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Testing Machines and Systemsfor Automotive Industry

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Preliminary Remarks

The automotive industry comprisesthose companies which producemotor vehicles. In particular, theseare the manufacturers ofmotorcycles, cars and trucks,buses and trains, the suppliers andthe equipment providers. Amongthe manufacturers of vehicles thereis a tendency towards a few, largeglobally companies, which areconcentrating increasingly ontheir main competence and which

entrust their suppliers with thedevelopment of componentsand component sub-assemblies,such as completed instrumentpanels.

In order to meet the requirementsof safety, economic efficiency, ridingcomfort and also the environmentalrequirements, all the companiesof the automotive industry haveto test their products in the differentdevelopment and production stages– as raw material, semifinished

product, component sub-assembly or as part, componentgroup or as finished product– as to their mechanical stabilityunder standardized and realisticconditions.

The Zwick Roell Group develops,manufactures and supplies therequired testing machines andsystems including the associatedservices.

Table of Contents

Preliminary Remark ................................................................................................................................... 2

Table of Contents ...................................................................................................................................... 2

Zwick Roell AG ................................................................................................................................... 4

Automotive Testing – And Where it All Began ............................................................................................ 5

Testing in the Automotive Industry – Today and in the Future .................................................................... 6An extensive range of products ......................................................................................................... 6An extensive range of applications .................................................................................................... 6

Applications Overview ............................................................................................................................... 7

Hardness Testing ...................................................................................................................................... 8Hardness testers .............................................................................................................................. 8Hardness testing machines .............................................................................................................. 9

Universal Static Testing ............................................................................................................................. 10Measurement and control ................................................................................................................ 10Load frames ......................................................................................................................................11

Static Systems Testing .............................................................................................................................. 14Accessories and supplementary units ...............................................................................................14Multi-channel force measurement system .........................................................................................14Switch contact ..................................................................................................................................15Switch control ...................................................................................................................................15The C-shape frame ........................................................................................................................... 15Zwick Z100/Z250 with single ball lead screw drive ........................................................................... 15Test system to determine the deformation of disk brake linings ........................................................ 15Test system for passenger car clutches ............................................................................................ 16Determination of abrasion and of the friction coefficient of sheet steel .............................................. 17

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testXpert® Test Software ........................................................................................................................ 18

Universal Dynamic Testing ...................................................................................................................... 22Servo-hydraulic testing machines .................................................................................................. 22Workshop 96 test software ............................................................................................................ 23Load frames .................................................................................................................................. 23Measurement and control .............................................................................................................. 23

Dynamic Systems Testing – Servo-Hydraulic Rigs and Systems ............................................................. 25Actuators ....................................................................................................................................... 26K7500 Servo-controller .................................................................................................................. 27QanTiM™ test and simulation software ......................................................................................... 28Vehicle safety impactor systems .................................................................................................... 29

High-Frequency Fatigue Testing ............................................................................................................. 30Testing of connecting rods ............................................................................................................. 30

Impact Testing ........................................................................................................................................ 32Overview on impact testing ........................................................................................................... 32Pendulum impact testers ............................................................................................................... 33High-speed testing machines ......................................................................................................... 34

Services ................................................................................................................................................. 35Advice and support ........................................................................................................................ 35Maintenance and repair ................................................................................................................. 35Calibration service according to ISO 9001 ..................................................................................... 35Hotline – Quick assistance in case of malfunctions ......................................................................... 35Modernizations .............................................................................................................................. 35Creation and adaption of test programs ......................................................................................... 35Seminars ........................................................................................................................................ 36Support line – Assistance for operation and application ................................................................. 36Spare parts .................................................................................................................................... 36

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The Zwick headquarter, development and production site is located in Ulm, Southern Germany,between Stuttgart and Munich

Roell Amsler is situated in Gottmadingen, Germany, near the Swiss border

Zwick Roell AG –More Than a Centuryof Experience inMaterials Testing

Mechanical testing is the oldestdiscipline of materials testing andits importance has increasedsteadily up to the present day. Asearly as in the 15th and 16th century,Leonardo da Vinci and Galilei werealready considering the flexuralstressing and the elastic behavior ofmaterials. The first testing machinesfor this purpose appeared in aboutthe middle of the 18th century inFrance.

Since the middle of the 19th century,the company Amsler (then based inSwitzerland) has been involved inmaterials testing. The companiesRoell & Korthaus (est. 1920) andZwick (est. 1937) share a similarheritage in the manufacturing andsupply of equipment, machinesand systems for the mechanicalmaterials testing.

Today, Zwick Roell AG offersa comprehensive product range –from manually operated hardnesstesting devices up to complextesting systems for productionline applications and the realisticsimulation of operational stresseson complete vehicles.

This brochure provides an overviewof devices, machines and systemsproduced by the Zwick Roell Group.It is designed to provide helpand advice to all those who areconcerned in materials testing inthe automotive industry, particularlywith respect to the testing ofmetals, plastics, rubber, compositesas well as the testing of componentparts, sub-assemblies andcomplete vehicles.

On the basis of many years ofexperience with a multitude of

systems supplied, supplementedby constant communication withusers, Zwick supplies economicalstandard machines as well asspecial designs for particular testjobs. Modern mechanics,high-performance electronics andapplication-oriented test softwareare the prerequisite for the versatilityand the high "intelligence" ofZwick Roell testing machines.

However, the services of theZwick Roell Group go far

beyond the supply of products.Already in 1994 the companyreceived the certification accordingto DIN EN ISO 9001 and thusguarantees a consistently highproduct and service quality.

As an accredited calibrationlaboratory, Zwick can vertify andcalibrate testing equipmentaccording to internationallyrecognized testing protocols.

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Automotive Testing– And Where it All Began

As the industrial revolution spreadacross Europe and the USA thepower source was steam. Steamboilers of every shape and size werebeing produced mainly for the firstrailways. The problem was thatthese first steam power plants hada tendency to explode. In 1870the journal “Engineering” reported40 deaths from boiler explosionscaused by fatigue.

From various accounts of thefailures, there was an obvious lackof understanding about materialproperties, stress raisers and surfacecondition. Fatigue was clearly aserious problem that required someurgent engineering attention. Someof the early fatigue tests wereconducted and documented byAugust Wöhler in 1829 workingas a superintendent for the railwaysin Germany. He was concernedabout failing railway axles and builthis first test machine investigatingthe effects of steady torsional strainon a bar to see the amount ofelongation before it broke.

The term fatigue associated withmetallic components is attributedto Poncelet (1788-1867), whowas responsible for the designof waterwheels with curved bladesof high efficiency.

The first fatigue conference was heldin Birmingham, UK on 24th October1849.

In 1859 William Fairburn receivedmoney from his Government "forthe purpose of ascertaining bydirect experiment the effects ofcontinued changes of load uponiron structures, and to what extentthey could be loaded withoutdanger to their ultimate security".

Cugnot's steam powered vehicle caused the first auto accident in 1789

Historical locomotive after a boiler explosion

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Testing in theAutomotive Industry –Today and in the Future

Due to rapidly progressing technicaldevelopment it is nearly impossibleto forecast the future developmentof automotive engineering.

We as consumers expect highlyefficient vehicles with improvedsafety and higher performanceat lower costs. Thus, the qualityand efficiency of each individualcomponent part becomes moreand more important – and so doesthe task of carrying out stringenttests.

An extensive range ofproducts

Zwick Roell offers an extensive rangeof testing machines and systems forthe automotive industry. It starts withportable, palm-sized shore hardnesstests for rubber and similar materialsand reaches up to computer-aidedtesting systems with up to 16digitally controlled actuators forthe simulation of actual road loadconditions on complete vehicles.

An extensive range ofapplications

The main application areas aretesting laboratories of research anddevelopment departments, wheretest range from materials selectionand qualification to durability testingof parts, component sub-assembliesand complete vehicles. Applicationsalso extend to quality control invarious stages of production.

Vehicle components are, in practicaluse, subject to high mechanicalstress, not least because of thedemand for saving weight. Thishas to be taken into considerationduring the development, and partsalso during production. The partshave to be tested mechanically andrealistically, and the forces generatedhave to be measured precisely andin the timely and cost-effective waypossible.

The loads appearing during practicaluse are therefore transposed "fromthe street into the laboratory" wherethe loads are applied, i.e. simulatedby a testing system. A comparabletransposition changes the

mechanical test "from the testingmachine into the processor". So itis e.g. possible with the finiteelement method to simulate theapplication of load component partsant their effects; even for a crashtest on complete vehicle. Thedemands for this type of test willhowever increase, because onlythe testing machine supply theinformation required for thesimulation and the verificationof the results.

In the production process"in-line"-tests will increase. Forparticularly safety-relevantcomponents, this will lead to100% testing. The aim beingto distinguish precisely between"good" and "bad" automaticallyand within the production cycle.

Zwick Roell testing systems,machines and devices exceed therequirements of practical operation.Mechanics and software arecontinuously developed andupdated. Continuous productmaintenance guarantees that theywill also cope with future demands.

Testing of shock absorbers for racing carsMotor cycle test rigShore A durometer with analog display

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Applications Overview

Application area Hardness testing Universal static testingMachines/systems testers testing machines BasicLine Standard Line Allround Line

Range Shore, Rockwell, 2 - 2500 N 500 N - 20 kN 1 - 250 kN 1 - 2000 kNVickers, Brinell, Shore, Rockwell, etc. Vickers, Brinell,

etc.Controller N/A N/A BasicLine testControl PC testControl PC

control variant control variant(Stand Alone (Stand Aloneoptional) optional)

Software N/A testXpert® Optional PC testXpert® testXpert®

control withtestXpert®

Application area Universal dynamic Dynamic system High frequency Impact testingtesting testing fatigue testing

Machines/systems servo-hydraulic servo-hydraulic vibrophores high speed testingtesting machines testing components machines

pendulum impacttesters

Range 10 - 1000 kN lose actuators 1 - 600 kN speed: up to 20 m/s5 - 1000 kN capacity: up to 750 Jhydraulic power supply or 100 kNand accessoriestest rig components

Frequency range 0 - 200 Hz 0 - 100 Hz 35 - 300 Hz N/A(specimen dependent)

Controller Amsler HydroWin 96xx K7500 VibroWin ImpactWinSpeedWin

Software Workshop 96 QanTiMTM - simulation VibroWin ImpactWinflexible toolkit for of real time loading testXpert® SpeedWinuniversal materials testXpert®

testing (application MecTest - multi channelspecific modules, such block program testingas damper, elastomerand LCF testing)

testXpert® test programsaccording to standardizedtest specifications

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Hardness Testing

Hardness testers

The main characteristics ofhardness testers are:• Hardness determined to a

1-point procedure• The force is generated by weights

or springs

Depending on the type of hardnesstester and its accessories, the test

procedure is controlled manually,semi-automatically or full-automatically.

Supplementary units andaccessories are available for:• Different specimens and

components• Different hardness tests and test

procedures• Simplified use, up to automatic

testing• Controll and calibration

Hardness tester Hardness test method Application range and special featuresZwick 31xx Shore A to D plastics, rubber and similar materialsShore hardness Shore 0 and 00 • handy portable units with analog or digital display with test datatesters memory

• option: test stand for fixed mountingZwick 3103 IRHD micro plastics, rubber and similar materials, especially for rubber shapedhardness testers IRHD macro, H parts, such as O-rings, seals and hosesto IRHD IRHD L and N • option: rapid centering device for O-rings

• option: rapid centering device for hosesZwick 3106 Rockwell A, B, C metals, carbon materials, plastics, hard rubber and similar materialsBall indentation hardness Rockwell L, M, Rhardness tester ball indentation hardness HZwick ZHV 10 Vickers HV 0,2 to HV10 metallic specimens and componentsVickers Knoop determination of case hardening and nitrate hardening depthshardness tester scratch hardness • comprehensive accessories for clamping various specimens,

compound table etc.Zwick ZHV 30 Vickers HV 1 to HV30 metallic specimens and componentsZwick ZHV 50 Vickers HV 1 to HV50 • optical indentation measurementVickers Brinell (optional) • special indentor holder for precise measurement even in recesseshardness tester or on the inner walls of holesZwick /ZHR Rockwell A ... V metallic specimens and componentsRockwell Super-Rockwell N • 3 models: for Rockwell A to V, for Super-Rockwell and as ahardness tester combination tester for both methods

• special indentor holder for precise measurement even in recesses or on the inner walls of holes

Rockwell hardness tester Zwick ZHRHardness tests on a valve (l), on a camshaft (m) and on a spherical joint bearing (r)

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Hardness testing machines

Hardness testing machines are acombination of Zwick materialstesting machines with digitalmeasurement and controltechnology, testXpert® test softwareand accessories for hardness tests.

The interchangeability of thisequipment permits use of materialstesting machines for hardnesstesting as well as for tensile,compression and flexure tests.

The main characteristics of thehardness testing machines are:• The testing force is generated by

the materials testing machine• The testing force is measured

by electro-mechanical load cells• The test procedure is controlled

by the testXpert® test software• The force and indentation depth

are measured continually bythe materials testing machine’selectronics and processed bythe testXpert® test software(sequence measurement)

The Zwick materials testingmachine enables automatic, precisereproducible test sequences andthus supplies highly reproducibleand test results.

Hardness measurement headin combination with hardnessequipment and accessories foroptical measurement, otherspecialized units and speciallydeveloped software modules fortestXpert® enable hardness teststo a variety of test methods andon different materials.

The Zwick ZHU 2.5/Z2.5 materialstesting machine measures theindendation depth to a resolutionof 0,04 µm, and automaticallyrecords the test load(s) andindentation depth(s).

In addition, the sequence of theloading procedure can also bevaried, for example, throughconstant hold of the test load orthe indentation depth over apreselected time.

Universal hardness testing machine ZHU2.5/Z2.5 with optional optics

Further details on the material’sbehavior can be derived fromthe test data which is recordedsynchronously and at an extremelyhigh resolution. This data can be,for example, correlated with the"classical" materials characteristicsresulting from the tensile tests.

Hardness testing Test load range and Application range and special featuresmachine hardness test methodZHV20/Z2,5 2 to 200 N metals and similar materialsVickers Vickers, Knoop • optical indentation measurement, or automatichardness testing Brinell • option: compound table for manual or automatic measurementmachine (up to ball dia. 2 mm) of hardness sequencesZHU2,5/Z2,5 5 to 2500 N all kinds of materials from rubber to ceramics and glassUniversal Universal Hardness HU • hardness measurement head with integrated, digital indentationhardness testing depths measurement system and interchangeable indentorsmachine Martens Hardness HM • determination of hardness and other material properties from

Rockwell (up to 2500 N) force-indentation depth curves, such as plastic hardness,ball indentation hardness H indentation modulus, creep and relaxation behaviorVickers HVT and Brinell HBT • option: optical indentation measurement(with depth measurement) • option: compound table for manual or automatic measurementVickers, Knoop and Brinell of hardness sequences(with option "Optics")

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Universal Static Testing

Field of application

Zwick materials testing machinesare not only used for tensile,compression and bending testson material specimens, but also fortests on component parts such assprings, wheels or complete seats.With these machines it is alsopossible to carry out functionaltests, such as tests on door locksor electro-mechanical switches.

Basic concept

The Zwick program includesuniversal testing machines astabletop and floor standing designswith different measurement andcontrol systems, load frames,drives and versatile optional units.

To offer the best machine for eachrequirement, Zwick has developedthree machine versions, each ofthem being completely different asto equipment, performance featuresand also as to the capability ofexpansion:• The BasicLine is particularly

suitable for functional tests oncomponent parts and for simplematerials tests

• The Standard Line is ideal forsolving simple test jobs reliably.It is a low-cost, sturdy solutionwhich covers many testing needs

• The Allround Line is the basis for alarge spectrum of demanding testjobs and can easily be expandedwhen requirements become moredemanding. It is thus a solutionthat can be relied on for futurerequirements

The decisive testing machinecomponent is the measurementand control system. Its conceptand its scope of performancedecide which drive can be

controlled, which measurementsystem can be connected to it andwhich functions can be controlledwith it – and they thus determinethe range of application and thetesting machine’s capability forfuture expansion.

Measurement and control

Zwick measurement and controlelectronics ensure optimal accuracyand reliability, ergonomicallypackaged in a single compact unit.

BasicLine control

BasicLine testing machines can beoperated in the Stand Alone modewithout a PC using function keys onthe testing machine.

The optional addition of PC controlwith testXpert® software brings withit the advantages of standardizedtests and many years of materialstesting experience.

Materials testing machine BasicLine Z005 Materials testing machine BasicLine Z020

testControl

For Standard Line and Allround Line:By using most recent technologiesand by achieving the highest qualitystandards testControl offersmaximum technical performanceand a long-term investmentguarantee. These are the particularfeatures of testControl:• Synchronous multi channel test

data acquisition with highresolution and measuringfrequency

• Real-time processing of the testdata in a 500 Hz cycle for themonitoring and event-related testsequence control (e.g. speedchange when reaching the yieldor proof stress) and for safety limitvalues

• Adaptive control for exactlyreproducible speeds andpositions

• The measurement, control anddrive systems are housed in asingle, compact unit, savingspace and drastically reducingcabling

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Load frames

Zwick develops and manufacturesstandard load frames for nominalforces up to 2000 kN. Projectspecific load frames up to 50 MNhave been produced (see tablespage 12/13).

Single-column load frame(zwicki)

These load frames employ very rigidaluminium high-precision extrudedprofiles. The working area is freelyaccessible from 3 sides. Thus, it isideal for the most varied functiontests on small parts and for Zwickhardness testing machines.It only requires a small floor space.Due to its light weight, it is easy totransport.

Load frames in tabletopversion

Table top load frames utilizepatented aluminium high-precisionextruded profiles used for guidance.

They are light, very rigid, and servesimultaneously as lead-screwguides and protection. T-shapedgrooves on the outer sides allow asimple fitting of accessories such assafety devices without beingimpeded by the crosshead.

All load frames with two profiles(except for BasicLine) can beequipped with legs. Advantages are:• Positioning of the working area

to an optimum height for the user• Comfortable seated operation with

absolute freedom for legmovement, also suitable forwheelchair users

Load frame as floor standingmodel

These load frames are equippedwith 2 or 4 hard-chrome platedround columns and 2 precision ballscrews. They are ideal for testingspecimens with large extensions,large specimens or large parts andthey are also used with largertemperature or climatic chambers.

One or (optionally) two workingareas are possible.

Electro-mechanic drive units

All electro-mechanical drive units arebased on a backlash-free, low-friction ball lead screw drive anddigitally controlled drive systems(load frames for test loads of morethan 600 kN are equipped withservo-hydraulic or hybrid drives).Together with the digitalmeasurement and controlelectronics, they have the followingadvantages:

• Extremely large, infinitely variablespeed range

• Very low speeds (adjustable fromapprox. 0,001 mm/min)

• High-precision and exactlyreproducible positions and speeds

The testing machines with the1-column (zwicki) load frames areequipped with DC-drives, all theothers with especially low inertia,brushless three-phase AC-drives.

Materials testing machine Z2.5 (zwicki) withtestControl Stand Alone variant with PC

Materials testing machine Z050 withtestControl Stand Alone variant with PC

Material testing machine Z100 withtestControl PC variant

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Features of the BasicLine, Standard and Allround Line

Machine component/function BasicLine Standard Line Allround LineLoad frame• Type of set-up * Table-top machine (nominal load) 500 N to 20 kN 1 - 100 kN 1 - 100 kN * Floor stand machine (nominal load) - 50 - 250 kN 50 - 2000 kN• Support and guidance * No. of columns 2 2 or 4 2 or 4 * No. of Aluminum profiles 1 (Z0.5) 1 or 2 1or 2• No. of working areas 1 1 or 2 1 or 2• Expanded design - ✓ ✓

Drive system• Electro-mechanical * No. of ball screws 1 or 2 1 or 2 1 or 2 * With DC motor ✓ zwicki only zwicki only * With AC motor - ✓ (except zwicki) ✓ (except zwicki)Measurement and control system• BasicLine (without PC possible) ✓ - -• testControl PC variant (standard) - ✓ ✓

• testControl stand alone variant - optional optionalSoftware• testXpert® test software (PC) optional optional optionalMeasurement transducer• Strain gauge load cell 1 (exchangeable) 1 (optional 2) 1 (optional 3)• Digital distance transducer included included included• Digital extensometer - 1 optional ✓ (up to 3 optional)• Analog extensometer - 1 optional ✓ (up to 3 optional)Connection and control of external measurement systems• Digital extensometer - ✓ ✓

• Analog extensometer - ✓ ✓

• Analog reduction-in-width monitor - ✓ ✓

• Video capture - ✓ ✓

• Switch contact - ✓ ✓

• Switch control - ✓ ✓

• Further measurement systems - ✓ ✓

Control of external systems• Grips (mot., pneum., hydr.) - - ✓

• Extensometer - semi-automatic fully-automaticSupplementary units (optional)• Torsion unit - - ✓

• Torque transducer - - ✓

• Multi-channel force measurement system - - ✓

• High-temperature test equipment - conditional ✓

• Low-temperatue test equipment - conditional ✓

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Load frames and driving systems Standard and Allround Line

Load frames and driving systems BasicLine

Series Z0.5 Z005 Z010 Z020• Load frame type zwicki table table table• Max. load [kN] 0,5 5 10 20• Working area max.* Height [mm] 596 561/1061 1041 1041* Width [mm] unlimited 420 420 420* Depth [mm] 99,5 unlimited unlimited unlimited

• Crosshead travel speed* Min. [mm/min] 0,001 0,001 0,001 0,001* Max. [mm/min] 1500 500 1000 500

• Crosshead travel resolution [µm] 0,226 0,05 0,09 0,045• Max. power consumption [kVA] 0,4 0,6 0,6 0,6

Series Z1.0 Z2.5 Z005 Z010 Z020 Z030 Z050• Load frame type zwicki zwicki table table table table table• Max. load [kN] 1 2.5 5 10 20 30 50• Working area*Max. height, low [mm] - 573 - - - - -- standard [mm] - 1073 1058 1058 1058 - -- extended [mm] 1373 1373 1458 1458 1458 1380 1380- extended height and math - - - 1787 1787 - -

*Width standard [mm] unlimited unlimited 440 440 440 440 440- extended width - - - 640 640 - -

*Depth [mm] 99,5 99,5 unlimited unlimited unlimited unlimited unlimited• Crosshead travel speed*Min. [mm/min] 0,001 0,001 0,005 0,005 0,005 0,005 0,005*Max. [mm/min] 1800 800 3000 2000 1000/20001) 1000 600

• Crosshead travel resolution [µm] 0,0002 0,0001 0,041 0,027 0,014/0,054 0,027 0,016• Max. power consumption [kVA] 0,4 0,4 2/1,9 1,9 2,1/2,6 2,3 2,3

Series Z050 Z100 Z100 Z150 Z250 Z400 Z600• Load frame type floor table floor floor floor floor floor• Max. load [kN] 50 100 100 150 250 400 600• Working area*Max. height, low [mm] - - - - - - -

- standard [mm] 1824 - 1824 1715 1715 1800 1940 - extended [mm] - - - - - - - - extended heigt and math 1765 1360 1765 1660 1660 - -*Width standard [mm] 630 640 630 630 630 630 740

- extended width 1030 - 1030 1030 1030 - -*Depth [mm] unlimited unlimited unlimited unlimited unlimited unlimited unlimited

• Crosshead travel speed*Min. [mm/min] 0,005 0,005 0,005 0,005 0,005 0,01 0,01*Max. [mm/min] 400/20001) 200/15001) 200/10001) 900 600 250 200

• Crosshead travel resolution [µm] 0,027 0,026 0,0136 0,0123 0,0082 0,031 0,025• Max. power consumption [kVA] 5 6 5 5,5 6 7/132) 20/262)

1) Depending on drive system

2) With hydraulic grips

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Spring test with 6-components forcemeasurement system

With the testXpert® test software the course of the force’s line of action through the spring withupper and lower intersecting point can be represented graphically and selected forcecomponents, sum forces and spring travel can be displayed in real-time.

Static Systems Testing

Accessories andsupplementary units

For Zwick materials testingmachines, an extensive range ofaccessories and supplementaryunits is available:• Sensors for force travel and

extension measurement• Measurement systems for

specimen dimensions, variationsline in length and width

• Test tools for the most diversetest jobs

• Temperature and climaticchambers

• Robot systems for fully automaticseries tests

The following units have particularlybeen developed for the automotiveindustry:

Multi-channel forcemeasurement system

Compression springs are foundtoday in many technical products,from ball-point pens to componentsin aviation and space flight. Thehigher the technical demands of aproduct are, the sharper therequirements are for the individualcomponent "spring". A good

example is the automobile industry.Here, compression springs ofvarious dimensions aremanufactured and used in e.g.automobile shock absorber struts,brake cylinders and valves.

If a compression spring is loadedvertical to its axle centre, theresultant force will normally notcoincide exactly with geometriccentre of the spring. Because ofthe helix, the force is guided in sucha manner to the stationary area, sothat the loading of the spring endsis not equal, which results in traverseforces and torque. These mustbe known for many applications.Therefore, it is necessary tomeasure, in addition to the verticalforce, the transverse force and todetermine its effective direction. Thenew six-channel force measurementsystem from Zwick makes it possibleto solve this complex task with highaccuracy and reproducibility.

The force measurement systemconsists of six load cells placedunder a massive compression plate.

Through the geometrical placementof the load cells, a 3-dimensionalcoordinate system with x, y andz-axes is created. The vertical andhorizontal forces applied to thecompression plate are transferredvia flexure-elastic double-crossedlinkages to the load cells. Becauseof these double-crossed linkages,only tensile and compression forces,but not transverse forces andtorque, can effect the load cells.

From the six measurements of theload cells, the vertical and bothhorizontal force components, andtheir respective distances to themachine axis, can be mathematicallycalculated and with these results,also the size and position of theresulting spring tension in space.

The new testXpert® test softwarecontrols the test sequence andthe test evaluation. During themeasurement cycle, the six forcevalues and the spring length areacquired time synchronously,stored, evaluated and displayedon the monitor. As a further

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Zwick Z010 materials testing machine withC-frame for compression and indentationhardness tests on larger parts of cellularplastics

The C-shape frame

The C-shape frame is speciallyadapted for compression andindentation testing of larger cellularplastic parts as used for seats incars and aircraft. The table canbe open on both sides in order toget a large anvil surface. In the testarea the table is perforated withholes to allow rapid air escapeduring indentation tests.

The test space is accessible fromthree sides to allow verycomfortable and fast operation.By use of adaptors, this load framecan be used for tensile testing.

Zwick Z100/Z250 withsingle ball lead screw drive

The force transmission occurs via acentral ball-lead screw.Thus a verygood force flow with direct force

transmission to the specimen isobtained during the test.

The moving crosshead ensures thelateral guidance of the test axis andis not subjected to bending loads.Separation of these loads withinthe frame and exact guidance ofthe columns ensures the highestprecision in the crossheadmovement. An especially good axiallongitudinal parallelism and a highlinearity in the movement of thegripping elements are the result.• Low-Cycle-Fatigue tests (LCF)

as mechanical, thermal orthermal-mechanical loading

• Examination of intercrystallinereactions and microstructuralmaterial behavior

• Stress-rupture tests in force orextension-controlled operation,also for medium-term and long-term intervals

• Mechanical fracture tests, crackgrowth and critical energy density

• Compression tests on platesprings or clutch springs

• Tensile, compression and bendingtests on ceramics, especially inthe range of high temperaturesup to 1600 °C

• Relaxation and retardation testsfor example on metals, ceramics,composites, component partsand springs.

Test system to determinethe deformation of discbrake linings

Disc brake pads are one of themost important parts of a wheelbraking system. For a betterevaluation of the quality of discbrake linings, the pad thicknessvariation is determined by meansof a unidirectional compressive forceapplied in the direction of the frictionarea normal to the disc brake pads.For this purpose Zwick materialstesting machines can be equipped

Testing of disk brake linings

development, in the master testprogram, from master test programfrom testXpert®, the test programcan be adapted quickly and easilyto any new circumstances. Inaddition to the automatic testing,manual tests can be performedwithout problems using the remotecontrol since the values are shownon the monitor at the same time.

Switch contact

Automatic event marking at switchprocedures, e.g. for tests onelectro-mechanical components.Switch Contact captures switchingevents for test control andevaluation in testXpert®.

Switch control

This electronic supplementaryunit is perfectly suitable for theacquisition of the characteristicsof switches and electro-mechanicalparts. It allows:• Time-synchronous acquisition of

switching forces and times of up to6 contacts

• Unambiguous detection of theswitch positions and combinations

• Simultaneous acquisition of the

switch-on characteristics (voltage-time-course) of up to 4 switches

• Acquisition of up to 4 external,analog measuring signals plusthe possibility of summation

• Additional acquisition of aresistance measuring signal

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Test system for passengercar clutches

For the testing of passenger carclutches Zwick has developed anew test system, which is a cost-efficient, user-friendly and extremelyreliable solution for the testlaboratory.

The test system is used to recordthe complete characteristic curvesfor the compression force, releaseload, liftoff as well as themeasurement of the verticaladjustment and the true runningof the diaphragm spring fingers.

For the acquisition of the pressureplate lift-off, three extensometersare installed, displaced by 120°at a time. Each extensometer canbe adjusted vertically and isprogressively adjustable via slidinggrooves between 160 and 300 mmin diameter. By means of a clip-ondevice, the extensometers areclipped on or lifted off at the same

time. Thus, additional settingoperations between the differenttest sequences are avoided.The test system can be used ineach floor test machine with thecorresponding measurementand control unit. The high accuracy,rigid load frames and linear, digitalextensometers of the Zwick testingmachines guarantee exact andreliable test results. Themeasurement and controlelectronics testControl makesany application user-friendly andextremely flexible.

Testing system for passenger car clutches

with a compression device withintegrated measuring system. Theforce is applied with a compensatingpressure plate connected to aspherical head. The effect is auniform load application. Thefree suspension and the own weightof the compensating pressure plateallow exactly parallel positioning onthe disc brake pad, thus ensuringan absolutely uniform andhomogeneous pressure application.The test position of the pressurepiston runs through the center axisof the disc brake pad’s center ofgravity. Both one-piece disc brakepads and disc brake halves canbe tested.

The deformation measurementis conducted with 3 precisiontransducers arranged on a pitchcircle of 260 mm, staggered by120°.

The testXpert® test software takesover all essential tasks such aspreparation, test performance,evaluation and documentation, dataand quality management.

With the software module "Mastertest program for clutch tests" theuser gets a finished "test pattern".All tests (compression force,releaseload and lift-off) are clearlyillustrated ina diagram.

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Draw-Bead Tester1. Holding-down force, 2. Strip-drawing force, 3. Exchangeable tool, 4. Upper specimen grip

Testing machine with installed Draw-Bead-Tester

Determination of thecoefficient of frictionof sheet steel

By determination of the coefficientof friction between sheet steel andthe deep-drawing die, optimumlubrication can be applied, in orderto avoid cracks and folds of thesheet steels but at the same timeensuring an optimum deep-drawprocess.

The Draw-Bead-Tester is easilyinstalled in a standard testingmachine by mechanical andelectrical plug connections. Forthe test, a typical sheet steel strip(300 mm x 30 mm x 2 mm) isgripped axially in the upperstandard specimen grip and theholding-down clamp is closed.Then the sheet steel strip is pulledthrough the Draw-Bead-Tester.The desired number of automaticrepetitions can be preset.

An independent measurement andcontrol system ensures a constantholding-down force throughout theduration of the test. The holding-down force is not effected byspecimen parameters, such asthickness and surface texture noris it affected by test parameters,such as drawing force and speed.

Holding-down forces from 600 Nto 10 kN or alternatively from1 kN to 50 kN can be preselected.

Depending on the requirements(standards, specifications etc.)there are holding-down clampswith different geometries available.A mechanical plug connectionallows easy rapid changeof the holding-down clamp.

The Zwick testXpert® test softwaregets the parameters and evaluatesthe desired test sequences andprovides graphical presentations

of the test data. The abrasionis determined separately afterweighing the specimen in µg.The results of this weighingprocess are recorded and evaluatedin testXpert®.

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testXpert® Test Software


testXpert® is the universal testsoftware for materials, componentsand functional testing. Itsapplication range goes fromZwick materials testing machines(tensile, compression, flexure anduniversal testing machines) tohardness testers, pendulum impacttesters, extrusion plastometers,automated test systems, etc.right up to refurbishment of testmachines of a variety of makesand models.

Duties and functions

The essential fields of use oftestXpert® are:• Verification and re-equipping

the test machine• Preparation of the test or

test series• Carrying out the test• Evaluation and documentation• Data management• Quality management• Data exchange between

testXpert® and other applications(Word, Excel etc.)

testXpert® supports the user forall tasks with software wizards andeditors, explanatory pictures andvideo sequences, situation specificuser tips, warnings, error messagesand online help.

Future oriented concept

The testXpert® test softwareuses the advantages of objectoriented programming with respectto a clear grouping in tasks andfunctions. Structure and contentsare determined by the Zwickapplication and software know-how.The concept is therefore aguarantee of the highest flexibilityand functional safety as well as

testXpert® - the strictly object-orientated software is available in several language versions;among others in English, French and German

simple usability. The essentialfeatures are:• Uniform basis software for all

applications• Modular system for test programs• User support through software

tools

Modular system

The test programs are compiledby Zwick from a selection ofseveral hundred software modules.The modules are sub-divided intoclasses such as test parameters,test sequence phases, screenviewsetc. They are continuouslydeveloped and expanded withrespect to new states of knowledgeand necessary supplements.

This makes testXpert® an intelligentsoftware, and thus enables therealization of test programs strictlyto test standards and test programsrelated to practical applications.Thanks to the numerouspossibilities of this system,

testXpert® can be put to universaluse for a wide application spectrumand for a variety of test machines.

Test programs

The test programs compiled byZwick stipulate how tests are tobe run. Their basis is a numberof selected software modulesthat are linked to one anotherand pre-configured through fixedparameters depending upon thefunctions required of them. Thusthe user receives from Zwick a"test template" in which onlyvariable parameters must beentered.

There are three variations availablefor a wide range of requirements:• Master test programs• Standard test programs• Customized test programs

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International quality standards

To comply with international qualitystandards, each and every versionmust be transparent and archivedfor 10 years. The testXpert® testsoftware fully meets these require-ments and even the particularlystrict guidelines of GoodManufacturing Practices (GMP).

The entire software developmentprocess and its components arediligently documented and archived,from the source code through tothe software tools used, for eachand every version. This is valid foreach phase from the analysis viathe specification, design andimplementation up to the test.Conformity to the standardISO 9000-3 for development oftestXpert® has been confirmedvia audit report no. QM-F-96/1016.

Safety in detail

Windows software is normally usedin offices. However, testXpert®

takes over an additional andespecially critical task: monitoringand controlling machines. Machinedamage and potential danger topersons must be ruled out.testXpert® has no overlappingwindows in the test mode to avoidhiding important displays or keyfields.

Automatic acceptance ofsystem data

Different test tasks require differenttest machines with different and,usually, interchangeablecomponents. Their specificproperties are characterised by thesystem data (nominal force, travel,speed range, mounting height,calibration factors, etc.).Organisational data also belongs tothe above, e.g. the series numberor the date of the last calibration.

The test data and the assigned video frames of the test arrangement are recorded and savedwith video capturing, as in our example of a compression test on a seal profile

testXpert® accepts this dataautomatically directly followingprogram start:• For the necessary settings• For determination of safety limit

values• For correct measurement signal

evaluation

Furthermore testXpert® checkswhether or not:• The test can be carried out

with this configuration• All settings have been made• The data has changed for

the current test

Simplest operation

Operation is reduced to a one-button operation, i.e. activatingthe start button, for standardapplications. This is possiblebecause testXpert® automaticallyrecords the test data, and,dependent upon this, controlsand monitors the test sequenceand determines and documents the test results.

Only two steps to testing

Preparation of a test series requiresonly two steps:• Call-up the test program foreseen

for the required application• Entry or selection of variable

parameters

Optimum user information

All displays necessary for carryingout a test or a test series, canbe grouped together in a clearand concise manner in one singlescreen setting:• Input fields for specimen specific

test parameters• Curve diagram (single or multiple

curves)• Tables for test results• Tables for results statistics

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Data saving for further use

Depending upon the preselectionin the test program, not only alldata but also selected results datafrom a test or test series can besaved. Saving of all data offersthe possibility of tracing the originof the results data as well as theconfiguration and for the testmachine. The standardizedmeasurement data, i.e. the dataconverted to its basic units canbe repeatedly displayed in thesimulation mode and can alsobe evaluated according to othercriteria.

Video capturing

The testXpert® test software notonly supports the user by meansof "help" videos. It is also possibleto carry out multimedia tests byusing a video camera and a videocapture card with the video picturesbeing recorded time-synchronouslywith the test data:

• With the cursor keys, a "videoreticle" can be moved over thetest curve and the correspondingpicture can be displayed

• The pictures can be capturedat a preselected separation ofthe measuring points or independence on the event

• The video can also be playedalone, independent of the testingmachine

• Distances between two pointsand angles between three points,radii, diameters and areas can bemeasured from the specimen inpictorial representation.

• Optionally, the pictures can beoutput with dimension lines andtest data

testXpert® in dynamicapplications

testXpert® was originally developedfor the control of screw-drivenstatic test machines and hasgrown to cover the widestspectrum of testing applications.The latest developments includethe dynamic application oftestXpert®.

Roell Amsler’s range of dynamictest software, machines andsystems boasts extensivefunctionality, based on yearsof experience in fatigue, impactand durability testing. The currentdevelopment processsystematically re-packages,improves and extends thisfunctionality into a range ofmodular testXpert® master testprograms.

testXpert®'s focussed applicationsolutions are a giant leap forwardfrom the open toolbox approachin which a user is continuallychallenged by functions andfeatures not relating to the testingtask at hand.

Typical development phases

Consider the Workshop 96software suite for servo-hydraulictesting machines as ademonstrative example of howdynamic applications are includedinto testXpert®. Workshop 96 isan extremely powerful packagethat offers the user unlimitedflexibility and functionality, nowbeing extended and re-packagedinto testXpert®. The first stepwas to create a layer on whichthe dynamic applications couldbe built; this included fundamentalsoftware building blocks rangingfrom controller interfaces todynamic visualization tools suchas oscilloscopes and graphs.

Application focussed testXpert®

master test programs followto gradually supersede allWorkshop 96 functionality. Thisdoes not mean that the existingpackages, such as Workshop 96,are being abandoned, but theirmaintenance and furtherdevelopment continues parallelto the testXpert® program. Onlywhen all functionality has beenreplaced will the fade out ofWorkshop 96 be considered.

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The list of dynamic testXpert®

applications is rapidly growing.Master tests programs are alreadyavailable for applications as diverseas:• High speed tensile and penetration

tests on Amsler high speed testingmachines

• Instrumented pendulum impacttesting on Amsler RKP pendulumtesters

• High cycle fatigue testing onAmsler servo-hydraulic testingmachines and high frequency"Vibrophore" testing machines

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Universal DynamicTesting

Servo-hydraulic testingmachines

Fast accurate test results areinstantly available enabling criticalmaterial, fatigue and durabilitydata to be processed. Tailoredto the automotive industry, thesemachines provide a cost effectivetesting solution that is easy to use,reliable and safe. Everything youneed with machines ranging from:• 5 kN to 1000 kN• Speeds up to 20 m/s• Software meeting ECE, EEC,

SAE, and FMLS standards


Automotive suppliers and OEMsaround the world use dynamicservo-hydraulic test machines toconduct dynamic fatigue tests intheir laboratories. These machinesare supplied with a comprehensivevariety of grips and fixtures to suitmost applications.

Universal dynamic testing machinesare used extensively to provide acomprehensive evaluation ofmaterials' dynamic properties,such as:• Fracture toughness determination

K1c, J1c, CTOD• Fatigue crack growth and fatigue

life determination• Low cycle fatigue at room

temperature and high temperature• High temperature materials

characterization• Composite material evaluation• Polymer and elastomer

characterization• High strain rate behavior• Advanced extensometry• Extensive automotive compliant

software library written to ISO andTickIT procedures and advanceduser programming facilities

Basic concept

Roell Amsler universal servo-hydraulic testing machines combinestructural rigidity with precisealignment to guarantee test dataof the highest possible integrity.The robust construction coupledwith refined engineering has evolvedover many years’ experience inthe materials testing industry.All load frames boast smooth hard

Servo-hydraulic testing machineAmsler HC10

Servo-hydraulic testing machineAmsler HA250

chromium plated columns, frictionclamped by deep one-piececrossheads producing a structuralplatform of exceptional stiffnessand rigidity with infinite fatigue lifeat rated capacity.

The testing machines are equippedwith high performance fatigue ratedservo-hydraulic actuators, availablewith hydrostatic bearings orpolymer based plain bearings. Loadcells are mounted either on thecrosshead or to the piston rod end.

Accurate alignment is achieved ineither direction using Roell Amsler'sstandard recess and spigottechnique. Standard tool mountingfaces with precise location ensuresaccurate alignment of grips andfixtures. Machines are matched withhydraulic power units and supplycombinations to ensure applicationspecific performance and efficiency.

Additional options to test machinesinclude protective enclosures,environmental simulation chambersand application specific specimenfixtures.

Servo-hydraulic testing machineAmsler HB125/80

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Technical data servo-hydraulic testing machines

Standard load frame/series Amsler HA Amsler HB Amsler HCConstruction type floor standing design floor standing design tabletop designLoad frame nominal force [kN] 50 - 300 50 - 1000 5 - 30Test stroke [mm] 100 or 250 100, 250 or 400 100 or 250Location of actuator lower crosshead upper crosshead upper crossheadUpper crosshead adjustment hydraulic hydraulic manual (hydraulic option)

Load frames

HA load frames – The actuatoris semi-integrated into the lowercrosshead for maximum stiffnessin all planes combined withalignment accuracy of the highestorder. Hydraulic adjustment andclamping of the upper crosshead isincluded as standard.

HB load frames – The actuator ismounted in the upper crosshead.The HB design provides a flexibletest space for optimal specimenmounting possibilities. Standardframes sizes are available up to1000 kN with an actuator stroke ofup to 400 mm. Hydraulic adjustmentand clamping of the uppercrosshead is included as standard.

HC load frames – These testmachines are designed to be of alightweight construction, with veryhigh frame stiffness. The actuatoris mounted in the upper crossheadresulting in a versatile frame, whichcan be tailored to customerrequirements. Optional hydraulicupper crosshead adjustment.

Measurement and control

Unrivalled performance is offeredusing the Amsler HydroWin 96xxcontroller series.• 10 kHz closed loop, giving high

speed, precise controland data acquisition

• 19 bit A/D conversion withreal-time linearisation

• MIMICS advanced adaptivecontrol for automotive testapplications

• Environmental management• Multi-channel control

Workshop 96 test softwarefor Amsler HydroWin 96xxcontroller

Workshop 96 is an universal testsoftware for materials andcomponent fatigue and durabilitytesting. Many application programsare available for standard testssuch as fracture toughness

determination, low cycle fatigue,damper testing and many more.

Upgrade programs are availablefor the modernization of oldframes mode by a variety ofmanufacturers.

Tasks and functionality

Working together with the AmslerHydroWin 96xx digital controland data acquisition system theWorkshop 96 software providesa fully integrated testing solutionin a user friendly Windowsenvironment that gives thematerials test engineer full controlof the test system.

Configuration 96

Configuration 96 allows thetest engineer to configure andreconfigure the test machine.Analog, digital and derivedtransducers can be configuredand assigned to channels.Plugging and unplugging oftransducers is automaticallydetected by the AmslerHydroWin 96xx controller andthe software.

Toolkit 96

Toolkit 96 provides an integratedtesting environment with real timegraphs and feedback displays thatcan be defined to monitor current,upper peak, lower peak, peak topeak or mean values.

Servo-hydraulic Testing Machine AmslerHB1000

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Script Writer 96

Events can be defined to controlthe flow of a script dependent uponthe condition of the controller anddata measured during the test.

Analysis of various parameterscan be performed and monitoredwhilst the test is in progress.These parameters include:• Phase angle• Stiffness vector• Dynamic stiffness• Loop area• Peaks• Amplitudes/means• Plastic deformation

Other 96xx features that areavailable in Script Writer 96 are:• Settable PID gain parameters

for each script• Use of MIMICS advanced control

system• Individual limits for each

feedback channel• Global events to monitor

feedback differences

Once scripts have been created,they can be executed using theScript Player. This provides accessto monitoring the status of controllerparameters, and also the ability tocontrol the hydraulic power at alltimes.

Numeric and graphical displays willbe updated in real-time, and resultswill also be displayed as they arecalculated.

All data for the test is stored in fileformats that can be used throughoutthe Workshop 96 software suite,and text files can easily be importedinto any spreadsheet/analysispackage.

Data Manager 96

Data Manager 96 is a powerfulintegrated program that allows alldata files in either Script Player orToolkit 96 to be graphically viewed,manipulated, analyzed and printed.

Data sets can be viewed in severalways, one graph at a time, multiple

graphs or multiple traces withup to a maximum of 20 in anycombination of the above.

Some of the advanced processingfunctions include:• Numeric differentiation and

integration allows the testengineer to derive, amongst otherthings, graphs such as velocityfrom stroke

• Advanced digital FIR filteringtechniques can be applied tostored data, to enhance low levelsignal data and to removeunwanted noise

• Truncation of data allowsreduction of long data captures toallow retention of the useful partsof the capture only

• Plotting and printing of allavailable data

Firmware Loader 96

Simply and quickly the user or oursoftware support staff can updateand maintain the firmware usedby the Amsler HydroWin 96xxcontroller.

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Three K7500 servo-controllers for simulation tests

Dynamic Systems Testing– Servo-Hydraulic Rigsand Systems

The automotive structure orcomponent under investigation issubjected to the equivalent fatiguedamage experienced on the roadduring the vehicles' lifetime but inthe controlled environment of thetesting laboratory.

Servo-hydraulic test systems aremostly used to conduct durabilitytests on dynamically loaded auto-motive structures and components.This means, by using actual field orsynthesized data input, weeffectively "bring the road into thelaboratory" performing complextests under controlled, repeatablelaboratory conditions. Rigs varyfrom simple single channel constantamplitude to complex multi-axisservice load simulation systems. Inall cases the essential elements ofthe test rigs are the same and ofmodular design.

Systems testing components

Zwick Roell supplies a wide rangeof dynamic test systemcomponents:• Hydraulic power supplies from

4 kW upwards – Supply ofhydraulic power to servo-hydraulic actuators and testingmachines. Power supplies areavailable for both 210 and 280bar system pressure and areavailable as water or air cooledunits. Optional sound proofingenclosures are also available.

• Hydraulic control stations from63 to 500 lpm – The hydrauliccontrol station serves as ahydraulic switch between aconstant hydraulic supply andthe consumer(s), servo-hydraulicactuator(s) or test machine(s).More importantly, it provides safeand accurate pressure/flowcontrol, a two-stage soft start anddistribution to multiple hydraulicconsumers.

• Servo-actuator assemblies from

5 kN to 1000 kN – The seriesLAH actuators are specificallydesigned for high performancedynamic testing applications. Thisincludes applications requiringhigh frequencies and pistonspeeds, as well as applicationsthat can induce side loads andbending moments on the actuator

• Digital servo-controllers – From stand-alone to 16 channel multi- axis• Test software - Data acquisition,

simulation (QanTiMTM), durabilitytesting (Dura) programmablewaveform generation and testanalysis (MecTest)

• Test rig fixturing – Standard andbespoke for various applicationsincluding body components,steering components andcomplete assemblies, seatingcomponents, exhaustcomponents and completeassemblies, suspensioncomponents and completeassemblies, wheels andmultipurpose components

Types of tests

We offer a wide range of automotivetest and simulation systemsdesigned to conduct testsexamining:• Fatigue and durability• Vibration• Squeak and rattle investigation• Motion simulation• Shock and impact loading

Key life tests are conducted onfull vehicles, assemblies, andcomponents.

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Actuators –Our two actuator ranges cover the complete spectrum of dynamic testing applications

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K7500 Servo-controller

Flexible automotive test rigs andsimulation systems require aversatile, compact digital servo-controller at the heart of the controland data acquisition.

The K7500 servo-controller hasoutstanding functionality at anaffordable price.

The portable K7500 units arestackable to build upward froma single channel to multi-channeloperation in master-slavearrangement.

Stand alone operation

• Full digital control of servoactuators with integrated functiongeneration, hydraulic and safetysystems

• Peak adaptation control forcontrolled or independentvariables

• Three control modes withbumpless transfer

• Automatic PID gain tuning• Parameter bank storage

Multi-channel operation

• Master-slave configuration• Synchronized and variable phase

waveforms• Integrated multi-channel safety

system

PC-based operationK7500 operating system

• System configuration• Front panel emulator• Parameter bank management• System monitoring

K7500 controller rear panel

QanTiM™

Service load simulation• Recreate transient and dc events• Signal generation test and analysis• Durability test management

MecTest

• Advanced wave form generation• Nested block loading• Advanced limit detection• Static test manager

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QanTiM™ test andsimulation software

QanTiM™ simulation testing enablesyou to bring greater realism,accuracy and repeatablily tomeachnical testing. Laboratorytesting helps shorten your productdevelopment cycle for structuresand components.

QanTiM™ simulation testing enablesyou to reproduce the actual real-time loading conditions for a vehicleor structure in a test laboratory.Real-time simulation testing offersthe only method of reliablyconducting interactive multi-axistests.

A QanTiM™ test and simulationsystem provides a completelaboratory solution with a suite ofcontrol and analysis softwaremodules for a wide range of testing.

Overview of real-timesimulation

The time domain based testingsystem QanTiM™ provides state-of-the art testing technology. QanTiM™

allows actual operationallymeasured response conditions tobe reproduced on the structure inthe laboratory. QanTiM™ providescontrol of randomly loaded singleor multiple axis fatigue test rigs,particularly for service-loadsimulation testing.

The objective is to measure thedynamic response of the teststructure during operationalconditions and to recreateconditions in a laboratory on thefull-scale structure loaded by servo-hydraulic actuators. Generally it isnot possible to measure the actualloads acting on the structure, andinstead the dynamic response to

Typical durability testing application

these loads are measured atpositions remote from the loadinputs. These remotely measuredresponses are subsequently utilizedto derive the system input forcing-functions (actuator drive signals).

The use of this new time domaintechnology has proven to exhibitperformance characteristics thathave to date been impossible usingtraditional methods. These includemuch greater capabilities at theextremes of simulation testing, suchas very low frequency events andefficient operation from shortduration input data, such as potholes.

This new approach to simulationtesting also results in a test systemthat is exceptionally easy to use,compared with traditional simulationproducts operating in the frequencydomain. In spite of itssophistication, QanTiM™ does notburden the user with its clevertechnology. The technology ishidden to enable the rapidexecution of tests. In this way, theefficient gathering of test resultsremains the prime objective.

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Vehicle safety impactorsystems

Safety is high on the list when itcomes to customers choice ofvehicle.

Vehicle safety test evaluationsystems provide vital safety data inmany new vehicle safety researchcentres.

Our experience extends to:• Steering system impactors• Headform impactors• Bumper (fender) impactors• Side and roof intrusion• Body panel impactors• Seatbelt anchorage test systems

The following impactor types areavailable:• Propulsion systems using high

velocity servo-controlled actuatorassemblies. That means systemswhich give a controlled impact tothe test piece

• Pendulum arm devices designedto achieve effective mass at thecentre line of impacts. Thatmeans systems which acceleratea predefined mass and launch itonto the test piece

• Hybrid systems, which are aservo-assisted pendulum armdevice

Our in house safety applicationsteam will advise on the mostsuitable system to meet yourapplication.

Headform impact tester

Seat belt anchorage test

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Vibrophore Amsler HFP5

High-Frequency FatigueTesting

Famous for the Vibrophore,introduced to the market in 1945,Roell Amsler now supplies the latestHFP 5100 electro magneticallydriven high-frequency resonanceoperation test machines.

Automotive test laboratories aroundthe world agree that the Vibrophoreoffers these significant advantagesover other forms of testing:• Minimal energy consumption

due to resonance operation• No supplementary cooling or

hydraulics needed• Maintenance free operation• Fast accurate test results


• Dynamic tests to define thefatigue strength of materials andcomponents, e.g. fatigue tests inaccordance with DIN 50100 (S/Ncurve), in tensile, compressiveand alternating load ranges

• Mechanical fracturing tests on CTand COD specimens. Fatiguestrength tests on componentssuch as crankshafts, connectingrods, steering knuckles, fasteners

• Production and quality control ofcomponents that are exposed todynamic loading during theirlifetime

• Simulation of variousenvironmental conditions(temperature, aggressive media)with corresponding specialfeatures

• Torsion and bending tests• All tests can be done in load or in

strain control

With load ranges from 1 to 600 kNand test frequencies in excess of300 Hz, the Vibrophore is theautomotive industry’s only choicefor speedy testing of steel, lightmetals, and ceramics:• Crankshafts• Conrods• Pistons• Timing gears• Chains• Sprockets• Gears• Fastening devices

The machines are controlled byusing Roell Amsler developedVibroWin electronics and testXpert®

test software.

Application example:Testing of connecting rods

For testing connecting rods, servo-hydraulic testing machines or high-frequency resonators of theHFP 5100 series with forces of50-600 kN come into considerationdepending upon the required testload (dependent on connectingrod size and load, i.e. customer-specific). These tests are preferablycarried out on a high-frequencyresonator owing to high testingcosts and the limited frequencyresponses of a servo-hydraulictesting machine.

Vibrophore Amsler HFP250Vibrophore Amsler HFP2 "Vibrolino"

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Series Amsler Amsler Amsler AmslerHFP1/2 HFP5/10 HFP20-250 HFP300-600Vibrolino

Type zwicki tabletop floor floorMax. test load [kN] 1; 2 5; 10 20 - 250 300 - 600Max. load amplitude [kN] 0,5; 1 2,5; 5 10 - 125 150 - 300Range of frequencies [Hz] 35 - 250 35 - 300 35 - 300 35 - 300Horizontal daylight [mm] 100 350; 500 530 600Connected load [kVA] 1 1 < 2,5 2,5

Con rod testing on a vibrophore underrealistic conditions

The connecting rods are held inthe testing machine by specialclamping devices. There followreferences to some special features:• The clamp orients itself to the

actual installation conditions withdefined play

• Lubricating oil introduced underpressure into the bearingssimulates real conditions(oil cushion)

• This lubricating oil can be cooledor heated (up to 180°C)

• A plexiglas safety device protectsthe environment

Technical data Amsler Vibrophores

The test itself consists of dynamicsinusoidal loading up to fracture.The load passes through the nullpoint,depending upon type of engine(high-speed engine, medium-speedengine etc.) into the compression ortraction region. The achievablefrequencies lie between 70-120 Hzdepending upon the connecting rod.

The available test results are theapplied force, the test frequencyand the achieved number of stresscycles. Customer-specific analysisis conducted in most cases.

Connecting rod in clamping device

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Impact Testing

Impact testing systems determinethe impact energy, impact strengthand notched impact strength ofstandard plastic, metals, ceramicsand even component specimens.High rate tensile and penetrationtests are typicallyused to determine material andcomponent characteristics underextremely high rate loading. Impacttesting systems can be divided intothree categories, each with its owncharacteristics and fields ofapplication:• Pendulum impact testers• Hydraulic high speed testing

machines

This section introduces the rangeof impact testing systems ashighlighted in the overview below.

Pendulum impact High speedtesters testing machines

Capacity < 750 J < 100 kN

Testing speed < 5,5 m/s < 20 m/s

Materials plastics, metals plastics, nonmetals, metals,composites, components

Tests standard tests (>90%) standard tests (<50%)Charpy, Brugger, IZOD tensile, penetration testing,tensile testing

Evaluation non-instrumented and instrumentedinstrumented

Overview on impact testing

High speed tensile test with laser extensometer

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Type Zwick 5113 Amsler RKP450 Amsler PSW750Max. capacity [J] 50 150/300/450 300/450/600/750Angle of fall [degree] 160/124,4 150 161Rate of fall [m/s] 3,46 / 3,85 5,23 5,42Hammer shape disc (C) box (U) disc (C)Instrumentation optional optional optional

Technical data pendulum impact testers

Pendulum impact testers


Pendulum impact tests todetermine the Charpy impact workup to 450 J, according to EN 10045or ASTM E-23.

Optional configurationsaccommodate additional teststandards such as IZOD, Bruggerand impact-tensile tests.

Key features

• Pendulum construction accordingto EN 10045 and ASTM E-23

• Automatic hammer lift drive andbrake system

• Ergonomic single column layoutgives easy access to specimenand tooling

• 300 J standard hammerwith options for 150/450 J

• Protective enclosure accordingto VGB 5

• Universal impact hammeraccommodates optional fixturesfor IZOD, Brugger and impact-tensile tests

• Rapid test execution (<5 sec)makes the impact tester idealfor testing tempered specimens,especially for cooled specimens(-40 °C) for the indirect verificationaccording to ASTM E-23

Pendulum impact tester Amsler RKP450 (without protection device)

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High-speed testingmachines

High-speed testing machines(Amsler HTM) are hydraulically drivenimpact machines able to producevelocities of up to 20 m/s inpenetration (compression) andin extension.

The test methods for penetrationtests are very similar or equivalent toinstrumented drop weight testers.High-speed testing machines aregenerally used for rigid plastics andat higher velocities, when dropweight tests would become veryhigh or would have to bespringloaded. The higher energy rateavailable at the impact point is afurther advantageof high speed testing machines.

Examples of applications:

Instrumented penetration tests fordetermination of impact behaviorof rigid plastics according to ISO6603-2 and ASTM D 3029:• Instrumented penetration tests

on plastic piping, ISO 3127,ASTM D 2444

• Instrumented high speed tensiletests on rigid or semi-rigid plastics

• Instrumented impact tests onfinished or semi-finished parts

Characteristics:• Hydraulic or mechanical clamping

and adjustment of the uppercrosshead

• Fixed lower crosshead to beused as a clamping table

• Loading unit in shock absorbingconstruction to reduce vibrationor shock transmission to the floor

• Double acting cylinder for tensileor compression loading

• Piston without sealing rings• Double-sided hydraulic

endposition damping• Mechanical piston brake prevents

unintentional movements

A complete range of standardclamping devices

For all types of penetration teststhe standards define standardspecimens as well as standardizedmethods of clamping. Amslerprovides a complete range ofclamping devices for moststandards currently used, specialtest rigs and jigs for componenttesting, as well as grips for highspeed tensile tests.

Testing in hot and coldconditions

High speed testing machines canbe used across a large temperaturerange.

SpeedWin control withtestXpert®

SpeedWin with testXpert® softwareis used to perform penetration andtensile impact tests on high speedtest systems. The fast digitalprocessor allows accurate controland measurement. testXpert® iseasy to operate, providescomprehensive evaluation of testresults, documentation and datastorage.

High speed testing machine AmslerHTM5020

Characteristics:• Simple creation of test programs

with the support of intelligentprogram wizards and intuitiveprogram operation

• Maximum flexibility throughpowerful configuration tools

• Creation of your own parametersand result parameters

• Custom programs can bereduced to optimized "one-buttonoperation"

• Data transformation and storagein ASCII format

The range of standard products

Type Amsler Amsler Amsler AmslerHTM2012 HTM2020 HTM5004 HTM5008

• Max. load [kN] 20 20 50 50• Max. velocity [m/s] 12 20 4 8

Type Amsler Amsler Amsler AmslerHTM5020 HTM5020B HTM10002 HTM10004

• Max. load [kN] 50 50 100 100• Max. velocity

[m/s] 20 20 2 4

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Services

Customer satisfaction is given toppriority at Zwick Roell. Therefore,nearly one third of employees areactive in the service field. Extensiveservices guarantee the bestpossible usage and high availabilityof the testing machines andsystems supplied.

Advice and support

Our technically competent andexperienced service personnelsupport the user directly at siteor by phone, fax or e-mail. Detailedinformation may also be lookedup in the internet or may bedownloaded in case of need.

Maintenance and repair

Service contracts with individuallyagreed service intervals for carefuland thorough maintenance andcalibration guarantee the correctand trouble-free operation of thetesting machines and systemssupplied. In case of a malfunction,a service engineer or technician is

quickly available at site. Differentresponse time agreementsguarantee the availability of atechnician within the shortestperiod of time possible.

Calibration serviceaccording to ISO 9001

The Zwick Roell maintenance andcalibration service is accredited asDKD1) and as a UKAS2) calibrationlaboratory. Thus, it is authorizedto check the testing machines andsystems at the place of installationand to issue DKD or UKAScalibration certificates for themeasured quantities of force,extension, energy and hardness.

These calibration certificates are notonly recognized within the EuropeanUnion, but also in almost everycountry of the world.

Particular advantage: Thetechnicians of the calibration servicecan, on the occasion of their servicevisit, not only service, adjust andcalibrate the Zwick Roell testingmachines and systems, but also

the machines and systems of othermanufacturers. This saves time andcosts. The regular maintenance andcalibration of testing machines arealso prerequisite for qualitymanagement systems according toQS-9000 and VDA 6.1.

Hotline – Quick assistancein case of malfunctions

For Zwick Roell, the perfectfunctioning of the testing machineis very important. Should, in spiteof the high quality standard, anymalfunctions occur on the machineor within the software, thencompetent specialists are availableon the hotline.

Modernizations

Testing machines are long-termcapital investments; their mechanicalcomponents are subject to lowwear and have therefore a longservice life. As a consequence,they have a high high ongoingvalue. When equipped with modernmeasurement and control electronicsand the corresponding software,these machines are updated tothe current state-of-the-art. Veryoften, this is more favourable inprice than the purchase of a newmachine.

Creation and adaptation oftest programs

With the test software of theZwick Roell Group many differenttest programs can be purchased.However, test requirements arenot always standardized. Expertswill adapt your existing testprograms individually or willcreate a new test programwhich is tailor-made to complywith your requirements.

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Seminars

Studies have shown that more thanhalf of the problems with technicalsystems are not caused by thetechnology itself, but rather by theuser. Good training of the userhelps to avoid problems and, as aresult, to reduce costs.

Zwick Roell seminars inform aboutthe theory and practice of materialsand components testing, theevaluation of the test data and testresults and the operation andmaintenance of the testing devices.

These seminars either take placeon the user's premises or at thelocations of Zwick Roell companiesor representatives.

Support line – Assistancefor operation andapplications

Alternatively to the visit to a seminaror to the service visit of a technicianto site, you can talk to our expertson the support line whenever youhave any questions. They will assist

you with the adaptation of the testsoftware, with the creation of testprogram, with questions regardingthe operation of the software orthe machine and they will give youapplication-specific support.

Spare parts

Standard components are mostlyavailable ex stock and will be sentto you by courier service it required.Special components, not beingcarried in stock, will bemanufactured "just in time" bymeans of the latest productiontechnology.

1) DKD = Deutscher Kalibrier-Dienst(German Calibration Service)

2) UKAS = United Kingdom AccreditationService

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Notes

testing machines and systems for automotive industry machines...testing machines and systems for...

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