Concrete Railway Sleepers And Bearers Static Testing Machine

Concrete Railway Sleepers and Bearers Static Testing Machine, has been designed basically to perform static tests according to EN 13230-2, EN 13230-3 and EN 13230-4 (Prestressed monoblock and twin-block reinforced sleepers and bearers tests) and also low vibrating track system (LVT-System) tests.

The machine consists of a testing frame with accessories and Advanced servo controlled hydraulic power pack, control electronics and a data acquisition system are also build in power pack unit. Main differences between static and dynamic test systems are the loading actuator and power pack.

The Testmak C5600 capacity of the frame is 600 kN. Load cell is used for load measurements to have better accuracy. The frames is supplied complete with test sample carrying and holding apparatus for easy test setup, upper and lower Articulated supports for static tests. Moreover this system may perform three and four point flexure test on concrete beams.

The load frame is a four column design carrying the piston fitted to the upper crosshead. The frames has a double acting stroking piston with over travel switch pro­tection to shut the machine down when maximum piston travel is reached. A 600 kN Capacity load cell is used for load measurements on the frame.

The maximum oil flow is 2 liters per minute, at 300 bar pressure. Accuracy of the system is 0.1 kN and minimum controllable load is around 10kN. Control unit can be connected to the computer through USB for advanced test cycles, data acquisition and reporting. All the calibration values of the transducers and also all the test parameters for the last test is automatically stored on the control unit. Power pack incorporates a pressure safety valve and a cooling unit.

Characteristics:
• High stability four column design
• 400 mm piston stroke with safety limit switch
• High accuracy load measurement with strain gauge load cells
• Can accept wide range of accessories for mentioned standards
• The distance between lower rollers can be set up to 2000 mm
• Can be connected to any TESTMAK compression machine or TESTMAK power pack
Automatic Power Packs with Proportional Valve, are advanced power packs with P.I.D. closed loop control. They can perform tests under load and displacement controls. The frequency of the P.I.D controller and data acquisition is 1000 Hz. Power pack is designed to supply the required oil to the load frame for loading and unloading. All the operations of Data Acquisition and Controls System can be controlled from the touch screen front panel of a 800x48 pixel LCD display or computer. There are total 4 analogue input channels. One is used for load cell and remaining three analogue channels can be used for other sensors such as LVDT’s, strain gauges, built in the system.

LCD DATA ACQUISITION & PC SOFTWARE
CONCRETE RAILWAY SLEEPERS & BEARERS STATIC TESTING MACHINE can be controlled by a computer with the software (given free of charge by TESTMAK). The advanced functions for data base management provide an easy navigation of all saved data. The test results certificate includes all descriptive information. Therefore, test parameters can be set and details about the test carried out such as client details, test type, specimen type, user info and other information required can be entered and printed out as well as test report and graph.
The software is developed for making test respect to EN 13230 standard. On the software there are submodules for making test on LVT samples, positive negative bending tests on sleepers. Loading rates, dwell times, delays and unloading are performed as in standard.
The software also includes an easy calibration check facility. The machine gives some constant load values and waits there for easy check mechanism. As standard requires the pace rate of 2kN/sec is suggested, but user can modify the test rate. For each type of different tests an easy report generation is available.

Features for Data Acquisition Control
• 3 universal analog input sockets (ADC)
• Each analog input with 18 bit precision (1/256000)
• 1 replacement analog input
• A total of 4 analog high-precision measuring capacities
• 2 analog output sockets (DAC)
• Analog outputs generate a 0-10V DC output signal
• Motor speed control devices, servo valves with this output signal, proportional valves, etc. reference signal is produced.
• PULSE / DIR outputs (PULSE / DIR / ENA) to control the servo and stepper motor drives
• 5 digital outputs for general purpose (can pull relays and control different electrical units)
• 5 digital inputs for general purpose (receives and evaluates input signals like limit contacts from the environment)
• Potentiometer input (reference signal input for calibration and remote control)
• 2 RS232 serial communication signal outputs (communicates with computers)
• It also connects to motor drives via serial communication via MODBUS connection
• USB communication signal output (communicates with computers)
• Connects to local networks and the Internet with Ethernet 10/100 network connection output (optional)
• Connects to portable devices via Bluetooth wireless connection (optional)
• 500 test results can be stored in internal memory
• Due to the SD (memory) card connection, a large number of test results can be stored in the device memory (40,000 test results).
• In addition, the results can be taken from the device memory and transferred to the computer as an Excel table. (Optional)
• Color TFT display supports 16M colors and supports 800x480 pixel screen resolution
• Resistive touch screen allows easy operation of device functions by touching the screen
• Access to frequently used functions with 6 membrane keypads
• The industrial standard operates with 24V DC supply voltage. Built-in voltage filter and regulator protects against input signal fluctuations
• Sensor modules are compatible with loadcell (load cell), pressure sensor (4-20 / 0-20 mA), potentiometric distance sensors, strain washers, thermocouples and all kinds of mV output sensors.
• Provides precise calibration with multi-point calibration (up to 10 points)
• Setting and calibration menus are password protected and prevent unauthorized use
• Allows testing with a computer or device
• There are many test sample information screens and test methods in the device memory and tests can be performed easily
• Different menu languages can be selected via the device via language support
• Speed control algorithm is closed loop PID control and all parameters can be adjusted on user side.
• The device can switch between one-touch load and deformation control modes
• The graphical field that visualizes the test results on the screen has the ability to change the scale automatically and automatically adjusts the optimal scale as the values change
• Firmware updates can be made via USB input. In addition, via the computer allows remote or internet update.

SOFTWARE
The software is developed for making test respect to EN 13230 standard. On the software there are submodules for making test on LVT samples, positive negative bending tests on sleepers. Loading rates, dwell times, delays and unloading are performed as in standard.
The software also includes an easy calibration check facility. The machine gives some constant load values and waits there for easy check mechanism. As standard requires the pace rate of 2kN/sec is suggested, but user can modify the test rate. For each type of different tests an easy report generation is available.