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| Specifications for the Model TO-15 |
| Tension/Compression/Torsion Testing Machine |
| (200 lb/1 kN Axial Capacity, 15 lb*in / 1700 N*mm Torque Capacity) |
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| Revised: May 9, 2000 |
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| Introduction |
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| The Model TO-15 is a computer controlled bench mounted testing machine for performing both rotational torsion and tension/compression testing. The test machine was originally designed for performing rotational torque rupture testing on fine diameter steel wire with the capability of maintaining a constant axial load on the wire as the rotations were applied. The Model TT-100 software was designed with this specific task in mind. The flexibility of the software control package also allows the machine to be used for a wide variety of applications in both quality control and Research and Development testing of other products and components. Additional software packages are also available for performing tension / compression, constant load creep, and low cyclic fatigue tests (ie. < 1 Hz.). Axial testing may be performed up to 200 lb (1 kN) with tension/compression rated load cells. The Model TO15B-x series biaxial type load cells used with the TO-15 are rated for 11 lb (50 N) maximum axial loads. |
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| The mechanical design of the TO-15 consists of an torsion output shaft protruding through the platen of the testing machine which is connected to the lower torsion loading grip. The drive motor is a DC servo electric motor with encoder feedback operating in a closed loop control mode for accurate speed control. The vertically adjustable axial loading platform is controlled by a second DC servo motor with encoder feedback. Figure 1 shows an overall view of the testing machine complete with a computer control system. The TO-15 requires an IBM PC type 486DX or Pentium computer system for control with an MS DOS 5.0 or higher, Windows95, or windows98 operating system. Views of the biaxial load cell and grips used on the TO- 15 for performing torque testing on wire are shown in Figures 2 and 3. Figure 2 shows a Model T015B-x type biaxial load cell mounted on the axial loading platform with the upper collet attached. The collet grips come complete with three different sizes of collets for gripping round wire in the range from 0.0 - 2.5 mm (0.000 - 0.098 in) diameter. Figure 3 shows a view of the lower collet grip which is mounted in the center of the rotary output shaft using a split type collar. |
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| Mechanical Specifications |
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| A summary of the mechanical specifications of the TO-15 given as follows: |
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| 1. Rotational Test Speed Range: |
| 0.05 - 100 RPM at 15 lb*in torque |
| (0.30 - 630 radls at 1,700 N*mm torque) |
| Axial Loading Range: |
| 0.002 - 2.000 in / min at 200 lb load |
| (0.05 - 50 mm / min at 1 kN load) |
| 0.020 - 20 in / min at 50 lb load |
| (0.50 - 500 mm 1 minute at 250 N load) |
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| 2. 30 in (76 cm) maximum specimen length. Other lengths available |
| on special order |
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| 3. Machine Stiffness: |
| 20,000 lb 1 in measured at 18 in height position |
| (3 kN / mm measured at 46 cm height position) |
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| 4. Loading mechanism consists of a mechanically speed reduced |
| output shaft protruding through the platen of the test machine |
| which is connected to the torsion loading collet grip. The axial |
| loading platform is positioned vertically along a rigid linear bearing |
| by a ball screw mechanically coupled to a driving motor. The load |
| cell is mounted on the lower surface of the axial loading platform. |
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| 5. The two drive motors are DC servo motors with rear shaft mounted |
| encoders. The encoders are used for output shaft angular position |
| and angular speed calculations for the rotary shaft and axial loading |
| platform position and linear speed calculations for axial loading. |
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| 6. Overall Dimensions of Test Machine Base: |
| 16 in wide x 18 in deep x 8 in height |
| (40.6 cm wide x 45.7 cm deep x 20.3 cm height) |
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| Overall Machine Height: 53.5 in (136 cm) |
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| 7. Weight/Mass of Test Machine: |
| Net: 120 lb (55 kg) |
| Gross Shipping: Approx. 200 lb (90 kg) |
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| 8. Power Supply Requirements: |
| 60 Hz Model: 110 - 120 VAC at 5 A, 1 phase |
| 50 Hz Model: 220 - 240 VAC at 2.5 A, 1 phase |
| Other power supply versions available upon request. |
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| Note: All Specifications and Dimensions are Subject to Modifications |
| without prior Notice |
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| Motor Control Syste Description |
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| The motor control system requires an IBM PC compatible type 486DX or Pentium system with a color VGA monitor, hard drive, 3.5" 1.44 MB high density floppy drive, minimum 1 MB RAM, a parallel port, and serial port. Two unused XT ISA type expansion slots on the mother board are required for the control and data acquisition boards. For report printouts, a Hewlett Packard Series 600 or 800 Deskjet printer (ie. Model 692C, 695C, 697C, 832C, etc.) or a Panasonic 24 pin dot matrix printer (ie. Model KX-P2023) is required. A 386DX IBM PC compatible type computer can also be used but data acquistion speed will be considerably reduced. The ATM software requires a Microsoft DOS Version 5.0 or higher, Windows95, or Windows98 as the operating system. The software packages run under DOS and should be run under the Real DOS mode if using Windows95 or Windows98. The software will not operate under WindowsNT or Windows2000. |
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| The motor control hardware consists of two additional XT type expansion boards, a motor control electronics system, and a combined DC and AC conditioners system. The two XT expansion boards consists of a 12 bits resolution combined A/D / D/A / I/0 board and a two channel servo motor controller board. The servo motor controller board uses the encoder feedback signals and software commands to derive the motor control command signals. The motor control system consists of two separate DC power supplies for powering the two drive motors and two DC motor servo amplifiers for amplification of the servo controller board command signals. Manual rotational control of the output torsion shaft and positioning of the axial loading platform is available by use of two toggle switches mounted on the base front panel. Figure 4 shows the front panel of the TO-15. The toggle switch labelled Up/Forward and Down/Reverse is used to move the loading platform Up or Down or to rotate the output shaft in either the Forward or Reverse direction. The second toggle switch is used for either Fast or Slow speed during the manual position movement. The speeds corresponding to Fast and Slow can be set independently for both the shaft speed and the axial speed. |
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| Two DC and two AC conditioners are built into the base of the TO-15. The DC conditioners can be used for excitation and amplification of the ATM line of load cells and extensometers. The AC conditioners can be used for amplification and demodulation of LVDT type devices supplied by ATM. Also, 15 turn potentiometers are accessible through the base right side panel for adjustment of the Gain and Input and Ouput offset adjust (ie. zero) for each conditioner output as shown in Figure 5. In addition, the DC conditioners have a push button Cal Chk switch for a quick check of correct transducer calibration. For the TO-15, DC conditioner 1 is used for the axial load signal and DC conditioner 2 for the torsion load signal. Provision is made on the base rear panel for monitoring the conditioner output signals through BNC type connectors. Figure 6 shows the input and output (BNC) connections to the DC and AC conditioners and the cable connections to the two computer boards (A/D and Servo connections). |
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| System Control Software |
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| The TT-100 software package is used for performing torsion/constant axial load testing on the TO-15. This software features a user friendly control environment to setup and control the TO-15. A DEMONSTRATION diskette is available which can be used to preview and test many of the software features. A brief description of the software is given as follows. The Main screen of the TT-100 software shown in Figure 7 presents the Operator with the current data set plotted on an X-Y graph. When the software is started, the data set plotted on the X-Y graph and the test parameters displayed are those which were current at the previous software shutdown. This data and test parameters are stored in the TESTBAK.000 file. The present maximum values of the current data set are displayed in the Present Data box located in the upper left hand corner of the screen. Below this box, the Limits Status Box will show if any axial load, torque loads, or other limits are being exceeded. The Current Test box shows test data such as the test speed, sampling rate, static axial load to be applied, and specimen type and dimensions. The design of the software package minimizes the keystrokes to perform changes to items such as the test speed, test display axes, etc. The lower right part of the screen displays the command descriptions of the function keys < F1 > to < F8 > and < Right > arrow keys. The Operator can make changes to the display screen with the < F7 > Change Setup key with minimum disruption of the background display. |
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| Up to 100 data sets can be stored at any given time in the directory which contains the software. The data file TESTS.NAM contains a listing of the data sets that are available for display. The individual test results are stored in a filename which is either manually entered by the Operator or automatically generated by the software. The resulting files are stored for future use by the software for performing data analysis or printing reports. The Operator may also erase stored test results from within the program. |
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| Performing of replicate tests is easily accomplished with a minimal number of commands. The < F2 > Zero Offsets command is used to remove an existing offset axial load or torque load represented by changes in the test grips or test setup. An Automatic Return at end of test feature may be selected which automatically or by Operator input returns the axial loading platform and rotary position to their positions at the start of the test. |
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| During a test, the results are displayed in Real-Time to the monitor on an X-Y plot. The current value of the individual point being displayed is also updated during the test in the Present Data box. The test is stopped at a preselected end point determined by such parameters as maximum time limit, rotations limit, after sample breakage, the % axial load drop, or by pressing the < Esc > key. The maximum torque load, rotations at maximum load, and time are displayed at the end of the test. At test completion, the Operator may also scroll through the individual data points using the < F5 > Trace Test Curve function with the < Left > and < Right > arrow keys, replot the data on a different set of axes or with different Engineering Units with the < F7 > key, and store the data under a different filename. Multiple data sets may also be displayed for comparison using the Load Data Sets < F12 > function key available in the < F8 > Data Functions key. |
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| For simplyfying multiple test setup requirements, up to 100 test setups may be stored and reloaded by use of the < F6 > Test Setups key. The available setups are stored in the SETUPS.NAM file. When a test setup is loaded, the displayed data set is reconfigured to the new test setup X and Y axes and Engineering Units. |
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| Other features of the software include capability of printing one page summary test reports on a Hewlett Packard 600 or 800 Series DeskJet printer (ie. Model 692C, 695C, 697C, 832C, etc.) or to a Panasonic 24 pin dot matrix printer (ie. Model KX-P2023). Figure 8 shows a sample test report. The Operator may change the axes scales of the graph and view the new plot on the monitor before printout. The test report contains information such as the material type, date and time of test, Operator identification, number of test points, applied axial load, maximum test torque, and a graph of the test results if required. |
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| Other software packages are currently available for performing such tests as tension/compression tests, creep tests, and low cycle (ie. < 1 Hz) fatigue cycling tests. In addition, existing software packages can be customized for unique testing requirements which can not be performed with the standard software packages. Please contact ATM if you have specific testing requirements which can not be accommodated by our standard software packages. |
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| Material Testing Grips |
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| The testing grips for torque testing on wire consist of two miniature collet type grips with 3 different collet sizes for the following ranges of wire diameters. |
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| Collet No. 161: Up to 0.030 " (0.75 mm) |
| 162: 0.030 - 0.059" (0.75 - 1.5 mm) |
| 163: 0.059 - 0.098" (1.5 - 2.5 mm) |
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| Also, an extensive line of material testing grips such as wedge loading and clevis grips, compression plates, 3 point and 4 point bending fixtures, and others can be provided for use on the TO-15 for performing axial loading type tests. |
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| Optional Features and Accessories |
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| A number of optional features and accessories are also available for the TO-15. Some of the currently available options and accessories are the following: |
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| a) Dust Enclosure for Ball Screw and Linear Track |
| (Part No. TO15.DEBS) |
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| This package consists of modifying the TO-15 to include a sliding enclosure on the front of the loading column and a full height panel enclosure on the rear of the loading column. The design minimizes exposure of the ball screw and linear bearing track to dust contamination. This option is recommended if the machine is to be used in a factory environment where there is a high level of metallic or nonmetallic dust in the air. |
| Note: This is a factory modification because of the extensive |
| changes required for mounting the dust enclosure components. |
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| b) Biaxial Load Cells (Torque/Tension/Compression) |
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| The recommended torque load cells for the TO-15 are the ATM model TO15B-x type. These are currently available in 3 torque capacities. The axial load capacity is 50 N (11 lb) for all three types. |
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| 15 lb*in (1675 N*mm) Capacity - Part No. TO15B-15 |
| 10 lb*in (1100 N*mm) Capacity - Part No. TO15B-10 |
| 5 lb*in (550 N*mm) Capacity - Part No. TO15B-5 |
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| c) Clear Enclosure around Wire Sample |
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| The clear enclosure consists of sections of split acrylic tubing 4" (10 cm) outside diameter and 3/16" (4.8 mm) wall thickness which are hinged along their lengths. They are available in different lengths and may be stacked together to form longer enclosures. One of the base units must be ordered as part of a set. |
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| i) Base Protective Clear Enclosure (Part No. TO15.BENC) |
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| Figure 9 shows a view of the base enclosure mounted on the TO-15. The |
| opening at the top allows some adjustment for the wire length to be tested. |
| The base unit includes the end mount which bolts to the top surface of the |
| base of the TO-15. Overall length is 10.2" (26 cm). |
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| ii) Additional Lengths of Hinged Protective Enclosure |
| 4" (10 cm) length - Part No. TO15.IOENC |
| 8" (20 cm) length - Part No. TO15.20ENC |
| 12" (30 cm) length - Part No. TO15.30ENC |
| Figure 10 shows the three additional lengths available which may be stacked |
| on top of the base unit for testing longer lengths of wire or other type of test |
| specimen. The individual lengths of protective enclosures may also be |
| stacked on top of each other for very long wire length testing. |
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| d) Torque Calibration System (Part No. TO15.TCS) |
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| Figure 11 shows the main component of the torque calibration system mounted on the upright tower of the TO-15. The base of the load cell is mounted against the upright tower and the torque calibration arm is mounted on the load cell in place of the upper collet grip assembly. The system contains all the necessary equipment for performing calibration of the torque load cell. The TT-100 software includes a function to create a new calibration file when used with the torque calibration system. Included with the torque calibration system are the following components: |
| i) Torque Calibration Arm |
| The torque calibration arm attaches to the end of the torque load cell. It |
| contains machined slots at 1 cm steps from the centerline of the load cell |
| for locating the torque calibration masses. |
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| ii) Torque Calibration Masses (ASTM Class 1 masses) |
| Consist of 1 each of the following sizes: |
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| weight (g) Class 1 mass tolerance (mg) |
| 1000 2.5 |
| 500 1.2 |
| 300 0.75 |
| 100 0.25 |
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| Combinations of these masses will give sufficient capacity increments to |
| calibrate the available torque load cells between 5 lb*in (550 N*mm) to |
| 15 lb*in (1675 N*mm) capacity. |
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| iii) Digital inclinometer |
| Digital level for aligning torque calibration arm accurately to the horizontal. |
| Digital level reads in degrees to +/- 0.1. |
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| e) Axial Load Calibration Post (Part No. TO15.AXCAL) |
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| Figure 12 shows the axial load calibration post. The post mounts on the lower surface of the Model TO15B-x types of load cell. The calibration post has a machined V groove to locate the center of the load cell to apply string on which calibration weights can be attached. Calibration weights are not included. |
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| f) Axial Load Calibration Weights |
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| Weights are of solid stainless steel design and are manufactured and calibrated to Class 4 of ASTM E617-91 Standard Specification for Laboratory Weights and Precision Mass Standards. They have a highly buffed satin-finished surface and come complete with a case. |
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| i) 5 kg - Part No. 13282 |
| ii) 3 kg - Part No. 13278 |
| iii) 2 kg - Part No. 13276 |
| iv) 1 kg - Part No. 13295 |
| v) 500 g - Part No. 13274 |
| vi) 200 g - Part No. 13272 |
| vii) 100 g - Part No. 13270 |
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| g) Additional Collet Package Set for Gripping wire (Part No. TO15.CSET) |
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| This package includes the pin type collet grip and three interchangeable collets for different filament diameters. One set is required for each end of wire. |
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| h) High Temperature Test Furnaces and Environmental Chambers |
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| ATM can supply two different lines of split tubular or box type testing furnaces in a range of temperatures up to 1200 F and a very high temperature line for materials testing up to a maximum temperature capability of 2800 F. These models mount on swing arms which attach directly to upright posts on the ATM line of load frames. When not in use, the swing arms permit the furnace to be moved completely out of the way of the load train. Lower temperature environmental chambers with temperature and/or humidity control are also available. These chambers are of mainly stainless steel construction and are designed with the same accessibility as the test furnaces. They are also designed for mounting on the ATM load frames by use of swivel arms. |
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| i) Extensometers |
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| ATM can provide linear, diametral, biaxial, and elevated extensometry equipment for most applications. Please contact ATM with your requirements. |
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| j) Other Electronics and Mechanical Adapters Available |
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| The ATM line of DC and AC conditioners may also be supplied in rack mounted versions for excitation and amplification of multiple source input signals. Other manufacturer's load cells and extensometers may also be adapted for use with ATM equipment. Please contact ATM for more details. |
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