1-ton casters walking test machine DR-LJ01

A large roller is used as the driving wheel to drive the tested casters, enabling "dynamic tests", "long-distance walking tests", and "static load tests". The tests are controlled by an instrument, featuring adjustable speed, speed display, walking distance, walking time (forward walking time, reverse walking time, and stop time), forward rotation test, and reverse rotation test functions. 

Function Description

1). Dynamic Experiment: It is possible to set the drum to rotate forward or backward, the dwell time for forward and backward rotation, up to ten consecutive change processes, and the total process can be cycled up to 9999 times.

2). Long-Distance Travel Experiment: The running time and mileage can be set. The machine will stop when the preset time and mileage are reached.

3). Static Load Experiment: The equipment is equipped with a 1-ton hydraulic cylinder to apply load, and the static load is applied when the drum stops rotating.

4). Castor Explosion Prevention Experiment: There is a photoelectric switch at the castor installation position to detect whether it is broken or damaged. When damage occurs, the machine will stop. 

Core technologies and configurations

Core Functions

Dynamic Walking Performance Testing

High-load Walking Simulation:

1. Maximum test load: 1 ton (expandable to 2 tons), walking speed: 0 - 10 km/h (stepless speed regulation), simulating the daily handling scenarios of forklifts, shelves, and other equipment.

2. Steering frequency: 1 - 10 Hz, testing the wear resistance and shock resistance of universal joints and bearings.

Complex Terrain Simulation:

1. Replaceable test tracks (smooth, gravel, slope, obstacles), recreating real industrial terrain conditions.

2. Walking speed: 0 - 30 km/h (stepless speed regulation), testing the traction and slip rate of drive wheels at different speeds.

Environmental Coupling Testing (Optional)

Temperature and humidity cycling: Temperature range -40°C to +80°C, humidity 10% to 95% RH, verifying the risk of plastic wheels softening at high temperatures and metal parts becoming brittle at low temperatures.

Salt spray/dust testing: Simulating coastal or factory environments according to ASTM B117 standards, testing anti-corrosion and dust-proof sealing performance (IP66 certified).

Intelligent Monitoring and Diagnosis

Real-time multi-parameter collection: Load force (accuracy ±0.5% FS), rolling resistance (±1N), wheel temperature rise (infrared thermal imager ±1°C), vibration spectrum (5 - 2000Hz).

Failure Warning System: AI algorithm analyzes data anomalies (such as abnormal bearing sounds, wheel surface cracks), automatically stops the machine and generates a fault report.

Data Traceability: Automatically exports PDF/Excel reports (including wear curves, thermal imaging maps), supports MES system integration. 

Technical Highlights

High-Precision Drive System

1. Servo motor closed-loop control, with speed accuracy of ±0.1 km/h, torque resolution of 0.1 N·m, and dynamic response ≤ 5 ms.

2. Modular track design for quick switching between test scenarios such as sand and gravel, and slopes.

Safety Protection

1. Explosion-proof test chamber (pressure resistance ≥ 3 MPa), mechanical limit switches, and emergency stop buttons, meeting ISO 13849 (PLd level) safety standards.

2. Automatic fire suppression system (CO₂/inert gas) to handle fire risks caused by high-load friction.

Energy Efficiency and High Performance

Energy feedback technology recovers 30% of the energy during testing, and standby power consumption is less than 200 W. 

Equipment Advantages

High Efficiency and Precision:

1. A single test cycle is ≤ 72 hours, equivalent to actual travel of 5,000 kilometers, with data repeatability error < ±0.5%.

2. Supports dual-station expansion (optional), increasing efficiency by 100%.

Comprehensive Coverage:

1. Compatible with casters with wheel diameters of 100 to 400mm, and load capacity ranging from 100kg to 1 ton (expandable to 2 tons).

2. Optional vertical crush test module (static load pressure test) is available.

Cost Optimization:

1. By intercepting early defects, it reduces after-sales claim losses by over 50%.

2. Laboratory testing replaces outdoor road tests, reducing overall costs by 60%.

Standard Compliance: Built-in 20+ test procedures including ISO, GB, DIN, etc., and can generate certification reports with one click. 

Application scenarios and industry value

Industrial casters production: Batch durability testing of forklift and warehouse shelf casters before leaving the factory.

Medical device industry: Life verification of silent and low-resistance casters for operating tables and hospital beds.

Research and development laboratories: Optimization of wheel body materials (polyurethane, nylon, cast iron) and bearing lubrication solutions.

Certification testing: Compulsory testing items such as ISO 22883 dynamic load and DIN 15106 rolling resistance. 

The drive wheel walking test machine, through laboratory-level high-precision working condition simulation and intelligent data analysis, transforms the traditional verification process that relies on actual operations into a standardized and traceable scientific test, helping enterprises overcome core challenges in drive wheel life, efficiency and safety. Whether it is to meet strict industrial certifications or ensure the reliable operation of heavy equipment, this equipment can serve as a core tool for drive wheel quality control, providing a solid guarantee for product competitiveness and brand value.

If you need to customize a test plan or obtain a technical demonstration, please contact our engineering team! 

After-sales Service

Warranty Policy: Most manufacturers offer a 1-year full machine warranty, supporting remote fault diagnosis and operation training.

Customization Service: Customization based on requirements, including custom fixtures and software functions according to testing standards (such as JIS/CNS) to meet special needs.

After-sales Service: 1-year full machine warranty, providing operation training and remote technical support.

Data Service: Optional cloud data platform for generating CNAS-compliant test reports remotely.

Technical Support: Free remote debugging, operation training, and annual equipment calibration services.

Spares Supply: Quick replacement service for consumable parts (fixtures, hydraulic seals).

Ordering Process

Requirement Communication: Provide testing standards and relevant parameters.

Solution Confirmation: Supplier provides 3D drawings and parameter lists.

Production and Delivery: 15-20 days for standard models, 30-45 days for non-standard customized models.

Acceptance and Training: Engineers install and debug on-site and provide on-site training.