ELECTRIC VEHICLE BATTERIES TEST FIXTURES

Additional Accessories

In addition to the common EV battery applications, Instron has a variety of other products that are used for testing in the industry.

Prismatic Cells

CP132303

Thermocouple conditioner module. Integrated into a standard pin output to be recorded by Instron’s Bluehill software. (Requires separate purchase of type J or K thermocouples)

-100 to +350 °C All frames

CP132190

Battery swell and compression testing platens with integrated lockable spherical seat for parallelism between platens. Platens have four integrated LVDT holders and are compatible with up to four LVDTs. Platens are temperature rated from -40 to 150 °C to allow for testing inside an environmental chamber.

50 kN All frames

3119-6XX

600 series environmental chambers provide extensive temperature testing capabilities for evaluating material properties under non-ambient conditions.

-100 to +600 °C

Table model and floor model frames

CP109871

135 mm single column test space extension kit. Includes crosshead and base extensions. Adds 135 mm (235 mm total) between test space axis and column cover on Instron single column test frames. This additional test space creates more test space for operators for ease of specimen insertion, cleanup, and fixture setup.

Consult factory Single column frames only

Fasteners Holders

Fastener accessories allow for the performance of static tensile testing of external and internal threaded fasteners. Instron® fastener holders in combination with washers, short bolt adapters and nut proof loading assemblies carry out tests to include axial and wedge proof loading and tensile as well as nut proof load tests in accordance with ASTM F606.

Fastener holder sets are standardly available with capacities ranging from 100 kN to 1500 kN (22,500 lbf to 337,500 lbf). Each fastener holder has a key slot opening to facilitate quick specimen insertion. A circular recess in the holder ensures that the specimen is installed properly and aligned axially while also preventing it from shifting in the holder. These features work together to improve throughput and repeatability without compromising safety.

The fastener holders are typically attached to the load frame using spherically aligned tension rods, couplings and/or attachment kits that mate with the standard Instron attachment adapting interface noted in the product description.

Principle of Operation

The most common inserts used with fastener holders are washers. Washers provide the interface between the fastener being tested and the holder. For a typical test, the operator fits an unthreaded washer under the head of a screw or bolt and a threaded washer onto the threaded section of the fastener (when testing studs, two threaded washers are used, one on each threaded end portion). After fitting the specimen with both washers, the operator places the fastener into the holder, applies a pre-load to ensure correct seating and adjust the alignment, and begins the test. Fasteners of a shorter length may require a short bolt adapter rather than a threaded washer.

Application Range

• Types of loading: Proof tests, axial and wedge tensile tests

• Specimen materials: Metal alloys

• Specimen types: Bolts, nuts, studs

Safety Advice

Review safety note on page 234

Fastener Holders

Fasteners Holders

ADAPTER BUSHINGS FOR USE WITH SPHERICAL ALIGNMENT ADAPTERS

QUICK CHANGE PIGGYBACK ADAPTERS

See spherical alighment adapters in section 2.12 for other recommentations on attachment kits

Fasteners

How To Order Holders

First, locate your machine model and serial number. Now work through the following steps:

Fastener

Start by determining the size of the fastener(s) to be tested. This includes the diameter, thread pitch and length for each unique fastener to be tested.

* Consult Instron when the fastener is high strength, and/or if dynamic testing will be performed

Holder

The holder is then selected by using the smallest and largest fastener size. If the range spans two or more holder series, then you will want to consider to piggybacking* one holder to another. However, this is dependent on the available tensile test space.

* See page 30 for piggyback adapters

WASHER/SHORT BOLT ADAPTER

Now, select the washers* to match the fasteners with respect to the holder series that you selected in step 2 and the test type shown in the section below. Standard washers are ASTM F606 compliant; if ISO 898 compliance is required, note this at inquiry.

* See pages 34 - 37 for types of washers

Spherical Tension Adapter

A spherical tension adapter is recommended to provide compensation for minor misalignment, hence minimizing the stresses to the fastener that could result in premature failure.

If a spherical tension adapter is already present, please provide the thread size of the tension rod to determine if additional adapters may be required to install the fastener fixtures.

If a spherical tension adapter is not available, we will help you to determine the appropriate one for the specific machine model and serial number. ADAPTER

Additional adapters may be required. This will be determined through the steps above.

Fasteners How To Order Holders

Short Bolt Adapter

Wedge Washer

Nut Proof Washer

Fixture Combinations By Test Type

Select the appropriate fixtures for the type of static* test to be performed as determined by the fastener type to be tested. Bolt holders are required for each of the configurations.

Headed Bolt

• Tensile - One plain washer and one threaded washer*

• Wedge tensile - One wedge washer ( ), one plain washer and one threaded washer*

Screw Head With Taper

• Tensile - One countersunk washer and one threaded washer*

Threaded Rod

• Tensile - Two threaded washers*

NUT ( )

• Nut proof loading mandrel fixture

Determine whether strain or extension measurement is required.

* When testing short fasteners, the threaded washer should be replaced with a short bolt adapter ( )

Fasteners Washers For Holders

Designed as an integral part of the fastener testing system, washers provide the interface between the specimen and the bolt holders. All washers are designed to conform to ASTM F606 standards in thickness, width and hardness. Each washer is engineered to fit a specific bolt holder, so it fits snug and secure in the recessed portion of the bolt holder. Numerous diameters and thread/pitch sizes are available, and washers can be engineered to meet customer specification for an exact fit.

Principle of Operation

There are several varieties of washers, each designed to fill different testing purposes: flat (for proof testing or axial tensile testing), wedge (used in conjunction with a threaded washer for wedge tensile testing), and countersunk (for testing fasteners with a vee shoulder head). For a typical test, the operator fits an unthreaded washer under the head of a screw or bolt, and a threaded washer onto the threaded section of the fastener. (When testing studs, two threaded washers are used, one on each threaded portion). After fitting the specimen with both washers, the operator places the fastener into the bolt holder, applies a pre-load to ensure correct seating and adjust the alignment, and begins the test.

Application Range

• Types of loading: Proof tests, axial and wedge tensile tests

• Specimen material: Metal alloys

• Specimen types: Bolts, studs

• All washers comply with ASTM F606, SAE J429 and ISO 8981

Notes:

1. Contact Instron for specific fixtures to comply with ISO 898

Fasteners Washers For Holders

Fasteners Washers For Holders

4° PLAIN WEDGE WASHERS

4° Plain Wedge Washers

Notes:

1. Specify diameter of specimen when ordering

2. Contact Instron for specific fixtures to comply with ISO 898

3. Compatible with W-5117/M, W-5155/M holders

COUNTERSUNK FLAT WASHER TO TEST 60°

Countersunk Flat Washer to test 10°

Notes:

1. Specify diameter of specimen when ordering

2. Contact Instron for specific fixtures to comply with ISO 898 3. Compatible with W-5117/M, W-5155/M holders

Countersunk

FLAT WASHER TO TEST 82°

Countersunk Flat Washer to test 82°

Notes:

1. Specify diameter of specimen when ordering

2. Contact Instron for specific fixtures to comply with ISO 898

3. Compatible with W-5117/M, W-5155/M holders

Countersunk Flat Washer to test 100°

COUNTERSUNK FLAT WASHER TO TEST 100°

Fasteners Washers For Holders

Notes:

1. Specify diameter of specimen when ordering

2. Contact Instron for specific fixtures to comply with ISO 898

3. Compatible with W-5117/M, W-5155/M holders

Threaded Flat Washers

Notes:

1. Specify diameter of specimen when ordering

2. Contact Instron for specific fixtures to comply with ISO 898

3. Compatible with W-5117/M, W-5155/M holders

Threaded Flat Washers W-5144-A

Threaded Flat Washers W-5144-B

Fasteners

Short Bolt Adapters For Holders

Short bolt adapters are used for bolts that are too short to be tested in bolt holders using conventional threaded washers. These adapters are available for all bolt holder series. There are two different types of short bolt adapters: top hat adapters for smaller diameter bolts, and dumbbell adapters for larger diameter bolts. The top hat adapters can generally be used on shorter bolts because a section of the adapter actually fits into the holder. If the bolt diameter requires a heavy duty adapter with thread attachment external to the bolt holders, a dumbbell adapter should be used.

Application Range

• Types of static loading: Proof tests, axial and wedge tensile tests

• Specimen material: Metal alloys

• Specimen types: Bolts, studs, nuts

Safety Advice

Review safety note on page 234

Threaded Flat Washers

Fasteners Short Bolt Adapters For Holders

Notes:

1. Test washers sold separately

2. Specify thread/pitch size and diameter when ordering

3. Designed for fastener strengths up to 1375MPa (200ksi). Max load rating stamped on part as supplied and may differ from the load rating of the matching bolt holder.

Dumbbell Style

Notes:

1. Test washers sold separately

2. Specify thread/pitch size and diameter when ordering

Fasteners

NUT-PROOF LOADING ASSEMBLY FOR HOLDERS

Nut-proof loading assemblies are designed for proof loading or cone stripping of threaded nuts. They are designed to be used in conjunction with fastener holders and are available for all of the fastener holders series. Nut-proof loading assemblies consist of a hardened proof loading mandrel and a proof loading plain flat washer. When used to perform cone stripping tests, an additional conically shaped plain washer must be used. Nut-proof loading assemblies are designed for a particular thread diameter and pitch. The mandrel stud is made of heat-treated tool steel and is built for extended use. The plain washer used for proof loading and the cone stripping conical washer used for cone proof loading are both hardened washers designed to ASTM guidelines.

Principle of Operation

Nut-proof mandrel studs are mounted in a matching fastener holder exactly like a fastener under test. The larger end of the mandrel is threaded, and a matching plain threaded flat washer is seated in the recess of the fastener holder to hold the stud. This allows the force applied to the fastener holder to be transferred to the stud. The other end of the mandrel is matched to the thread and pitch of the nut under test. A plain flat washer is slipped over the stud before threading on the nut. The plain flat washer’s inner diameter is a close tolerance fit to the mandrel stud, and the outside diameter is the same as the recess in the fastener holder being used. Users can very easily switch from proof-loading bolts to proof-loading nuts without changing the fixturing, saving time and increasing operator productivity.

Application Range

• Types of loading: Static tension

• Specimen materials: Metal alloys

• Specimen types: Nuts

Safety Advice

Review safety note on page 234

ADAPTER BUSHINGS FOR USE WITH SPHERICAL ALIGNMENT ADAPTERS

Fasteners Shear Fixtures

The single and double shear test fixtures are designed to test the ability of a fastener to withstand load applied transversely to the axis of the fastener. ASTM F606 provides guidance for single shear testing of tower bolts, but refers to MIL-STD-1312 test 13 for double shear and test 20 for other single shear applications. The single shear fixture is made of a high strength, heat treated alloy steel for durability. It is a tension type fixture using a closed hole design to capture the fastener. This design requires a nut to be used on the bolt or stud being tested to prevent the fixture from separating. A separate fixture must be purchased for each size fastener being tested. The double shear fixture is made of a hardened tool steel to accommodate the high stress involved in a double shear test. It is a compression type fixture, consisting of a mandrel and an anvil, both with U-shaped cutouts. The anvil supports the fastener during the test, and the mandrel applies the compressive force. The mandrel and anvil of the fixture are precision machined as a matched set for a specific size fastener. A separate fixture must be purchased for each size fastener being tested.

Principle of Operation

The single shear fixture is designed for mounting to spherical tension rods. The fixture can be adapted to frames without tension rods, provided a spherical alignment device is utilized as part of the load train. The fastener is passed through both halves of the fixture, with the nut maintaining both halves of the fixture in contact with one another. Applying a tensile force to the fixture causes a shear force to be applied to the fastener. The double shear fixture is designed so that the lower half (anvil and base) rests on the machine table. The mandrel is mounted to the test frame adjustable crosshead with a mounting plate that is matched to the frame being used. The fastener is placed in the U-shaped cutouts of the anvil and base. The mandrel fits between the sides of the anvil with a very close tolerance, and has a corresponding U-shaped cutout. A compressive force is applied to the fixture, which induces a shear force at two different points on the fastener.

Application Range

• Types of loading: Shear tension, shear compression

• Specimen material: Metal alloys

• Specimen types: Bolts, studs

Safety Advice

Review safety note on page 234

Fasteners Shear Fixtures

Fastener Shear Fixtures

Fibers Grips

Fibers and filaments can have a wide variety of thicknesses and tensile strengths, and require very specific gripping methods. These lever action grips provide the ideal means to hold single fiber specimens. The grips are simple, lightweight and symmetrical in design. The o-ring type of grip is designed to hold very small diameter fiber specimens during tensile testing. The rubber vee-groove provides a gradually increased frictional hold on the specimen, and helps reduce grip face pinching and subsequent specimen jaw breaks. Special consideration is built into the design, where the U-shaped bend provides sufficient area for specimen loading.

Principle of Operation

Lever action grips are generally used for the thicker range of specimens. These grips have an adjustable clamping force, self-aligning hard rubber-coated faces, and provide ease-of-operation similar to a clothes pin. Another approach used for much thinner fibers is the micro fiber grip, also know as the o-ring fiber grip. This grip utilizes two rubber o-rings sandwiched between two knurled wheels. These wheels thread on a stud and compress the o-rings to achieve desired gripping force on the specimen.

Application Range

• Type of loading: Tensile

• Specimen material: Fine wires, filaments

• Specimen shapes: Round, flat

FIBER