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Test Fixture The test fixture consists of a shaft with a hub mounted on one end and a pulley on the other. The fixture

is provided with a special bearing hub and spindle assembly. The fixture shaft is belt driven by a motor mounted under the test bench.

Load Application Electric servo motors mounted under the test bench are used to provide the required to actuate rotational torque and speed through bearing, shaft and belt. This load is transmitted through an actuator that is designed to carry radial and axial load. Load cells are installed in line with the cylinders for the feedback of the bearing forces to the controller.

The tester is programmed to test for a variety of load capacities. Actuator System The design requires a background in electric motors including eng and parts selection of gears, etc. Control System The control system considered for the bearing tester center around a programmable controller. Monitors the shaft speed, once the desired speed is achieved the loading process begins. A vibration sensor on the spindle is used to determine the bearing failure. Calibration of this sensor need to be made for each type of hub assembly tested to accurately account for any background noise. A temperature sensor can be used to detect the bearing failure caused by excessive heat generation. Operating Procedure A schematic drawing of the wheel bearing tester is shown in figure including a listing of the major elements and specifications. Test parameters normally include speed, radial and axial forces, cornering force, cooling requirements, and lubrication. Test engineer is responsible for the selection of specimen bearings and appropriate production spindles, axles, and drums or in the case of prototype testing, custom fixturing for the machine. Prior to each test the characteristics for bearing failure such as maximum temperature, vibration limits, size of spalling areas, etc. are defined. l


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This motor test system able to test BLDC, AC

induction type assembly motors(50 ~ 400W) widely used in appliance of wash machine, water pump, air compressor, vacuum cleaner, etc. It can also inspect stator coil resistance, surge, insulation of each 3 phase windings, and in case of single phased motor, each of the test items of main, sub coils.

The design of the test-bench is composed of a high-speed inverter-driven induction motor as a load and a torquemeter specially designed for this speed level. In addition, a controlled cooling system is applied to guarantee certain operating points during the measurements. The principle set-up is shown in the block diagram below (figure).

The test results will be displayed in real-time on the screen of the computer. When after those tests, it checks the idling current, idling power consumption and judges the product to be good or bad in 7 ~ 8 sec.

Dynamometer Bench

The load of this test-bench is composed of a electromagnetic hysteresis absorber . Cooling is accomplished by air. The grid couplings provide three degrees of freedom to compensate misalignment along the

dynamometer shaft. In addition to this limitation, which limits the maximum speed of the entire test-bench The induction motor itself is supplied by a frequency inverter and control unit. The motor may be operated with field oriented control (FOC) or just by using a voltage-frequency-

characteristic.

2. Motor test Dynamometer


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Electric Characteristic of Motor test system

A. Test item : single phase 220 V, induction motor of grade a 50 ~ 400W

B. Test object: ① Surge test : 3 times (Between main, sub coil from each phase to

phase or single phase) ② Resistance test : 3 times (Main, sub coil from each phase to phase

and single phase) ③ Hipot(puncture) test : 1 time (Between coil and core) ④ Insulation Test : 1 time (Between coil and core) ⑤ Idling current (high / low preset) ⑥ Idling electric power (high / low preset)

Control and Data Acquisition Full-Featured HMI

The high-speed control option includes serial interface: ① Dual digital signal processors (DSPs) ② All aspects of the drive connected to the torque meter and power analyzer. ③ Control capabilities for load, drive motor, and product under test ④ Internal torque feedback estimator (99.5% accurate) ⑤ The data acquisition system is set up to acquire 10~20M readings per second. ⑥ The measured data can be stored directly to an excel-file. ⑦ DAQ Instrumentation records shaft power, AC power, voltage, current, or power. ⑧ Speed, torque and power are displayed with the temperatures at some critical spots. ⑨ Simply click on a virtual connectors in configuration screen ⑩ Windows XP OS Based Software ⑪ Multiple test sequences


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Edyne reviews all the data and evaluates motor stator and rotor condition, motor performance, and power quality, and alerts the technician to conditions outside of the normal range using alarms. Alarm thresholds can be adjusted for an individual motor if needed, either to reduce spurious alarms or to increase sensitivity to certain motor performance or power quality characteristics. Alarms include:

▲Three-phase AC motor measurement using Analysis Plots Trend plots, and Histograms using any of the parameters calculated by the system. Signature Analysis When more detailed analysis is called for, Edyne signature analysis feature.

3Phase back EMFs and back zero-crossings

Motor speeds and waveform of load current


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Power Analyzer

Three -Phase General Purpose Power Analyzer Checks the status of incoming signals and alerts the technician if a probe is not functioning

properly or is not properly connected to the correct phase. The technician can then correct the condition and use the graphical and textual feedback from Probe Check to ensure that the test data will be properly acquired. • DC, AC one phase three phase • Sample rate100 kHz • Amps, watts, volt-amps, frequency, crest factor, Vpeak, Apeak and power factor

Power analyzer system configulations

The 2553 Power Analyzer incorporates the ideal combination of precision, speed and ease-

of-use in an instrument so economical it can be on every bench.

Quality and Reliability Using the latest digital signal processing and circuitry,

XiTRON’s sophisticated technology gives our customers the edge in design verification and product manufacturability.

Measures and displays power, frequency, harmonics, THD, CF, K-Factor, Triplens & Inrush

Up to 1500 volts peak, 40 amps peak internally & up to 10,000amps with the use of

External Current Transducers DC and 20mHz – 100kHz Frequency Range Graphics Display shows numerical results, waveforms, bar graphs & history plots 16-bit A-D takes up to 220k samples/second Simple 6-key user interface


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Electric Charicteristic

Acceleration from 300 to 800 rpm. From top to bottom: (1): Reference speed (rpm), (2) Rotor speed (rpm), (3) Stator flux (Vs), (4) Estimated torque (Nm), (5) Torque limitation (Nm), (6) Load angle (deg), (7) DC link voltage (V).

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Air Cooled Shakers Air-cooled shakers are the workhorses for many component testing

applications such as automotive assemblies and consumer electronics equipment. The equipment range includes many shaker models with axial guidance bearings and 2 inches (50mm displacement) and our largest air-cooled model offers 2.5 inches (63.5mm) continuous displacement. This has been proven to be a highly reliable, high performance shaker

which is available in several configurations. Optional features include: automatic armature centering, economy field supply, vertical isolation mounts, isolated trunnions, air glides, chamber interfaces, and monobase systems for three axis testing.

Chamber Interfaces (Shake and bake systems)

Sequential Testing An optional Sequencer Unit allows the shaker system to remain

dormant, during the ESS cycle, until required for use. Optional software within control system permits various tests to be sequenced without manual intervention. On completion of the vibration tests the chamber control system

opens a contact and the shaker system shuts down. This facility to sequence tests has two main advantages: a) Long term tests can be performed without any need for

personnel to be present. This reduces any associated manpower costs.

b) By allowing the shaker to remain powered down during the climatic cycles there can be a significant saving in energy costs.

V26 shaker showing guidance handle, foam thermal barrier and air glides. KS Testing’s shakers and integrated monobases are easily combined with climatic chambers for environmental stress

screening applications (ESS). A range of thermal barriers is available using either phenolic type solid material or closed cell polyurethane foam types, depending on the required temperature range and the application. Chamber supports are standard for designs which require the chamber floor to be removed with the shaker. Shakers can be located below the chamber or removed for maintenance using a simple air-glide system. Automatic load support ensures the shaker armature is always centralised when payload is added or removed. This ensures full displacement is always available, protects the suspension system from distortion and removes the need for operators to check armature position. Automatic temperature and vibration cycling

removes the need for manual intervention during unattended testing periods.

6 Shaker


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Quality temperature/humidity chambers

Stainless steel exterior Energy-efficient refrigeration Specialized humidity controls Unique thermal break around door Casters, cable port, shelf, & optional RS-232 ETL-listed electrical panel conforming to UL 508A

Out Size: about W1000XD1000XH15000mm

Inner Size: 500X500X500mm

Temperature control: -40℃ to 200℃ Humidity 40~100%

7 Thermal Chamber


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8 Bearing Test Introduction

CLUTCH BEARING TEST RIG

Washing Machine bearing had to be designed to withstand high loaded torque have a low rotation torque in the free spinning direction and operate as quietly as a standard bearing. Additionally, the bearing had to fit the envelope demensions of a standard bearing while resourcing the total number of parts used in washing machines. Fundamental and endurance performance of the new one-way clutch with built in ball bearing.

This Test rig is designed for Endurance testing of clutch bearing. The bearing is loaded axially using suitable pneumatic circuit. The bearing is kept rotating at set speed and axial loading is done cyclically to simulate actually field conditions. Bearing outer range Temperature I continuously monitored to sense the failure. The bearing tester consists of a number of control elements such as vibration and sound analyzer, load cells, temperature and pressure sensors.

Stroking Endurance Test

In order to confirm endurance performance by cycling the free/lock of the clutch a stroking

endurance test should be conducted using the test machine under the conditions of below.

Loaded torque: 7~70Nm

Axial Load: 1800N

Load Cycle: 3Hz

Reciprocating Angle: approx 30°

Temperature: room temperature

Stroking endurance machine


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Rotating Endurance Test

In order to confirm endurance performance when rotating, the rotating endurance test should be

conducted using the rotating endurance test machine under the conditions of below.

Rotation ring: Inner ring

Shaft rotation speed: 1000rpm

Axle load: 300N(Load weight 6 step)

Rotating time: 3000h

Temperature: room temperature

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KSTM’s UTM and fatigue testers are efficient, robust and are made in the KOREA. Our testing equipment are known for their superior performance, accuracy and reliability. We has found various uses in different industrial applications, including University, Laboratory, Quality inspection, Automotive parts, Steel manufacture, Chemistries, industries. Our range includes test

Universal Testing Machines Metal Testing, Plastic Testing Fatigue Tester Rotational Torque Test Automotive Parts Testing Equipments Bearing, Gear, Pump Test Motor Dynamometer Vibration, Seismic Tester and Simulator

Also we provides grips, fixtures and accessories including fluid baths, heating and cooling systems to meet a diverse set of testing requirements. We have always achieved a good growth rate and success, which is a result of our dedication, pursuance and efficient service to trade and industry. Our strict adherence to supply and understanding of customer requirements has made it possible for us to achieve a position of repute in the industry. We are a customer-oriented company and work in close coordination with our clients to provide efficient solutions to their testing needs for steel, automotive industries. We are capable to manufacture products as per the requirements of our clients and our flexible production capacity, enable us in meeting the bulk and immediate requirements of our clients in time.

Established in 1992, KSTM's innovative and comprehensive mechanical testing systems are backed by a responsive team who will provide friendly support from day one. KSTM is manufacturer & distributor of fatigue test and universal testing systems for tension, compression, flexure, torsion & biaxial testing.

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