TestLine™

be certain.

MTS TESTLINE IDEA BOOKMTS TESTLINE IDEA BOOK

PAGE THREE

What are MTS TestLine Solutions?
MTS TestLine Solutions are a selection of components that help you
build modular test systems that can be reconfigured as your needschange. MTS provides the premium-quality products and components— you provide the imagination.

The TestLine philosophy is focused on you. Recognizing that your mechanicaltesting needs are frequently as unique as your products, MTS developed
TestLine Solutions as a way for you to engineer a test system that’s specific toyour needs, yet modular enough to accommodate changing requirements.
TestLine Solutions comprise a versatile and reliable set of standard products, test
components and software tools that enable you to create a cost-effective testsystem. If you have the in-house experience and design capability, MTS canequip you with the proven, high-quality TestLine components to build your test
solution right the first time. The products, components and software used in a
TestLine Solution are the same as those integrated into the most advanced MTS
custom test systems. They are precision-engineered to the highest quality anddesigned for seamless integration.
TestLine Solutions are widely used in many industries, including automotive,aerospace, off-road, and rail testing. These products and components have also
been used to test wire rope, bicycles, tools, seats, bones, bearings, bolsters andmore. If you need to do mechanical testing, it is highly likely you can build yourtest system with a TestLine Solution.
The following pages offer just a few examples of the premium-quality products
and components that can be a part of a TestLine Solution. But when you useyour imagination, the possibilities are endless.

TESTING IDEA #1142
31 Actuators

2 Servovalve Manifold Assembly

The family of MTS actuators ranges from Series 244 actuators
for precise control of high-frequency motions and forces, to theeconomical Series 201 actuator for static or low-frequency testing,to heavy-duty rotary actuators that deliver reliable torque generation.

Installed between the servovalve
and actuator, the servovalve
manifold makes it simpler to swap
out servovalves without having todisconnect hoses.

Force ratings range from:» Series 201 - Tension: 32 kN (7 kip) to 1775 kN (400 kip)Compression: 63 kN (14 kip) to 2595 kN (590 kip)
» Series 242 - 2.7 kN (0.6 kip) to 14.7 kN (3.3 kip)
» Series 244 - 15 kN (3.3 kip) to 250 kN (55 kip)
» Series 248 - 10 kN (2.2 kip) to 160 kN (35 kip)
Rotary actuator torque ratings range from:» Series 215 - 226 N·m (2000 lbf·in) to 11.300 N·m (100,000 lbf·in)

PAGE FIVE

Motor Mount Test
S Y STEM DESCRIPTION :This motor mount test system is an example of a three-axis (X, Y, Z) test configuration.
Three actuators configured with load cells and rod end swivels are mounted on
adjustable horizontal base assemblies. Two actuators apply direct load to the specimen.
A reaction stand with bellcrank converts lateral force from a third actuator into verticalforce applied to the specimen.

3 Load Cell

4 Rod End Spacer Assembly

Dynamic fatigue-rated load cells reduce errors
caused by extraneous side loads or loadingchanges from geometry shifts in the specimen.

TestLine rod end and solid spacers areused in bellcrank and lever assemblies.
The swivel spacer provides a pivoting
and rotating connection to actuators,struts, or other components.

» Low deflection and high stiffness for better
dynamic performance» High output for excellent resolution andreading accuracy» Force Rating: 50 kN (11 kip)

» Simple mounting makes installation andremoval easy

» Rod end thread: M24X2» Variety of sizes for versatility» Weight: 4 kg (8.7 lb)

TESTING IDEA #2

241

3

1 Bellcrank Mounting Plate

2 Adapter BlockThis horizontal mounting plate isused to mount a bellcrank or lever
to a reaction stand in a horizontal
orientation. The slotted holes allow
for precise height adjustments when
mounted on the reaction stand.

This adapter with M24X2 center hole andfour M12X1.75 tapped holes can connect toeither end of the strut assembly, as a meansof connecting the strut to other components
such as load cells or actuators using athreaded stud (included).

» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available» Weight: 22.5 kg (49 lb)» Weight: approx. 2.7 kg (6 lb)

PAGE SEVEN

Knuckle Test
S Y STEM DESCRIPTION :This example shows a common configuration for struts, bellcranks and reaction
stands in a TestLine system. Bellcranks can be used to redirect forces from anactuator to save space in the test lab, or to apply forces in places where there isinsufficient space for an actuator. Note: This example is intended only toillustrate the use of individual TestLine components.

3 Rod End Block Assembly

4 Reaction Stand AssemblyThis rod end block assembly allows
struts, actuators, and other fixturing to be
mounted to a reaction mass, structuralbase or bedplate.

This reaction stand is configured
with a bellcrank mounting plate,
two pillow blocks and a bellcrank
assembly with rod end spacer
assemblies.

» Force Rating: 50 kN (11 kip) (shown)Higher capacities available withMTS Series 249 Swivels» Weight: approx. 3.5 kg (8 lb)» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available

TESTING IDEA #323

1

1 Reaction Stand Weldment

2 Universal Struts

Reaction stands are used to support
bellcranks as well as other parts orassemblies. A series of holes in the standallows for multiple height adjustments.

These components are primarily used totransfer loads in the axial direction ofthe strut. However, the universal ends
allow additional struts or actuators to beconnected perpendicular to the axis of thestrut for biaxial loads or motion.

» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available» Weight: 382 kg (840 lb)» Lengths: 500 mm (19.68 in),1000 mm (39.37 in) &1800 mm (70.87 in)» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available

PAGE NINE

Axle Torque Test
S Y STEM DESCRIPTION :In this example, a torsion load is applied to an axle. The reaction stand,lever assembly and strut are used to transmit force from the actuator to a4

lever on the specimen. The lever allows for the load to be applied a greater
distance from the floor without the need for a taller reaction base.

3 252 Servovalve

4 Actuator Base Assembly

These two-stage, four-way-valve servovalves
are designed specifically for servocontrol ofhydraulic systems. These high-performancecomponents are available in variety of flow
rates ranging from 4 – 227 lpm (1–60 gpm).

The actuator base assembly provides
static support to the actuator so thatits physical weight is not applied tothe specimen.

» High resolution and low hysteresis for
precise flow control» 31 MPa (4500 psi) maximum operatingpressure» Internal filtration protects nozzle orifices
from contamination» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available

TESTING IDEA #4

3

4

1 Bellcrank Assembly

2 Pillow Block Bearing

This durable, versatile component
features multiple connection points toaccommodate a variety of bellcrankmechanical ratios. The bellcrank
assembly includes two swivel rod ends
and two pillow block bearings with
25 mm (one inch) mounting spacers.

This self-aligning bearing is used tosecurely and precisely mount bellcranks
and levers to a reaction base or stand.
Bearings can be mixed and matchedwith bellcranks, struts and levers tocreate a robust custom test system.

» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available

PAGE ELEVEN

Lower Control Arm Test
S Y STEM DESCRIPTION :Shown here is a three-axis test utilizing a portal frame and bellcrank assembly.
The portal frame allows the vertical force to be applied directly by an actuator
2

above, and the bellcrank allows a lateral load to be applied where there would
otherwise not be enough space for an actuator.

1

3 Vertical Bracket - Pillow Block

4 Tee-Slot Bedplate

Plates and hardware for mounting
bellcrank or lever assembly verticallyon reaction stand.

Steel bed plates provide secure mounting
surfaces for test fixtures and reaction
brackets to help ensure safe and efficienttesting. Slots in the bed plate allow for
convenient placement of test fixtures.
Bedplates can rest on rubber isolation pads
or be anchored with grouting to a concrete
floor. A seismic mass is not required.

» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also availableTESTING IDEA #5

Other Available Components
Adjustable Height Mounting L Brackets
with Pillow Block Bearing
Low mount assembly is used to mountpillow block bearings near the floor level.
Brackets can be adjusted vertically for
precise locating of test components.
» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available

U-Joint Assembly
Universal joint allows rotation in
two axes while restraining the third
twist axis.
» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available» Weight: 15 kg (32 lb)

PAGE THIRTEENConfigure it your way
The examples on the left show an adjustable actuator base assembly pairedwith a lever and low-mount assembly, which can be configured in many ways
to fulfill different testing needs. In the example on the far left we’ve placed theoutput strut further from the pivot point to increase stroke and velocity capacity
while reducing force capacity. The example on the right shows the leverconfigured as a force multiplier by placing the output strut closer to the pivot
point than the actuator. Note: This output force should not exceed the capacityof any component connected to it.

Lever Assembly

Rod End Spacer

This component is typically used to obtaina mechanical advantage in either force ordisplacement, while isolating actuators frommoments and side loads. It can also be used
to change load direction or multiply force,velocity or displacement. When used as aforce multiplier, output should not exceed
rated force. The assembly includes two
swivel rod ends and two bearings.

Rod end spacer for use with 11 kip
bellcrank and lever assemblies.

» Force Rating: 50 kN (11 kip) (shown)160 kN (35 kip) also available

S TA N D A R D P R O D U C T S
MTS Standard Products
MTS complements the TestLine offering with an array of standard MTS products— the same products used by industry-leading test professionals worldwide— to help you build the custom system you need from a single, trusted resource.

MTS SilentFlo™ 515 Hydraulic Power Units
Operating at or below sound levels commonly found in labs and factory floor
environments, the SilentFlo HPU can be deployed directly in the lab, eliminating theneed for costly pump housing facilities and reducing supply line length and spacerequirements.
With features that maximize electrical efficiency and minimize water consumption,and options for remote monitoring of pressure, temperature and fluid level, theseHPUs will help reduce facility energy costs. For additional energy savings, the larger
units can be equipped with a run-on-demand option that reduces electrical power andcooling water consumption when the system is not running at full capacity.

MTS Hydraulic Service Manifolds
MTS Hydraulic Service Manifolds (HSMs) provide independent pressure regulation
for precise control, isolation and distribution of hydraulic fluid to test stations. By
installing MTS HSMs into the hydraulic lines between the HPU and servovalve, you
can turn each hydraulic circuit on or off and independently set low-pressure levels.
This allows convenient, efficient test setup, operation and maintenance of individual
test systems without disturbing other systems.
MTS HSMs also minimize the effects of the rapid application and removal of highpressure, reducing unexpected actuator movement that could damage the test article
or the test system. They also provide rapid pressure reduction to ensure safety, aswell as store energy for transient events that require peak performance.

PAGE FIFTEEN

MTS Hydraulic Actuators
All MTS hydraulic actuators feature fatigue-rated designs, which means they arebuilt to exceed their rated loads for millions of cycles. You can expect highly reliable
performance over a long functional life, helping to maximize your uptime andminimize total cost of ownership.
MTS actuators are engineered for precision. They deliver exceptional fidelity over thefull range of motion, along with a superior ability to react to and counteract multiaxialforces. Proprietary materials and processes minimize friction for excellent reliability,wear-resistance and energy-efficiency.

MTS Software

Take control of your testing with MTS TestSuite™ Multipurpose Software.
With modules and options that are designed to be adaptable to your evolving
needs. MTS TestSuite offers an intuitive, graphical depiction of workflow, making
it easy to create and modify tests, and to view and edit the underlying calculations.
This single environment allows you to create the right test to meet your objectives.

Easy-to-use component RPC Pro software is ideally suited for low-channel-countapplications and component testing. In addition, this software’s modular design
allows for an affordable and scalable solution to meet your specific simulation
requirements. Preconfigured templates, interactive wizards, informative graphicaldisplays, integrated data management and context-sensitive online help guide allusers through the testing process.

MTS FlexTest® Digital Controllers
MTS FlexTest digital controllers deliver the tools you need to define and automate
virtually any material, component or structural test. This versatile, modular family ofcontrollers provides high-speed closed-loop control, function generation, transducer
conditioning and data acquisition for a full range of testing needs.
The MTS FlexTest offering features higher speeds and channel densities to keep pacewith evolving test demands, and all models share common hardware boards and userinterface tools, helping to simplify test standardization and optimization. Centralized
processors and test resource boards can also be easily upgraded in the field, giving
you flexibility to meet new future test requirements as they arise.

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MTS, FlexTest and RPC are registered trademarks andMTS TestSuite, TestLine, and SilentFlo are trademarksof MTS Systems Corporation. RTM No. 211177.
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100-356-819 TestlineIdeaBook • Printed in U.S.A. • 07/24