D-RPA Testing instruments Software systems Sample cutters Modernisation

Transcription

1 Testing instruments Software systems Sample cutters Modernisation

2 Rotorless, dynamical rotational shear Vulcameter with a closed test chamber system The D-RPA 3000 is designed as an advonced Rubber Process Analyser for measuring the viscoelastic properties of polymers and elastomeric compounds before, during and after cure. The acquired data is giving exact information about the processability, the cure characteristics, the cure speed, as well as the behaviour of the compound at the after-cure. The D-RPA 3000 fulfils the complete range of all test requirements: Polymer or raw materials as well as basic, finished and cured compounds can be characterized. Besides the cure properties the cure characteristic and the processability can be determined and evaluated too. Due to the rugged and flexible construction of the D-RPA 3000 this device can be used for extended quality controls purposes not only in the laboratory, but also directly in the production area. The high flexibility of the D-RPA 3000 allows the user to program and execute arbitrary test sequences with the MonControl Analyses Software. Isothermal tests, non-isothermal tests, amplitude sweeps, frequency sweeps, temperature sweeps, shear rate sweeps, relaxations, retardations, hysteresis and tensile tests can be defined, as well as a combination of each sequences.

3 Overview Because of the very high measuring precision of the D-RPA 3000 smallest variations of the ingredients can be detected in the test result data, which simplifies makes the quality control and the development of new rubber compounds a lot. Due to this there a lots of important advantages for the user: Lower costs per test Faster batch release - with only one test all essential physically characteristics can be determined. (Quality control data, cure characteristics and properties can be determined with only one test of one test sample) Significantly reduction of scrap and rework Efficiency increase of the production process Faster and significantly simplified development cycles Intuitive, simple operation of the MonControl Analyses Software No separate sample preparation necessary For the best possible determination of all relevant test parameters the D-RPA 3000 is equipped with a large variety of test methods, test parameters as well as calculation and evaluation options. The following measurands can be determined: Shear modulus G and G Complex shear modulus G* Torque S and S Complex torque S* Dynamic real viscosity n Dynamic imadinary viscosity n Dynamic complex viscosity n* Loss angle d Tangent-delta Pressure (optional) Modulus under extension/compression E*, E, E Compliance under extension/compression D*, D, D Spring rate K s, K c, K p Damping coefficient C

4 System description The testing instrument consists of the machine case, a PC with screen, keyboard and mouse as well as a printer. Because of the unique full metal housing the testing instrument cannot only be used in the laboratory but also directly in the production area. The data acquisition and the controlling of the testing instrument is made by the PC by means of the MonControl analysis software. For the storage and analysis of the determined measurement data a modern SQL database structure is provided. To protect the user a motorly operated safety shield is lowered before the test chamber is closed. Between tests the test chamber can manually be closed in a stand-by mode. A delay time for opening the safety shield can freely be configured in the software. Furthermore there is the possibility of the attachment of a suction for produced waste gas to the back of the instrument. For the exact production of test samples for the D-RPA 3000 the R-VS 3000 sample cutter for rheometers is optional available. Especially for dynamic tests the usage of a volume cutter is recommended because this ensures reliable and reproducible test results.

5 Test chamber system The two test chamber halves form a closed, biconical system. That means the test chamber is formed by two conical test dies. This ensures a constant shear rate which is independent of the die radius in the sample. Reaction Test sample torque Motor preset Die Sealing ring The test chamber is equipped with a pneumatic closing system, which moves the upper test chamber half to the lower test chamber half to completely close the test chamber and keep the test sample during the test or cure under pressure. The default closing force is 11,6 kn at 4,5 bar air pressure. Optional a regulation of the pressure is available. During the test the lower die performs a sinusoidal movement with a variable amplitude and a variable frequency. This movement is generated by a high precision torque motor system with integrated ceramic bearing and precisionpath-recording which is mounted directly at the shaft of the lower die. This motor is regulated by a corresponding highresolution motor controller - this controller is freely programmable by the MonControl Analyses Software. Because of an integrated overload protection the drive will be switched of and the current test will be stopped if the maximum permitted torque is exceeded. The measurement of the reaction torque is made by a DMS torque transducer with a very high resolution which is directly mounted above the upper test die. With this transducer it is also possible to measure the current pressure in the test chamber (optional).

6 Test chamber system The temperature control of both electrically heated test dies is made by the MonControl Analyses Software with a separate control system for each test die. The temperature control and temperature measurement is performed by PT 100 resistance thermometers. For the heating of both test dies a heating film is used - one film for each test die. The heating film has a spiral shape with different distances between the windings. Therefore a heat concentration is prevented and a uniform temperature spreading is ensured. Additional the D-RPA 3000 is equipped with a pneumatic operated cooling system. This cooling system which is operating separately for the upper and lower test chamber makes it possible to cool down the sample within a very short time period. The cooling system can be operated with normal compressed air or with precooled compressed air either. The form and type of the temperature stabilization is generic and adjustable by the user at every step in the test program. MonControl Analyses Software: Isotherm a test MonControl Analyses Software: Relaxation with preheated test sample

7 Cooling systems: Pneumatic cooling system (Standard) Both chambers are cooled separately by a PID-controlled forced air cooling system. Also the cooling system can be freely programmed in the test definition to also run the cooling process during test sequences to conduct any friction heat from the sample. MCool 10 Integrated cartridge cooling system that separates the provided air streams into cold (-45 C) and hot (+110 C) fraction. The cold fraction of the air is then used for the separate cooling of both test chambers down to +8 C. Only a forced air supply with at least 4 Bars is required - there are no additional chillers or cooling liquids required. (Performance of the cooling systems depends on supplied air). This technology is worldwide patented by MonTech. MCool -40 Liquid cooling system with external chiller system. Both dies are separately chilled and cooled by an external cooling unit that is connected with the instrument. The cooling system works as an adition to the pneumatic cooling system - only if lower temperatures are required the chiller will be started. The total heating system of the dies remains unchanged so that instruments equipped with this devices are absolutely comparable with any other Moving Die Rheometer. This technology is worldwide patented by MonTech.

8 Advanced technology options: Axial force measurment device. Features a combined torque / forced transducer to measures torques as well as the pressure within the test chamber. Before each test, the transducer and amplifier is balanced automatically. The system also includes a second channel amplifier system for realtime simulataneous measurements ot torque and normal force. Cavity pressure controller system With this option, that cavity pressure can also be controlled either to a pre-programmed or to an online calcluated pressure level. Therefore the closing force as well as the die gap are designes as a variable, independent axis, so that the cavity pressure can be precisely controlled. This system is especially suitable for test sequences that include curing as well as a cool-down of the sample for a dynamical mechanical analyses. Therefore the system can be utilized to compensate material shrinkage as well as to avoid any slippage in the test chamber. This technology is worldwide patented by MonTech. High Speed data acquisition system The high speed DAQ option offer unique result stream resulotion as well as an ultimate level of precision for torque as well as the motor position signal. Therefore both channels are sampled and processed simultanously with a resolution of 24Bit at a data rate of 180KHz. All data streams are provided on the PC an calculated online in a Realtime kernel. Also it is possibe to save the raw data streams to the PCs memory. This makes the system especially suaitble for FT-Rheology purposes.

9 Automation options: 5 samples linear This system features an automated sample loading and unloading with a linear queue of 5 test samples. This is ideally sutiable for online testing purposes. 10 samples linear This system features an automated sample loading and unloading with a linear queue of 10 test samples. This is ideally sutiable for online testing purposes as well as a laboratory usage. 24 samples tray This system features an automated sample loading and unloading with a direct tray to chamber handling system. A rotary table with a atock of 24 samples is attached at the right side to the instrument. The samples are picked from this tray and directly placed into the test chamber. This system is especially suitable for an operator-less operation over long testing times. 10 X 24 samples tray This system features an automated sample loading and unloading with a direct tray to chamber handling system as well as a separate tray handling mechanism. Up to 10 rotary tables with a atock of 24 samples each can therefore be stored in the instrument an automatically processed. Trays are automatically moved into loading and unloading positions where the samples are picked from thie trays and directly placed into the test chamber. This system is especially suitable for a long-time operator-less operation over long testing times, nights or whole shifts.

10 Test programs The D-RPA 3000 in combination with the MonControl Analyses Software offers a huge variety of generic test parameters, which makes it possible to determine the sample properties in a very wide range. MonControl Analyses Software: Amplitude sweep The following test parameters are freely definable by the user: Temperature Oscillation frequency Oscillation amplitude Time Sampling rate Number of measuring cycles Pressure / Closing Force 1 1 Die gap The following test programs are available with the D-MDR 3000: Amplitude Sweep Frequency Sweep Temperature Sweep Shear rate Sweep Relaxation Retardation Hysteresis Tension tests... The MonControl Analyses Software enables the user to configure, combine and execute the respective tests. After inserting the test sample the actual test sequence is executed fully automatic without any intervention of the operator.

11 Amplitude Sweep The deflection angle (Amplitude) is changed during test at a predefined frequency and temperature. Frequency Sweep The frequency of the oscillation is changed during test at a predefined amplitude and temperature. Temperature Sweep The temperature of the test chamber is changed during test at a predefined amplitude and frequency. Shear rate Sweep Changing of the shear rate during the examination. The shear rate sweep represents a sequence of different retardation cycles. Relaxation Relaxation describes the unstressing after a strain. Stable physical systems return to an outer perturbation over relaxation processes nearly into their ground state. The relaxation time is a time constant which is characteristic for the given relaxation process. If the quantity f(t) of the relaxations follows an exponential rule: f(t) = exp( - t / t) * f(t = 0) then t is the accompanying relaxation time.

12 Retardation Examination of the fatigue behaviour of a material under a constant load. Besides the elastic deformation the material experiences a time-dependent reversible (viscoelastic) and an irreversible (plastic) deformation. At the transition to the plastic condition the tension remains constant in the material. The force-time graph describes an e-function. If the stress is too high it comes time-dependently to a break of the material. Hysteresis The change of the viscosity under influence of one constant shear gradient, depending on the duration of the influence. With increasing duration of the influence by the shear force the hysteresis effect is increasingly irreversible. Tension test A material identification value which indicates the lasting prolongation of the break related to the initial measuring length. and many test programs more...

13 Oscillation as a function of the frequency storage modulus G' loss Modulus G'' viscosity loss angle Time angular frequency Modulation with a constant speed amplitude storage modulus G' loss modulus G'' Time angular frequency Modulation with a superimposed shear 0 storage modulus G' loss anlge Time angular frequency

14 Determinable measurements Elastic Torque The peak amplitude torque component which is in phase with a sinusoidally applied strain. Viscous Torque The peak amplitude torque which is 90 out of phase with a sinusoidally applied strain. S' S'' Loss Shear Modulus The ratio of (viscous) G'' peak amplitude shear stress to peak amplitude shear strain for the torque component 90 out of phase with a sinusoidally applied strain. Complex Torque The peak amplitude S* torque response measured by a reaction torque transducer for a sinusoidally applied strain. Loss Factor The ration of loss modulus to storage modulus, or the ration of viscous torque to elastic torque. Tan-Delta Storage Shear Modulus The ratio of (elastic) G' peak amplitude shear stress to peak amplitude shear strain for the torque component in phase with a sinusoidally applied strain. Complex Shear Modulus The ratio of peak amplitude shear stress to peak amplitude shear strain Pressure (optional available) The axial load exerted on the die during the test. Loss Angle The phase angle by which the complex torque (S*) leads a sinusoidally applied strain G* P

15 Real Dynamic Viscosity The ratio of the loss shear modulus, G to the oscillation frequency in rad/s n' Dynamic Complex Viscosity The ratio of the complex shear modulus, G*, to the oscillation frequency in rad/s n* Imaginary Dynamic Viscosity The ratio of the storage shear modulus, G to the oscillation frequency in rad/s n'' Vulcanisation speed First derivation of the elastic torque S V (lin,log) Further derived measurements Compliance Modulus under extension/compression Compliance under extension/compression

16 Technical specifications International standards ISO 6502 / ASTM D 5289 / ASTM D 6204 / ASTM D 6601 / DIN Test chamber Test chamber gap Force measurement Closing system Oscillation frequency Biconical, closed System 0,45 mm nominal Torque transducer mounted at the upper test chamber Soft closing to prevent foil rips and damage of test samples 0,001 Hz Hz Oscillation amplitude Torque range Sample volume Temperature control system Temperature check system Units of measure Subroutines Air pressure Electrical variable 0,01 to 225 dnm ca. 4,5 cm³ 30 C to 240 C, precision +/- 0,03 C both microprocessor controlled Recordings of the temperature gradient on the screen, microprocessor monitored Torque (dnm, lbf.in, kgf.cm) Shear modulus (Pa, dynes/cm², psi) Dynamic viscosity (Pa s) Temperature ( C, F) Pressure (bar, kg per cm²) Time (min - min / min - sec) Frequency (Hz, cpm) Shear rate (1/s, rad/s) Amplitude Sweep, frequency Sweep, temperature Sweep, shear rate Sweep, relaxation, retardation, hysteresis, tensile tests,... min 5 Bar Single phase 220 V V, 8 Amps

17 Machine case 152cm 152cm 68cm 60cm Rugged solid metal case, heavy-duty type Connection possibility for suction ( 100 mm) Net weight approx. 230 kg

18 R-VS 3000 Rheometer volume cutter The Rheometer volume cutter serves fast and exact production of test samples for the Rheometer measurement. Especially for rotorless systems. This volume cutter works with a doubly working pneumatic cylinder system. This always ensures an equal volume of the test samples. The volume adjustment is made very simple by the adjusting ring underneath the stamp. For safe operation the volume cutter is equipped with a two-hand safety operation system. The production of Rheometer test samples is made in two steps: Compression of the material to a constant volume Cutting of the test sample Volume adjustment Pressure arm Cutting knife Machine table Rheometer volume cutter Copyright 2008 MonTech Werkstoffprüfmaschinen GmbH, technical changes and explanations reserved, printed in Germany

19 R-VS 3000 Technical specifications Cutting - diameter Max. thickness Reproducibility Sample-volume (adjustable) Compression - time (adjustable) Dimensions (H x W x D) Weight Pneumatics 35mm 12mm 0,1% 2cm³ to 8cm³ 1sec to 15sec 600mm x 430mm x 380mm 50kg min. 5,5 Bar The MonTech material test equipment GmbH and their subsidiaries does not secure the completeness and correctness of the information and recommendations given in this product description after best knowledge and certain (Informations.) too. The information is given alone in the acceptance that the receiver before their use clarifi es, whether the information for the ranges of application intended by it is, it products or process engineering (. products or process engineering) is applicable. MonTech does not take over adhesion, directly from which argument, for damage, which results from the fact that the customer trusted in the given information or on the product or process engineering described in the information. It is to be examined thing of the receiver whether by the given information or, on use of the products or process engineering described in the information, patents third are hurt. MonTech does not assure anyhow that by use of the information no patents are hurt. With exception of the reduced guarantee for the rubber and india rubber test equipment and equipment agreed upon in the sales contracts of MonTech MonTech secures thus neither too nor ensures MonTech that any of the given information and the products described in the information or process engineering. 1. for by the receiver intended using possibilities or in connection with other devices or information are applicable or 2nd purpose always constituted for one like to be used can. If the given information or the products and process engineering, to which in the information is referred, article of negotiations and a sales contract locked due to these negotiations become, are considered them only then as promises of certain characteristics and/ or suitabilities of the products or procedures for a certain intended purpose, if it of MonTech in writing and expressly as warranty (in Germany in the sense of 459 BGB; in Austria in the sense by 923 ABGB) to be designated. In all other respects each warranty claim is impossible. Due to managing regulations nevertheless if necessary an existing warranty will fulfi ll MonTech by supply of a faultless thing, improvement or a supplement of the absence. Every other kind of the guarantee is impossible. In the same way also claims for damages are limited in cases of roughly negligent violation of contract and the height after with the value of the supplied commodity limited. The replacement of escaped profi t is at all impossible. Certified according to DIN ISO Accredited according to DIN EN ISO/IEC 17025:2005 Rheometer volume cutter Copyright 2009 MonTech Werkstoffprüfmaschinen GmbH, technical changes and explanations reserved, printed in Germany