PWS 150H Computer Controlled 150KN Electro-Hydraulic Servo Fatigue Testing Machine

Main Technical Specifications:

1. Main Loading Frame

· Standardized unit product from our company.

· Two-column mainframe, with hard chrome-plated and polished columns.

Effective column spacing: 635 mm

Column diameter: 75 mm

· Upper crossbeam:

Hydraulic lifting and hydraulic locking mechanism

Maximum adjustable test clearance: 800 mm

· Worktable height: 950 mm

· Frame stiffness: 3 × 10⁸ N/m

2. Servo Actuator

· Maximum test force: Matched according to model specifications.

· Maximum stroke: ±100 mm (total stroke 200 mm)

· Dedicated dynamic servo actuator for static and dynamic testing.

· Double-rod piston design with a specially treated high-finish surface, ensuring suitability for long-term dynamic testing.

· Sealing components:

High-speed sealing elements between piston & cylinder body, and piston rod & end cover (Treble servo Glyd Ring, Step Seal from Germany).

High-speed wear-resistant support rings (Treble, Germany) for improved actuator stiffness and lateral load resistance.

· Integrated sensors:

Built-in displacement sensor

External electro-hydraulic servo valve and force sensor

Dual closed-loop control for force and displacement

· Force sensor position: Installed at the piston rod head with a pre-stress ring, ensuring secure and reliable connections during dynamic testing.

· Hydraulic cushioning at the actuator’s extreme positions to prevent damage due to operational loss of control.

Sensors:

· Force Sensor:

Model: Load cell from Interface (USA)

Function: Bi-directional fatigue loading (tensile and compressive)

Maximum force: ±50 kN

Overload capacity: 150%

Accuracy: ±1% (in coordination with the control system)

Pre-calibrated before delivery

· Displacement Sensor:

Model: AMT (China) Magnetostrictive Non-Contact Displacement Sensor

Effective range: ±100 mm

Accuracy: ±0.5% FS (in coordination with the control system)

Pre-calibrated before delivery

Servo Valve:

· Model: MOOG (USA) Servo Valve

· Configuration: Dual-valve parallel setup for a 300 kN actuator

· Flow rate per valve: 63 L/min

· Total flow rate: 120 L/min (combined)

· Pressure rating: 21 MPa

· Integrated mounting: Directly installed on the actuator via servo valve manifold block

3. Constant Pressure Servo Power Source

The constant pressure servo pump station is typically installed centrally in a designated pump room. Hydraulic oil is delivered near the main unit via the piping system and then connected to the servo actuator through a flexible hose-distributor-flexible hose setup.

The pump station is a standardized and modular design, allowing it to be cascaded into larger stations with virtually any flow capacity, providing excellent scalability and flexible operation.

· Total flow rate: 36 L/min, pressure 21 MPa (adjustable based on testing requirements).

· Total power: 7.5 kW, 380V, three-phase, 50 Hz, AC.

· Standard modular design, mature technology, stable performance, and equipped with a relay pressure stabilization module for connection to the actuator.

· Components: Hydraulic pump, motor, high/low-pressure switching valve assembly, accumulator, oil filter, oil tank, and piping system.

· Three-stage filtration system:

Oil pump suction port: 100 μm

Oil source outlet: 3 μm filtration precision

Relay pressure stabilization module: 3 μm filtration precision

· Pump type: Rexroth (Germany) intelligent variable displacement pump, which supplies oil as needed, ensuring low noise, excellent durability, and long service life.

· Hydraulic system start/stop is controlled by a high/low-pressure switching valve assembly.

· Fully enclosed standard servo oil tank, with a minimum capacity of 150 L, featuring:

Temperature measurement

Air filtration

Oil level display

4. Forced Clamping Fixtures

4.1 Hydraulic Forced Clamping Grip (One Set)

· Hydraulic forced clamping mechanism

· Working pressure: 21 MPa, suitable for high and low-frequency fatigue tests crossing zero-load conditions.

· Adjustable working pressure: 1 MPa - 21 MPa

· Open structure for easy jaw replacement.

· Self-locking nut design, connecting to the load sensor at the top of the main unit and the piston of the actuator at the bottom.

· Clamping jaws for round specimens: 2 sets

· Clamping jaws for flat specimens: 2 sets (expandable)

4.2 Compression Test Grip (One Set)

· Diameter: φ80 mm

· Designed to match the hydraulic grip

· Additional accessories compatible with the hydraulic grip

4.3 Fixture Interface Drawings Provided

5. Piping System

· All hydraulic hoses are sourced from PARKER (USA).

· Pipe length between the main unit and pump station: 3-6 meters (based on laboratory layout).

· Other hydraulic hoses:

Hydraulic grip hoses

Lifting cylinder hoses

All other hoses are also imported from the USA.

6. Electrical Control System

· Cabinet-style structure, placed near the pump station, using Siemens PLC for intelligent remote control.

· Designed to comply with national electrical safety standards.

· Automatic high/low-pressure switching for the pump station: low-pressure startup, high-pressure operation.

· Total power: 7.5 kW, AC 380V, three-phase five-wire system.

· Control cabinet features:

Voltage and current meters

Individual control buttons for each motor’s start/stop functions

Multiple protection and alarm functions, including:

Low oil level

Overtemperature warning

Filter clogging alert

Motor overload protection

Well-organized electrical wiring, ensuring easy maintenance, user convenience, and an aesthetically pleasing appearance

o Power supply provided by the customer

Remote Control Cabinet

· Installed in the control room, using PLC to manage the start/stop of three motors.

· Clear and reliable alarm and operation indicator lights.

· Equipped with a remote electronic pressure gauge to monitor pump station pressure and display multiple alarm indications, such as:

Filter clogging alert

Overtemperature warning

· Operates at a safe 24V working voltage, ensuring safety, aesthetics, and ease of operation.

7. Closed-Loop Cooling System (Provided by the Customer)

· The supplier will provide relevant parameters and design the installation layout.

8. Control System & Computer Software System

8.1 Controller Main Configuration

· Test force signal conditioning unit (1 set)

· Displacement signal conditioning unit (1 set)

· Secondary servo valve drive unit (1 set)

· Signal generator unit (1 set)

· Hydraulic control unit (pump station on/off, high/low-pressure switching, etc.) (1 set)

· Fully digital closed-loop control system, capable of real-time data acquisition and full digital PID control, with a closed-loop control frequency of up to 5 kHz.

· Built-in signal generator:

Frequency range: 0.001 - 600 Hz

Frequency resolution: 0.001 Hz

· Supported control waveforms:

Sine wave

Triangle wave

Square wave

Ramp wave

Sawtooth wave

Random wave

Custom waveforms and waveform combinations

· Control modes:

Force control

Displacement control

Strain control

Smooth, disturbance-free switching between control modes

· System functions:

Sensor calibration and zeroing

High-speed data communication with the computer via Ethernet

Comprehensive hydraulic control features, such as pump station on/off control and high/low-pressure switching

Multiple interface boards compatible with various sensors and drive units

8.2 Software System

The software system is a multi-channel dynamic testing platform, widely applicable due to its broad testing standard coverage, flexible operation, and efficient data import/export features. It is particularly suitable for research institutions.

Key Features:

· Developed on Windows 7/10 platform

· Fully integrated dynamic testing capabilities

· Customizable dynamic test waveforms to form test spectra and processes, enabling complex dynamic fatigue tests.

· For static tests, the software integrates key international and domestic GB standards in the field of materials testing, making it suitable for both scientific research and industrial applications.

· Fully programmable functions:

Data acquisition

Test sequencing

Data storage

Test protection mechanisms

Event-driven programming to assist users in complex test operations

8.3 Computer & Printer

· ASUS computer 

· 24" LCD display

· Windows 10 operating system

· HP A4 laser printer

9. Test Fixtures

· Tensile test accessories

· Compression test accessories

10. Spare Parts & Tools

· Spare filter element （filtration precision: 3 µm） – 1 piece （for replacement when the oil filter is clogged）

· Flushing module solenoid valve – 1 piece

· Dedicated equipment tools – 1 set