Wire, Rope and Cable Testing Solutions

Wire, Rope and Cable Testing SolutionsAdvanced Materials Testing Systems for Extended Length Specimens

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Wire, Rope and Cable Testing

4,800 kN (1.1 millionlbf) capacity frame

with 4.8 m (16 ft) ofstroke for rope testing

267 kN (60,000 lbf)capacity TVL series

frame suitable for wire,cable, or rope testing

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22 N-m (200 in-lb)capacity 55MT series

frame suitable for torsiontesting of wire or cable

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Systems to pull, haul, lift, hoist, and hold

objects are dependent on the performance of

wire, rope, or cable. Whether you’re

concerned with quality, safety, performance, or

liability, classifying and testing these products

for breaking strength, working load, and

elongation is critical. For well over 100 years,

Instron® and the SatecTM Systems family has

been working with the wire, rope, and cable

industry to meet these testing challenges.

Our series of equipment offers reliable and

affordable testing solutions for the smallest

fibers to the strongest finished designs.

Testing Equipment is Our Business

At Instron testing equipment is our business

not our latest project. Unlike ‘job shops’ we

understand that accurately measuring

specimen strength and stretch is vital for

quality control and new product designs. As

the experts in materials testing systems, we

select the optimal load cell and strain gauge

technology for your applications. Whether

your material stretches 3 inches or 30 feet

with a breaking strength of 1 pound or 2

million pounds our testing systems can

automatically measure specimen elongation

and capture the breaking strength or

your products.

Proven Controls and Software

Our test systems use proven electronics and

software technology to ensure accurate

results. With thousands of control systems

installed worldwide you can be assured that

your investment can be upgraded and

supported in years to come.

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Tailored Systems

Notes:1. Series brochures are available detailing available models

and full frame specifications. Please ask your local salesrepresentative for more details.

2. Varies from model to model

Designed specifically for tensiontesting of wire, rope, and cable thesehydraulically actuated frames featurea horizontal opening for testing fulllength samples and high strengthfinished designs.

Frame 1 Description Performance 2

Full lengthsamples; sling

construction; highcapacity samples

Challenge/ Solution

Economicaltension testing of

wire, rope, orcable samples

Testing of wire orcable with low

elongation or hightensile strengths

tension testing ofhigh elongation

samples, delicatefibers, or samples

requiring fasttesting speeds

torsion testingof wire

SATECTM Series HLModels

Capacities available from:135 kN - 13,500 kN(30,000 - 3,000,000 lbf)

Maximum speeds up to:3,657 mm/min(144 in/min)

Maximum travel up to:4,876 mm(192 in)

Capacities available from:50 - 1,000 kN(11,000 - 220,000 lbf)

Maximum speeds up to:508 mm/min(20 in/min)

Maximum travel:305 mm(12 in)

Capacities available from:300 - 3,000 kN(67,000 - 600,000 lbf)

Maximum speeds up to:52 mm/min(6 in/min)

Maximum travel up to:305 mm(12 in)

Capacities available from:0.5 - 200 kN(112.5 - 45,000 lbf)

Maximum speeds up to:2,500 mm/min(100 in/min)

Maximum travel up to:1,635 mm(63.4 in)

Capacities available from:22 - 13,540 N-m(200 - 120,000 in-lbf)

Maximum speeds up to:120 RPM

Maximum travel up to:36,000 rotations

58/55/3300 Series 1

SATEC TVL Series 1

Models

SATEC Series 1

5590-HVL Models

55MT Series and RTM Series 1

5800/5500/3300 EM Seriesd

5590-HVL Seriesd

TVL Seriesd

55MT Seriesd

Horizontal Seriesd

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Available in 6 models, thesehydraulically powered tension testersprovide a large test opening at aconvenient working height whileoffering an economical solution forwire and rope testing.

Available in 9 models, this series ofhydraulically powered universaltesters features a highly flexibledesign. Practically any size samplecan be tested through a variety ofoptions including wide testing space,extended height, open-crossheadsand hydraulic grip actuators.

Available in single column, table-top,and floor standing models, this seriesof mechanically powered universaltesters provides the ultimate in high speeds, large test openings, long travel and precision position measurements.

The 55MT Series (pictured left) isdesigned for low capacity torquetesting and features a compact, table-top design. The floor standingRTM Series is designed for highcapacity testing.

As the world leader in materials testing, we have a

diverse line of testing equipment. The process of

defining a testing system involves a detailed review

of your application and laboratory operations.

We’ll assist you in designing a testing solution that

includes the optimal choices for test frames,

electronics, software and grips.

Horizontal Frames for Long Specimens

Designed specifically for wire, rope, and cable

testing this series uses a horizontal test opening to

accommodate long specimens and high elongation

demands. These test frames are powered by

hydraulics for high strength testing and can be

customized in length to meet a variety of

application requirements.

Vertical Frames for Sample Testing

Available in a broad range of models and

capacities, vertical style test frames are the ideal

choice for testing cord, yarn, twine, or wire

samples. These frames provide a cost effective

solution and require minimal floor space.

Torsion Testing

Perfect for torsion testing of wire and cable the

55MT and RTM models provides high torsional

stiffness and minimal

axial friction.

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Grips for Your Application

External Grips for Sample Testing

Perfect for cord, yarn, rope, twine or wire testing

external grips provide a flexible solution for low

capacity testing.

Built-In Grips for HighStrength Testing

Designed for high strength testing, built-in grips

allow users to test specimens at full frame capacity.

Available in pin and clevis, wedge style or shoulder

end holders these grips use the strength of solid

steel crossheads to secure specimens at loads up to

10 MN (2.25 million lbf.)

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These grips overcome holding problems bydistributing stress over a specially designedhorn and using a pneumatically-cushionedgripping force to hold specimens without pinching.

These grips clamp specimens with flatfaces which are compressed by aircylinders. This design allows users to adjust the air pressure for optimum gripping pressure.

Capstan grips use a clamp or knot to securespecimens against initial slippage.Specimens are wrapped around thecapstans to provide a positive non-slipgripping action. This method of grippingdistributes the clamping force over a greaterlength of the specimen, thus eliminating grip breaks.

Both drill-type chuck grips and collets spinclosed to clamp specimens and self-tightenduring torsion testing. The jawsof drill-type grips extend well beyond thechuck nose to accept a broad range ofwires and cables. Collet style grips accepta smaller range of specimen diameters butcan withstand higher torsional forces.

Side-acting hydraulic grips are used whenboth high tensile strengths and externalgrips are required. Powered by hydraulicsthese grips close symmetrically to thetensile axis and ensure that gripping forceremains constant during testing.

Designed to fit inside of the machinecrossheads, built-in grips provide aneconomical solution for high capacitytesting. These grips uses a wedge action toclamp specimens and are actuated by usinga crank and pinion or hydraulic leverassembly.

Designed for high strength rope testingthese grips use a pin and clevis assembly tosecure the sling ends of a rope to themachine crossheads. This designeliminates stress points normally caused byclamping and minimizes grip breaks.

Built-in shoulder end holders are ideal fortesting high strength wire rope. This designuses the strength of the solid steelcrosshead to secure a potted end specimen at tensile loads up to 10 MN (2.25 million lbf.)

Grip Description

Securing twine,wire, or cord

without creatingpinch points

Clamping wirefor torsion

testing

Pneumatic hornstyle

Pneumatic side-acting

Capstan

Side-actinghydraulic

In-head wedge

Holdingspecimens with

high tensilestrengths

Drill type chucksor collets

Clampingdelicate yarnsand fine wire

Challenge/ Solution

Capstan style grips Side-actinghydraulic grips

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Pneumatic hornstyle grips

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Pneumatic side-acting grips

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Pin and clevis

In-head shoulderend holder

In-head wedge grips withhydraulic grip actuators

Pin and clevis stylespecimen holders

In-head shoulder endstyle specimen holders

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From delicate fibers to high strength wire rope

the ability to accurately measure specimen

stretch and strength is vital for quality control

and new product designs. At Instron®, we are

experts in instrumentation. We will work with

you to select the best load cells and strain

gauge technology for your applications.

Load Cells Accurately DetectSpecimen Strength

Our series of strain gauged load cells make it

possible to detect, graph, and analyze load

changes that occur during prestretching,

specimen setting, or failure.

g Closed loop servo control enables testing atuser-defined loading rates

g 40 kHz data sampling and up to 500 Hz data acquisition enables detection of peak load and breaking strength.

Extensometry AutomaticallyMeasures Specimen Stretch

Perhaps the biggest challenge for wire, rope,

and cable manufacturers is determining

specimen stretch. Because specimens under

load could break catastrophically, manually

measuring elongation is dangerous. At

Instron, our selection of specimen measuring

Experts in Instrumentation

devices work automatically and continually

capture specimen elongation.

g Clip-on style extensometers for lowstretch materials

g String type transducers for high elongation materials

g Some designs to withstand specimen failure such that elongation can be calculated for any percentage ofbreaking strength.

Series 2603 frame-mounted extensometer

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CE Series clip-on styleextensometer

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g Potentiometer based extensometer for high elongation specimens

g Frame mounted

g Designed to withstand shock of specimen failure

g Adjustable gauge length

g LVDT type extensometer designed for wire and cable

g Extensometer heads rotate to compensate for specimen twisting

g Fixed gauge length

g Strain gauge extensometer designed for wire and cable

g Many gauge lengths available to meet a variety of specimen requirements

g String styleextensometer for high elongation specimens

g Typically mounted on horizontal test frames

g Designed to withstand shock of specimen failure

g Adjustable gauge length

Extensometer Description Gauge Length Travel

rigidspecimens

with lowelongation

rigid or flexiblespecimens

with highelongation

HE Series stringstyle extensometer

flexiblespecimens withmedium to high

elongation

Challenge/ Solution

Series 2603 frame-mountedextensometer

CE Series clip-on styleextensometer

E-Series,model 3543clip-on styleextensometer

adjustable 250 mm10-200 mm (10 in)(0.4-7.87 in)

600 mm 30 or 60 mm(24 in) (1.2 or 2.4 in)

50, 101, 152, 25 - 100 mm203 or 254 mm (1-4 in)(2, 4, 6, 8, or10 in)1

adjustable 304 - 2,438 mm304 - 2,438 mm (12 - 96 in)2

(12 - 96 in)2

Notes:1 Custom gauge lengths also available upon request2 Other gauge lengths and travel ranges available upon request

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With thousands of 5500 control systems

installed worldwide you can be assured that

your wire, rope, or cable tester will be outfitted

with the industry’s most advanced software

and electronics. By using proven controls and

software, your testing system can be supported

by Instron®’s worldwide network of field

service engineers and upgraded with new

electronics in years to come.

Advanced Digital Electronics

5500 electronics feature advanced designs that

provide fast response, high accuracy and

exceptional reliability. A dedicated controller

provides accurate point-to-point, high speed

data communications with the system’s

computer without compromising data

integrity. The advanced digital design allows

synchronous data capture on all channels at

up to 500 Hz. This means no data skew and

the best possible fidelity even during the

rapidly changing conditions seen during

specimen setting and fracture.

Ergonomic Control Panel

By combining a user control panel with a

software console, Instron’s wire, rope, and

cable test systems provide the optimum in

real-time and post test flexibility. The user

control panel provides instant access to the

most widely used testing functions, including

start and stop, channel zero, load/unload and

reset gauge length.

Proven Controls

Load

SpecimenExtension (strain)

Crosshead Positionor Stroke

16 Channel Data Acquisition Unit

Transducers& Amplifiers

Analog/DigitalConverters

32-bit Digital Signal Processor

PC running Windows® &PartnerTM Software

Load, position, and specimen extension are detected by transducers,captured by the 5500 controller, and recorded by Instron software.

The 5500 series user controlpanel is designed to work

with the system software toprovide a friendly, flexible

user interface. Convenientlymounted on the load frame,

this panel provides all thecontrols you need to

run tests.

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Controller Technology

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Industry Standard Software

Load-Elongation curve of cycleand break test run with Instron’sPartner Software

Cycle and break testrun with Instron’sPartnerTM software todetermine breakingload, elongation atfailure, and elongationat 10%, 20%, and 30%of breaking strength.

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Load-Time graph of a prooftest run with Instron’sPartner Software

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Notes:1. Software brochure also available detailing test set-up, calculations, filestorage options and result reporting. Please ask your local salesrepresentative for more details.

d1. Quick report;2. Multi-specimen

report generatedwith built-in

reporting tools

Proven, Tried, Tested

Instron® and the SatecTM Systems family provides

industry proven software with your wire, rope,

and cable test system. Unlike one-shot,

custom applications our software has been tried

and tested. We’ve invested decades of

development time and installed thousands of

reliable systems. Furthermore, Instron software

is backed by premium service and support. Our

toll free software hotline and online multimedia

help system enable users to resolve problems

faster, experience less downtime, and reduce

service visits!

Business Integration

Instron software manages and automates the

entire testing process from entering pretest

parameters through report generation and

distribution. Application-specific modules allow

test technicians to run tests quickly while an

open architecture provides advanced capability

for the power user. Networkability, a database

structure, and built-in Emailing capability allow

users to share test results with other

departments. The end result is a testing system

which integrates seamlessly with other

business operations.

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Challenge/ Solution Cycling Standard test templates for cycling materials and an optional

module for complex cyclic testing.

Proof Loading Standard test templates for ramp and hold testing as well asan optional module for complex multi-ramp and hold segments.

Capturing Results Libraries of standard calculations enable uses to capturecritical specimen data.1 Calculations include:

g Breaking Strengthg Peak Loadg Maximum Elongationg Elongation at any % of Breaking Strengthg Cycle Time

Data Analysis With a variety of storage options and the ability to customizestorage templates, Instron software saves test data in usableformats.1

g Microsoft® Access database (test results)g ASCII files: csv, txt, prn, asc (data points and results)g Serial port (test results)g Customized ASCII files (test results)

Graphing Any combination of recorded measurements can be graphedduring testing and analyzed afterwards including load-elongation, stress-strain, load-time, and more!

Reporting Single specimen reports can be printed with one-clickg Multi-specimen reports can be generated with

built-in reporting toolsg Custom reports can be designed in Microsoft Access

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Full Service and Support

By using proven controls and software, your

testing system can be calibrated and supported by

our worldwide network of over 200 field

engineers and support offices. These skilled

Instron® personnel provide continuing services to

ensure that your testing system remains in

perfect order.

Leverage Your Original Investment

Why spend money on a test system created by a

‘job shop’ that can’t be supported or upgraded?

By using Instron standard electronics and

software, your original frame investment can be

continually updated resulting in years of

extended and enhanced performance and

reliability. Imagine being able to infuse your test

frame 10 years from now with new found

abilities, fresh functionality, and the latest

software technology! 4,800 kN (1.1 million lbf) capacity frame with 4.8m (16 ft) of stroke outfitted with pin and clevisstyle specimen holders for rope testing

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Instron is a trademarks of Instron Corporation. Satec and Partner are trademarks of Instron Corporation. Microsoft, Windows and Windows NT are U.S. registered trademarks of Microsoft Corporation. Copyright © Instron 2002. All rights reserved. All of the specifications shown in this brochure are subject to change without notice.

WB1160B

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