With the continuous development of China's economic construction, a wide range of major projects have been implemented. Engineering tests play a crucial role in ensuring the quality and safety of these construction projects. The accuracy of test results directly depends on whether the testing equipment meets the required specifications. Among the essential tools used in various tests is the universal material testing machine, which is vital for reliable and consistent performance. This article provides a detailed guide on the installation and routine maintenance of such a machine in real-world applications.
1. Preparation Before Installation
The testing machine should be installed in a clean, dry, vibration-free environment with a controlled temperature ranging from 0°C to 35°C. The room must have enough space, at least 70 cm around the machine, to allow for both testing and regular maintenance. A hole should be dug at the installation site, larger than the base of the machine, with a width exceeding 50 cm and a depth of at least 30 cm. Concrete with a strength grade of not less than C20 should be poured into the pit, leaving holes for anchor screws and wiring for circuits and sensors. The concrete foundation should be leveled properly before proceeding.
The testing machine must be connected to a three-phase four-wire power supply. The power system should include an air switch and a leakage protection device. The wires should be placed more than 150 cm above the ground, and a manual electric switch should be installed to control the power of the testing machine.
2. Preliminary Correction of Installation Accuracy
To ensure the verticality of the machine’s column, use a frame level or a wire hammer from the accessories. Adjust by inserting small iron pieces under the base. Secure the anchor screws with spring washers. Pour high-strength cement mortar into the screw holes and fill the gaps between the machine and the floor. Water the area for over a week before tightening the screws.
3. Hydraulic System Connection
First, remove all bundles and clean the inside of the tubing with clean kerosene, especially the connecting threads. Check that the gaskets are intact; if damaged, replace them to prevent oil leakage under pressure. Use a suitable wrench to connect the tubing. For seamless copper tubing, connect it to the mainframe and adjust the console end accordingly. Drain any residual oil from the tank and remove any residue. Uncover the hydraulic control box to access the oil filter. Fill the tank through the filter using appropriate hydraulic oil—higher viscosity in summer and lower in winter. Always monitor the oil level during refueling to avoid underfilling or overfilling, which can cause operational issues or leaks.
4. Electrical Installation
The testing machine requires a three-phase 380V electrical connection between the main body and the hydraulic control box. Before powering on, open the control box door, check the wiring, and clean the interior. Once confirmed, press the “Power†button on the panel. The indicator light will show the power is on. Start the oil pump and verify the rotation direction matches the arrow indication. If not, swap two connections. Then, lift the clamp seat, remove the wooden block, and unscrew the oil valve to raise the piston. Check the piston stroke limit switch against the scale on the main column.
5. Testing Machine Debugging
Turn off the oil pump motor and unplug the MS plug on the oil pump. Drain air from the pump by letting out a small amount of oil, then reinsert the plug. Repeat this process by starting the oil pump to remove air from the cylinder and tubing. Move the beam without lifting it by pulling the cold-bending supports equidistantly. Install the spherical lower pressing plate on the platen and lift the moving beam so that the upper and lower plates are about 20 mm apart. Start the oil pump, close the oil return valve, and open the oil delivery valve to slowly raise the platen and increase pressure. Check all oil pipe joints for leaks. If any leakage is found, tighten the joint after unloading.
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