Introduction

The test rig is designed to perform four-point bending tests on processed glass and uPVC frames, supporting loads up to 5 metric tonnes.

Technical Specification

• Max Load: 5 MT
• Dimensions: 2250 L × 1700 W × 2500 H mm
• Vertical (Z-axis) Adjustment: 200 mm (manual)
• Workspace: 1000 × 2000 mm
• Load Cell: 500 kg capacity
• LVDT Stroke: 300 mm
• Hydraulic Actuator: 500 kg load / 300 mm stroke
• Roller Fixtures: 50 mm Ø, self-aligning bearings

Test Sizes:

• 1100 × 360 mm specimen
• 2000 × 1000 mm specimen

Monitoring Parameters

• Load vs Time (kgf/s)
• Deflection vs Time (mm/s)

Reports:

• Load vs Deflection
• Load vs Time
• Deflection vs Time

Test Details

Four-Point Bending Test with closed-loop hydraulic control:

• Uniform Load Rate: up to 10 kgf/s (load-cell feedback)
• Uniform Deflection Rate: up to 55 mm/min (LVDT feedback)

The test stops automatically on specimen breakage or when max load/deflection is reached. Peak load, deflection, and time are logged automatically.

Main Components

Hydraulic Power Pack

• Pressure: 100 bar max
• Reservoir: 30 L
• Motor: 1 HP 1440 RPM 3-phase
• Pump: 1.8 L/min
• Filter & Gauge: 280 bar
• Valves: Proportional & Relief types

Hydraulic System

• Cylinder: 14 MPa capacity
• Proportional Valve Controller: 24 V DC / 1 A max
• Counter Balance Valve: CBS10T4-05

Installation

• Place machine on level floor.
• Inspect for mechanical or electrical damage.
• Tighten all bolts and remove debris.
• Verify earthing and three-phase supply (as per diagram).
• Only qualified personnel may install and connect power.

Control System Software

Windows 10, 64-bit, GUI-based DAQ control software. Users can program test parameters, create schedules, and generate reports.

Main Functions

• Login / Password management
• Manual Mode testing
• Automatic test execution
• Raw data and graphical report generation
• Secure exit from DAQ software

Running a Test

1. Power ON mains, computer, and electronics.
2. Assemble specimen and enter details (client, size, type).
3. Select units (kg / N) and sampling rate.
4. Start test → view live data → system records max load & deflection.

Report Generation

• Raw Data: Excel format (Load, Deflection, Time).
• Graphical: User-defined X/Y axes (Time, Displacement, Load).
• Saved automatically to the desktop report folder.

NI Card (USB-6008) Pin Map

• Analog Input: AI0 = Load Cell, AI1 = Deflection, AI2 = Emergency
• Analog Output: AO1 = Load Set (Power Pack)
• Digital Output: P0.0 = Fault Lamp, P0.1 = Ready, P0.2 = Run, P0.4 = Fwd Valve, P0.5 = Rev Valve

Troubleshooting

Power Issues

• Verify main MCB and phase/neutral supply.
• Check SMPS input (230 V AC) and output (24 V DC).

Sensor Issues

• Check load cell resistance and excitation (10 V).
• Verify LVDT coil ohms and signal variation.

Software Issues

• Re-plug the USB DAQ card if connection fails.

Maintenance

• Regularly check hydraulic oil level.
• Oil Type: Hydraulic Oil 68.
• Keep machine and electronics clean and dry.

Manufacturer

Precision Engineering Company 📧 info@manufacturer.com