Deformation tests on bodywork components using electrical testing actuators

The specific requirements of customers in the automobile industry are now catered for better than ever thanks to Zwick’s expanded range of electromechanical servo testing actuators. These offer a cost-effective alternative to hydraulic systems for static and cyclic component tests, both for in-production testing and in long-stroke fatigue testing of components in which material properties are tested to their limits.

With a speed of 1 µm/min to 30 m/min, a force range of 0.1 mN to 30kN, a standard stroke of 200 or 400 mm and positional accuracy up to ±2µm, the electrical testing actuator is an ideal solution for varied and complex applications. These performance characteristics open up a wide range of testing applications, from head-rests, steering-columns, gear-levers and brake assemblies to foams, plugs and solenoids.

For example, deformation tests on bodywork components can also be carried out, for which the actuator is installed flexibly in a small test stand. To supplement deformation measurement directly at the load point via the testing actuator, additional measuring transducers can be used to measure the deformation at other points. This data is synchronously recorded in the testControl electronics for effortless display and evaluation in the testXpert^® II testing software. In this way all the functions of a standard testing machine are available, including defined travel to positions with maximum accuracy, adjustable force control and seamless switching between these operating modes during a test.

These actuators embody the same mechanical concept as Zwick testing machines, allowing all fixtures and accessories in the Zwick range to be used. Special fixtures can be attached as required for additional uses of the actuator in processes such as joining, force-fitting or assembly.

Mounting the actuator on a test device is easy thanks to its flexibility. It can be installed in the customer’s own test frame or a production line in any position required or installed as a second test axis to supplement a testing machine.

The electrical testing actuator is extremely maintenance-friendly, as it needs neither oil, pump nor pneumatic system but is simply connected to a single or 3-phase electrical supply, making it ideal for users who are looking for a flexible, affordable, high-performance testing system requiring little or no maintenance.