The electro-hydraulic servo horizontal tensile testing machine is a high-precision heavy-duty equipment that integrates mechanical, hydraulic, electronic, and computer technologies. Scientific and standardized maintenance is the lifeline for its long-term stable operation, ensuring testing accuracy and data reliability.
1、 Core ideas and principles of maintenance
1. Prevention is the main focus, and regular maintenance should be carried out to avoid "no damage, no repair". Potential faults should be discovered and eliminated through regular maintenance.
2. Record and track with evidence: Establish a detailed "Equipment Maintenance Record Form" to record the time, content, discovered problems, and handling results of each maintenance.
3. Safety first, power off and pressure relief: Before any maintenance operation, the main power must be turned off and all pressure in the hydraulic system must be released.
4. Dedicated person in charge, professional operation: Designated trained personnel are responsible for the maintenance of complex or critical components, which should be guided or carried out by professional personnel from the manufacturer.
2、 Daily maintenance (after each use or daily)
This is a fundamental and important step.
1. Cleaning work:
Wipe the exposed parts of the equipment casing, guide rails, screws, etc. with cotton cloth to remove dust, oil stains, and metal debris.
Clean sample debris: After testing, immediately clean the broken sample residue on the jaws and workbench to prevent it from damaging the jaws or falling into the guide rail.
2. Hydraulic system inspection:
Check if the hydraulic oil level is within the range of the oil gauge (should be checked while the machine is stopped).
Check for any oil leakage at the oil pipe joints and valve block interfaces.
3. Fixture inspection:
Check if the jaws are worn or cracked, and if the fastening bolts are loose.
4. Safety device inspection:
Confirm whether the emergency stop button and travel limit switch are flexible and effective.
5. Software and Data:
Normal shutdown of control software and computer, backup of important test data.
3、 Regular maintenance (carried out according to the cycle)
1. Weekly/every 50 operating hours maintenance
Key cleaning: Thoroughly clean the guide rail and ball screw once, remove old grease and dirt, and then apply new lubricating grease.
Tightening inspection: Check and tighten all visible bolts and nuts, especially at the joints of fixtures and sensors.
Hydraulic oil observation: Observe the oil tank window and check whether the oil color is transparent, whether there is turbidity or emulsification (whitening) phenomenon. If so, it indicates that there may be water ingress or oxidation.
2. Monthly/every 200 operating hours maintenance
Filter inspection: Check the oil filter in the hydraulic circuit. Clean or replace the filter element according to the indicator alarm or instructions. This is the key to protecting precision servo valves!
Electrical inspection:
Check for dust and debris inside the electrical cabinet, and clean it with dry compressed air or a soft bristled brush.
Check for any signs of looseness or overheating in the wiring terminals.
Sensor inspection: Check whether the connecting wires of the force sensor and displacement sensor are intact, whether they are firmly fixed, and avoid pulling.
3. Maintenance every six months/every 1000 operating hours (critical maintenance)
Hydraulic oil detection and replacement:
This is an important maintenance project! It is recommended to replace all hydraulic oil every six months or every 1000 working hours, or at least once a year.
When replacing, the fuel tank should be thoroughly cleaned at the same time. New oil must use the "anti-wear hydraulic oil" brand specified in the equipment manual and ensure that the refueling equipment is clean.
System accuracy verification:
Use a standard force gauge (or a third-party calibrated standard sample) to perform a simple comparison of equipment force values.
Check whether each control mode (force control, displacement control) is stable and free of overshoot.
Comprehensive lubrication: Apply specified lubricating grease to all lubrication points (such as bearings and hinges).
4. Annual maintenance (it is recommended to contact the manufacturer or professional organization)
System calibration: Invite metrology department or manufacturer engineers to conduct annual statutory metrology calibration of equipment to ensure absolute accuracy and traceability of measurement data such as force values and displacements.
Key component inspection: Professional personnel inspect the working status of electro-hydraulic servo valves, pump stations, and seals.
Control system diagnosis: Conduct a comprehensive inspection of the performance of electronic components such as control boards and amplifiers.
4、 Key points for special maintenance of key components
1. Electro hydraulic servo valve: This is the "heart" and "brain". Ensuring absolute cleanliness of hydraulic oil (relying on the filter element) is the only secret to its longevity. Once unstable control and slow response occur, the first suspicion is oil contamination.
2. Hydraulic cylinder and seal: Regularly check the surface of the piston rod for scratches and oil stains. If there are oil stains, it may indicate that the sealing ring is worn and needs to be dealt with in a timely manner to prevent further pollution.
3. Load sensor:
Overloading is strictly prohibited: never exceed its maximum range.
Anti lateral force: Ensure alignment when installing the specimen to avoid lateral impact.
Electrical protection: prevent moisture and corrosive gases from entering.
4. Guide rail and screw: Keep clean and lubricated to prevent dust and metal particles from causing wear and accuracy degradation.
5、 Seasonal/Special Environmental Maintenance
Damp environment: Add desiccants to the electrical cabinet or activate the electrical cabinet heater to prevent short circuits caused by moisture in the circuit.
High temperature environment: Ensure good ventilation of the equipment and check if the hydraulic oil temperature rises abnormally (usually<60 ℃).
Long term shutdown:
Before stopping the machine, the equipment should be cleaned and rust proof oil should be applied to the exposed metal parts such as guide rails and screws.
At least once a month, power on the hydraulic system and let it run without load for 10-20 minutes to lubricate all components and dissipate electrical moisture.
6、 Maintenance records and spare parts management
1. Establish archives: Detailed records of each maintenance, repair, and calibration.
2. Spare parts list: Always have vulnerable parts, such as sealing ring kits, filter cartridges, fuses, pliers, relays, etc.
Following the above systematic maintenance process, your electro-hydraulic servo horizontal tensile testing machine will be able to maintain good working condition, greatly extend its service life, and always provide you with accurate and reliable test data. For specific operations, please refer to your device's "User and Maintenance Manual" as the basis.
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