Computer-Controlled High-Strength Bolt Testing Machinery

I. Product Application

This testing machine is designed and manufactured in accordance with various standards, including DLT1236-2021, EN14399.2C, ISO16047, GB/T32076.2, JGJ 82, NB/T31082, GB/T1231, GB/T 50205, and JB/T 9370. It is capable of testing the fastening axial force, fastening torque, torque coefficient, fastening angle, and total friction coefficient of high-strength bolts with large hexagonal heads (M36-M72). The system can automatically calculate friction coefficients when either the end face or thread friction coefficient is pre-determined. After completing a set of tests, the machine automatically calculates the average axial force, average torque, average torque coefficient, average friction coefficient, standard deviation, and coefficient of variation for the tested specimens, and can display and print these results. This equipment is mainly used for testing bolts in large steel structures and large wind power installations.

This machine features high precision, powerful functionality, easy operation, and reliable stability. It is widely applicable in universities, research institutes, testing organizations, aerospace, military, metallurgy, machinery manufacturing, transportation construction, construction materials, and other industries. It can be used for process qualification tests on materials or products.

II. Technical Innovations

The new generation model testing machine is a high-strength bolt tester developed by our company in response to testing machine development trends and market demand. Innovations include:

New External Independent Controller: This controller adds a manual control unit, providing a new solution for measurement, control, and operation. RS232 data transmission supports laptops, tablets, and desktop computers, making it a key part of testing machine technology development.

Equipment Operation Monitoring System: Includes phase sequence and phase loss self-check indicators, and electrical overcurrent and overload protection functions, ensuring safe and reliable operation.

Sample Clamping Assembly: Converts manual push-pull adjustment to electric servo motor tuning, making operation easier and reducing labor intensity.

Power Unit: The cycloidal reducer has been upgraded to a planetary gear reducer, increasing transmission efficiency, reducing energy consumption, and minimizing noise.

Axial Force Testing System: A front-mounted axial force sensor directly detects the axial force, avoiding inaccuracies caused by clamp friction. This structure is more precise compared to rear-mounted axial force sensors.

Safety Guard: Features a full-perforated cold-rolled steel safety guard that prevents foreign objects from flying out during tests, improving safety while allowing operators to observe in real time.

III. General Overview

The testing machine consists of several components: the main machine, measurement and control system, computer data processing system, and test result output system.

(A) Main Machine

Testing Platform: Welded from 45# steel plates, stress-relieved, and precision machined, ensuring the foundation for equipment accuracy.

Power Output Assembly: Driven by a servo motor connected to a planetary gear reducer, providing stable and controllable speed, ensuring test accuracy.

Sample Clamping Assembly: Made from welded 45# steel plates, stress-relieved, and precision machined. The elongated body ensures a wide range of sample lengths. The self-centering design minimizes clamping errors, with electric adjustments for sample length and base movement.

Test Fixture: Forged from special materials, precision machined, and surface-treated for rust prevention, significantly extending the fixture's service life.

Sheet Metal Protection Assembly: Made from cold-bent steel plates with a sprayed surface for rust prevention, ensuring operator safety and enhancing equipment aesthetics.

(B) Measurement and Control System

The external independent controller is our newly developed static testing machine controller, integrating measurement, control, and transmission functions into one unit. It features signal acquisition, amplification, data transmission, and servo drive units, with an added external manual control unit, providing a new solution for measurement, control, and operation. USB data transmission fully supports laptops, tablets, and desktop computers.

(C) Testing Machine Control Software

The software uses DSP technology and a neuron adaptive control algorithm to achieve various closed-loop control modes, such as constant rate test force, constant rate angle, and constant rate strain. The control modes can be freely combined and smoothly switched. The software includes a network interface for data networking and remote control capabilities.

IV. Applicable Standards

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

JB/T 7406.1-1994 "Terminology for Materials Testing Machines"

JB/T 9370-2015 "Technical Conditions for Torsion Testing Machines"

JJG269-2006 "Torsion Testing Machines"

DLT1236-2021 "Anchor Bolts and Nuts for Transmission Towers"

GB/T16823.3-2010 "Fasteners - Torque-Tension Test"

JGJ 82-2011 "Technical Specification for High-Strength Bolt Connections in Steel Structures"

GB/T 50205-2020 "Code for Acceptance of Construction Quality of Steel Structures"

NB/T31082-2016 "High-Strength Bolt Connection Assemblies for Wind Turbine Towers"

V. Main Technical Parameters

Testing Machine Level: Level 1

Axial Force Range: 100-3000KN

Axial Force Measurement Error: Better than ±1% of the displayed value

Axial Force Measurement Repeatability Error: Better than ±1% of the displayed value

Axial Force Sensor Resolution: 1/500000FS

Torque Range: 1000-30000Nm

Torque Measurement Error: Better than ±1% of the displayed value

Torque Measurement Repeatability Error: Better than ±1% of the displayed value

Torque Sensor Resolution: 1/500000FS

Angle Measurement Range: 0 - Unlimited

Angle Measurement Error: Better than ±1% of the displayed value

Angle Measurement Repeatability Error: Better than ±1% of the displayed value

Angle Resolution: 0.001°

Speed Adjustment Range: 0.01-4r/min

Speed Measurement Error: Better than ±1% of the displayed value

Data Acquisition Frequency: 1000Hz

Bolt Specifications: M36-M72

Bolt Length: 200-600mm (customizable)

Control Method: Computer

Display Method: Computer LCD display

Main Machine Dimensions (mm): 36009501000

Total Weight (kg): Approximately 5000

Total Power (kW): 16.0

Power Supply: Three-phase, five-wire system, 380V/50Hz

VI. Equipment List

(A) Main Machine

Worktable: 1 unit, made of 45# welded steel

Servo Motor: 1 set, domestic brand (optional import)

Drive Reducer: 1 unit, well-known Chinese planetary reducer brand

Guide Rail Assembly: 1 unit, from Hiwin

Test Clamping Assembly: 1 unit, made of 45# welded steel

Fully Enclosed Protective Cover: 1 set, cold-rolled steel, fully sprayed, safe, and durable

(B) Measurement and Control Electrical Components

Controller: 1 set, Nake brand

Test Machine Measurement and Control Software: 1 set, Nake brand

Strong Electric Board: 1 set, Chint brand

External Handheld Control Box: 1 set, Nake brand

Torsion Sensor: 1 unit, Nake brand

Axial Force Sensor: 1 unit, Nake brand

Computer/Printer: 1 unit each, Lenovo desktop (optional laptop)

(C) Test Accessories

Force Application Sleeve: 1 set, M36-72

Anti-Rotation Insert Plate: 1 pair, M36-72

Inner Plate: 1 pair, M36-72

Outer Plate: 1 pair, M36-72

Random Tools: 1 set

VII. Included Documentation

Packing List: 1 copy

Certificate/Warranty Card: 1 copy

Main Machine User Manual: 1 copy

Software User Manual: 1 copy

VIII. Services and Support

(1) After-Sales Service

The company has a dedicated customer service department and hotline, always ready to respond to user inquiries and complaints.

We provide a one-year warranty and lifetime maintenance service for the product. Regular follow-up calls or visits to customers will be conducted to understand the product's usage and operation status and to offer guidance on equipment maintenance and upkeep.

Our technical staff is always available for consultation, troubleshooting, and resolving any product faults or issues the user may encounter.

We provide comprehensive user manuals, equipment operation videos, and maintenance videos, among other relevant materials.

(2) Usage and Maintenance

Operators must carefully read the main machine manual, software manual, and testing standards; they must follow the correct operating procedures and methods.

Each day, before testing, the equipment should be started and warmed up for 10 minutes, especially in lower temperatures during winter. After testing, the machine should be properly shut down according to the correct sequence, and all power sources should be disconnected.

The screw rods and transmission parts should be regularly lubricated to prevent dry friction that could damage the transmission system.

If self-made testing fixtures are used, they must not alter or damage the original structure of the product.

If any abnormal situation occurs during operation, the power should be immediately cut off to stop the testing machine from running.

IX. Installation Requirements and Foundation

Personnel Preparation: Arrange for operators who are proficient in using computers; personnel with a metrology operator's certificate will be better equipped to master the operation.

Material Preparation: Install a three-phase five-wire air switch on the wall closest to the equipment's oil source.

Foundation Construction: The foundation should be made as illustrated below. When planning the installation location, full consideration should be given to the convenience of maintenance and repair. It is recommended to reserve 500-800mm of space between the equipment and obstacles on the rear and both sides. The front of the equipment should have a minimum operating space of 2000mm.

Equipment Positioning: After positioning the main machine, place a level on the workbench to adjust the machine's level. Once leveled, the four anchor bolt holes should be filled with cement mortar. After the cement has set in the anchor bolt holes, the anchor nuts can be tightened

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