This is a Propsal for a new type of testing machine
Scope
Purpose
This specification provides a standard for the design, manufacture,
installation, inspection, performance and procurement of a
Cable Tension Testing Machine.
This standard lists minimum requirements and is not intended
to limit design advances (or variation in individual manufacturerrs
products).
Classification
The machine will be of the following type and size.
Type
Tester, Cable Tension.
Size
The tester will be approximately 244 wide, with a working
height of 300 and a minimum working length of 112 feet
pin-to-pin. Total length will be (approx.)
1200, 6 each 199 section and leach 66 (approx.) section.
Overall size is secondary to working capacities and will
be determined by the stroke length of the cylinder pull,
the physical size and location of the control equipment rack,
and structural design as required to satisfy specification
parameters.
Class
Semi-Automatic Manual Loading; Single Head; Program Controlled
Cycle after input of performance data into the database.
Intended Use
The machine described by this specification is intended for
use within the aerospace manufacturing industry to test the
tensile strength of all fabricated cables, up to a maximum
pull load of 11 .36 MTON (25,000 lbs.).
Supplier Responsibility
The supplier is responsible for furnishing all machine hardware,
computer hardware, and any purchased computer software as specified
within this document. The supplier is responsible for furnishing
the signals between the machine and the machine control unit
necessary to support machine operation.
Customer Responsibility
The customer is responsible for supplying the fixtures, clamps
or jaws required to physically connect the test machine to
the control cable. Customer is responsible for the adapters
from test machine pin to fixtures, clamps or jaws required
to physically connect the test machine to the control cable.
Applicable Specification, Codes, and Standards
The latest revision of the following specifications, codes, and
standards are included as a portion of this specification.
International Standard (ISO) 7500/1 - Metallic Materials
Verification of Static Uniaxial Testing Machines
American Society for Testing Materials -
ASTM E-4 Standard Practices for Force Verification of Testing
Machines
Requirements
All items not specifically mentioned herein, but which are incidental
to or necessary for the complete and satisfactory performance
of the equipment for its intended use, will be furnished as if
called for in detail by this specification.
Design
The dimensions and capacities will be detailed in Section 3.b.
The manufacturer has the choice of configuration and the functional
operation of the equipment.
This specification covers the requirements for tension
testing cables at 25,000 lbs., or less, or force.
All equipment will be of new and current standard manufacture.
Materials and workmanship associated with the equipment will
be of the highest quality. Any device required for the protection
of the equipment or
personnel will be included.
All replaceable parts will be manufactured to definite
tolerances, clearances, and finish to permit replacement
without modification of mating parts and/or adjacent parts.
Where practical, parts will be permanently and
legibly marked with the manufacturerrs part number; otherwise,
parts packages will be identified by name and number.
Periodic maintenance, adjustments, and calibration periods
will be a minimum of 30 calendar days, excepting items specifically
identified as machine supplies. All systems/components will
be designed for ease of maintenance. Easy access to hydraulic
systems such as fluid reservoir, control valves, and drains.
Easy access to electrical components such as fuses, switches,
motors or other regular wear parts that may need periodic
replacement. Easy access to chains or belts that may be used
to operate covers on trays. Easy access to computer panels
to repair or replace worn
components.
The overall design will emphasize accessibility and maintainability
of components subject to deterioration. Replacement and/or
adjustments of these components will be possible without
major machine disassembly.
The design will include a load cell, integral to the machine,
capable of sensing applied forces within the tolerances specified
in the specification.
All computer equipment and peripherals will be furnished
by one designated manufacturer where practical.
All components, where practical, will be mounted in standard
electronic racks, and the rack will supply the power and
interface requirements for all peripherals.
The System will be modular in construction with each subsystem
segregated for easy maintenance.
Dimension and Capacities
The tester will be capable of applying a maximum load during
tension test of 25,000 lbs.
The tester will have a 300 test bed working height, 112
foot minimum pin-to-pin working length, 88 clear width between
rails, cylinder pull of 4 foot stroke, and cylinder working
height (center) of 22. The test bed will be built in 6 each
19-foot sections and 1 each 6 foot section.
The tester will output performance reports as specified.
See attachment 2.
Power Source; 400 VAC, 3PH, 50HZ. Computer Control to Control
Voltage 200VAC, 1 PH, and 50HZ. Transformer will be supplied
to step down the voltage from 220V to 1 1OVAC.
Test bed to have a 66 parts holder tray along entire length
of working side of machine. Interior surface of tray will
be free of obstructions; edges will be rolled or ground smooth
to prevent injury to operator.
Test bed will have hydraulically operated, hinged lids
of construction capable of protecting operator in case of
cable breakage during pull test. Lids will be designed in
19-foot sections and will be counter-balanced to limit force
required to open to 25 lbs. or less per section.
The machine design will prevent pressure surges. The applied
pressure is to be related to force and will rise smoothly
from the minimum to the maximum setting rate preset by the
operator.
The machine will be capable of testing
wire diameters up to 2 diameter.
Construction
This machine will be constructed to comply with the requirements
of this specification and the specifications referenced in
Section 2.
The equipment will be constructed with sufficient strength
and rigidity to withstand vibration, bending and torsional
forces during normal operations.
Suitable devices for hold-down and leveling will be incorporated
in the design and construction of this equipment.
Frame
The machine frame will be a rigidly constructed weldment
to ensure proper seating.
Computer Hardware and Software
Microsoft XP software and Roberts Proot Test Certificate
software.
Laptop or desktop.
Keyboard The System will come
equipped with a sealed membrane-type keyboard, with tactile
feel, that protects against moisture and dirt found in an industrial
environment.
Computer and Software are data acquisition only and are not part
of the measurement system and have no control over the accuracy
of the measurement system.
System will be able to conduct the following readings and them
in a relational DataBase.
Pounds Pulled
Prestretch Length
Poststrentch Length
Shop Order Number
Reference Number
PCWA Number
Date in format mm/dd/yy
Time in format hh:mm:ss
Proof Test Minimum Value
Proof Test Maximum Value
A suitable cabinet will be provided to protect the computer
from the shop environment.
Operatorrs Control
Complete operation of the machine will be from a control panel
conveniently located at the operatorrs normal workstation.
All operating control switches, levers, indicators, warning lights,
etc., will be located convenient to the operator when he is in
the normal and established operating positions.
The controls will be arranged to provide both automatic and manual
override operations.
The control system will provide the capability to jog the equipment
through each step of normal operation on a step-wise basis.
Remote switching capability will be provided to assist operator
during load/unload and program start/stop functions. For location
of switches see Attachment 1.
Electrical Equipment
All electrical equipment and its installation will conform to the
latest revision of Electrical Standards for General Purpose Machine
Tools.
All inter-connecting wiring, conduit, and wireways will be furnished
by the manufacturer.
Controls using 115 volts will be supplied by a transformer from
the single power source.
All motors and/or servos will be protected from contamination
and foreign matter and be of ball bearing type. All motors will
be suitable cooled.
All motors will provide ample power to drive their respective
components. Under normal conditions, no motor will operate at overload.
If D.C. motors are used, the manufacturer will include the equipment
required to convert A.C. to D.C. (applicable when D.C. motors are
permissible).
Electrical components will be protected from damage due to power
surges, transient power failures, friction and abrasion normal
to the system operation, etc..
Overload relays will be supplied with all motors with an interlock
provided to actuate the cycle stop in the event of motor stoppage.
A manually operated fusible disconnect or circuit breaker will
be provided for, by customer.
All relays rated at less than 117 volts A.C. will be of the sealed
plug-in type.
Maintenance trouble shooting data will be supplied in manual
form. Reference section 5.a.
Hydraulic, Pneumatic, and Servo-Mechanical Equipment
All hydraulic and/or pneumatic and/or servo-mechanical equipment
and its installation will conform to standard Industrial specifications.
Lubrication
Automatic and adequate, but not excessive, lubrication will be
provided for sliding and rotating parts, excepting motors and pumps
with non-additive pack seal bearings.
All points of adjustment will have readily accessible lubrication
provisions for periodic lubrication.
The lubrication system will be equipped with a low-level oil
sight gauge. All filler and/or lubrication points will be properly
identified. Instructions regarding procedures, frequency, and type
of lubrication will be described in the machine manual. The types
of lubrication will be identified at each applicable location wherever
practical.
Safety
The machine will be provided with adequate safety devices. Moving
parts which are hazardous to personnel will be suitable protected.
Ample protection against electrical shock will be provided.
An interlock to prevent operation when the safety shield is open
will be provided.
Interchangeability
All replaceable parts will be manufactured to definite standards
for tolerance, clearance, and finish in order that any such part
may be field installed without further machining.
All parts will be permanently and legibly marked with the original
manufacturer's part number, where practical and listed and defined
in the illustrated parts breakdown section of the operations manual.
Environment and Facilities
The machine will be capable of operating satisfactorily in a
normal factory environment with ambient air temperature of 60 degrees
to 120 degrees F and a relative humidity of 10% to 100%.
The machine will produce not more than 85 DBA sound at 10 feet
from the noise source.
Paint and/or Finish
All surfaces of the machine and control cabinetry which are normally
painted will after surface preparation and priming, be painted
with Basic Industrial Paint with textured finish.
Replacement Parts
All replacement parts will be available from the equipment vendor
or designated supplier within the continental United States.
A recommended spare part list, with reference to construction
drawing page, for each type of equipment will be furnished. Original
design, OEM, and standard off-the-shelf equipment provided by the
equipment vendor will be identified and included.
A complete listing of items identified as equipment supplies
will be provided including all consumables and each item with an
expected replacement period of less than thirty days.
Inspection and Acceptance
Classification of Test
The machine will be subject to the following tests for compliance
with the specification unless approved deviation is obtained from
the customer.
Verification of "Standards" in Section 2 and "Requirements" in
Section 2.
Satisfactory completion of each test defined in Section 4.b and
Section 4.c.
Test Conditions
Each machine will be tested under the following conditions unless
waived in writing by the customer.
At the manufacturers plant by the manufacturer, with certified
test results furnished to the customer.
At the customerrs option; at the manufacturerrs plant by the
manufacturer observed by the customer.
At the customerrs plant the performance test described in Section
4.c.i will be conducted.
Performance Test
The machine will be functionally tested for manual/remote switch
operation and utilizing the System Control Unit and resident software
program.
Manual proof loads and software program runs of various cable
size, cable length, and intensity of pull will be run, determined
by current shop order
requirements. Tests will be run with subject materials representing
all types used in production until test results are conclusive
that machine will maintain
accuracy as specified in MD-80. Maintenance Manual Paragraph 4.
Proof loading and prestretching.
Proof load cells will be applied for at least fifteen seconds
to each swaged terminal. The proof load will be applied evenly
and gradually to the assemblies in not less than three seconds.
The load will be released evenly and gradually
Acceptance of Machine
Final acceptance will be at the customerrs plant after all requirements
of this specification have been met.
Final acceptance will be made only after satisfactory completion
of testing described in Section 4.c
Operating and Installation Data
The Manufacturer will furnish one reproducible master and one copy
of the data required by each Paragraph 5.a through 5.i.
Maintenance Manual, including sectional drawings and/or illustrated
parts breakdown showing all machine components together with the
part name and original Manufacturerrs identification number.
Preventive maintenance schedule for mechanical and electrical
requirements indicating periodic servicing required to satisfy
manufacturerrs warranty will be included in the manual.
Operatorrs Manual
The Operatorrs Manual will include full description of each mode
of operation: normal, manual, semi-automatic, etc., as applicable.
The Operatorrs Manual will include recovery procedures for malfunction
conditions.
### The Operatorrs Manual will include full instructions relating
to usage of software.
5.c Parts listed including component names and manufacturerrs identification
number.
Scaled drawings showing plan view, front elevation, end elevation;
major dimensions consisting of all work clearances, overall height,
width, and length dimensions. Peripheral equipment, such as control
cabinets, will also be dimensioned and their relationship to the
equipment established.
Installation drawings will be furnished. These drawings will
show the location and sizes of all services, outline of floor area
required to clear all machine motions, total net weight and major
individual component weights. Drawings will also show bolt layout
and the purpose of each bolt.
Complete list of all motors showing H.P. , amperage, voltage,
speed. cycles, frame specification, and manufacturer.
Electrical wiring and schematic diagrams.
Operator Training
The manufacturer will provide training for shop personnel in
the full operation of the machine and attached computers to reflect
complete operational features and capabilities.
The manufacturer will provide training for Maintenance Personnel.
Training to reflect complete operational features and capabilities.
Ordering Data
Preservation and Packing
Preservation and packing will be in accordance with Paragraphs
6.a.i, 6.b.i, and 6.b.ii.
For shipment within the continental United States, equipment
and tools will be packed, crated or skidded so as to ensure acceptance
by common or other carrier for safe transportation at lowest rate,
to point of delivery. All loose parts. attachments, and accessories
will be suitably boxed. Whenever practical, smaller boxes will
be secured inside the skid, crate or box containing the equipment.
In all cases, the equipment will be preserved in accordance with
best commercial practice and adequately protected from contamination
and physical damage in transit.
For shipment overseas, equipment and tools will be packed, crated
or skidded so as to fit inside standard shipping container, either
200 or 400. All loose parts will be suitably boxed, palletized
or packaged.
In all cases, the equipment will be preserved in accordance with
best commercial practice and adequately protected from contamination
and physical damage in transit.
Shipping Instructions
Complete information concerning the gross weight, size quantity
of shipping units or crates and the contents of each will be forwarded
to the customer, no later than time of shipment.
Each shipping unit or crate will be clearly and permanently marked
to show destination, manufacturerrs order number, gross weight,
size, units or crates in shipment, e.g., I of 6, 2 of 6, etc..
Manufacturerrs Responsibility
The manufacturer will be responsible for the design, manufacture,
performance, reliability, and packaging of all components and systems
defined in this specification, whether or not such components and
systems are of his design and manufacture. This responsibility
will
include technical direction during installation, maintenance assistance
and support for the duration of the warranty period, and responsibility
for completion of all training requirements as listed in this specification.
The manufacturer will provide warranty and guarantee of equipment
performance. The warranty will be for a minimum period of one year
from date of final acceptance of the machine. During this period,
the equipment manufacturer will be responsible for replacement
or repair of any defective parts, components, or systems, the failure
of which is due to faulty materials, workmanship, or engineering.
Exceptions may be made on low cost perishable components, which,
because of preventive maintenance procedures, may require replacement
before one year has expired.
All equipment furnished by Roberts Testing Equipment,
Inc. is warranted against defects in workmanship and material for
a period of one year, with the exception of load cell electrical
cords and batteries. Roberts Testing Equipment, Inc. will not be
liable for damages from improper handling, overloading, transportation
damage, improper storage, incorrect voltage, or other commonsense
operator mistakes. This warranty does not cover freight for the
equipment or travel expense for a Roberts
Testing Equipment, Inc. representative, whichever is applicable.
The repair or replacement of any product or component by Roberts
Testing Equipment, Inc. fulfills its obligation to the purchaser.
Roberts Testing Equipment, Inc. will not be liable for any losses
or damages incurred otherwise.
