Equipment Overview

1.1 Name and Model

Name: Fully automatic bending and compression testing machine
Model: DYE-300-10S

1.2 Implement the standards GB/T 17671-2021 and JC/T960-2022 "Test Method for Strength of Cement Mortar (ISO Method)"

1.3 Function Overview: This testing machine is mainly used for the flexural and compressive strength test of cement mortar, widely used in the construction industry. With a compact structure and simple operation, it is an essential equipment for cement plants, construction engineering units, quality inspection stations, and colleges and universities. This machine adopts hydraulic loading, electronic force measurement, and is equipped with a dedicated hydraulic valve group to achieve constant loading speed and automatic loading. The computer automatically controls the testing process and data processing, with a color screen and Chinese menu prompts, force value and loading curve tracking display, standard keyboard input, automatic storage and processing of test data, automatic printing of test reports and long-term storage of data for easy access, as well as overload protection functions.

Technical Specifications

Installation of testing machine

The installation foundation of this testing machine should be firm and reliable. In order to adapt to operation and ensure correct readings, the foundation can be appropriately raised above the ground, and the height should be determined according to actual needs. A space of no less than 0.7m should be left around the testing machine for maintenance and operation. The anchor bolt (M12 × 300mm) should be grouted twice to ensure correct bolt installation.(See the installation foundation diagram)

Basic diagram of testing machine

During installation, the testing machine should be kept level (levelness ≤ 0.2/1000) and applied
0.1/1000. A frame level is used to measure the plane of the lower pressure plate. If the horizontal or vertical level exceeds the specified limit, a shim can be added under the bottom plate for correction, and then the foot nut can be tightened. Then connect the power cord, and the local electrical appliances should have grounding safety protection devices. The voltage variation of the power supply should not exceed ± 10% of the rated value.

Repair and maintenance

4.1 The testing machine is installed in a clean, dry, uniform temperature, vibration free environment, and free from the influence of corrosive gases.

4.2 The testing machine should be kept clean, and parts without protective layers should be regularly wiped with oil to prevent rust.

4.3After using the testing machine for six months to one year, the oil should be changed once. When changing the oil, the oil tank and filter should be thoroughly cleaned. The method of cleaning the fuel tank can be to add kerosene into the tank, clean it, and then release it. Repeat this process several times until it is completely clean, then wipe the bottom of the tank with a towel and add clean hydraulic oil. If it is found that the hydraulic oil is severely turbid and cannot be used anymore, it should be replaced immediately, otherwise it will accelerate the wear of various parts of the hydraulic system, based on the accuracy of the influence value.

4.4 Hydraulic oil specifications, depending on the temperature, the following suggestions are recommended:
(1) When the ambient temperature is 10-20 ℃, use GB-443-84N46 # (equivalent to 30 # mechanical oil).
(2) When the ambient temperature is 20-30 ℃, use GB-443-84N86 # (equivalent to 40 # mechanical oil).

4.5 If not in use, the machine should be covered with plastic.

Main structure and working principle of the machine

This testing machine is mainly composed of a main engine, hydraulic system, computer, and control system.

5.1 Main unit of flexural compressive testing machine

The main unit of this testing machine consists of a 30T compression resistant part, a 1T bending resistant part, and a box body. The 30T compression resistant part includes: upper beam, spoke sensor, column, upper pressure plate, 30T compression resistant fixture, lower pressure plate, tray, oil cylinder, and piston; The 1T anti bending part includes sensors, 1T anti bending fixtures, lower pressure plates, pads, trays, oil cylinders, and pistons. Its working principle is that the oil pump supplies oil to the working oil cylinder, and the lower pressure plate is driven up and down by the movement of the piston to conduct compression and bending tests.

5.1.1 Oil cylinder and piston

The oil cylinder and piston are the core parts of the main engine. The oil cylinder is directly placed on the tray, and the piston is installed inside the oil cylinder. The sealing of the pressure oil is maintained by the gap between the oil cylinder, sealing ring, and piston. The return stroke is completed by the self weight of the piston. There are two screw holes at the lower end of the 30T oil cylinder, which are respectively connected to the inlet pipe from the hydraulic valve group and the return plastic pipe for the overflow oil of the cylinder piston; The two screw holes at the lower end of the 1T oil cylinder are respectively connected to the inlet pipe from the hydraulic valve group and the return plastic pipe for the overflow oil of the cylinder piston.

5.2 Oil source system

5.2.1 Measurement and Control System

The system adopts EHC series measurement and control devices and EasyTest measurement and control software to form a microcomputer controlled electro-hydraulic pressure testing machine measurement and control system. The measurement unit adopts high-precision hydraulic sensors, which can achieve real-time load collection of the pressure testing machine and automatic processing of test data. It has the characteristics of high control accuracy, strong adaptability, and good long-term stability. The spoke sensor is installed on a 30T crossbeam, and the 1T composite sensor is installed on a 1T crossbeam.

5.2.2 Hydraulic System

The hydraulic system consists of a hydraulic pump, a drive motor, a digital valve, a pressure reducing valve, an electromagnetic directional valve, an oil tank, an oil filter screen, joints, and oil pipes.
The hydraulic pump is an axial piston ultra-high pressure pump, driven directly by an electric motor and installed on the oil tank. Automatically adjust the oil intake of the cylinder through the hydraulic valve group to achieve the desired loading speed. After the experiment is completed, it will automatically unload and allow all the oil in the cylinder and from the oil pump to flow back to the oil tank. During the experiment, the oil in the tank enters the oil pump through the oil filter screen and then enters the oil cylinder through the hydraulic valve group. Under the action of pressure oil, the piston moves upward to drive the lower pressure plate, thereby driving the fixture to complete various loading tests on the sample.

5.2.3 Pressure reducing valves, digital valves, and electromagnetic directional valves

The pressure reducing valve can change the oil inlet rate and the kinetic energy of the oil inlet to cause different pressure losses, thereby achieving the purpose of pressure reduction.
The digital valve is powered by a motor and drives the movement of the valve core through the transmission of gear and screw pairs, thereby controlling the opening of the valve port and the rate of loading.

The electromagnetic directional valve opens or closes different oil discharge holes by controlling the movement of the valve body, and the inlet hole is normally open. Hydraulic oil will enter different oil discharge pipes and then push the piston in the cylinder through the pressure of the oil.

Installation and debugging

6.1 Installation

This testing machine should be installed in a clean, dry, and temperature uniform room, and the fluctuation range of the power supply voltage should not exceed ± 10% of the rated voltage. The electrical system of this machine should have a grounding safety protection device. Due to the use of hydraulic oil, there should be safety and fire prevention measures in the surrounding area. The foundation can be appropriately raised 30-50mm above the ground. The distance between the testing machine and the wall should not be less than 0.8m,
There should be sufficient activity range and passage around for inspection. When finding the level of the host, the level can be placed on the test bench, and the level can be found in two positions and directions according to the vertical and horizontal directions of the body (using a level with an accuracy of 0.2/1000mm to find ± 2 grids). After the machine is stabilized, securely place the measurement and control system on the corresponding part of the top of the right box, and then plug in the pressure sensor and wire socket separately.

6.2 Selection of hydraulic oil specifications

In hydraulic transmission, high-quality medium viscosity mineral oil should be used, and the oil should not contain water, acid, or other mixtures. It should not decompose or thicken at room temperature. And it must be filtered before being injected into the machine. Due to improper use of oil, valves and oil circuits may become blocked, and even the accuracy of the testing machine's readings may be inaccurate, affecting the normal use of the testing machine. Reference specifications for oil: This equipment usually uses L-HM46 anti-wear hydraulic oil. In areas with higher temperatures, hydraulic oil with higher viscosity should be used. L-HM68 anti-wear hydraulic oil can be added as needed to increase viscosity.

6.3 Refueling and draining

Open the front door of the control cabinet and you can see the small circular cover. Pushing open the small circular cover has a small hole. When refueling, the oil should be injected into the fuel tank through this hole. The amount of oil injected at a time is about 46 liters, based on the oil gauge scale installed on the front of the fuel tank. The amount of oil should not be too small.  
The usage period of oil is determined according to the climate in different regions. If the oil starts to mix and cannot be used, it should be replaced with new oil.  

6.4 Initial Operation and Test Run

6.4.1 Before starting for the first time after installation, check whether the oil in the tank is sufficient. You can check the fuel card. If it is insufficient, open the small round cover and add it to the tank until the liquid level is at the fuel card.
6.4.2 Check whether the oil pipe joints and fasteners are loose, and tighten them if they are loose. Check that the dust cover is intact and undamaged. Check if the wiring and voltage of the power supply are correct.

6.4.3 Turn on the power of the computer system and controller to enter the testing state. For specific experimental procedures, please refer to the attached "User Manual for Pressure Testing Machine Measurement and Control Software". (Please note: Before entering the operating system of the pressure testing machine, be sure to close all other real-time control software and applications in the computer, and ask users not to install non genuine software into the computer to avoid virus infection, otherwise the consequences will be borne by themselves.)

6.4.4 Start the oil pump motor and eliminate the air in the main oil cylinder of the testing machine to avoid affecting the stability of the load. The elimination method is to start the oil pump, click on the test interface to run and make the piston rise a certain distance, then click stop to let the oil flow back from the main engine cylinder to the oil tank. Repeat this several times to exhaust the air.

6.4.5 Clean the surface of the test piece and inspect for any obvious defects. If there are any that can affect the test values, replace the non-destructive test piece.

6.4.6 Place the fixture in the center of the lower pressure plate by pressing down on the positioning wire frame, and then place the specimens into the corresponding fixtures. Adjust the fixtures to the appropriate positions according to the size of the specimens.

6.4.7 Enter relevant data such as reset and timely modification according to the operation steps.

6.4.8 Click to run and conduct the loading test smoothly at the required rate until the specimen is crushed and the load decreases.
After the experiment is completed, click the "Report" button to print out the test report for that time.
Note: The removal of air from the oil pump and cylinder is only carried out during the first test drive, and will only be carried out in the future unless the oil is changed or deemed necessary.

6.5 Precautions to be taken during operation

6.5.1 Before use, carefully read this manual and the attached "User Manual for Pressure Testing Machine Measurement and Control System Software". During the test, if the oil pump suddenly stops working due to some special reason, the power should be immediately cut off and the added load should be unloaded. After inspection, turn on the power again for testing, and do not start with negative to avoid damaging the oil pump.

6.5.2 In the experiment, if the control suddenly fails, the power should be immediately cut off to stop the machine from running.

6.5.3During operation, the height of the lower pressure plate should not exceed 4cm to avoid accidents.

6.5.4 It is prohibited to place any part of the human body, such as hands, between fixtures during operation; Operators are prohibited from standing in front of the testing device during the experiment and should be aware that fragments may break and injure people when the specimen is broken.
Immediately remove the broken test blocks after the 6.5.5 test, and wait for the next test. When no longer conducting experiments, cut off the power supply.

6.5.6 Non operators are prohibited from operating the machine.

Packing List