Computer Controlled 100KN Electro-Hydraulic Servo Fatigue Testing Machine

Overview: The PWS Series Electro-hydraulic servo fatigue testing machine is used to test the dynamic characteristics of metals, non-metals, and composite materials under room temperature (or high/low temperatures and corrosive environments). The machine can conduct the tension and compression...

Send Inquiry

Product Introduction

Overview:

The PWS Series Electro-hydraulic servo fatigue testing machine is used to test the dynamic characteristics of metals, non-metals, and composite materials under room temperature (or high/low temperatures and corrosive environments). The machine can conduct the tension and compression tests.

The closed-loop servo control system, which consists of an electrical controller, servo valve, load sensor, displacement sensor, extensometer, and computer, automatically and accurately controls the test process and measures parameters such as test force, displacement, deformation, torque, and angle.

The machine is capable of generating sinusoidal waves, triangular waves, square waves, sawtooth waves, etc. It can perform tension, compression, bending, low-cycle, and high-cycle fatigue tests. An environmental testing device can also be configured to simulate different temperature conditions.

The machine features flexible and easy operation, with vertical beam lifting, locking, and specimen clamping all performed via buttons. Advanced hydraulic servo drive technology is used for loading, with high-precision dynamic load sensors and high-resolution magnetostrictive displacement sensors for measuring the specimen's force and displacement.

The fully digital measurement and control system allows PID control of force, deformation, and displacement, with smooth transitions between control modes. The testing software operates in a Windows Win7/Win10/Win11 environment, offering powerful data processing capabilities. Test conditions and results are automatically saved, displayed, and printed. The entire test process is controlled by the computer. This machine is an ideal, cost-effective testing system for scientific research institutions, metallurgy and construction industries, national defense, military, higher education, mechanical manufacturing, and transportation industries.

Relevant Standards:

GB/T 2611-2007 "General Technical Requirements for Testing Machines"

GB/T16825.1-2008 "Verification of Static Uniaxial Testing Machines - Part 1: Verification and Calibration of Force Measuring Systems for Tensile and (or) Compression Testing Machines"

GB/T 16826-2008 "Electro-Hydraulic Servo Universal Testing Machines"

JB/T 8612-1997 "Electro-Hydraulic Servo Universal Testing Machines"

JB9397-2002 "Tensile and Compression Fatigue Testing Machine Technical Conditions"

GB/T 3075-2008 "Methods for Axial Fatigue Testing of Metals"

GB/T15248-2008 "Methods for Axial Strain-Controlled Low-Cycle Fatigue Testing of Metals"

GB/T21143-2007 "Unified Test Method for the Fracture Toughness of Metallic Materials under Quasi-Static Conditions"

HG/T 2067-1991 "Technical Conditions for Rubber Fatigue Testing Machines"

ASTM E399-09 "Standard Test Method for Linear Elastic Plane Strain Fracture Toughness of Metallic Materials"

ASTM E1820-2001 "Standard Test Method for Measurement of Fracture Toughness (JIC)"

The main components of this test equipment:

1. High-rigidity double-column portal main loading frame;

2. Intelligent constant-pressure silent power source;

3. Fully digital dynamic and static control system;

4. Advantech industrial computer and office printer;

5. Test-related conventional auxiliary tools

Attached is the overall three-dimensional schematic diagram of the test bench:

Two-column fatigue test machine appearance

1754269600050

Four-column fatigue test machine appearance

Main Technical Specifications:

Model PWS	100H
Maximum test force KN (dynamic and static)	±100
Load frame	Four columns
Effective width of column mm	555
Test space mm	800
Test force measurement range	Dynamic 2%～100%FS
Force accuracy and fluctuation	Better than 1% of the indicated value; Amplitude fluctuation is not greater than ±1%F.S of each gear
Test force resolution	1/250000 code
Test force indication accuracy	Dynamic ±1%; Static 0.5%
Displacement measurement range	100mm(±50mm)
Displacement measurement resolution	0.001mmm
Displacement indication accuracy	Indication accuracy 1% and within ±0.5%FS
Deformation	Indication accuracy 2% and within ±0.5%
Frequency range	Standard machine 0.01-50HZ (depending on the controller)
Main waveforms	Static pressure support 0.01-100HZ
Auxiliary tools	Sine wave, pulse wave, square wave, sawtooth wave, random wave (mainly supported by the controller)
Auxiliary tools	Forced flat push clamp, equipped with stretching rod and edge cutting jaws

V. Key Components

1754269663005

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

1754269729209

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

1754269801690

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)

1754269912992

4.2 Compression Test Grip (One Set)

Diameter: φ80 mm

Designed to match the hydraulic grip

Additional accessories compatible with the hydraulic grip

4.4 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 US

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

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)

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