78-B7140 Dynapave Two-Point Bending SW - Rev 1 - EN - 30.05.2012.pdf

DYNAPAVE SOFTWARE MODULE for Two-Point Bending Test

MANUALE DI ISTRUZIONI INSTRUCTION MANUAL

Manuale di Istruzioni DYNAPAVE Software DYNAPAVE Software Instruction Manual

CONTENTS 1.0

INTRODUCTION ............................................................................. 1

1.1 1.2 1.3

Icons appearing in the manual.......................... ............. .......................... ........................... .......................... ................... ....... 2 Manual revision history ................................................................................... 3 Safety information ............................................................................................ 4

2.0

DESCRIPTION ................................................................................ 6

2.1

Main features .................................................................................................... 6

3.0

SOFTWARE COMPONENTS .......................................................... 7

3.1 Overview of the software ................................................................................. 7 3.2 System buttons ................................................................................................ 7 3.3 System status display bar ............................................................................... 7 3.4 Main panel ......................................................................................................... 7 3.5 Specimen Setup panel ..................................................................................... 8 3.5.1 Viewing the panel ........................................................................................... 8 3.5.2 Specimen information cells ............................................................................. 8 3.5.3 Initial specimen dimensions table ................................................................... 8 3.5.4 Initial specimen conditions .............................................................................. 9 3.5.5 Test standard control .................................................................................... 10 3.5.6 Test control parameters ................................................................................ 10 3.5.7 Loading shape control .................................................................................. 12 3.5.8 Test termination parameters ......................................................................... 13 3.5.9 Calculation reference transducer control ...................................................... 14 3.6 Test Stage panel ............................................................................................. 15 3.6.1 Viewing the panel ......................................................................................... 15 3.6.2 Start test button ............................................................................................ 15 3.6.3 Stop test button ............................................................................................ 15 3.6.4 Maximum cycles indicator ............................................................................. 15 3.6.5 Results table ................................................................................................. 16 3.6.6 Show cycle cell ............................................................................................. 16 3.6.7 Temperature data ......................................................................................... 16 3.6.8 Temperature error indicators ........................................................................ 16 3.6.9 Transducer data ........................................................................................... 16 3.6.10 Termination stiffness modulus indicator ......................... ............ .......................... .......................... .................. ..... 16 3.6.11 Termination displacement/load indicator ...................................................... 16 3.6.12 Graph options ............................................................................................... 17 3.6.13 Cycles to view cell ........................................................................................ 18 3.6.14 Graph ............................................................................................................ 18 3.6.15 Export to file button ....................................................................................... 18 3.6.16 Test report button ......................................................................................... 18 3.6.17 Test report panel .......................................................................................... 19

4.0

THE TWO-POINT BENDING JIG .................................................. 21

4.1 4.2 4.3 4.4 4.5 4.6 4.6.1 4.6.2

Description ..................................................................................................... 21 Main features .................................................................................................. 21 Intended use ................................................................................................... 22 Technical specifications ................................................................................ 22 Unpacking and inspection ............................................................................. 23 Use of the equipment ..................................................................................... 23 Installing the loading ram .............................................................................. 23 Installing the load cell ................................................................................... 24

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Two-Point Bending Test Rev.0 EN

Manuale di Istruzione DYNAPAVE Software DYNAPAVE Software Instruction Manual

4.6.3 Connecting the load cell ........................... .............. .......................... .......................... .......................... .......................... ............... 25 4.6.4 Installing the external LVDT ......................... ............ .......................... .......................... .......................... ....................... .......... 25 4.6.5 Installing the two-point bending jig in the test frame .......... .......................... ............. ............... 27 4.6.6 Machine verification ...................................................................................... 28 4.7 Maintenance .................................................................................................... 28

5.0

USING THE SOFTWARE .............................................................. 29

5.1 5.2 5.3 5.4 5.5 5.6 5.7

Preparing the system for a test ........................... .............. .......................... .......................... .......................... ................ ... 29 Setting up the test specimen .......................... ............. .......................... ........................... .......................... .................... ........ 32 Entering the test parameters .......................... ............. .......................... ........................... .......................... .................... ........ 36 Running a test ................................................................................................. 39 Creating a printed test report ........................................................................ 41 Creating an ASCII data file .......................... ............. .......................... .......................... .......................... ......................... ............ 42 Ending a test ................................................................................................... 43

6.0

APPENDIX .................................................................................... 45

6.1 6.2 6.3

Calculations used in the software......................... ............ ......................... .......................... ........................... ............... 45 Example test report ........................................................................................ 48 Example ASCII file .......................................................................................... 49

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This instruction manual is an integral part of the machine and should be read before using the machine and be safely kept for future reference. CONTROLS reserves all rights of this manual; no part or whole can be copied without the written permission of CONTROLS . The proper use of this machine must be strictly adhered to, any other use must be considered as incorrect. The manufacturer cannot be held responsible for damage caused by incorrect use of the machine. The machine must not be tampered with for any reason. In case of tampering, the manufacturer declines any responsibility of functioning and safety of the machine. This Manual is published by CONTROLS . CONTROLS

reserve the right to update its manuals without notification in order to correct possible typing errors, mistakes, updating of information and/or updating of programs and/or accessories. Such changes will be inserted in the latest edition of the current manual. This present in English is the original version. Printed in Italy. Two-Point Bending Test Rev.1 EN

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1.0 INTRODUCTION This test module allows the user to carry out a two-point bending test, using Controls’ DYNPAVE 30kN test frame (78-B7030) and a 2-point bending jig (78B7140), in order to calculate the fatigue life or stiffness modulus of a trapezoidal asphalt specimen. The software enables a test to be performed to EN 12697-24 Annex A or EN 12697-26 Annex A test standards. The user can choose the control mode for the fatigue test (displacement, strain, stress or load), and also select the wave shape. Once a test is started, all the parameters are controlled by the software as it applies the loading cycles to the specimen. During the test the software displays real-time test data and calculated cycle summary data. A graph is also displayed, which the user can adapt to show a wide variety of different data sets, for example, real-time load or displacement values against time or cycle number, cycle summary data for load, stress, strain, modulus, phase angle or temperature, or a hysteresis loop of stress against strain. A test report and an ASCII file containing all the relevant information, data and results of a test can be easily generated after a test has been completed. A provision to create template files means that the user can quickly and easily set up repeat tests without re-entering any test parameters. The software also contains functions for managing the DYNAPAVE system, which allows the user to calibrate transducers, set system limits, edit the language of the software and tune the control channels. Details of these features, which are common to all the test modules, can be found in the Dynapave Main Software manual.


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1.1

Icons appearing in the manual



This icon indicates a NOTE; please read the items marked by this icon carefully. This icon indicates an WARNING message; the items marked by this icon refer to the safety aspects of the operator and / or the service engineer. This icon indicates an WARNING message; the items marked by this icon refer to the risk of hand injury to the operator and / or the service engineer. This icon indicates that INFORMATION about how the item is calculated can be found in the Appendix (Section 6.0).

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1.2

Manual revision history Revision / Date Rev. 1 (SwV 0.0.253) 30.05.2012


Change description First release

3

Author Julia Wawrzynowicz

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1.3

Safety information NOTE: Please read this chapter thoroughly.



CONTROLS designs and builds its equipment in compliance with relevant safety requirements; furthermore it supplies all information necessary for correct usage and warnings related to use of the equipment. CONTROLS will not be held responsible for: Use of the equipment other than the intended use; Damage to the equipment and/or to the operator, caused by use of either installation or maintenance procedures other than those described in this manual, or by incorrect use; Mechanical and/or electrical modifications performed during and/or after the installation, other than those described in this manual. Installation and any technical intervention must only be performed by qualified service technicians authorised by CONTROLS. Only authorised and qualified service technicians may remove the covers and/or gain access to the components under voltage. During normal use, if the operator detects irregularities or damage, he/she should immediately inform the authorised and qualified service technician. Below is a list of all the warnings found in this manual; details of each safety related issue can be found in the relevant sections. WARNING: The test specimens and jigs can be heavy and awkward to carry. To avoid injury, take care and use appropriate personal protection equipment when loading/unloading specimens from the test frame.

WARNING: The correct test frame must be selected in the software before the pressure is switched on. If the incorrect test frame is selected in the software when the pressure is switched on, there is a risk of damage to equipment and danger to personnel due to uncontrolled movement of the actuator.

WARNING: Keep hands/fingers away from the moving parts of the jig and the test frame while applying load to the specimen.

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WARNING: When working with the jig in the test frame, keep hands/fingers away from the moving parts of the jig and the test frame.

WARNING: The door of the thermostatic cabinet must be kept closed when a test is running. Table 1-1 details those parts of the system that may present some residual risk to the safety of personnel if the instructions provided in this manual and the hardware manuals are not duly followed. Personnel Operator

Action Loading/unloading a test jig into/out of the test frame

Residual risk Manual handling injury

Applying load to the specimen in the frame

Injury to the hand

Preparing the test jig in the frame

Injury to the hand

Switching the test frame on

If the incorrect test frame is selected in the software when the system is switched on, there is a risk of damage to equipment and danger to personnel due to uncontrolled movement of the actuator.

Safety advice Ensure the item is not too heavy for you to carry before lifting it to/from the frame. Ensure that you have a good grip on the item before moving it. If it is necessary to stoop during the operation, ensure that you bend your knees and do not bend from the waist. Wear suitable personal protective equipment (e.g. gloves, safety shoes). Ensure that hands are kept well clear of the moving parts of the frame during this procedure. Since there is potential for the actuator piston to move, even when the pump is switched off, hands must be kept clear of the jigs. Use the appropriate, recommended tools to make adjustments instead, wherever possible. Ensure that the correct test frame option has been selected in the software before using the system. Refer to Section 4.1 of the relevant hardware manual for details.

Table 1-1


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2.0 DESCRIPTION 2.1

Main features Allows the user to carry out a two-point bending test to EN12697-24 Annex A or EN12697-26 Annex A standards Tests can be performed in load, stress, displacement or strain control Temperatures and transducer readings are displayed and monitored throughout the test Different wave shapes can be selected for the test, including a user-defined wave shape Measured and calculated test data are displayed for the loading cycles, including: complex modulus, bending displacement, load, stress and phase angle User-defined plots of cycle data are displayed for actual readings, cycle summary (peak and valley), or a hysteresis loop Tests can be automatically stopped according to user-defined termination criteria ASCII files can be created, containing all the test information and data, transducer readings and test results A one-page test report can be generated, containing specimen details, test parameters and tabulated and graphical test results Previous tests can be reviewed and printed.

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NOTE: The two-point bending test can only be performed with the 30kN servohydraulic test frame (78-B7030).

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3.0 SOFTWARE COMPONENTS 3.1

Overview of the software The software comprises five main elements: system buttons for viewing real-time transducer data and for ending a test, a display bar which indicates the status of system components, the main panel which contains the functions needed to set up a test and manage the system, the specimen setup panel in which the initial measurements and test parameters are entered, and the test stage panel where the functions to start, monitor and stop a test are located. These elements are detailed below. (See Fig. 3-1)

3.2

System buttons This component is common to all the test modules. Dynapave Main Software manual for details.

See Section 4.2 of the

3.3

System status display bar This component is common to all the test modules. See Section 4.3 of the Dynapave Main Software manual for details.

3.4

Main panel The components that you see on this panel are common to all the test modules. See Section 4.4 of the Dynapave Main Software manual for details. 3.4

3.5

3.6

3.3


3.2

Fig. 3-1

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3.5

3.5.1

Specimen Setup panel This panel is for entering information about the specimen such as identification details and dimensions, and for setting the test parameters. See Fig. 3-2. Viewing the panel Select the ‘Specimen Setup’ tab to view the panel.

3.5.3

3.5.5

3.5.1

3.5.6

3.5.2

3.5.4

3.5.8

3.5.7

3.5.9

Fig. 3-2

3.5.2

Specimen information cells For entering the following information about the test and the specimen: Test reference – the reference number of the project / job / batch Operator – the name or initials of the person carrying out the test Specimen no. – the identifying number of the test specimen Location – the name of the location or site where the specimen is f rom Comments – any comments that you want to be recorded about the test or the specimen All the items listed above are shown on the test report generated by the software.

3.5.3

Initial specimen dimensions table For entering the length of the large base and small base, the thickness and the height of the specimen (see Fig. 3-3), in millimetres, as measured during the preparation of the specimen. Up to four measurements of each dimension may be entered, taken at different points on the specimen. Click on a cell to enter a value. You can use the tab key to move to the next cell in the table. A number with up to four decimal places may be entered.

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Fig. 3-3

3.5.4

Initial specimen conditions Calculated values and inputs relating to the initial condition of the specimen. See Fig. 3-4.

3.5.4.1

Average large base indicator Displays the mean initial length of the large base of the specimen, in millimetres, calculated using the large base measurements entered in the Initial specimen conditions table (Item 3.5.3).

3.5.4.2

Average small base indicator Displays the mean initial length of the small base of the specimen, in millimetres, calculated using the small base measurements entered in the Initial specimen conditions table (Item 3.5.3). 3.5.4.1

3.5.4.2

3.5.4.5

3.5.4.4

3.5.4.3

3.5.4.7

3.5.4.6

3.5.4.8

3.5.4.9

3.5.4.10

Fig. 3-4 3.5.4.3

Average thickness indicator Displays the mean initial thickness of the specimen, in millimetres, calculated using the thickness measurements entered in the Initial specimen conditions table (Item 3.5.3).


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3.5.4.4

Average height indicator Displays the mean initial height of the specimen, in millimetres, calculated using the height measurements entered in the Initial specimen conditions table (Item 3.5.3).

3.5.4.5

Specimen mass cell For entering the initial mass of the specimen, in kilograms.

3.5.4.6

Specimen density indicator Displays the calculated bulk density of the specimen, in kilograms per cubic metre.

3.5.4.7

Mass of moveable parts cell For entering the total mass of the moveable parts of the two-point bending jig, including the mass of any adhesive (if used), and the mass of the load frame between the load cell and the loading mechanism, in kilograms.

3.5.4.8

Constant relative to maximum strain indicator Displays the calculated constant that enables the displacement of the small base of the specimen to be converted into maximum strain, in inverse metres.

3.5.4.9

Form factor indicator Displays the form factor (a function of specimen size and form), in inverse metres.

3.5.4.10

Mass factor cell Displays the mass factor (a function of specimen mass and the mass of the moveable parts that influence the resultant force by their inertial effects), in grams.

3.5.5

Test standard control For selecting which standard you want to perform the test to. To select a test standard, click on the arrow to the right of the cell and pick an option from the list.

3.5.6

Test control parameters For specifying how you want the test to be controlled. See Fig. 3-5.

3.5.6.1

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Control mode For selecting which measurement will give feedback in order to control the loading pulses. To select a mode, click on the arrow to the right of the cell and pick from the following options: ‘ Displacement (Vertical LVDT)’ to subject the specimen to a constant level of displacement on each load cycle, with feedback provided by the external LVDT; ‘ Strain (Vertical LVDT)’ to subject the specimen to a constant level of strain on each load cycle, with feedback provided by the external LVDT; ‘ Load ’ to subject the specimen to a constant level of load on each load cycle, with feedback provided by the load cell; 10



‘ Stress’ to subject the specimen to a constant level of stress on each load cycle, with feedback provided by the load cell; ‘ Displacement (Actuator position)’ to subject the specimen to a constant level of displacement on each load cycle, with feedback provided by the internal actuator LVDT; ‘ Strain (Actuator position)’ to subject the specimen to a constant level of strain on each load cycle, with feedback provided by the internal actuator LVDT. 3.5.6.1

3.5.6.4

3.5.6.3 3.5.6.2

3.5.6.5

3.5.6.6

Fig. 3-5 3.5.6.2

Target amplitude cell For entering the amplitude you want for the loading pulses. See Fig. 3-6 & Fig. 3-7. The type of amplitude depends on which C ontrol mode is selected: If ‘ Displacement (Actuator position)’ or ‘ Displacement (V ertical LVDT)’ is selected, the amplitude value required is displacement, in micrometres; If ‘ Strain (Actuator position)’ or ‘ Strain (Vertical LVDT)’ is selected, the value required is strain, in microstrain; If ‘ Stress’ is selected, the value required is stress, in kilopascals; If ‘ Load ’ is selected, the value required is load, in newtons. This cell will be locked if ‘ User defined ’ is selected for the Loading s hape control (3.5.7).

Fig. 3-6


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Fig. 3-7 3.5.6.3

Target temperature cell For entering the temperature, in degrees Celsius, that the test is to be carried out at. The skin and core temperature probe readings are monitored during the test and if either reading exceeds the target temperature by more than +/- 0.5 degrees, a warning light will be shown in the Test Stage panel (see Item 3.6.8).

3.5.6.4

Frequency cell For entering the frequency required for the test, in Hertz. This cell will be locked if ‘ User defined ’ is selected for the Loading s hape control (3.5.7).

3.5.6.5

Maximum readings per cycle indicator Displays the maximum number of readings that can be logged for each loading cycle at the requested frequency (Item 3.5.6.4).

3.5.6.6

Readings to log per cycle cell For entering the number of readings you want to be logged for each loading cycle. The number must not exceed the value displayed in the Maximum reading s per cycle indicator .

3.5.7

Loading shape control For selecting a wave shape for the loading cycles of the test. To select a wave shape, click on the arrow to the right of the cell and pick an option from the list. A graphical representation of the selected wave shape is shown to the right of the control. If you want to use your own wave shape, select ‘ User defined ’ and then load the wave shape file using the Us er defined file function.

3.5.7.1

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User defined file For loading in a wave shape file that you have created defining a wave shape for the loading cycles. See Fig. 3-8. This function is only available if you have selected ‘ User defined’ for the Loading s hape control.

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A wave shape file is a .udw file, which is created using the progr am ‘UDW Generator’ that accompanies this software. Click the open folder icon to the right of the cell to locate your required .udw file. For information on how to create a .udw file, see the Dynapave Main Software manual, Section 5.9.

Fig. 3-8

3.5.8

3.5.7.1

Test termination parameters For specifying how and when you want the system to automatically stop the test. See Fig. 3-9. Three termination conditions are available (Items 3.5.8.1 to 3.5.8.3). For each termination condition that you want to be taken into consideration during the test, enter a value in the cell and tick the adjacent check box. If more than one condition is ticked, the one that is reached first will determine when the stage stops. The test cannot be restarted after it has stopped. 3.5.8.1

3.5.8.2

3.5.8.3

Fig. 3-9

3.5.8.4

3.5.8.1

Maximum cycle count cell For entering the maximum number of loading cycles that you want to be applied to the specimen before the system stops the test. The maximum number that can be entered is 10,000,000.

3.5.8.2

Displacement/load termination cell For entering the amount that you want to allow the displacement or load readings to decrease from their initial value by, in percent, before the system stops the test. The value required depends on which C ontrol mode is selected:


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If ‘ Displacement (Actuator position)’, ‘ Displacement (Vertical LVDT)’ , ‘ Strain (Actuator position)’ or ‘ Strain (Vertical LVDT)’ is selected, the input is for displacement; If ‘ Load ’ or ‘ Stress’ is selected, the input is for load. The initial value is calculated using the cycle numbers specified in the Initial cycle number cells . 3.5.8.3

Modulus termination cell For entering the amount that you want to allow the stiffness modulus to reduce from its initial value by, in percent, before t he system stops the test. The initial value is calculated using the cycle numbers specified in the Initial cycle number cells .

3.5.8.4

Initial cycle number cells For entering the first and last cycles that you want to use calculate the initial values for the termination conditions. An average of the complex modulus, displacement and load values at each cycle between those specified will be calculated.

3.5.9

Calculation reference transducer control For selecting which displacement measurement device readings will be used to calculate deformation and strain data during the test. Click on the arrow to the right of the cell to select from the following options: ‘ Vertical LVDT’ to use readings from the external LVDT; Actuator ‘ position’ to use readings from the internal actuator LVDT.

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3.6

3.6.1

Test Stage panel This panel contains all the functions necessary for starting, stopping and monitoring the test as well as for generating a test report and exporting the data to an ASCII file. The panel displays live transducer readings, calculated results and a graph of the test data. See Fig. 3-10. The panel is only available after the New test button on the Main panel has been clicked. Viewing the panel Select the ‘Test Stage’ tab to view the panel.

3.6.4 3.6.3

3.6.16

3.6.13 3.6.2

3.6.12

3.6.10 3.6.1

3.6.5

3.6.6

3.6.11

3.6.9

3.6.7 3.6.8

3.6.15

3.6.14

Fig. 3-10

3.6.2

Start test button Starts the system applying loading cycles to the specimen, in accordance with the parameters specified in the Specimen setup panel (see Item 3.5.6).

3.6.3

Stop test button For stopping the system applying cycles, if it is necessary to do so manually before any of the termination conditions entered on the Specimen setup panel (Items 3.5.8.1 to 3.5.8.3) have been met. The active cycle will be completed before the cycling stops. When the test has been stopped, it cannot be restarted.

3.6.4

Maximum cycles indicator Displays the maximum number of loading cycles that will be carried out.


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This value is taken from the Maximum cycle count cell (Item 3.5.8.1) on the S pecimen s etup panel. 3.6.5

Results table Displays measured and calculated data for the loading cycles. The data shown in the table is for the most recent complete pulse. The pulse number is shown in the header row of the data column. After the test has finished, data for any one cycle of the test can be viewed in the table by entering the cycle number in the S how cycle cell (Item 3.6.6).

3.6.6

Show cycle cell For entering the number of the cycle that you want to see the data for in the Results table. Click on the arrows to the right of the cell to increase or decrease the value, or type a number in directly. The cell will only be available when the test has finished.

3.6.7

Temperature data Displays live readings of the temperature probes attached to the dummy specimen, in degrees Celsius.

3.6.8

Temperature error indicators Indicates whether or not the measured temperature is within the specified range. The normal status of the indicators is green. If either of the probe readings exceed the specified test temperature (Item 3.5.6.3) by more than half a degree Celsius, the indicator will display a red warning colour. The user can decide whether to stop the test and reject the results if this occurs.

3.6.9

Transducer data Displays live readings of the system’s transducers. Level indicators underneath the two displacement readings indicate the current absolute position of the transducers within their full range. The readings shown are relative to any zero offset that has been applied (see Section 4.7 of the Dynapave Main Software manual).

3.6.10 Termination stiffness modulus indicator Displays the stiffness modulus at which the test will be terminated, if and when it is reached (if it was selected as a termination condition). The value is in megapascals and is a percentage of the stiffness modulus at the initial cycle (see Item 3.5.8). 3.6.11 Termination displacement/load indicator Displays the displacement or load reading at which the test will be terminated, if and when it is reached (if it was selected as a termination condition). The value is in millimetres or newtons and is a percentage of the displacement or load at the initial cycle (see Item 3.5.8). The value shown depends on which C ontrol mode (Item 3.5.6.1) is selected:

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If ‘ Displacement (Actuator position)’, ‘ Displacement (Vertical LVDT)’, ‘ Strain (Actuator position)’ or ‘ Strain (Vertical LVDT)’ is selected, termination deflection is shown; If ‘ Load ’ or ‘ Stress’ is selected, termination load is shown. 3.6.12 Graph options For selecting what data is shown on the Graph and how it is displayed (see Fig. 3-9). 3.6.12.1

3.6.12.2

3.6.12.3

3.6.12.4

3.6.12.5

Fig. 3-11 3.6.12.1

Graph control For selecting whether to plot transducer readings, cycle summary data, or a hysteresis loop on the graph. Click on the arrow to the right of the cell to select from the following options: Actual ‘ values’ plots live measured readings for the transducers; Cycle summary ’ plots peak and valley data for all the cycles completed so far; ‘ Hysteresis’ plots a hysteresis loop of the most recently completed cycle. With Actual ‘ values’ selected, only the most recently completed cycles are plotted - the number of cycles depends on the number entered in the C ycles to view cell .

3.6.12.2

Y-axis control For selecting which group of data to display on the graph. Click on the arrow to the right of the cell to select an option. Availability of the options depends on what is selected from the Graph control. With Actual ‘ values’ selected, the options are: Displacement and Load. With ‘ Cycle summary ’ selected, the options are: Displacement, Strain, Load, Stress, Modulus, Phase angle and Temperature. With ‘ Hysteresis loop’ selected, the options are Load vs Displacement and Stress vs Strain.


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3.6.12.3

Graph legend Provides a colour key for the data on the graph and controls which individual elements of the selected data group are plotted. Tick the check boxes for the data that you want to be plotted; Clear the boxes of the data that you don’t want to see.

3.6.12.4

X-axis control For selecting whether time (in seconds) or cycle number is used for the xaxis. This control is not available when ‘ Hysteresis loop’ is selected for the Graph control. Click on the arrow to the right of the cell to select an option from the list.

3.6.12.5

Y-axis scale control For selecting whether the y-axis of the graph is scaled automatically or manually. Click on the arrow to the right of the cell to select an option from the list. With ‘ Manual scale’ selected, the minimum and maximum values of the axis can be changed by double-clicking on the value and then typing in a new one. This control is not available when ‘ Hysteresis loop’ is selected for the Graph control.

3.6.13 Cycles to view cell For entering the number of cycles that you want to see displayed at one time on the graph. This function is only applicable when Actual ‘ values’ is selected for the Graph control. The maximum number that can be selected is 10. Click on the arrows to the right of the cell to increase or decrease the value, or type a number in directly. 3.6.14 Graph Displays graphical test data. The type of data displayed on the graph depends on which options are selected from the G raph options (Item 3.6.12). 3.6.15 Export to file button Creates an ASCII file containing all the specimen information and test parameters from the Specimen Setup panel, as well as the data shown on the graph and the Results table at the time the file is created. The button will only be unlocked when the test has finished. The ASCII file is a semicolon delimited text file. It can be opened and viewed in a spreadsheet program such as Microsoft Excel. 3.6.16 Test report button Opens the Test report panel (see Item 3.6.17) from which a report of the test can be printed. The button will only be unlocked when a test has finished.

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3.6.17 Test report panel Displays a preview of the one-page test report, with functions at the bottom of the panel for printing it. The report contains specimen details, initial specimen conditions and test parameters taken from the Specimen setup panel, as well as a duplicate of the Graph and the Results table displayed on the Test stage panel at the time the button is clicked. See Fig. 3-12. To view any unseen sections of the panel, use the vertical scroll bar on the right-hand side of the panel.

3.6.17.1

3.6.17.3

3.6.17.2

Fig. 3-12 3.6.17.1

Printer selection box For choosing which printer you want to print the test report on. Use the vertical scroll bar to scroll through the list. Click on a printer to select it - the printer will be highlighted when it is selected. Only printers that are already set up on the PC will be shown on the list.


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3.6.17.2

Print button Prints the test report on the selected printer.

3.6.17.3

Cancel button Closes the Test report panel.

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4.0 THE TWO-POINT BENDING JIG 4.1 Description The two-point bending jig (78-B7140) is designed to be used with the 30kN DYNAPAVE test frame (78-B7030) to subject a trapezoidal asphalt specimen to two-point bending. It conforms to EN 12697-24 Annex A and EN 12697-26 Annex A standards. The jig is a reinforced L-shaped frame into which the specimen is secured using two end plates. The specimen is held rigidly at the base, while a cyclic loading is applied to the top of the specimen. The resulting movements are measured by the load cell and external LVDT (linear variable differential transducer) which are supplied with the jig. The jig is designed to hold specimens with a nominal height of 250mm. The following figure identifies the main component parts of the jig:

TEST SPECIMEN LOAD CELL

END PLATES LVDT PORT

EXTERNAL LVDT

Fig. 4-1

4.2

Main features Conforms to EN 12697-24 Annex A and EN 12697-26 Annex A standards Specimens of all sizes specified in the test standard can be tested High precision 1mm LVDT and 3kN load cell are included Withstands static vertical forces up to 3kN for use with the CONTROLS DYNAPAVE 30kN test frame Frequency range from static to 60Hz


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A locking mechanism secures the jig to the test frame to ensure that the jig does not move during cycling Includes a set of end plates (one base, one top) to be glued to the specimen for mounting in the jig 4.3

Intended use The two-point bending jig may only be used to perform asphalt material tests to relevant international standards as specified in the current version of the CONTROLS general catalogue. The jig is designed to be operated by one person, who will mount the asphalt specimen, install the jig into a test frame and start the test using the software installed on the PC. During normal use, the working area of the system for the operator is in front of the PC, which should be located adjacent to the test frame. WARNING: The test specimens and jigs can be heavy and awkward to carry. To avoid injury, take care and use appropriate personal protection equipment when loading/unloading specimens from the test frame. The jig must never be used for reasons other than those for which it was designed and manufactured. Any other use of the jig must be considered improper and consequently dangerous. CONTROLS will not be held responsible for damage or injury caused by improper use of the jig.

4.4

Technical specifications The main characteristics of the equipment are listed below. Two-point bending jig: Overall dimensions: 117 x 450 x 420mm (W x D x H) Weight: 11kg Maximum loading capacity: 3kN Operating temperature: -40°C to +100°C Specimen sizes: 70 x 25 x 50 x 250mm, 70 x 25 x 25 x 250mm, 56 x 25 x 25 x 250mm (large base x small base x thickness x height) External LVDT: Capacity: +/- 1mm Sensitivity: 200mV/V/mm Accuracy: 1µm Resolution: < 1µm Repeatability: 0.15µm Load cell: Capacity: 3kN Sensitivity: 2mV/V Combined error: ≤ ±0.023% Non-repeatability: ≤ ±0.015%

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4.5



4.6

Unpacking and inspection The equipment was carefully checked before shipment and left CONTROLS in good working order. Before installation, it should be inspected for any damage that may have occurred in transit. NOTE: If the delivery crate or packaging material is found to be damaged, it should be retained until the equipment has been checked. If the equipment is damaged and/or the contents are incomplete, notify your local CONTROLS representative. If the delivery crate is damaged or shows signs of stress, notify the carrier as well as your CONTROLS representative. Retain the shipping material for the carriers’ inspection and, if possible, take photographs. Use of the equipment The two-point bending jig should only be used with the DYNAPAVE asphalt testing system. Instructions of how to carry out an two-point bending test using the jig are described in Section 5.0 of this manual. When carrying the jig, ensure that it is held securely with both hands. WARNING: The test specimens and jigs can be heavy and awkward to carry. To avoid injury, take care and use appropriate personal protection equipment when loading/unloading specimens from the test frame.

4.6.1

Installing the loading ram The load cell supplied with the two-point bending jig will be used as the load control channel for the system so, for this test setup, the test frame load cell is not needed. The loading ram connects the test frame actuator to the load cell on the jig. The ram type shown in Fig. 4-3 must be used for a two-point bending test; it should be connected as follows:

1.

Disconnect the test frame load cell connector from socket ‘C1’ in the rear panel of the CDC unit (see Fig. 4-7) and pull the cable in through the hole in the side of the thermostatic cabinet.

2.

Unscrew and remove the test frame load cell and round-ended loading ram (shown in Fig. 4-2) to leave the actuator piston with nothing attached (as shown in Fig. 4-4).

3.

Screw the flat-ended loading ram (shown in Fig. 4-3) onto the actuator piston. The procedure for connecting the ram to the two-point bending jig is covered in Section 5.2.


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Test frame load cell

Round-ended loading ram

Flat-ended loading ram

Actuator piston

Fig. 4-2

4.6.2

1.

Fig. 4-3

Fig. 4-4

Installing the load cell This section describes how to attach the load cell to the loading ram. The load cell is supplied with the two-point bending jig. To carry out the procedure, you will need a 10mm Allen key and spanner. Undo the Allen bolt and nut securing the eye bolt of the load cell to the small base mounting block of the jig (see Fig. 4-5). Remove the load cell.

LOAD CELL

EYE BOLT

SMALL BASE MOUNTING BLOCK

Fig. 4-5

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2.

Screw the piston connector on top of the load cell into the loading ram connected to the actuator of the test frame (see Fig. 4-6). LOADING RAM

PISTON CONNECTOR

LOAD CELL

Fig. 4-6

4.6.3

1.

Connecting the load cell The following procedure describes how to connect the load cell supplied with the two-point bending jig to the CDC unit. The test frame load cell should have already been disconnected, as described in Section 4.6.1. Feed the load cell cable through the hole in the side of the thermostatic cabinet.

Fig. 4-7

2.

4.6.4

1.

Plug the connector into its transducer conditioning module and then connect the 9-pin D-connector to socket ‘C1’ in the rear panel of the CDC unit (see Fig. 4-7). Do up the screw-pins to secure the connection. Installing the external LVDT This section describes how to install and adjust the 1mm external LVDT which is included with the two-point bending jig. To carry out the procedure, you will need a 2mm Allen key. Fully unscrew the upper ring nut securing the LVDT port to the jig (see Fig. 4-8). Remove the port by pulling it downwards through the hole in the bar. Put the ring nut and spacers to one side.


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RING NUT SPACERS

LVDT PORT

Fig. 4-8

2.

Loosen the grub screw on the LVDT port using the Allen key (see Fig. 4-9).

LVDT PORT

Fig. 4-9

LVDT

Fig. 4-10

3.

Push the LVDT up into the LVDT port until you see its tip coming out at the top (see Fig. 4-10). Adjust its position so that when the tip is fully pushed in, it is hidden within the port (this will prevent the LVDT being damaged if a specimen breaks during testing). Tighten the grub screw to hold the LVDT securely in place in the port.

4.

Insert the port back into place on the jig and replace the spacers and the upper ring nut as shown in Fig. 4-8.

5.

Place the jig onto the lower platen of the test frame in the thermostatic cabinet and feed the LVDT cable out through the hole in the side of the cabinet. Plug the connector into its transducer conditioning module and then connect the 9-pin D-connector to socket ‘C4’ on the rear panel of the CDC unit (seeFig. 4-11).

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Fig. 4-11

4.6.5

Installing the two-point bending jig in the test frame Before using the jig for testing, it must be secured to the base platen of the test frame to prevent any possibility of lifting during the extension portions of the loading cycles. To carry out the procedure, you will need a 12mm Allen key. The procedure is as follows:

1.

Make sure there is enough clearance between the loading ram of the actuator and the jig – if necessary, move the crosshead of the test frame up until the eye bolt of the load cell is about 12cm above the LVDT mounting bar (see Fig. 4-12). (See the relevant hardware manual for instructions on moving the crosshead.)

2.

If there is a central locating pin in the base platen of the test frame (directly underneath the actuator piston), unscrew and remove it.

3.

Position the jig with the central hole in its base over the central hole in the base platen of the test frame.

4.

Insert the locking bolt into the hole (see Fig. 4-12) and fully tighten it using the Allen key.

LVDT MOUNTING BAR

LOCKING BOLT

Fig. 4-12 Two-Point Bending Test Rev.1 EN

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4.6.6

Machine verification An embedding check of the two-point bending jig can be carried out using the aluminium calibration beam available from Controls (78-B7142). The procedure is outlined in EN 12697-24 Clause A.3.3.

4.7 Maintenance Periodic inspections and maintenance should be carried out according to the following table: Action Check to ensure that there is no damage to the equipment and that all moving parts are working correctly Clean off any sample debris

Who Operator

When Before every working session

Operator

Check that all fixings are tightly fastened Calibrate load cell and LVDT

Operator

At the end of each working session Monthly

Qualified service engineer

Yearly or at intervals recommended by laboratory standards

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5.0 USING THE SOFTWARE WARNING: The correct test frame must be selected in the software before the pressure is switched on. If the incorrect test frame is selected in the software when the pressure is switched on, there is a risk of damage to equipment and danger to personnel due to uncontrolled movement of the actuator.

WARNING: Keep hands/fingers away from the moving parts of the jig and the test frame while applying load to the specimen.

WARNING: When working with the jig in the test frame, keep hands/fingers away from the moving parts of the jig and the test frame.

WARNING: The door of the thermostatic cabinet must be kept closed when a test is running.

5.1





Preparing the system for a test NOTE: Installation of the system must have been completed according to the instructions given in the relevant hardware manual before carrying out a test. Before starting-up the system, ensure that the appropriate transducers for the Two-Point Bending test are connected into the correct sockets on the rear panel of the CDC unit. See the relevant hardware manual for details.

NOTE: In order to carry out a Two-Point Bending test, the relevant test module must be licensed and registered on the system PC. For further information, see Section 5.8 of the Dynapave Main Software manual.

1.

If you haven’t already done so, switch the system on according to the instructions in Section 4.1 of the relevant hardware manual.

2.

Make sure the thermostatic cabinet is switched on and is set to the temperature required for your first test.

3.

On the Main panel of the software, select ‘Two-Point Bending’ from the Test method control (see Fig. 5-1).


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Manuale di Istruzione DYNAPAVE Software DYNAPAVE Software Instruction Manual Test method control

Fig. 5-1

4.

Open the Manual control panel by clicking the Manual control button (see Fig. 5-1).

Actuator up button

Actuator down button

5.

Transducer reading indicator

Movement cell

Fig. 5-2

Move the actuator to approximately 2mm above the centre of its travel by entering a small value (e.g. 0.5mm) in the Movement cell and repeatedly clicking the Actuator up button or Actuator down button until you see that the position is reached in the Transducer reading indicator (see Fig. 5-2).

Fig. 5-3

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6.

Check the reading of the load cell in the Transducer reading indicator . If it is not reading 0N +/- 5N, click the Display button (see Fig. 5-3) to open the Realtime values panel. Click the Zero button in line with the load cell reading (see Fig. 5-4) to set the load reading to 0N and then click the Close button to close the panel.

Fig. 5-4

7.

Check the function of the LVDT by pushing in the stem and watching for movement of the reading in the Transducer reading indicator on the Manual control panel in the software.

8.

Close the Manual control panel by clicking the Close button.


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5.2

Setting up the test specimen NOTE: In order to monitor the temperature of the test specimen during the test, a dummy specimen of similar material and dimensions should be available, to which temperature probes can be attached. See the relevant test standard for details.



1.

Measure the height, thickness and large and small base widths of the specimen at up to 4 points along its length, and weigh the specimen, in accordance with the relevant test standard. Make a note of the measurements.

2.

Glue the end plates to the large base and small base of the specimen, in accordance with the relevant test standard.

3.

Label the specimen and place it a controlled-temperature environment until it has reached the required test temperature.

4.

Place the pin of the small base plate through the elongated hole in the small base mounting block and secure it with the washer and nut (see Fig. 5-5). SPECIMEN


SMALL BASE PLATE

SMALL BASE PLATE

Fig. 5-5

5.

Using a 3mm Allen key, tighten the two grub screws located at the bottom of the small base mounting block (see Fig. 5-6) to ensure that there is no gap at the top of the small base plate. SMALL BASE MOUNTING BLOCK

SMALL BASE PLATE

Fig. 5-6

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6.

Put the dummy specimen into the thermostatic cabinet next to the two-point bending jig, but make sure it won’t get in the way during the test. Attach the core and skin temperature probes to the dummy specimen.

7.

Place the specimen in the two-point bending jig, as shown in Fig. 5-7, and screw in the two bolts that secure the large base plate to the jig. (A washer should be fitted between each bolt head and the base plate.) LARGE BASE PLATE

Fig. 5-7

8.

Check that the tip of the LVDT is touching the bottom of the small base mounting block and check the reading of the LVDT in the Real time values on the Main panel of the software (see Fig. 5-8). Ideally, you want the reading to be in the middle of its range. This value depends on how the LVDT has been calibrated – if it was calibrated from 0 to 1mm, you want it to read 0.5mm (+/-0.005mm). If it was calibrated from -0.5 to 0.5mm, it should read 0mm (+/-0.005mm). If it needs adjusting, follow the next step. If it is already reading mid-range, go to Step 10.

Fig. 5-8

9.

To adjust the LVDT position, turn the ring nuts (see Fig. 5-9) until you see that the tip of the transducer is touching the small base mounting block and the reading is in the middle of its range.


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SMALL BASE MOUNTING BLOCK RING NUTS

Fig. 5-9

10.

Make a note of the LVDT reading.

11.

Gradually move the crosshead of the test frame down (see the relevant hardware manual for instructions on moving the crosshead) until the hole of the eye bolt is in line with the hole in the small base mounting block (see Fig. 5-10).

Fig. 5-10

12.

Check that the reading of the load cell is still zero and the LVDT is still reading the value you noted in Step 10 to make sure no stress or strain is being applied to the specimen.

13.

Insert the bolt through the hole and do up the nut to secure it. (A washer should be fitted behind the bolt head.) Repeat Step 12 and if the readings have changed, adjust the actuator position (using the controls in the Manual control panel) to bring them back to their original readings.

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Fig. 5-11

14.

Close the door of the cabinet.


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5.3

Entering the test parameters

1.

On the Main panel, enter a name for the test in the Test name cell and then click the New test button (see Fig. 5-12). All the data files generated during the test will be saved with the name you enter. The location of the saved files is shown in the Log directory indicator . (If you want to change the location, enter a different file path in the Log file path cell in the C onfig panel.) Test name cell

Log directory indicator

Fig. 5-12

2.

If you want to load a template from a previous test, click the Load template button and find the file. A template file contains all the specimen details, test settings and parameters used for the test that was active when the template was created. Loading in a template file allows you to perform a duplicate test without re-entering any details or parameters. All that needs to be changed is the Tes t name. (See the Dynapave Main Software manual, Section 4.4 for more information.)

If you loaded in a template (in the previous step) and do not need to change any specimen details or test parameters, go straight to Section 5.4. Otherwise, proceed to Step 3. 3.

Click on the ‘Specimen Setup’ tab to display the Specimen Setup panel and enter the test reference, operator name or initials, specimen number and location, and any comments you may have about the test or the specimen in the Specimen information cells (see Fig. 5-13). The text in these cells is printed on the test report.

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4.

Enter the dimensions of the specimen that you took in Step 1 of Section 5.2 in the Initial specimen conditions table. Conditions such as average large and small base length, thickness, height and specimen density will be calculated using the values you enter.

5.

Enter the weight of the specimen in the Specimen mass cell. Enter a value in the Mass of moveable parts cell for the total mass of the moveable parts of the two-point bending jig, including the mass of any adhesive (if used), and the mass of the load frame between the load cell and the loading mechanism, in kilograms. Specimen information cells

Initial specimen conditions table

Mass of moveable parts cell

Specimen mass cell

Fig. 5-13

6.

From the Test standard control (see Fig. 5-14), select which test standard you want to perform the test to. Test standard control

Target amplitude cell

Control mode

Loading shape control

Initial cycle number cells

Fig. 5-14

7.

Enter the following parameters for controlling the test (see Fig. 5-14): From the Control mode, select which type of measurement you want to use to control the loading pulses. For example, if you want the system to maintain a constant level of displacement during cycling, as is required by the EN12697-26 standard, select ‘ Displacement (vertical LVDT)’ or ‘ Displacement (actuator position)’ . In the Target amplitude cell, enter your required amplitude for the loading pulses. The type of amplitude depends on what you selected for the C ontrol mode. In the Target temperature cell, enter the temperature that the test will be carried out at, in degrees Celsius


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If the temperature deviates by more than 0.5ºC during the test, a warning light will be shown. Enter your chosen Frequency for the test, in Hertz. Enter the number of readings you want to be recorded in the data file for each cycle in the Readings to log per cycle cell The maximum number that can be entered is shown in the Maximum reading s per cycle indicator, and depends on the test frequency. 8.

Select a wave shape for the pulses from the Loading shape control. If you want to use your own wave shape, select ‘User defined’ from the list and then click on the open file button next to the User defined filepath and find your file. For information on creating your own wave shape file, see Section 5.9 of the Dynapave Main Software manual.

9.

If you want the test to be stopped automatically, tick the check box and enter a value for one or more of the Test termination parameters (see Item 3.5.8). Enter the first and last cycle numbers that you want to use to calculate the initial values in the Initial cycle number cells (see Fig. 5-14). The test will stop when one of the ticked termination conditions is reached; whichever is reached first, unless it is stopped manually.

10.

If you want to save the information and parameters that you have entered so that subsequent tests with the same parameters can be set up more easily, create a template file by clicking the Save template button on the Main panel and entering a name for the template when prompted.

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5.4

Running a test

1.

Click the ‘Main’ tab to open the Main panel. Check that the specimen is at the required test temperature (see Fig. 5-15) and then click the New test button to open the Test stage panel.

Fig. 5-15

2.

Click the Start test button to start the test. Cycles to view cell

Graph options


Fig. 5-16 39

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The system will start to apply loading pulses according to the parameters you entered in Section 5.3. Results for each cycle will be calculated and displayed in the data column of the R esults table as the cycle is completed. The active cycle number is displayed in the header row of the table. Live data will be displayed on the Graph for the number of cycles specified in the Cycles to view cell . The type of data plotted on the graph can be changed using the G raph options . 3.

The test will end automatically when one of the termination conditions that you selected in Step 9, Section 5.3 is reached, whichever happens first. If you want to end the stage manually, click the S top test button.

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5.5

Creating a printed test report A test report can only be created after a test has finished.

1.

After the test has stopped, stay on the Test stage panel and ensure that the data you want to see on the test report is shown on the Graph and in the Results table (see Fig. 5-17). Use the G raph options to change which data are plotted, if necessary. If you want to change the cycle number shown in the table, use the S how cycle cell. Results table

Show cycle cell

Fig. 5-17

Graph options

2.

Click the Test report button (see Fig. 5-17) to open the Test report panel.

3.

Check that the data on the panel is correct and then, if you want to continue and print the report, select a printer from the list in the Printer selection box and click the Print button.

Printer selection box

4.

Fig. 5-18

Click the Cancel button to close the panel. An example test report is shown in the Appendix, Section 6.2.


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5.6

Creating an ASCII data file An ASCII file, containing all the relevant information and recorded data from a test, can be created after a test has finished. The file created by this procedure is a semicolon delimited text file.

1.

After the test has stopped, stay on the Test stage panel and click on the Export to file button (see Fig. 5-19). A standard Windows dialogue box will appear choose a name and location for the file and click the Save button. The file can be opened in any spreadsheet program, for example Microsoft Excel. An example file, opened in Microsoft Excel, is shown in the Appendix, Section 6.3.

Fig. 5-19

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5.7

Ending a test

1.

When the test has finished, click the Unload test button (see Fig. 5-20). The actuator will move to return the load to zero. The Main panel will be displayed and control of the system will be returned to you.



NOTE: Clicking the Unload test button before a test has finished will cause the test to be aborted. You will be unable to restart or recover the test after the unload command has been confirmed. Test data up to the unload point will be saved in the location specified in the Main panel.

Fig. 5-20

2.

Open the thermostatic cabinet and undo and remove the Allen bolt securing the eye bolt of the load cell to the small base mounting block (see Fig. 5-21). LARGE BASE PLATE

EYE BOLT


Fig. 5-21

3.

Unscrew the two bolts securing the large base plate to the jig and remove the specimen from the jig.

4.

Using a 3mm Allen Key, loosen the two grub screws located at the bottom of the small base mounting block (see Fig. 5-22).


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SMALL BASE PLATE

Fig. 5-22

5.

Undo the nut securing the small base mounting block to the small base plate and remove the block (see Fig. 5-22).

6.

Remove the temperature probes from the dummy specimen and remove it from the cabinet.

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6.0 APPENDIX 6.1

Calculations used in the software The table in this section contains details of how the values reported in the software are calculated. Abbr.

Item in manual

Average large base width

B

3.5.4.1

Mean of inputted large base lengths

mm

Average small base width

b

3.5.4.2

Mean of inputted small base lengths

mm

Average thickness

e

3.5.4.3

Mean of inputted thicknesses

mm

Average height

h

3.5.4.4

Mean of inputted heights

mm

3.5.4.5

Inputted value

kg

3.5.4.7

Inputted value

kg

Description

Specimen mass Mass of moveable parts

m

Specimen density

3.5.4.6

Formula

M / ((e x (b + B) x h / 2) x

1,000,000,000) 2

2

Units

kg/m

2

3.5.4.8

( B x ( B – b) ) / (4b x h x ((b – B) x 2 (3 B – b) + 2 B x ln( B / b))) x 1000

Form factor

3.5.4.9

((12 x h )/(e x ( B – b) )) x ((2 – (b / (2 x B))) x (b / B) – (3 / 2) – ln( b / B)) x 1000

Mass factor

3.5.4.10

135 x M + m

g

Constant relative to maximum strain

K

3

Loading force Minimum / Maximum load Bending displacement Minimum / Maximum displacement

m

-1

m

-1

3

F

3.6.5

Measured value (see Fig. 6-2)

N

-

3.6.5


N

z

3.6.5


mm

-

3.6.5


mm

Inputted value

Hz

Test frequency

3.5.6.4

Bending strain

-

Measured phase angle

K

3.6.5

3

x z x 1000

Measured value (see Fig. 6-3) x (( F / ( z / 1000)) x cos( ) + ( u /

degrees

Real component of complex modulus

E 1

-

Imaginary component of complex modulus

E 2

-

Complex modulus

E*

3.6.5

( E 1 + E 2 )

MPa

EN

3.6.5

( E* x ) / 1000

kPa

simp

3.6.5

EN 12697-24 stress Simplified stress

1000) x (

2

x 2 x ) ) / 1,000,000

x (( F / ( z / 1000)) x sin( )) / 1,000,000 2

2

x ( F / z ) x K x z / 1000

MPa

MPa

kPa

Table 6-1 Two-Point Bending Test Rev.1 EN

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Fig. 6-1

Fig. 6-2

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Fig. 6-3


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6.2

Example test report

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6.3

Example ASCII file


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78-B7140 Dynapave Two-Point Bending SW - Rev 1 - EN - 30.05.2012.pdf

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