The automatic control system of railway prestressing bridge static load test is the comprehensive system of the computer full-automatic control of the bridge static load test developed according to the TB/T 2092 Post-tensioned Pre-cast Concrete Simple-supported Girder for Railway Bridge Pro-stress. The system has the function of synchronous loading, maintaining pressure automatically and carrying out test of the load, deflection and mid-span stress automatically, realizes the prediction, judgment and pre-warning of the deflection span ratio and inference of crack automatically, realizes the connection with girder field BIM system, directly acquires the bridge parameters and uses them to the loading test, transmits the test data to the integrated management platform of China Railway Corporation in real time, and sends the test results back to BIM model. 

Patent: 

An automatic control device for bridge static load test 

An automatic control device for bridge static load test and automatic control method 

A universal full-automatic prestressing bridge static load test device 

Software copyright: 

Automatic control system software of railway prestressing bridge static load test 

Delta PLC software of automatic control system of railway prestressing bridge static load test 

Hardware structure: 

1. Master control set for test; 2. Loading executive device; 3. Load measuring device; 4. Deflection measuring device; 5. Strain measuring device 

1. Master control set for test 

It consists of the industrial control computer (IPC), power module and wireless data uploading module. It not only realizes the full-automatic loading control, test data detection, storage and data uploading, but also has the function of prediction and judgment of test results. 

2. Loading executive device 

It consists of the centralized hydraulic pump station, branch cabinet and jack, or mechanical jack and corresponding branch cabinet. It has the function of automatic and manual load application. It has the secondary safety overload control. 

3. Load measuring device 

It consists of the force sensor and digital transducer. It can carry out the direct detection of load data without the supporting calibration of the jack. The device is calibrated by the qualified third party independently. A transducer can be connected with 6 measuring cells, and the internal battery can guarantee that the transducer and measuring cell keep working for 6 hours. 

4. Deflection measuring device

It consists of the standard electronic dial indicator and wireless transmitting and receiving module. Without artificial reading, it can transmit the deflection measuring data to the IPC directly. It is installed and used conveniently, and there is no need to drag and drop many data transmission cables, thus avoiding the personnel stumble on the site. The wireless module battery can guarantee the continuous working for 6 hours through one time charge. 

System Flow Diagram: 

Control unit and drive execution unit; The receiver unit feeds the data back to the main control unit. 

Software functions: 

1. Auxiliary calculation of loading force value at every stage 

2. Automatic loading 

3. Automatic acquisition of displacement data and force value data in the test process 

4. Dynamic calculation of deflection value and deflection span ratio in the test process 

5. One-key output of calculation report and test report 

6. Uploading test data to the engineering management center platform 

Main system interface 

Parameter entry interface 

The static load test data can directly come from the platform after login, and the static load test parameters can be obtained only by entering the beam number. 

Static load device setting 

The interface is used for entering the information about connecting device. 

Interface of uploading data 

After the test, the calculation report and test report can be output by one key, and the relevant information filled in the Engineering Management Center Platform can be uploaded. 

Technical specification

1. The system meets the requirements of TB/T 2092 (and new standard). 

2. The measuring equipment (including instruments) used for the system test passes the verification of the legal measuring and verification institution, or the calibration results meet the requirements of the standard, and is within the period of validity. 

3. The temperature conditions of the working environment of the system are as follows: (-10~+50)℃; Humidity is ≤95%RH. 

4. The content and format of the static load test result report of the system conform to TB/T2092 (and new standard), and these can be generated automatically and uploaded to the railway engineering management information platform. 

5. The system can calculate the static load bending test calculation sheet automatically and realize the automatic loading control in the whole process, and the content and format of the calculation sheet conform to the Appendix A. It can realize the automatic detection and recording, display the load data of various loading points and displacement data of deflection measuring point, and realize the confirmation by electronic signature. It can realize the automatic alarm in the case of overload of test data or abnormal loading. It can realize the manual and automatic switch and manual control function. It can realize the immediate stop of loading and data storage in the case of abnormal loading or failure, power outage and other emergency situations. It has the synchronous calibration facilities of loading and deflection measurement. It can realize the self-inspection of the equipment and instrument state. 

6. The relative deviation of the performance loading of the system is ≤1%, and the loading synchronization deviation is ≤7kN. The hydraulic and mechanical jack can be used. 

7. The range of pressure sensor for the system measurement meets the load measurement requirements of the maximum loading level, and is 1.5～2.0 times of the maximum test load value. The relative indication error is ≤0.1%F.S.  The range of pressure sensor for the verification meets the load measurement requirements of the maximum loading level, and is 1.5～2.0 times of the maximum test load value. The relative indication error is ≤0.5%F.S.  The range of displacement sensor for the measurement is not less than 1.5 times of the vertical displacement in the measuring part of test beam, and the resolution is ≤0.005mm. The range of displacement sensor for verification is not less than 1.5 times of the vertical displacement in the measuring part of test beam. 

Product advantages: 

1. It can realize the automatic loading in the test and replace the manual loading operation, saving both time and labor. 

2. The equipment can realize the automatic data acquisition and cancel the artificial reading. 

3. The system loading has good synchronism and high precision. 

Automatic control system - a computer can control 10 jacks at the same time, and the loading synchronization is carried out according to the characteristics of hydraulic oil pressure balance, automatic speed regulation of frequency converter and fast computer operation speed. The force sensor is directly used to test the loading force value, thus reducing the traditional median error (including jack friction, loss of pressure of extended range of hydraulic oil, pressure difference caused by the hydraulic height difference) brought by the indirect conversion of force value of the pressure gauge. The IPC can read all data of force sensor with 0.2 seconds and carry out the controlled operation, thus making the loading control precision reach ±0.5% and greatly improving the loading precision. 

Traditional test - it is difficult to guarantee the loading synchronization and precision. The deformation by force of the test beam and reaction frame is different in various loading points, and the elongation of the jack is different, so the loading in both ends is fast, while the loading in the middle is slow. Every hydraulic pump is operated by different persons separately, so it is difficult to realize the synchronous loading of 10 loading points. The manual loading precision is poor. 

4. One-key generation of calculation report and test report 

Automatic control system - it can generate the bridge static load test calculation sheet and static load test report directly, greatly reducing the workload of data preparation and sorting before and after the test. 

Traditional test - the workload of data recording and sorting is larger. The load value and corresponding deflection value at all levels shall be recorded, and more than ten forms shall be filled in after the test. 

5. Connection of test data with engineering management center platform 

Vocational certification: 

In November 2012, the comprehensive test was carried out on the 2000t test bench in Hubei Institute of Measurement and Testing Technology, and it was approved. 

In January 2016, the expert appraising meeting of static load test system was held in Wuhan, and the system was highly recognized. 

In August 2016, the pilot work was approved by China Railway. 

In 2017, it won the Science and Technology Award of China Railway Society. 

The system passes the experts' technical evaluation, technical appraisal of Engineering Management Center and software evaluation and testing of the third-party authority, and finally passes the review of the system software review meeting organized by the railway engineering management center. It was promoted and used successively in Shangqiu-Hefei-Hangzhou High-speed Railway, Zhengzhou-Fuyang High-speed Railway, South Shandong High-speed Railway, Yinchuan-Xi'an High-speed Railway and Taiyuan-Jiaozuo High-Speed Railway. In August 2018, it was formally used in the railway construction engineering network, which represented the owner's official recognition of the system. 

Customer feedback: 

In October 2018, Xiongxian County Beam Fabrication Site of The Fourth Engineering Co., Ltd. of Shanghai Civil Engineering Group Co., Ltd of CREC used the automatic static load test system provided by Wuhan Simutec Co., Ltd., and the test effect is good. 

On Jan. 5, 2017, West Fuyang Beam Fabrication Site completed the static load test through the automatic static load test system provided by our Company, and the test was very smooth. 

On Dec. 10 and Dec. 20, 2016, Fuyang Beam Fabrication Site of No.3 Construction Company of China Railway No.10 Engineering Group used the automatic control system of railway bridge static load developed by our Company to carry out the bridge static load test of the bureau-level production verification and evidence acquisition and review on the beam site.