As the core equipment for testing the mechanical properties of materials, the debugging quality of the dynamic and static universal testing machine directly affects the accuracy of test data and the service life of the equipment. The standardized debugging process is explained from four dimensions: mechanical calibration, electrical joint debugging, software adaptation, and safety verification

1、 Precision calibration of mechanical systems

Space neutral adjustment

After installing the extensometer, monitor the coaxiality of the upper and lower fixtures through a micrometer, and the error should be controlled within ≤ 0.5mm;

Adjust the clearance of the screw pair to the minimum state, and manually rotate the wheel to feel smooth and free of jamming, eliminating the no-load friction torque.

Optimization of Load Transfer Chain

Install the bolt torque of the pre tightening force sensor to the specified value (refer to the manual) to prevent loosening after being subjected to force;

Use standard weights for static calibration, load in stages (recommended at 10%, 30%, 70%, 100% of full scale), and record the indication error to be ≤± 0.5%.

Verification of actuator positioning accuracy

Using a grating ruler to calibrate the displacement measurement system, take any 5 detection points within the full stroke range, and the deviation between the actual displacement and the displayed value is ≤± 0.02mm;

Observe whether there is any crawling phenomenon of the hydraulic cylinder piston rod during low-speed operation, which can be solved by adjusting the dead zone of the servo valve.

2、 Joint debugging of electrical control system

Signal link integrity testing

Before powering on the controller, use a multimeter to gradually check the output voltage of the power module (such as ± 15V,+24V) to ensure stable power supply to each circuit board;

Connect the computer and controller, send step signals through specialized debugging software, observe the response curve of the servo motor, and ensure that the overshoot is less than 3%.

Closed loop control parameter tuning

The initial setting of PID parameters adopts the critical proportional method: gradually increase the proportional gain until the system oscillates, and take 60% of this value as the basic parameter;

Adjust the integration time constant based on the stiffness characteristics of the sample. Flexible materials need to shorten the integration period to improve response speed.

Channel synchronization correction

When working with multiple channels, the main control channel is used as the reference, and the delay time of other channels is compensated by a pulse triggered counter, with a synchronization error of ≤ 1ms.

3、 Deep adaptation of software functions

Template based configuration of experimental plan

Import the national/industry standard test method library and set key parameter thresholds (such as fracture determination conditions and yield strength calculation intervals);

Custom data collection frequency, brittle materials should be set at 1kHz or above, and plastic deformation stage can be reduced to 100Hz.

Logical reliability verification should be conducted

Simulate emergency stop button triggering, check if the crossbeam brakes immediately and maintains its current position;

Artificially creating overload conditions to verify whether the circuit breaker can cut off the power supply within 0.1 seconds.

Automated testing for report generation

Complete the standard test procedure once and verify whether the report includes the original data curve, characteristic value annotation, and compliance conclusion.

4、 Security protection system verification

Physical protection effectiveness check

Confirm the sensitivity of the infrared sensing device of the protective cover. If any area is blocked, the machine should be stopped immediately;

Verify the limit switch of the limit stroke, and the motor must be powered off when the set displacement range is exceeded.

Noise and leakage detection

The operating noise measured at a distance of 1 meter from the equipment is ≤ 75dB (A), and abnormal noise indicates the presence of air in the hydraulic system;

Apply soapy water to the oil pipe joint and tighten it promptly if bubbles are found to eliminate the risk of high-pressure leakage.