PC Based 4 Station Life Tester

Introduction:

The PC-based four-station life tester is a highly flexible control system suitable for durability testing of mechanical equipment equipped with 12V DC motors (maximum current 70 amps) or unpowered mechanical equipment using suitable fixtures and pneumatic actuators.

The basic model of this tester operates only DC motors, but can accommodate up to four motors. It can be a four-motor assembly (e.g., a six-way motorized seat rail with bidirectional electric adjustment), four single-motor assemblies (e.g., independent seat adjusters or power window adjusters), or a combination of both. Furthermore, it is not necessary to use all four output channels.

Operating Guidelines:

Please note that suitable mechanical fixtures are required in almost all testing scenarios. Customers can provide their own test fixtures, or we can provide them at a highly competitive price. Our PC-based four-station life tester features a polished steel plate top surface (for mounting magnetic devices) with integrated mounting holes for mechanical fixtures. The upgraded version of this tester adds a valve assembly at one end, containing four dual solenoid valves, each with a pressure regulator and quick-disconnect connector below each station.

Each valve is linked to a motor output, so all the above functions can be easily applied to pneumatic actuators on the test fixture, instead of motors. This means the tester can accommodate up to four actuators. Even a mix of motor and pneumatic actuators can be used!

Once the mechanical test setup is complete, the tester can be manually programmed using a keyboard and mouse to simultaneously operate any or all motors (or actuators) in any combination of directions according to any of the four operating modes (current, time, voltage, or limit switch). These four modes refer to the input signals required to make the tester execute the next step in the desired sequence.

For "current" control, the tester detects the motor stall current (e.g., end-of-stroke current), which is set in the test sequence, and the stall current value can be different for each step in the sequence for each motor channel. For "time" control, the tester sets the running time (in seconds) of the motor in a given direction. After the motor has run for a preset time, it shuts off and proceeds to the next step in the motor sequence.

For “Voltage” control, the tester connects to an analog output device, such as an LVDT, load cell, linear potentiometer, thermometer, or other analog output (+10VDC to -10VDC) device. The voltage value output by the device is set by the user in the test sequence; when the voltage value reaches the set value, the tester proceeds to the next step. Finally, the “Limit Switch” mode allows testing between two limit switches; the tester only detects the closure of almost any type of electrical contact, or the closure of a two-wire or three-wire proximity switch. The tester can be set to run more than 1000 consecutive steps.

Each step includes settings such as ignoring inrush current (because motor start-up typically generates stall current), minimum stall time (for detecting jamming mechanisms), stall time (required by some test specifications), and motor cooling time (because any type of durability test typically generates excessive heat). Test sequences can also include wait periods, data saving steps (for saving data to a .csv file for Excel analysis), test blocks, and nested sequence loops. The main screen includes local or remote voltage detection (required by some specifications), the desired operating mode (see above), voltage settings, and loop counting and reset functions. The software also allows you to assign analog and limit sensors to any channel.

Additionally, the main screen displays fault detection functions and messages, as well as a test sequence display showing the current step in the sequence (in case the tester is in a "loop" and there is currently no operation). The software in these testers includes a help screen and operating instructions.

Features:

Typically, due to the intuitive and user-friendly software interface, most operators can quickly write relatively complex test programs with little or no training!

Configuration:

Our PC-based four-station life tester uses 115V AC (requires 15A circuitry) and can also use compressed air if equipped with an air valve upgrade kit. Weighing 180 lbs, the tester is mounted on omnidirectional locking casters, allowing it to roll in any direction and navigate standard doorways.

This PC-based four-station life tester can be transported in the back of a pickup truck or van.