Application Note Successful modernization of Materials Testing Machines Initial situation and technical specifications can no longer be maintained because there are no spare parts for it. A materials testing machine is made up of many different technologies: mechanical engineering, precision engineering, electrical engineering (electro-mechanics / mechatronics, power electronics, measurement and control electronics, optoelectronics), informatics (hardware and software) and fluid mechanics (hydraulics, pneumatics). The mechanical components, such as the load frame for example, age very slowly and can be used for several decades. By contrast, electrical, electronic and informatics components can quickly become obsolete due to the rapid rate of development in these areas of technology. Modernizing, also known as retrofitting, an old testing machine can give you the performance of a modern testing machine at a fraction of the cost of a new one. However, each machine component ages differently depending on its function. This aging process can be due to material fatigue, wear or various environmental influences or the technology can simply become out-ofdate or obsolete. This can cause problems if, for example, a component no longer conforms to the stateof-the-art, no longer works with newer components or Existing sensors (load cell, extensometer, …) can be adapted with retrofit kits When a machine component needs updating or renewing, it is important that it is not replaced in isolation, but that all components that interact with it are also checked. All testing machine components work together and, if a machine is to be modernized, it is important to consider the whole picture. For example, when updating the electronics, it is very important to also consider the drive unit. Modernizing the electronics in isolation may be cheaper in the short term, but when lthe drive needs modernizing later you may find the electronics need updating again, or even replacing, resulting in higher costs overall. testControl measurement and control electronics Testing Software testXpert®, incl. software training EAI 00308 New AC drive Page 1 of 8

Application Note Successful modernization of Materials Testing Machines Why choose Zwick to carry out a modernization? When modernizing your testing machine, it is important to choose a reliable and competent partner. The Zwick Roell Group has more than 150 years of experience in manufacturing testing machines and a proven history of service, maintenance, repair and spare parts supply on a global basis through its international support network. Zwick has already modernized thousands of testing machines and based on this experience has built many kits to fit legacy Zwick products and many non...

Application Note Successful modernization of Materials Testing Machines Points to consider when modernizing your testing machine Zwick’s engineers have many years of experience regarding the different components that make up a materials testing machine and how these components age. This gives them a unique understanding of the machine as a whole and how the different components age differently and interact with each other. The modernization team knows exactly what to consider and what to do in each case. Using the corresponding modernization package, adapted to the different machine types, electromechanical,...

Application Note Successful modernization of Materials Testing Machines The testing machine drive unit Most modern testing machine drives operating above a certain load capacity use AC motors instead of DC motors. When modernizing a testing machine it is important to consider replacing older DC motors with AC motors because they offer several advantages: · Despite approximately half the weight (and thus also size), nominal power and torque are more than twice as great. Simply put, the ratio between motor weight and power is 1 (AC) to 4 (DC) which means that a DC motor of same power is four times...

Application Note Successful modernization of Materials Testing Machines Reduction drives or gearboxes between motor and lead screw drive AC motors are extremely powerful and relatively small. Using digital position control their torque and speed range is so high that the maximum test load of the load frame can be achieved over the entire speed range and with enough spare for accelerating and braking. Only one reduction drive, usually in the form of a toothed belt drive, is needed which removes the need for multi-stage or manually operated gearboxes. If a target position is to be driven to, then...

Application Note Successful modernization of Materials Testing Machines As well as testing material properties Zwick machines are also being used with increasing frequency for functional tests, as they not only generate loads/forces and travels, but can also measure these very accurately and can control them independently. One example is the pressing of bushes or pins into interference holes. Positions must be very accurately and reproducibly driven to whilst the press-in force measured and evaluated as a function of the press-in depth. This is only possible with a position-controlled drive....

Application Note Successful modernization of Materials Testing Machines Extensometry Most existing extensometers can continue to be employed after retrofitting of new connectors. However, a major benefit to users is that modern high resolution digital or non-contact devices offer advantages in accuracy, higher resolution, or longer measuring range. Operator influence is significantly reduced as these devices are normally equipped with mechanical drive units which save testing time and improve accuracy and reproducibility of test results by allowing part or full automation. Zwick offers the widest...

Application Note Successful modernization of Materials Testing Machines Testing software Summary Zwick’s unique testXpert® testing software has been sold more than 15,000 times and is currently available in 9 different languages Zwick offers customers a complete service from consultation and advice regarding the modernization possibilities for their existing electro-mechanical testing systems. Standardized modernization kits to suit most major brands are supplied, and engineering expertise to carry out and support projects anywhere in the world is offered. After systems have been fully modernized,...