With the continuous development of China's economic construction, major projects have been implemented on a large scale. Engineering testing plays a crucial role in ensuring the quality of these construction projects. The accuracy of test results directly depends on whether the testing instruments meet the required specifications. Among these instruments, the universal material testing machine is an essential piece of equipment, and its reliability is vital to the testing process. This article will explain the installation and routine maintenance procedures for a universal material testing machine in practical applications.
1. Preparations Before Installation
(1) The testing machine should be installed in a clean, dry environment with no vibration and a temperature range between 0°C and 35°C. The room must have enough space, with at least 70 cm of clearance around the machine for both testing and maintenance purposes.
(2) A hole should be dug at the installation site. The size of the hole should be longer than the base of the testing machine and wider than 50 cm, with a depth of at least 30 cm.
(3) Pour concrete with a strength grade of not less than C20 into the pit.预留 holes for anchoring screws and piping for circuits and sensors during the pouring process. Ensure that the concrete foundation is level.
(4) Connect the testing machine to a three-phase four-wire power supply. The power supply should include an air switch and a leakage protection device. The wiring should be 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 Adjustment of Installation Accuracy
The main body of the testing machine should be adjusted using a frame level or a wire hammer from the accessories to ensure verticality in two perpendicular directions. Adjust by inserting small iron pieces under the base. Install anchor screws with spring washers. Fill the screw holes with high-strength cement mortar, seal the gap between the machine and the ground, water it for over a week, and then tighten the screws.
3. Hydraulic System Connection
(1) Remove all bundles and clean the inside of the tubing with clean kerosene, especially the connecting threads.
(2) Check that the gaskets at the joints are intact. If damaged during transportation, replace them with new ones to prevent oil leakage under high pressure.
(3) Use a suitable wrench to connect the tubing. For seamless copper tubing, connect it to the mainframe and adjust the spacing by moving the console.
(4) Drain any residual oil in the tank and remove the residue.
(5) Open the iron gate of the hydraulic control box to access the screen oil filter. Fill the fuel tank through the oil filter. In summer, use hydraulic oil with higher viscosity; in winter, use oil with lower viscosity.
(6) Pay close attention to the oil level when refueling. Too little oil may cause the machine to malfunction, while too much can lead to oil leakage from the working cylinder port.
4. Electrical Installation
The testing machine operates on a three-phase 380V power supply. Before powering on, open the hydraulic control box’s iron door and check the wiring, fuse condition, and clean any dust or debris. After confirming the connection, press the “Power†button on the control panel. The indicator light confirms the power is on. Start the oil pump and check the direction of rotation against the arrow. If it’s opposite, swap two connections. Then press the clamp seat lifting button, remove the wooden block on the platen, and loosen the oil supply valve to raise the piston. Check the piston stroke limit switch according to the scale on the main column.
5. Testing Machine Debugging
(1) Turn off the oil pump motor, unscrew the MS plug on the oil pump, drain the air (a small amount of oil will flow out), and then reinsert the plug after venting. Repeatedly start the oil pump to lift the piston and drain air from the cylinder and tubing.
(2) Pull the cold-bending support evenly on both sides without lifting the beam.
(3) Install the spherical lower pressing plate on the platen and lift the moving beam so that the upper and lower plates are separated by about 20 mm.
(4) Start the oil pump, close the oil return valve, open the oil delivery valve, and slowly increase the pressure.
(5) Check each oil pipe joint for oil leakage.
(6) If there is oil leakage, tighten the joint after unloading.
This comprehensive guide ensures that the universal material testing machine is properly installed, maintained, and operated, contributing to accurate and reliable engineering tests.
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