universal Testing Machine

Technical Proposal

I. Introduction

The WAW-1000D Computer-Controlled Electro-Hydraulic Servo Universal Testing Machine adopts a lower-cylinder host structure and is mainly used for tensile, compression, bending, and shear tests of metallic and non-metallic materials.

It is suitable for industries such as metallurgy, construction, light industry, aerospace, aviation, materials, as well as colleges, universities, and research institutes.

The test operation and data processing fully comply with the requirements of GB/T 228-2010 "Metallic Materials — Tensile Testing at Room Temperature".

Standard:

ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM E4 Standard Practices for Force Verification of Testing Machines
ASTM E8 Standard Test Methods for Tension Testing of Metallic Materials
ASTM E9 Standard Test Methods of Compression Testing of Metallic Materials at Room Temperature
ASTM D638 Standard Test Method for Tensile Properties of Plastics
ASTM D882 Standard Test Method for Tensile Properties of Thin Plastic Sheeting
ASTM D3039 Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials
ASTM D3479 Standard Test Method for Tension-Tension Fatigue of Polymer Matrix Composite Materials
ASTM E517 Standard Test Method for Plastic Strain Ratio r for Sheet Metal
ASTM D695 Standard Test Method for Compressive Properties of Rigid Plastics
ASTM D6641 Standard Test Method for Compressive Properties of Polymer Matrix Composite Materials Using a Combined Loading Compression (CLC) Test Fixture
ASTM D3410 Standard Test Method for Compressive Properties of Polymer Matrix Composite Materials with Unsupported Gage Section by Shear Loading
ASTM D7791 Standard Test Method for Uniaxial Fatigue Properties of Plastics
ASTM D412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension
ASTM C165 Standard Test Method for Measuring Compressive Properties of Thermal Insulations

ISO 6892 Metallic Materials — Tensile Testing
ISO 527-3 Plastics — Determination of Tensile Properties — Part 3: Test Conditions for Films and Sheets
ISO 527-4 Plastics — Determination of Tensile Properties — Part 4: Test Conditions for Isotropic and Orthotropic Fibre-Reinforced Plastic Composites
ISO 7438 Metallic Materials — Bend Test
ISO 7500-1 Metallic Materials — Calibration and Verification of Static Uniaxial Testing Machines — Part 1: Tension/Compression Testing Machines — Calibration and Verification of the Force-Measuring System

EN 10002-4 Metallic Materials — Tensile Testing — Part 4: Verification of Extensometers Used in Uniaxial Testing
EN 826 Thermal Insulating Products for Building Applications — Determination of Compression Behaviour
EN 1606 Thermal Insulating Products for Building Applications — Determination of Deformation Under Compressive Load and Long-Term Compression
EN 1607 Thermal Insulating Products for Building Applications — Determination of Tensile Strength Perpendicular to Faces
EN 12430 Thermal Insulating Products for Building Applications — Determination of Behaviour Under Point Load

GB/T 228-2002 Metallic Materials — Tensile Testing at Room Temperature
GB 16491-2008 Electronic Universal Testing Machine
HG/T 3844-2008 Rubber, Vulcanized or Thermoplastic — Determination of Tensile Stress-Strain Properties
QB/T 11130-1991 Testing Method for Tensile Properties of Textile Fabric
GB 13-22-1991 Test Method for Metallic Materials — Tensile Testing
HG/T 3849-2008 Determination of Tear Strength of Rubber
GB 6349-1986 Mechanical Testing of Metals — General Requirements
GB/T 1040.2-2006 Plastics — Determination of Tensile Properties — Part 2: Test Conditions for Moulding and Extrusion Plastics

II. Program Description

1. Main Frame

The testing machine adopts a lower-cylinder host structure.

The tensile test space is located above the host frame, while the compression and bending test space is located between the upper crossbeam and the working table of the host machine.

2. Transmission System

The movement of the lower crossbeam is driven by a motor through a reducer, chain drive mechanism, and screw pair transmission, enabling the adjustment of the tensile and compression spaces.

3. Control System

1. The system adopts a fully digital closed-loop control system, representing the most advanced level of control system development.

2. It achieves closed-loop control of test force, specimen deformation, piston displacement, and test process, and features constant stress rate, constant strain rate, constant test force rate, constant displacement rate, force holding, and displacement holding control modes.

It supports real-time display of test force, peak value, specimen deformation, piston displacement, and test curves on screen.

All operations are performed via mouse input, and the control mode expert system allows intelligent and flexible setting and smooth switching between various control modes, providing maximum system flexibility.

a)The system fully complies with GB/T 228-2022 "Metallic Materials — Tensile Testing at Room Temperature" for data processing requirements.

Test processes can be simulated and replayed, and data reanalysis is supported.

Multiple control modes are available:

· Single-step program control includes constant stress rate, constant strain rate, constant displacement rate, force holding, and displacement holding closed-loop control.

· Multi-step program control includes metallic tensile tests and other complex processes.

b)The system uses a variable-structure PID control algorithm to regulate the loading process, achieving:

· Constant-speed control error ≤ 5%

· Force-holding control error ≤ 0.5%

A Control Program Editor is provided for professional users to customize specific control programs as needed.

1. The Windows-based test software features a fully digital programmable amplifier, enabling automatic zero adjustment and sensor calibration by computer.

2. User access is managed via hierarchical permission control.

3. The software supports multiple graphical display windows and unit conversion functions.

4. Test data are managed in a database structure, supporting network database communication and management.

4. Safety Protection System

Overload Protection: When the test force exceeds 2%–5% of the maximum load range, the system automatically unloads.

Stroke Protection: When the piston rises to the upper limit position, the travel protection activates, and the oil pump motor automatically stops.

5. Grips and Fixtures

A complete set of test accessories is included, consisting of:

· Tensile grips

· Compression platens

· Bending fixtures

6. Additional Accessories

Installation and debugging tools, sealing elements, user manual, certificate of conformity, packing list, and other technical documents are supplied with the machine.

III. Main Technical Specifications

No.ItemSpecification

1 Maximum Test Force 1000 kN

2 Test Force Measurement Range 20–1000 kN (no range shifting)

3 Test Force Indication Accuracy ±1%

4 Piston Stroke 250 mm

5 Maximum Piston Movement Speed 50 mm/min

6 Displacement Measurement Resolution 0.01 mm

7 Displacement Indication Accuracy ±1%

8 Deformation Measurement Equipped with a 50 mm gauge length, 10 mm maximum deformation extensometer

9 Maximum Tensile Test Space 600 mm (including piston stroke) (height optional upon request)

10 Maximum Compression Space 550 mm (height optional upon request)

11 Flat Specimen Clamping Thickness 0–40 mm

12 Round Specimen Clamping Diameter φ13–φ60 mm

13 Compression Platen Dimension 220 × 220 mm

14 Gripping Method Hydraulic Clamping

15 Load Sensor Type Load Cell

IV. System Configuration List

No.ItemSpecificationQuantity

1 Main Testing Machine Lower-cylinder main frame 1 set

2 Hydraulic Power Control Cabinet Equipped with low-noise high-pressure gear pump 1 set

3 AC Servo Motor — 1 set

4 Italian Marzocchi Gear Pump — 1 unit

5 Multi-stage precision oil filtration system with clearance-sealed cylinder — —

6 Dual-channel programmable amplifier (proprietary technology) — 1 set

7 Load Cell — 1 pc

8 Extensometer (Model YSD-100/25) — 1 pc

9 Computer Measurement System with Tensile, Compression, and Bending Test Software — 1 set

10 PC Branded mainstream configuration 1 unit

11 Printer HP A4 Inkjet Printer 1 unit

12 Tensile Grips Flat grips 0–20 mm, Round grips 26–40 / 40–60 mm 1 set each

13 Compression & Bending Fixtures — 1 set each

V. Functional Features

1. Flexible protective covers are installed on the two sliding surfaces above the lower crossbeam and the upper section of the jaw clamping plates. This design prevents oxidation inclusions from falling into the mating surfaces of the working jaws and clamping plates during tensile testing, thereby extending the service life of the clamping components.

2. The upper and lower jaws adopt a dual-cylinder hydraulic automatic clamping system, operated by a movable hand-control box. This control box allows for manual control of jaw clamping/releasing and lower crossbeam lifting/lowering.

3. All parts and components are manufactured under the company’s ISO 9001 Quality Management System, and all key purchased components are original imported parts, ensuring high accuracy and long-term stability of the machine.

4. The unique pressure-following hydraulic technology enables the working pressure of the oil cylinder to vary synchronously with the loading force. This effectively reduces working noise and oil temperature, while enhancing hydraulic control accuracy.

5. The system is equipped with a console-type integrated hydraulic power cabinet, featuring high integration, convenient operation, and reduced floor space requirements.

6. Low noise operation: less than 50 dB even under maximum load — practically silent.

7. Compared with conventional systems, the pressure-following system saves up to 70% energy and achieves control accuracy up to 0.01% (1/10,000), compared to 0.5% (1/2,000) in traditional products.

8. It has no control dead zone, a control start point of 1%, and a highly integrated oil circuit with minimal leakage points.

9. Multiple high-speed CPUs operate in parallel, enabling true multitasking performance.

10. Modular unit design: various accessories can be interchanged flexibly; the industrial bus-based electrical hardware facilitates easy expansion and maintenance.

11. The modular structure with industrial control bus slots allows convenient function expansion and maintenance services.

12. The system adopts a high-precision ±500,000-count data acquisition card, ensuring ultra-high resolution and maximum utilization of the sensor’s measurement range.

13. Incorporates Plug-and-Play (PnP) technology of the Windows system for automatic recognition of inserted interface cards.

14. Sensor calibration data backup enhances reliability and measurement accuracy.

15. Scene-based operation menus provide clear and intuitive navigation between different functional interfaces.

16. Active test table position memory protects the preset positions through software control.

17. The maximum digital counting frequency of 10 MHz guarantees zero data loss for displacement and large-elongation measurements.

18. The anti-vibration frequency-multiplying technology of the encoder signal greatly enhances displacement and large-elongation resolution.

19. The system supports multi-channel closed-loop control, not limited to load, displacement, and strain, but capable of additional channel integration.

20. The fast independent overload protection function ensures immediate response to overload conditions, protecting the equipment.

21. The three-level correlated position limit protection ensures the utmost operational safety.

22. Software system: Operates under Chinese Windows 7 or higher versions, featuring an elegant and user-friendly interface.

23. It includes user authorization management, requiring operators to log in with passwords and system verification before test software activation.

24. Versatile applications: Suitable for tensile, compression, bending, shear, peeling, and tearing tests of metallic, non-metallic materials, and structural components.

25. Complies with ISO, JIS, ASTM, DIN, and GB test method standards.

26. User-friendly operation: Equipped with operation wizards and online help functions, ensuring ease of use.

27. Automatic specimen dimension input: The computer automatically captures specimen dimensions, reducing manual data entry errors and ensuring accurate test results.

28. Programmable test methods: Users can freely program test methods according to specific testing requirements.

29. Memory return function: After the test, upon removing the specimen and pressing the return button, the upper jaw automatically returns to the initial test position.

30. Automatic calibration: Load and elongation can be automatically calibrated according to the applied standard values.

31. Automatic recognition: After specimen fracture, the system automatically detects breakage and stops, readying for the next test sequence.

32. Peak value holding: During testing, the maximum test value is continuously displayed on the screen in real time.

33. Control modes: Supports multiple control modes, including displacement control, load control, elongation control, stress control, strain control, constant load, and constant strain modes.

34. Programmable complex test sequences:

35. For example, a four-stage test can be configured:

· Stage 1: Preload

· Stages 2–4: freely selectable control modes among displacement, load, elongation, strain, stress, or speed control.

· Each stage’s control parameters can be customized, and transitions between stages are smooth and impact-free.

1. Easy zeroing: Load, elongation, and displacement can be manually zeroed with a single key; the system can also automatically zero at test initiation.

2. Data editing: After testing, the operator can edit test data directly on the curve using the mouse.

3. Unique displacement method for determining the yield strength of materials without a distinct yield point — calculates the non-proportional elongation stress Rp0.2.

4. Multiple curve types:

5. Options include true stress–strain, engineering stress–strain, load–elongation, load–time, stress–time, strain–time curves.

6. One curve is displayed in real time during testing, and can be switched to other types as needed.

7. Curve comparison:

8. Curves of specimens from the same group can be overlaid for comparison or printed.

9. Extended analysis:

10. Any segment of the test curve can be locally magnified for detailed analysis.

11. Report programming:

12. Reports can be customized according to user requirements and output in different formats.

13. Automatic calculation of standard test parameters in accordance with GB/T 228-2010, including:

14. Fm (Fb), Feh, Fel, Fp, Rm (σb), ReH (σsu), ReL (σsl, σs), Rp0.2, Rp0.1 (σp0.2), Rp0.05 (σp0.05), Rp0.5 (σp0.5), E, Et, Ec, Z (ψ), A (δ), τ, etc.

15. Users can select the parameters to output, and data files can be stored in multiple formats.

16. The powerful testing software supports network integration with inspection data management systems.

VIII. Working Environment and User-Supplied Requirements

The user shall be responsible for hoisting and positioning the machine, while the supplier shall provide free on-site installation and commissioning.

1. Installation Requirements:

2. The testing machine shall be installed in a clean laboratory free of corrosive media, electromagnetic interference, spark sources, or vibration impact sources.

3. Environmental conditions:

· Ambient temperature: 23 ± 5 °C

· Relative humidity: ≤ 80%

· Power voltage fluctuation: within ±5% of rated voltage

· Power supply: 380 V, 50 Hz, with reliable grounding

· Base and frame levelness: ≤ 0.2‰ m

· Space shall be reserved for convenient operation, maintenance, and auxiliary facilities.

1. The user shall construct the foundation according to the supplier’s foundation drawing and notify the supplier after the site meets installation conditions.

2. The supplier shall dispatch an engineer within three (3) days for free installation assistance.

3. The user shall provide 100 L of anti-wear hydraulic oil, model No. 46 or No. 68.

4. Three-phase power supply: 380 V ± 10%, 50 Hz, 3 kW (three-phase four-wire system).

5. Single-phase power supply: 220 V, 50 Hz, 200 W (for the computer).