Wazau TRM 1000 User manual

DR.-ING. GEORG WAZAU Mess- + Prüfsysteme GmbH
Keplerstraße 12 > D-10589 Berlin > Germany > Fon [phone](89), Fax [phone]
Web www.wazau.com, E-Mail [email protected]
Manual
TRIBOMETER
TYPE TRM 1000
Rev. 02-2007

0. INTRODUCTION 2
1. CONNECTING CONTROL RACK, TEST RIG AND PC 3
1.1 COMPONENTS .................................................................................................................................................. 4
1.1.1 CONTROL RACK ............................................................................................................................................ 4
1.1.2 COMPUTER.................................................................................................................................................... 6
1.1.3 TEST RIG ...................................................................................................................................................... 6
1.1.4 ELECTRICAL CONNECTIONS ........................................................................................................................... 8
2. CONTROL RACK 9
2.1 MODULE OUTPUT ........................................................................................................................................... 9
2.2 MODULE FORCE ........................................................................................................................................... 10
2.3 MODULE WEAR ............................................................................................................................................. 11
2.4 MODULE TORQUE ........................................................................................................................................ 12
2.5 MODULE TEMPERATURE............................................................................................................................. 13
2.6 MODULE MOTORCONTROL......................................................................................................................... 14
2.7 MODULE FORCE CONTROLLER.................................................................................................................. 15
2.8 MODULE FRICTION FORCE (OPTION) ........................................................................................................... 16
3. TEST RIG 18
3.1 MOUNTING THE SPECIMENS ............................................................................................................................ 19
3.2 STANDARD SPECIMEN POT FOR LUBRICATED TESTS ........................................................................................ 20
3.3 BALL HOLDER /PIN HOLDER ............................................................................................................................ 21
3.4 DISC HOLDER................................................................................................................................................. 22
3.5 MOUNTING OF THE RING HEATER (OPTION) ..................................................................................................... 23
3.6 COMPRESSED AIR CONDITIONING .................................................................................................................... 24
4. TRIBOMETER SOFTWARE 25
4.1 SOFTWARE INSTALLATION ...............................................................................................................................25
4.1.1 USB SERIAL CONTROLLER .......................................................................................................................... 26
4.1.2 MCC DAQ .................................................................................................................................................. 29
4.1.3 TRIBOCONTROL........................................................................................................................................... 32
4.2 SETUP WINDOW ............................................................................................................................................. 35
4.3 MEASURING SETTINGS AND LIMITS -SUBWINDOW ............................................................................................ 36
4.4 PROGRAM SELECTION SUBWINDOW ................................................................................................................ 37
4.4.1 MODE ROTATION ......................................................................................................................................... 37
4.4.2 MODE RAMPS.............................................................................................................................................. 38
4.4.3 MODE OSCILLATION..................................................................................................................................... 38
4.4.4 MODE LINEAR OSCILLATION......................................................................................................................... 40
4.5 DATA FILE SETUP WINDOW ............................................................................................................................. 41
4.6 CONTROL WINDOW......................................................................................................................................... 42
4.6.1 PLOT COLUMNS........................................................................................................................................... 42
4.6.2 NUMERICAL DISPLAY ................................................................................................................................... 43

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4.6.3 FURTHER BUTTONS AND DISPLAYS............................................................................................................... 44
4.6.4 CONTROLLER TEMPERATURE....................................................................................................................... 44
4.6.5 CONTROLLER FORCE................................................................................................................................... 44
4.6.6 MENU OPTIONS ........................................................................................................................................... 45
4.6.6.1 Settings................................................................................................................................................... 45
4.6.6.2 Autotuning Temperature / Normal Force ................................................................................................ 46
4.6.6.3 Lift Operation .......................................................................................................................................... 46
4.7 ANALYSIS WINDOW......................................................................................................................................... 47
4.8 RECIPE CONTROLLER ..................................................................................................................................... 48
5. STARTING A TEST 53
5.1 TURNING ON AND OFF ..................................................................................................................................... 53
5.2 INSTALLING SPECIMENS /OFFSET ADJUSTMENT ............................................................................................... 54
6. SETTING UP THE WEAR MEASURING SYSTEM 55
7. LINEAR OSCILLATION (OPTION) 57
7.1 LINEAR OSCILLATION ...................................................................................................................................... 58
7.1.1 ADJUSTING THE AMPLITUDE ......................................................................................................................... 59
7.1.2 ASSEMBLY OF THE LINEAR OSCILLATION ...................................................................................................... 60
7.1.3 DISASSEMBLY OF THE LINEAR OSCILLATION ................................................................................................. 61
7.2 AIR-BEARING UNIT.......................................................................................................................................... 62
7.2.1 ASSEMBLY AIR-BEARING UNIT...................................................................................................................... 63
8. FOUR-BALL APPARATUS (OPTION) 64
8.1 MOUNTING BALL CARRIER .............................................................................................................................. 65
8.2 ASSEMBLY BALL HOLDER................................................................................................................................ 66
9. SPECIMEN DIMENSIONS 67

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0. INTRODUCTION
The tribometer serves for the investigation and simulation of friction and wear processes under sliding conditions. It can be
operated for solid state friction without lubrication and for boundary lubrication with liquid lubricants. Thus both material
and lubricant tests can be executed.
According to the standard test principle a stationary test specimen (pin or disc) with a defined normal force is pressed
against the surface of a rotary disc. Both specimens are perpendicularly arranged one on the other whereby the rotary
disc is on top. Other test configurations are possible. The normal force is applied by the movable drive block and the drive
spindle. The normal force is damped by means of a spring located below the linear table. The tribometer is driven by a
servo motor steplessly adjustable from 0.1 rpm to 3000 rpm.
The actual test equipment essentially consists of the motor unit, the drive and the load section. The shiftable modules are
one on the other fastened to two perpendicularly columns. Pin and disc are in a specimen pot heatable up to approx. 150
°C. During the test the normal force, the temperature inside the pot, the linear wear amount of both specimens and the
friction torque are continuously measured.
The measurement of the normal force is done by a force sensor arranged between counter load spring and lower
specimen restraint. The temperature is measured by a NiCr-Ni-thermocouple in the pot. The wear is measured over the
changing displacement between lower and upper specimen restraint. The measurement is done contactlessly by a laser-
optical displacement sensor. The friction torque is measured by a rotary torque sensor.
All measuring signals are transferred to the control rack to be conditioned there. Data acquisition is done by an USB
measuring module with a solution of 16 bit. The measured values of rotational speed and temperature are digitally
monitored with temperature values sampled at 2 Hz and rotational speed sampled at 5 Hz.

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Specification
Strain collective
Type of motion Sliding
Mode of motion Continuous
Normal force By means of a drive-spindle system adjustable from 5 – 1000 N
Rotational speed From 0.1 to 3000 rpm steplessly adjustable
Testing temperature From RT to 150 °C steplessly adjustable
Tribological values Measured value
FR – friction force FR= M/r
M = torque
r = friction track radius
=> friction coefficient FR / FN
FN= Normal Force
wl – wear amount displacement (abrasion)
=> wear rate wl/t t = time
T - Temperature
1. Connecting Control Rack, Test Rig and PC
1 Connect PC and control rack via USB cable cable (see Software Installation).
2 Connect the sensor interface cable and the sensors with the slide-in unit of the control rack.
3 Connect the cables of the drive and the lift-drive as well as the heater.
4 Set up the power supply for three-phase alternating current 3x400 VAC/50 Hz and 230 VAC.
Hint: All plugs match only with the corresponding socket connector on the control rack except for the RS-232/USB
converter cable.

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1.1 Components
1.1.1 Control Rack
The control rack incorporates the plug-in unit with all amplifiers and power supply for all modules, the drive controller, and
the drive itself. The compressed air conditioning and the main power switch are located at the bottom of the control rack.
Control Rack
Slide-in unit of the control rack

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Main switch and compressed air conditioning
Rear side of the control rack with connections for lead, drive, lift, heater, and compressed air (IN/OUT)

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Rear side of the control rack with removed rear wall to change fuses
1.1.2 Computer
The USB measuring module and the RS 232/USB converter cable for data acquisition and controlling the test rig are
connected to the computer.
1.1.3 Test Rig
The test rig represents the mechanical measuring unit other add-in modules can be added to.

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Sensor Interface
TEMPERATURE Type-K Thermocouple input for specimen pot and IR ring heater (if connected).
FORCE Normal force sensor input.
The sensor inputs are automatically identified by its coded plugs and assigned to the corresponding measuring ranges of
the software. Plug in a sensor’s plug carefully to prevent the pins of the multi-pole plugs from bending which may cause a
bad electrical contact or no contact at all.
Normal Force Sensor Markings
8435 – 5200200 N Measuring range
8435 – 5500500 N Measuring range
8435 – 60011000 N Measuring range
8435 – 60022000 N Measuring range
8435 – 60055000 N Measuring range
Heating System Connection
By means of the slot the feedback control system is connected to heating system of the specimen pot.

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1.1.4 Electrical Connections
Power supply: Three-phase current connection 3 x 400 V/50 Hz, plug: 5 x CEE plug, 5 x 32 A.
If a FI risidual-current circuit-breaker is used, it must be suitable for applications for frequency inverters (suitable for type
U).
Fuses
The conrol rack contains fuses on the rear side for he following loads:
Drive Fuse (F1) 3x16 A type C
Slide-in unit Fuse (F2) 6 A E 14
Circuit board “Brake” Fuse (F3) 2 A E 14
Power Supply Unit„Lift“ Fuse (F4) 2 A E 14
Heater Fuse (F5) 10 A E 14
Plug-in unit Fine fuses 2 x 2A 5 x 20 mm slow-blow fuse
There are two fine fuses on the rear side of the control rack.