materials testing - dcu · zimt (zwick interpreter for materials testing) is a problem orientated...

~ZwickMaterials testing

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09.03/ KAlnhalt / V4.7

Copyright (C) 1995-2002 Zwick GmbH & CoAugust-Nagel-StraBe 11, ~ Ulm, DeutschlandTelefon: +49 ~ 1 02 25Telefax: +49 ~ 1 02 00Zwick im Internet: http://wIIIN.zwick.com und http://www.zwick.deEMail: [email protected]

~List of contents

testXpert

List of contents

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testXpert ..............................testXpert install ."...,.....RS devices, install .......testXpert deinstall ........testXpert Program helptestXpert Philosophy....Configuration level.......Machine .......................Run a test ....................

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Manual calibration ,

Your safety ,

Hardware requirements ,

Software requirements ..........................Cabling the materials testing machine...Sensor plug ..........................................Test program ........................................Test program KalOOO ............................Control of the materials testing machine

Index 59

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09.03/ KAlnhalt / V4.7 Zwick technical documentation

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Videos

tes~rt

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About this section

This section introduces you to the testXpert basics.We'll show you how to quickly find the described topics in testXpert. Therespective menu call-ups are contained in the margins. These areindicated with the? symbol.

We assume that you are acquainted with operation of Windows

programs.

Rights for your PC

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12.03/ tXlnstal/ V4. 7 b Zwick technical documentation

~crInstallation

testXpert

RS devices, install

You'll be asked about installation of RS devices during installation oftestXpert. The procedure at installation is described here.

You can remove installed RS devices at any time, or install new ones intestXpert. The RS device installation program must be called-up via theWindows "Start menu":

1. Select Start menu "Program" in the Windows "Start menu"

2. Select "Zwick applications" here

3. Call-up the command "Periphery setting'

All installed peripheral devices are listed in the shown list. This list isblank at the first installation."Editing" as well as ,Adding-on" new RS devices are almost the same

sequences.

The difference?- Settings are already preset for "Edit"- They must first be selected for "Add-on'However the dialogues both look alike.

Once the corresponding button has been activated you'll be asked aboutthe type of RS device. For example, the interface and/or channel arerequested depending upon the type of RS device.

Example of an RS device not in the list.Select the type "Free RS device" under "Specimen measurementdevice", Give this RS device an explicit name.The configuration for this RS device is made later on in testXpert in themenu "Machine" via the button "Configure". The data to be entered therecan be taken from the description of your RS device. Further informationis made available by the testXpert online help.

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~Program helptestXpert

testXpert Program help

testXpert offers a help system. The testXpert help system iscompatible with the Windows help system. This enables you to outputall required help information to a printer.""

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The help system in testXpert is called-up in testXpert via

Selection of the menu "Help" in the uppermost menu bar.You can select and call the corresponding commands in the openedsub-menu "Help".

The <Help> button in the active dialogue.A help message relating to the possibilities and operation of thisdialogue is obtained following activation of this button.

The <F1> function key on the PC keyboard.Help can always be called-up in testXpert. This then refers toexactly that test task which can be seen on screen. If the cursor isat a parameter's input field, you'll obtain help on that parameter bypressing function key <F1>.

The "Help icon" in the toolbar.This symbol isn't available all of the time in testXpert. The helpindex appears by calling up the help via this "Help icon".

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Activate the button <Print> in the help window to obtain the "Print"dialogue. You can make all necessary printer settings here asdescribed under index help in Windows, and you can also startprinting.

01.03/ tX_BEIe / V4.5

Screen elementstestXpert

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--Operating elements in the softwareThe most important operating elements that are required for operatingthe test programs are listed here.

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Display

I,Control box

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You can adapt the user interface to your requirements

Text, adaptYou can adapt text via the command "Desktop" in the menu "Options'Here you can set the font size, the desktop layout, keyboardoperation, selection dialogues, toolbar, etc.

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01.03/ tX_BEIe / V4.5

Menu "Options",command .Desktop.

~Philosophy oftestXpert

We'll introduce you to the testXpert philosophy now that know how tocall-up the testXpert help, the videos and the most important testXpertscreen elements.

testXpert Philosophy

testXpert knows user levels with different access rights

Test level,without menu access (Tester without configuration possibilities), orwith limited menu access (Tester with limited configurationpossibilities).

Configuration level(Administrator with all configuration possibilities)

This description is designed to get you acquainted with thepossibilities of the configuration level.The administrator prepares Administrator) the system and the pro.gram for a test at this level.Here you can edit the existing user levels or you can create newones. You can define different access rights for these user levels.

Testing takes place with test programs within testXpert. YOu canonly utilise the complete scope of function of the standard or mastertest programs in the configuration level.

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01.03/ tX_Phil/ V4.5

~Philosophy oftestXpert

About the test sequenceThis help contains the sequence program. The description of the testsequence in all test phases is contained here.All results, formulae used, recording and evaluation channels, andparameters are also described. All of this information can be seen onscreen, or it can be output to a printer.

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Test standard databaseYou can use this database to select existing test programs.Whereby you can make your selections using different selectioncriteria. All test programs found and there descriptions are shown.These test programs correspond to the test standards listed here.Master test programs are independent of test standards, thus theywon't be shown here.

Menu "Help",command "Test

standard database"

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After the testXpert philosophy we'll now start with the possible inputsin the configuration level.

01.03/tX_Phil/V4.5 Zwick technical documentation

r.Menu "Help",

Command "About thetest sequence..."

~Configuration leveltestXpert

ParametersAre changeable quantities that describe the properties of a test pro-gram. There are parameters for, dor example, specimen dimensionsgauge lengths, test speeds, all required quantities, etc.

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Menu "Configuration",command

"Parameters..."

Parameters are offered in a parameter list under menu"Configuration", command "Parameter...". Here parameters can bepreset, edited, prepared for reports, etc.A test program tailor-made for a certain test problem can be created ina master test program via these parameter properties.You can compile these test relevant parameters in dialogues.

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Menu "Configuration"command

"Dialogues..."

DialoguesThe dialogues present you with the possibility of giving testXpert itsown appearance.Creation and management of dialogues takes place in the menu"Configuration", command "Dialogues...". You can determine thecontents of existing or new dialogues there.You can make created dialogues available to the user at the materialstesting machine.

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Menu "Configuration",command "Menu

Inputs"

MenuYou can compile dialogues for the menu "Inputs". Sub-menus are alsopermitted here.This menu structure is created and edited under menu "Configuration",command "Menu, inputs".

Now that we're able to make preselections you "probably" want to beable to record results.

01.03/ tX_Phil/ V4.5 Zwick technical documentation

Configuration leveltestXpert

System scripts- Contain a sequence of instructions and/or ZIMT commands- Can assign values or text information to parameters- Can run actions or functionsthat are not contained in testXpert- Can be run

- before saving- after a test program has been loaded- before printing a report- before start of test- after the test- at the end of a series- always when an event occurs

Scripts are input in the ZIMT syntax.ZIMT (Zwick Interpreter for Materials Testing) is a problem orientatedinterpreter language. You can solve individual tasks in the testprograms with the help of ZIMT. This language is being continuouslyexpanded so that exact and detailed information can only be via thetestXpert help system.

The dialogue for creating scripts is called-up via menu "Configuration",command "System scripts...". The accelerator <ALT>+<F2> offers helpfor inputs. It calls-up a selection dialogue with all existing parametersand actions. Further help can be called-up via the accelerator<AL T>+<F3>. This enables the input to be shown in plain language.

Menu "Configuration'command "System

scripts..."

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ExampleA message should appear on screen if a measured result (Fmax) isundershot.Select the setting "After evaluation" from selection field "System script'in the dialogue "System scripts". Write the following text in the inputfield "Script". Please note that all results are used in the basic units(Here result 36875 in "N").

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II~0i If Result(36875) < 4500

infobox ("Inform the responsible person immediately'Endif

Message if thecondition is undershot

01.031 tX. Phil 1 V4.5

~Dialogue 'Verification'testXpert

Machine

The following description refers to Zwick materials testing machines.testXpert automatically detects the line of materials testing machines.When loading the driver software, testXpert receives all of thematerials testing machine's data and that of the installed electronicallycontrollable tools (e.g. Vernier gauge). Owing to specimendimensions, mechanical tools and special arrangements. testXpertcannot detect the drive position. Thus you must provide testXpert withthis information in the dialogue +Verification+ each time the workplace is changed.

VerificationInform testXpert of the missing machine quantities in the dialogue"Verification" of menu "Machine". You can influence all machinecomponents and important machine limits here.These are, amongst others,- The test area,- The traveVposition limits of the materials testing machine and, if

one exists, the extensometer- The force limits of all connected load cells- The load limits of a safety device- The control of an extensometer- The control behaviour (Force/position/strain control)

The force and position limits are software limits. The mechanicallyadjustable limits are not altered via the verification dialogue~

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There are interchangeable hardware parts in addition to the machinecomponents. The information for these hardware parts are compiled indevice modules

01.03/ tX_Einr / V4.5 '2

r.Menu "Machine'

command"Verification...-

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Dialogue "Verification"testXpert

Verification dialogue

Device modules

Dialogue "Verification dialogue",

The active links are visible in the dialogue 'Verification dialogue",

Double click on "Crosshead SN:" to obtain the dialogue" OptionCrosshead travel monitor".

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JDialogue "Optional crosshead travel monitor".

Zwick technical documentation01.03/ tX_Einr / V4.5 ?~


The extensometer can also be setup via the 'Verification dialogue"

Dialogue "Verification dialogue".

The dialogue "Option Longstroke" appears by double clicking at"Longstroke SN".

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Dialogue 'Optionallongstroke extensometer"

You can control the automatic extensometer here, e.g. clamp,unclamp, or you can set LO.

01.03/ tX_Einr / V4.5

~TesttestXpert

Run a test

testXpert, startRequirement for operating a materials testing machine with testXpert:- The PC must be switched on and testXpert must be installed- The materials testing machine must be connected to the PC and

must also be switched on (Standard; COM1)11r..

"Start menu"Programs",

"Zwick applications"and here

"testXpert Machine"

- Select topic "Start" in the Windows "Start menu"- Now select "Programs"- Select "Zwick applications"- Call "testXpert Machine" with a double clickThe program is loaded. The frontispiece appears. All required driversare installed simultaneously.testXpert informs you that it's ready for testing following initialisation.

testXpert CloseYou can close testXpert with the command "Close testXpert" in themenu "File" ".You'll be asked by testXpert if you want to save it if you've run a test. Ifyes, the dialogue "Test program or series, save". testXpert is closedfollowing saving.

Tester logontestXpert can be protected against non-authorised usage(Userprotection). The settings for this are made by your systemadministrator.

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User protection setup:A window with the input fields for the following appears after thefrontispiece- Your name, known here as "User 10" and- Your "Password"Enter both and then activate the <OK> button. The window with thepossibility of selection of test programs appears if the input wascorrect.

User protection not setup:The window with the possibility of selection of test programsappears following the frontispiece.

01.03/tX_Prue /V4.5 Zwick technical documentation '7

..Menu "File-,

command "ClosetestXperf'

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TesttestXpert

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Initial position (LE)The initial position can be set via:

- The corresponding icon in the toolbaror- Via the command 'LE approach".

This command is to be found under the menu "Machine"Menu -Machine-,

command "LEApproach-

Tensile

Specimen

Specimen, insertInsert the specimen. This means that

the specimen will be gripped at a tensile test in that specimen gripthat is mounted on the load cell.

The specimen is placed centrally on the respective supports for acompression or flexure test.

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Specimen data, inputThe input window is setup dependent upon the test program. Theactive window is the one with the blue boundary. Not only that, but ablinking cursor can be seen in the first input field.

Now enter the required information

You can automatically enter the current values if you have anelectronic specimen measurement device connected to your PC bypressing the action buton (It's displayed in front of the input field.

01.03/ tX_prue / V4.5

~TesttestXpert

Sequence of a test:Start the test, pre-load is approached.

When using additional extensometers the materials testing machinehalts.Automatic clamping extensometers are clamped.A message is generated for manually clamping extenso meters that

requests you to clamp the extensometer on the specimen andthen to acknowledge this to testXpert.

The materials testing machine starts in the test.All test data is recorded and used for evaluation

The materials testing machine drives until the end of test.The end of test can be triggered via- Specimen break (Tensile, flexure tests)- A preselected force or travel limit (tensile, compression or flexure

tests) being reached- etc.

The materials testing machine halts

&Remove the specimen remainsThe materials testing machine can automatically return to the initialposition (LE) for uncritical specimen (remains). Otherwise thespecimen remains must be disposed of before the machine can driveback to the initial position (LE).Dispose of specimen

remains

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You can enter the specimen data for the next test after setting theinitial position (LE).The sequence repeats itself as already described.

01.03/ tX_Prue / V4.5 Zwick technical documentation

TesttestXpert

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Specimen list Specimen managementYou can make each recorded test to the current specimen. For thispurpose click on the required specimen in the "Specimen list", Theselected specimen will be optically highlighted in the "Results table",

In the menu "Specimen management", the selected specimen can be- Eliminated via the command "Invalidate". This specimen is marked

in the results list as being invalid. Although it's still opticallyavailable, it won't be used any more in the statistics.

- (Invalid specimen) accept it to the statistics again. For this purposeuse the command 'Validate"

- Delete it from the specimen list and the statistics. The specimen isnow irrevocably lost. The command is "Delete. The numbering inthe specimen list isn't automatically refreshed. Thus you can see ifand which specimen has been deleted.

- You can run a new specimen numbering through for the test seriessubsequently. For this purpose use the command "Specimen,number through".

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~,iI 3~ 4)'"--cLSelected current

specimen

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Menu .Specimenmanagement.,commands:.Invalidate.,"Validate",.Delete. ,

.Specimen, numberthrough.

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Manual calibration

This section contains information that is required for monitoring and/ormanual calibration of your load cell and extensometer.

Your safety

Pay attention to the safety remarks in section 1 "Safety remarks".The manual calibration may only be used if all safety relevantrequirements are adhered to..

Pay especial attention to:

IIDanger of irreparable damage!

Your reference sensor could become irreparably damagedas the test program doesn't monitor the reference sensor.

Check your calibration or test configuration very carefully.

Please bear in mind:- the materials testing machine's control takes place via

the inbuilt sensor that is to be checked- the test machine must be switched oft before

plugging-in or unplugging sensor plugs.I

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User group

Manual calibration is foreseen for the test personnel from test institutes,taking into account all safety relevant aspects.

01.03/ KA_Mask / V4.5 Zwick technical documentation

~PreparationtestControl

Cabling the materials testing machine

You can see here what you must check before beginning with manualcalibration. You'll see where you have t%r may plug-in your sensor plug

We don't make any indications on the complete wiring of your materialstesting machine. This information is to be found in the correspondingsections before this description.

Different test data recording modules can be used in testControl. Thesemodules are slotted into testControl slots. Whereby the exact location ofthe individual modules cannot be indicated. Forthis reason eachcalibration wiring is assigned to a display of the required test datarecording module. The free slots are at the rear of the testControlelectronics console.

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TC MODCSCC Module

An eventually existingremote control unit~

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Example:A TC-MODCSCC module for connection of a load cell

Plug-connections forthe following are shown on the following pages

load cell calibration

incremental extension calibration

analogue extension calibration

01.03/ KA_Verk /V4.5

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,,' ~"PreparationtestControl

Incremental extension calibration

You must have the following plugged intotestControl:

Load cell in TC MODCSCC ModuleIncremental sensor in TC-MOINCRC module in TC MOINCRC ModulePC connection atX9

You must plug the sensor plug into the respective indicated module of thetestControl electronics.

The modules are detectable by their plugs:TC-MODCSCC module = 25-pin pin plug for load cells

TC-MOINCRC module = 37 -pin socket plug for incremental width

mon itors or extensometers

Incremental reduction in width monitor

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Showing the configuration for amaterials testing machine with aload cell and extensometer.

System display:Rear of the testControl console

01.03/ KA- Verk / V4.5 Zwick technical documentation

,~~Pre~rationSensor plug

Sensor plug

Zwick sensor plugs are protected against being inadvertantly written to.Each sensor plug has a data memory. All data that is important for thesensor is saved to this memory, e.g. nominal value, limit value, referencepoints, etc.Changes to this data must only be made by authorised centres such asmaterials testing centres, official test centres, etc. or by ZwickService.

Changes to the data memory by anyone other than authorisedcentres/persons exempts Zwick from any guarantee liabilities,and the user accepts liability for any resulting consequences.

As you can also connect your own sensors, we'll describe here how tomake any necessary changes in the sensor plug. The sensor plug mustbe unplugged, i.e. zero-potential, before doing anything.

Open the sensor plug. You can see a jumper on the inbuilt p.c.b

Slip it onto the two pins

Close the sensor plug

Plug the sensor plug into the electronics

Switch the materials testing machine on

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I The fig. shows the protected sensor plug. Writing to the data memory is not possiblein this position.

InputstestXpert

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Test program

Select the command "Open" in the menu "File":

The window 'Test program or series, load",

Dialogue "Load test program".

All test programs are listed.The calibration program is saved to another directory for safety reasonsWe'll now go to this directory and load the calibration test program.

Activate the button <Expanded...>.

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The following window appears:

Expanded dialogue "Open". It is Windows standard.

01.03/ ~Pauf / V4.5 Zwick technical documentation

~Test programtestXpert

Test program KalOOO

This calibration program can be used to monitor sensors and to write

any necessary adjustment factors to the EEPROM.

But first of all we'd like to explain the temls calibration and adjustment.

CalibrateCalibration is understood in measurement technology as being thedetermination of any measurement deviation at the measurementdevice. There's no technical intervention at the measurement device atcalibration.

AdjustmentAdjustment is understood as being setting or adjusting a measurementdevice so that any measurement deviation will be as small as possible.

Adjustment usually requires some sort of re-adjustment to themeasurement device that normally results in a permanent change to thedevice.

First of all we'll describe a calibration. Nothing must be undertaken if thedetermined deviation(s) is(are) within the permitted range.

Should, however, an impermissible deviation be determined, an attemptcan be made to correct the said sensor by adjusting it.

The sensors can be used in two directions (Positive and negativemeasurement directions). Thus it's absolutely necessary to enter plausi-ble values (Adjustment factors) for both measurement directions. Pleasepay attention to the examples at the end of this paragraph..§

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01.04/ KA_Kali / V4.7 c Zwick technical documentation

~Test programtestX~rt

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You must eventually press the <ON> button again. Thus you can switchthe drive system to active again.

You can see the current test data in the display bar of the dialog forrecording the test data.

Resolution of the monitor displayYou can set the test data required and the decimal places for this testdata, via the context menu by yourself. For this purpose place the cursoron the required display bar and press the right mouse button. Select the

function "Status line, configure" in the context menu. You can set therequired test data with the number of decimal places on the following tabcards.

We want to show you two examples on how to check and, if necessary,

correct sensors.For this purpose we select a- Load cell and- An analog fine strain extensometer

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See section" Wiring the materials testing machine" to see how toconnect them.


Test programtestXpert

Overshoot travelThe overshoot travel is to be found in the dialog "Inputs" on tab card"Test". The overtravel is- Entered as a percentage value related to the calibration steps to be

approached- Driven only at the last calibration step of the last ascending row if a

descending row is to be driven after it.

Example

FinN1000950900

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Force/Time diagram of the entered force stages

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Press the button <Inputs> in the toolbar,

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TestprogramtestXpert .

You can start the test if you have checked all parameters, and correctedthem if necessary.

You can begin with evaluation once you have recorded the test data. Youcan end calibration and skip the following description if you haven'tdetected any impermissible deviations.You must adjust the sensor now if you've detected any impermissibledeviations. Please note that this test data has been corrected via thecurrent adjustment factor.

You can display this current adjustment factor via:

Menu "Inputs", command "Adjustment, display",

or if you want to then alter the value

Press the button <Adjustment> in the toolbar.

The mask for selecting the sensor appears following both call-ups.

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Dialog for selection of the sensor type.

Select the calculated sensor, this is the "Standard force sensor" for our

example.

01.04/ KA_Kali / V4.7 c Zwick technical documentation ~

~Test programtestXpert

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These altered adjustment first become active after testXpert has beenrestarted! You must quit the program and restart testXpert to check youradjustment values. Only then can you check your entered values with arenewed test row.

You must protect the sensor plug from inadvertantly being written to aftercalibration and any writing of data to the data memory.

The procedure has been described under section "Sensor plug'

Our example shows you how you can check, and if necessary correct, ananalog fine strain extensometer. A description of connecting theseextensometers is contained in the section "Wiring the materials testingmachine".

Example:The input dialog appears after testXpert has been called-up and after thetest program "kaIOOO.zpv" has been selected.

First check the currently selected sensors in the "Verification dialog"

Select the command "Verification..." in the menu "Machine".orPress the button <Machine> in the toolbar.

The ,t Verification dialog" appears then. You must link the analog finestrain extensometer as the standard extensometer in this verification

dialog.

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Press the button <Inputs> in the toolbar.

Select the type of test to be calibrated on the tab card "Type of test"(" Tensile" for our example).


We now want to check the analog fine strain extensometer using anexternal calibration device (e.g. a micrometer).

Set the fine strain extensometer to the calibration device

Press the button <Travel 0>0 ~m is shown in the status line

Adjust the calibration device by a value that is permissible for the finestrain extensometer. We're using 2 mm for our example.

Read off the value from the display bar It must be identical to the valueset at the calibration deviceIf the fine strain extensometer has been correctly calibrated, we canread-off 2,000 ~m for our example.

If there is a difference you'll have to repeat this check. Note therespective differences. Make a table with set value, displayed value(actual value) and the factor: set value/actual value.

Adj ustment form u laYou can enter a corrected "Set value" in tensile and compressiondirections in the dialog ,Adjustment, enter".

Input formula!

I Set valueInput =

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01.04/ KA_Kali /V4.7 c

Control of the materials testing machine

We'll show you here how to drive your materials testing machine. Controltakes place via the testControl electronics' control buttons. First getyourself acquainted with its functions and then install your test and

calibration arrangement.

Check the red <EMERGENCY OFF> buttonIt must be unlocked.

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EMERGENCY OFFunlock

Switch the drive system on via the button <ON>.The lamp in the <ON> button illuminates.The status display now has a green background. The machine is nowready for use.

A.3

Press <POS> button.The <pas> button illuminates

<pas>

If you want to drive upwards with the moving crosshead, you must

Press the <UP> drive button and hold itThe crosshead moves upwards with ever increasing speed. Release thedrive button and the crosshead remains idle.

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.~<UP> drive button

If you want to drive downwards with the moving crosshead, you must

.~~ Press the <DOWN> drive button and hold itThe crosshead moves downwards with ever increasing speed. Releasethe drive button and the crosshead remains idle.

<DOWN> Drive button

01.03 I KA_Steu I V4.5

ContentstestX~rt

Index 24~

Crosshead position ........Crosshead travel monitor

15,. 5192919404551511349.634

35.5020

11111111

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33

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AAbout the test sequence ....About this section ..............Accelerator """"""""""""

Action button ......................Actions """""""""""""""Adjusting analogue sensors

Adjustment ........................Adjustment, display...........Adjustment factor ...............Administrator .......................Ascending row ....................autorun ................................Average value ......................

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.............49,53,46,53,.......................................

BBody.......................Button .....................

Adjustment ........Expanded ...........Inputs .................Machine .............Steps """""""'"Test environmentTravelO """"""" .......

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DDanger of irreparable damage ...........

Date.................................................Definition of software element

Button .........................................Display........................................List field ......................................Option field ..................................

Definition Software elementControl box .................................Icon .............................................Icon text.......................................Menu bar ......................................Scroll bar .....................................Title bar ........................................Toolbar .........................................Windowfield.................................

Deinstall testXpert .............................Delete ...............................................

Descending row ................................

Desktop ............................................Desktop elements .............................

Desktop layout ..................................Device module...................................

DialogAdjustment, enter ........................Load stages .................................Sensor type selection ..................Test speeds .................................Verification dialog .........................

Dialogue ............................................Load test program ........................Optional crosshead travel monitorOptionallongstroke extensometerVerification dialogue .....................

Diskette ............................................

Display..............................................Display bar ........................................

Drive using the POS button ...............Driver software ...................................

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EElectronics unit ................................................

Error .................................................................Event................................................................

ExampleCalculation of the correction reference point

CCalibrate ...........................Calibration

Analogue extensometerIncremental extension ..

Calibration program ...........Calibration steps ...............CAUTION ..........................CD ROM ...........................

Channel.............................

ClosetestXpert...................Company logo ....................Company name..................Compression platens .........

Compression test ...............

Configuration level..............Context menu ....................

Control box ........................

Correction formula ..............

Zwick technical documentation01.03/ KAlndex / V4.5

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Report ..................Create .............Editor ..............Preview ...........

Results ................Display............Print ................

Rights for your PC

RS device .............

RS devices, install

......

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Screen elements ,

Scroll bar """"" '.""""

Selection criteria ,

Selection dialogues ..............

Sensor plug ..........................

Sequence program ...............Series properties ..................

Socket plug """""""""""""

Software limit switch ............

Specimen .............................Data input .......................Insert...............................List .................................Management .""."""""'"Measurementdevice .......Numberthrough ..............

Specimen grip ......................

StandardDeviation .........................Report .............................Test program ...................

Start a test ...........................

Start menu ...........................

Statistics ""'..""""""'."""",

Status line ............................

Sub-menu ............................

Sub-series ............................

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Tab cards ...........................

Tabdialog...........................Control parameter .........Test...............................

TC MOACSCC Module .......

TC MODCSCC Module .......

TC MOINCRC Module ........

Tensile test .........................

TestEnvironment ...................Personnel.......................Program .........................Run ................................Series ............................Setup .............................Start ...............................Test standard database..Tools ..............................

Test end ..............................

Test level.............................

Testsequence.....................Test standards ....................

testControl electronics ........

Tester logon ........................

testXpertChannel.........................Close ..." """"""""""Deinstall.........................Install .............................Interface .........................Multiplexer .....................Philosophy.....................Program help .................RS devices, install .........Start ...............................Videos ...........................Windows XP. specialities

Text, adapt ..........................

Title bar...............................

Toolbar ................................

Tools ...................................

Trademarks .........................

Type of result.......................

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Verification dialog ....Verification dialogueVideos """"""""""

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WWARNING.........................Window field ......................Windows XP and testXpert .

WiringAnalogue extensometerIncremental extension ...Load cell .......................

WIZard ...............................

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ZIMT Syntax.....................................Zwick mechanics instruction manual

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Checking an extensmoter .............Fine strain extensometer. calibrateLoad cell. calibrate ........................System script ...............................

Expanded results ...............................

ExtensionCalibration .....................................

Extensometer ....................................

Extensometers...................................

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LLimit switch ...............

Line of products ........

List field ....................

Load cellLoad cell ..............

Load cell calibration..

Load removal.............

Load theTest program, load 28,43

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......

36,14,21,........................

,..............

FFlexure test...............

Font size ...................

Footer .......................

Force, zero ...............

Formula for correction

Frontispiece ..............

Function keys ...........

Functions ...................

MManual calibration ...............

Master sensor .....................

Master test program ............

Materials testing machine...

Measurement amplifier ........

Measurement amplifier, load

Mechanical limit switch .......

Mechanical requirements ....

Menu ...................................

Menu bar .............................

Menu Help ...........................

MicrosoftWindows ........................

Monitor display....................

Monitor resolution ................

Multiplexer ..........................

......

......24,

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GGraph ..............................

Graph, adapt ...................Grip to grip separation LE

Guarantee ........................44747.8

HHardware requirementsHeader ........................Help system ................

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Icon ............................................Icon text .....................................Incremental extension calibrationInitial position .............................Install

RS devices .............................testXpert ................................

Interface ......................................

Interpreter language .....................Invalkjate .....................................

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Operating elements in the software

Operating system ...........................

Option field .....................................

Options ..........................................

Overshoot travel .............................

pPage numberParameter

Liste .. .. . .. .

Properties

20

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KKALOOO.ZPV ..........Keyboard operation

Zwick technical documentation

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;00Test programtestX~rt

Example:We measured in the tensile direction for our analog fine strainextensometerwith a reference preset length of2,OOOO mm.

Set = 2,0000 mmActual = 1,9837 mm

2,0000

1,9837

Input = ,0082169=

We enter:

External adjustment tensile: 1,0082169

The altered adjustment factors are first active after testXpert has beenrestarted!You must quit the program and restart testXpert to check your adjustmentvalues. Then can you check your entered values with a renewed test row.

We've checked the fine strain extensometer in one direction only (Positi-ve count direction). As negative values can also be supplied when

clamping on a specimen, plausible values must be entered for both

adjustment factors.Thus we enter the same value just determined in both adjustment factors.

testXpert appears with the input dialog after the new adjustment hasbeen written to the EEPROM.

The altered adjustment factors are first active after testXpert has been

restarted!You must quit the program and restart testXpert to check your adjustmentvalues. Only then can you check your entered values with a renewed testrow.

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56 Zwick technical documentation

~Test program

testXpert

A defined value is entered in the dialog ,Adjustment, enter" so that wedon't have to calculate the currently valid adjustment factor. The dialog,Adjustment, enter" can be accessed via:

Toolbar, <Adjustment> button.Now select the standard extensometer in the mask for selection of thesensor. Enter the value 1 at "External adjustment, tensile" in the following

dialog ,Adjustment, enter". Acknowledge via the <OK> button.

Quit testXpert and start it anew.

Recheck and set the following:

In menu "Machine", command "Verification.,orToolbar, <Machine> button.

The analog fine strain extensometer must be linked to the standardextensometer in the verification dialog.

Toolbar, <Inputs> button.

The corresponding type of test must be selected on the tab card "Type oftesf (n Tensile" for our example).

The <Travel 0> button enables the travel display to be zeroed.Go with the cursor to the required display bar and press the right mouse

button if you require a different resolution. Set the required resolution viathe context menu.

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~

Input dialog for adjustment of the selected sensor.

Dialog" Adjustment, enter"

This dialog shows you all adjustment factors for the selected sensor.

The adjustment factors for this sensor determined at the manufacturer'spremises are depicted in the upper part of the dialog. You can't alterthese values.

The current valid values are shown in the middle part.Please use these "External adjustment factors" for calculating the newadjustment factor. Calculate this adjustment factor into your test data.You'll then get a new adjustment factor. Enter the newly recorded valuehere I.

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Press the <OK> button to write the entered value to the EEPROM


~

TestprogramtestXpert

Tab dialog. Test speeds'

Enter all parameters required for calibration in this tab dialog.

The following parameters are deactivated as standard:- Tab dialog" Tesf

"Control type hold at calibration steps" = "Position controlled hold"- Tab dialog "Control parameter"

"Controlled positioning ?"

These settings ensure that the materials testing machine cannot enterinto force control.

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~

We'll begin with the load cell.The load cell to be calibrated is linked as the standard load cell in theverification dialog. You can see this on the previous page.

Press the button <Steps> in the toolbar.

The mask for input of the calibration steps appears after call-up.

Dialog for input of the load stages

You can enter up to 11 calibration steps in this dialog. The selected andentered calibration steps are approached in the directions of loadapplication and load removal.The uppermost step at load removal is passed over if you haven'tactivated an overshoot travel (Overshoot travel = 0).

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Zwick technical documentation.8

~"" ccTest p~ramtestXpert

First check the currently selected sensors. You can do this in the

"Verification dialog".

Select the command "Verification..." in the menu "Machine".orPress the button <Machine> in the toolbar.

The "Verification dialog".

Dialog. VerifICation dialog",

You can see the active links here. In this example we've connected amaster load cell with measurement amplifier as a free RS device. Thismaster sensor has been given the name "Master" in the periphery setup.We've linked the master load cell to the device module "Measurementamplifier, load" for our calibration.

The link is necessary only if the master sensor's measurement datashould appear on the report. You can run calibration without this link if youdon't need the master sensor's test data on the report hardcopy.

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Further settings for the verification dialog have been shown in the firstpart of this section.

You can quit the dialog "Verification dialog" via the button <OK>.

.6Zwick technical documentation

~

InputstestXpert

~

Activate the button for the superior folder.

Windows now shows the superior directories. Select the directory "kali-mit" here and press the <Open> button.

The window now displays the selectable calibration programs

Dialogue "Open" with a display of test programs.

Select the calibration test program "KAlOOO.ZPV"Finally, activate the button.

The test program is loaded, and the start dialogue appears

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Dialogue for recording the test data


PreparationSensor plug

You must protect the sensor plug from inadvertantly being written to aftercalibration and any writing of data to the data memory.

switch the materials testing machine off again

unplug the sensor plug

open the sensor plug again

remove the jumper and slip it onto one pin only

close the sensor plug

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~2

PreparationtestControl

Adjusting analogue sensors

You must have the following plugged into testControl

Load cell in TC MODCSCC ModuleIncremental sensor in TC-MOI NCRC module in TC MOl NCRC ModuleAnalogue sensor in TC MOACSCC modulePC connection atX9

You must plug the sensor plug into the respective indicated module of thetestControl electronics.The modules are detectable by their plugs:TC-MODCSCC module = 25-pin pin plug for load cells

TC-MOINCRC module = 37 -pin socket plug for incremental width

monitors or extensometers

TC-MOACSCC module = 25-pin plug for analogue width monitor orextensometer, there's an additional hole onthe fixing part as an ID.

Analogue extensometer or width monitorHole

e;~~\I~

ft~~~ E :.--tf T~NCRC nKXUe~

" ~-f~~DCSCC roodu~Incremental reduction in widthmonitor ,

Load cellI0~

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System display.- Rear of the

testControlconsole

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PCShowing the configuration for amaterials testing machine with aload cell and extensometer.

PreparationtestControl

Load cell calibration

You must have the following plugged intotestControl:

Load cell in TC MODCSCC ModulePC connection at X9

The load cell is plugged into the testControl electronics' TC-MODCSCCmodule. This TC-MODCSCC module is slotted into one of the 'moduleslots'. The module can be recognised by its 25-pin plug.

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System display:Rear of the testControl console

Showing the configuration for amaterials testing machine with aload cell.

38 Zwick technical documentation

~RequirementstestXpert

Hardware requirements

The electronics unit can only have the following plugged-in at the most:- one load cell and- one extensometer

Only one load cell must be plugged in if the crosshead travel is to beindicated. The correct link for the sensor can only happen automatically atstart in this manner.

The crosshead travel monitor must always be plugged-in!

Master sensor with measurement amplifierThe master sensor with measurement amplifier is connected as an RSdevice. Therefore you require a second RS interface in your PC.

Mount the master sensor in the calibration setupConnect it to the measurement amplifierPlug the measurement amplifier's output lead in the PC's second RSinterfaceEnter the measurement amplifier as a free RS device in the peripherysetup. Give it an explicit name in the periphery setup, e.g. "Master".This name will then appear in the verification dialogue.

Software requirements

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Two test programs are supplied as standard for manual calibration. Thistest program "KALOOO.ZPV" enables a selection of several waitingpoints.


TesttestXpert

StatisticsThe statistics are built over all valid specimen in testXpert. The displaytakes place as described under section "Results, display". Please alsopay attention to the section "Specimen management".The statistics can be printed at any moment in time.Statistics window field

The average value, the Standard deviation and the coefficient ofvariation are set as standard in the test programs.

Further statistical quantities can be added via the optional report editoror via the context menu.The context menu can be called up by pressing the right mouse buttonon the statistics window field. Select the command "Statistics table,configure"' here.You can make all required settings in the displayed sections.

The inputs for a test are now finished

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r.Menu "Configuration"

Command "Reporteditor"

TesttestXpert

Results, display, -=._=c~ ., The determined results can be displayed on screen. A double click on

the screen with the left mouse button on the graphic display switchesI 3 the display.Results window field

You can only define a test program anew if no result window field isprepared in it. For this purpose select the command "Screen layouts.in menu 'View". You can make the required settings in the followingwindow.

11r..

Results, printResults can be printed:- Automatically after each test- After the end of a test series, or- Manually

Whereby you have the usual setup possibilities for the printer asavailable under Windows.11

r-..

The dialogues affecting the printer are called-up under menu "Files'You have here the following for selection:- "Print device- "Report preview

- Report, print

Menu "Files",Commands: "Printdevice", "Report

preview" ,"Report, prinr

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Menu 'View",command "Screen

layouts..."

~~

TesttestXpert

Force, zeroThe force must be zeroed once all previously described activities havebeen finalised.Activate the

The corresponding icon in the toolbaror

Command "Force, zero-set" in menu "Machine'Menu "Machine",command "Force,

zero-set" The second specimen grips is now closed for tensile tests.

Start a testYou can start the test directly at the materials testing machine or viatestXpert.

Start the test via'.Menu "Machine",

command "Test, start" - The menu "Machine" with the command "Test, start"or- The corresponding icon in the toolbar

There's only one icon available in the toolbar for many test program,These test programs are thus reduced to one-button operation.

The sequence described here is exemplary only and may slightlydeviate from that of your test program. An exact description of the testsequence corresponding to your test program can be found in menu"Help" under command "About the test sequence",Menu "Help",

command "About thetest sequence"

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~:TesttestXpert

';i"r.

test programTest programs can be loaded in many ways.

- Select the menu "File". Select the command "Open.

dialogue that is now open.in theMenu "File",

command "Oen"

Activate the icon "Open" in the toolbar.

- Call-up the command "Test standard database" in the menu "Help".The procedure has already been described under chapter "testXpertPhilosophy", paragraph "Test standard database".

Menu "Help",command "Test

standard database"

A window with all of its available test programs is displayed for the firsttwo possibilities. Select the required test program and call it up.The test program will be loaded and testXpert goes into the inputwindow that is still required.

Mechanical requirementsA load cell and corresponding test tools (Specimen holders,compression platens, flexure tools, etc.) must be mounted on thematerials testing machine. Mounting is described in section 4 "Opera-tor manual" under chapter "Retrofit".

<ON> Button, press The <ON> button at the materials testing machine must beactivated.

All necessary settings are transmitted to the materials testing machinewith the test program. You can drive the materials testing machine toits initial position if testXpert finds an error.Please adhere to the teStXpert instructions should an error occur. Allerrors together with the solution are clearly displayed on screen.

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Dialogue 'Verification"testXpert

You can save the newly created test environment in the dialogue'Verification dialogue". For this purpose select the button <Testenvironment> .

Now that you've been introduced to the testXpert and machine inputs,we would like to explain preparation of and running a test.

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Check and, if necessary, alter the inputs in dialogue "OptionCrosshead travel monitor".Crosshead position

indicator\

Cross head positionYou can read off the current crosshead position with the help of thecrosshead position pointer at the load frame's yardstick.

Limit switchThe limit switches indicated here are "software limit switches"!Setting the mechanical Limit switches is described in section 4 "Ope-rator manual" under chapter "Safety remarks", "Limit switchs" and"Types of operation".

Mechanical limitswitch's stop

EquippingThe "Software limit switch" that is to be entered here must be set forequipping so that you'll still have sufficient room for mounting anddismantling the test tools.

Ranges of the- Mechanical

limit switch- Software

limit switchTestThese "Software limit switches" should be set in the test so that theyterminate the cross head motion before the mechanical limit switchesare tripped.

I

Grip to grip separation LEThe "Current grip to grip separation" is usually the free space betweenthe test tools.

:;'L.' Tensile~ Flexure

. Compression-- I

Specimen LE

Quit the dialogue by pressing the button <OK> once all entries havebeen made.

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Device modulesDevice modules are active tools, measurement devices or peripherals,They represent the Interface interface between the machinecomponents and testXpert

You cannot configure the module "Machine".

The dialogues for configuring the other device modules consist of oneor more tab cards. You can make all required settings on these cards.You can grant the following for a module- An icon- An abbreviation- A name- An identification number (10).

You can link these device modules to machine components in theverification dialogue. Thus you can also define an extensometer asthe standard extensometer.

All of this information is known as the test environment.

Test environmentYou can save the now known machine components and devicemodules as a test environment under any name. You can call this testenvironment at any time without having to make the settings again.Thus you can assign a test environment to each and every test setup.

testXpert always links the current test environment to the current testprogram.

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Following are some dialogues which serve as an example. Thesedialogues don't necessarily have to coincide with your machine

configuration!!



1,-r..

Report, createEach test program contains a standard report. This can be altered in asimple manner via the report editor. The 'Report editor' is to be foundunder menu 'Configuration".Menu 'Configuration'

command menu'Configuration" The report is always composed of 3 existing boundaries.

F - HeaderYou can enter your company logo, the company name, thedepartment, the date, etc. in the header.

-- .-- --- - --. .=~_-'a~ ati--&- 1- -

!:_~=:- :' :

: I~~:-,I _llllI8ili~~~ ~ ~--

Body.You can use this for the series data, result or statistics table, graphetc.

~ FooterThis is for the page number or for further information.

Report layout

Following the input possibilities under testXpert, let's take a look at themachine related inputs. i0

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Configuration leveltestXpert

ResultsYou can select the results prepared in the test program under menu"Configuration", command "Results, edit...".Should these be insufficient, you have the possibility of determiningyour own results. These are determined under menu "Configuration"command "Expanded results, create...". You can determine newresults her via the type of result.

Menu "Configuration",command "Expanded

results, create.,,"You can compile tests in series and sub-series in addition topreselections and results.

'flr..

Series propertiesYou can determine the size of a series in the series properties. Hereyou can- Determine sub-series- Determine the series' name- Input the sub-series' name- Determine whether or not a report should be printed at the end of a

seriesMenu .Specimen

management",command .Series

propel1ies. You can call-up this dialogue via the menu "Specimen management"command "Series properties".

System scripts are available to enable you to react as flexibly aspossible externally to the test.

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18

r.Menu "Configuration"command "Results,

edit.."


Configuration level

Preselection for your test program are made in the configuration level

Standard test programTest methods to standards can beadapted to your test requirementswith a standard test program.You can call-up all important tabcards via the dialogue "Inputs"when calling-up a standard testprogram.

Master test programYou can create new customized,test standard independent testprograms with a master testprogram.The wizard is startedautomatically when calling-up amaster test program.

Inputs

WizardThis guides you through allrequired dialogues. It's guidanceensures that all preselection havebeen paid heed to. After the lastdialogue you'll be requested tosave the created test programunder a new name.

11r..

Tab cardsEach tab card contains allimportant input possibilities foryour topic. Call-up all offered tabcards and make the requiredalterations.You can save the altered testprogram under another name viamenu "File", command "Save

"as... .

Menu 'File', command'Save as...'

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testXpert uses parameters for communication purposes


Philosophy oftestXpert

Test programsTest programs can be configured and saved in the configuration level.The standard test program (Known as test program) ensues from asequence program. It determines the specific properties of a test(Specimen's material, teype of test data, etc.). These properties aredetermined by (Test) standards (DIN, ASTM, EN, etc.). The propertiesof a test such as the type of test, material, etc. are laid down in thesestandards. This could possibly cover several standards dependingupon the test standard's scope and possibilites. The test program isthen parameterised so that it corresponds to the required standard(s).

Master test programMaster test programs are optional parts and must be purchased as

required.They represent a special case as rhey are unchangeable. You cannottest with them.Customised test programs are created with help of the master testprograms. A master test program must first be saved under anothername before it can be used as a functioning test program that can beused for testing. This mechanism ensures that the master test pro-gram remains an unchangeable original.

Sequence program n

It roughly determines the sequence of a program and/or suppplies the ~data necessary for certain test applications. It's laid out so that it's valid ~for several similar test situations. No tests can be performed using the §sequence program on its own. Test specific information is required for ~this purpose. This information supplies the test program. i

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Screen elementstestXper1

~

Software's desktop elementsThe display can consist of several window fields.

Window field

Status line

Display a testXpert graphic dialogue.

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Graph, adaptA mouse click in one of the window fields with the right mouse buttonopens a context menu. You can make further selections andpreselections for this window field in this context menu.

Window field, swap ~0Double click in the graph window field with the left mouse button to i

activate the graph display over the entire screen width. Another double ~click resets the display to its previous form. ~


Screen elementstestXpert

Videos

~r.Menu "Help",

command "Video..."

testXpert offers video sequences as additional help. These showcomplex sequences. Thus enabling you to obtain rapid and explicitinformation on the test system's operation.You can start, halt, call-up as single frames or rapid play videosequences via the control buttons.The video sequneces are called-up via the menu "Help". Now selectthe command "Video..." in the sub-menu. The following window offersyou all of the installed videos.Select the required video.They are played via the button <Play...> or by double clicking on thevideo's name.

Screen elements

Some screen elements that you'll be confronted with in testXpert areshown and named below. You can navigate in testXpert in exactly thesame manner as in any other Windows program.

Desktop elements

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Screen section, upper left.


~Installation

testXpert

Interface:The interface used by testXpert can be interrogeted via the button 'MTMCom', i.e. materials testing machine and serial RS (COM) interface. Thusenabling you to detect interfaces in your PC that are still free and that canbe used.

Channel:Several measurement devices can be connected to one multiplexer.Each measurement device can be connected to a "Channel" and the

multiplexer can be connected to a COM port. testXpert then knows wherethe individual measurement devices are connected, and can requestdata from the correct measurement device.Further information can be taken from the multiplexer's description.

testXpert deinstall

The deinstallation program can be used to delete testXpert from your PCand its system. The sequence is described below.

Before you install a new version of testXpert on your PC, you should firstremove the old one. Use this deinstallation program for this purpose.This deinstallation method doesn't delete any files created by yourself,i.e. test programs, test environments, database entries, etc.

Sequence:

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Select Start menu "Program" in the Windows "Start menu",

2. Select "Zwick applications" here

3. Call-up the command "Uninstaller".testXpert is removed from your system following acknowledgement ofa safety interrogation.


~

~

Installation

testXpert

~

The test program testXpert is supplied on a CD ROM and on a 3,5"diskette. This chapter describes the installation of testXpert with linkingof your RS measuring device; deinstallation is also described.

testXpert install

Generally you only have to insert the testXpert CD ROM in your CD ROMdrive. Installation is started automatically as soon as the disk drive isclosed .

Should this automatic function be switched off or not function you can stillcarry out "manual" installation.

1. Insel1 the CD ROM with testXpel1 into your CD ROMdisk drive

2. Select Start menu .Run" in the Windows .Start menu"

3. Enter "x:\autorun", whereby "X" represents the letter for

your CD ROM drive.

4. Acknowledge via the <OK> button.

Follow the instructions for installation

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During installation of testXpert you'll be- Requested to insert the supplied diskette in your disk drive- Asked whether or not you want to use RS devices (Such as a Vernier

gauge, a cross-sectional area monitor, scales, etc.) together withtestXpert. A description of this installation is to be found on the next

page.

Remove the CD ROM and the diskette from their drives at the end ofinstallation.


~testXpert

Trademarks

Microsoft, Windows2000, Windows NT as well as Windows XP aretrademarks of the Microsoft Corporation.testXpert is a trademark of Zwick GmbH & Co.

To simplify matters Microsoft Windows95, Microsoft Windows98, Micro-soft Windows2000, Microsoft Windows NT and Microsoft Windows XPwill hereafter simply be called Windows.

Zwick testXpert works under the graphical user interface MicrosoftWindows developed by the Microsoft Corporation. These operatingsystems give Zwick testXpert and all other Windows programs astandardised appearance. You must have a licensed version of MicrosoftWindows to be able to work with Zwick testXpert under MicrosoftWindows 95, Microsoft Windows 98 or Microsoft Windows NT.

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~testXpert

Document: I nstallation of testXper1 andManual calibration with testXper1from testXper1 version V7.1 on

Version:Print date:

V4.7cNovember 2005

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All rights reserved

Tips, remarks and constructive criticism are welcome. Please directthese to:

Zwick GmbH & CoTechnical documentationAugust-Nagel-Stral1e 110-89079 Ulm

Fax: +49 7305 200


materials testing - dcu · zimt (zwick interpreter for materials testing) is a problem orientated...

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