Quality Applications

Instron Corp.'s TestMaster Automation System Benefits No operator involvement Capability to test tensile and flex specimens 24 hours a day, seven days a week Reduces standard deviations Provides accurate testing data www.instron.com

Automation System Reduces Standard Deviations, Operator Involvement
Instron Corp.'s TestMaster Automation System

When Reichhold Inc., a supplier of unsaturated polyester resins and synthetic materials for the thermoset composites industry, needed to keep up with the greatly increased number of requests for physical testing, the company turned to Instron Corp. to help meet the demand.

 Working together, Reichhold Physical Testing Manager Bruno Belanger and the Instron Automation Team defined the specifications of a fully automated testing system that would help Reichhold significantly increase its composites' physical testing capabilities. As a result, Reichhold installed a customized Instron TestMaster Automation System, which measures and tests composite laminate and clear casting specimens.

 "We were looking at innovative ways to create a 24-hour operation without having people on-site, adding people or adding equipment," says Belanger. "We chose to work with Instron for the automation because of product quality, reliable service, its long-standing reputation in the industry and a long-time partnership with Reichhold. We've looked at other systems, but we found that Instron had more versatile equipment that allows for future expansion."

 Reichhold is involved in testing a wide variety of mechanical, flexural, tensile and other properties, performing close to 100 different tasks, from raw materials to final products. With every piece of new equipment, testing results must be validated. Because Reichhold tests so many different products, it was previously almost impossible for testing personnel to identify every product and substrate that might be used in the future. The Instron TestMaster Automation System has improved Reichhold's ability to deliver value-added services and has helped the company adapt with various grip faces.

 With the system, Reichhold is now also able to provide customers with "total solutions" more quickly than in the past. It has reduced turnover time by as much as 50 percent for testing performed for both internal and external customers. The company was also able to implement a 24-hour operation without adding personnel.

 In order to facilitate the process, a customer acceptance visit at the Instron factory is required to validate, confirm and approve the original product specifications and capabilities. After this step, Instron makes any necessary adjustments and modifications. Reichhold's system was shipped preassembled with some components to be installed on site. During the installation, a group composed of the project engineer--who supervised the unit--and two field service engineers--who service the unit following implementation--were present to work out any small start-up problems and assist in operator training. This process took four days. The complete integration and implementation of the TestMaster Automation System was finalized within one month. Reichhold is currently working with Instron's engineers to add compression-testing capabilities to the unit.

 The automation system is controlled by a master software suite that coordinates and supervises the actions of both a material-handling robot and a universal testing instrument. The robot moves the specimens from storage magazines or racks through an automatic identification and measurement sequence and then installs the specimen in the grips of the testing instrument. The universal testing machine performs the required test, collects data, analyzes data and prepares a report of test results. Once the sequence is started, the process takes place with no operator involvement. Because the TestMaster Automation System tests laminates and castings without relying on an operator to load, measure and test each specimen, standard deviations are reduced and more accurate testing data is provided.

 The unit is capable of testing material up to 45,000 lb in both the tensile and flexural modes by using different fixtures. Users can either run tensile or flexural, but not at the same time. The TestMaster Automation System is capable of testing under ASTM D638 Tensile properties of plastics and ASTM D790 Flexural properties of plastics. It can run more than 200 specimens in tensile mode and more than 100 in flexural mode.

 The equipment includes a measuring device to determine the thickness and width of each specimen. A bar coding system allows users to identify each specimen or batch of specimens. To navigate the specimen from the storage magazines to the measuring device and the testing frame itself, an automated robot arm ensures precise movements. Finally, a high-resolution digital extensometer executes the strain measurements after the specimen is positioned in the tensile grips.