This equipment is mainly designed in accordance with the European standard EN12527 and the national standard GB/T14688. It uses a large circular disc as the driving wheel to drive the tested casters. ...
This equipment is mainly designed in accordance with the European standard EN12527 and the national standard GB/T14688. It uses a large circular disc as the driving wheel to drive the tested casters. With the addition of obstacles, it can conduct tests such as "obstacle crossing test", "long-distance walking life test", and "load-bearing test". It is microcomputer-controlled and can set different operation modes for distance and obstacles, such as running forward for 2 minutes, stopping for 2 minutes, then running backward for 2 minutes, stopping for 2 minutes, or running for 3 minutes, stopping for 1 minute, and then continuing. The load application uses a stack of weights for direct pressure, which more realistically simulates the test environment and conditions. It is controlled by a touch screen, making the setting and operation very convenient. It can display the walking time and distance in real time and is suitable for testing the wheels of suitcases, roller skates, office furniture casters, trolleys, and industrial casters, etc.
Function Description
1) Dynamic Experiment: The disc can be set to rotate forward or backward, with the option to specify the duration of forward and backward rotation. Up to ten consecutive change processes can be set, and the total process can be cycled up to 9,999 times.
2) Long-Distance Travel Experiment: The running time and distance can be set. The machine will stop when the preset time and distance are reached.
3) Static Load Experiment: The equipment is equipped with 40 weights of 25KG each, with a total weight of 1,000KG, and the weights can be added to the load. Static load testing can also be conducted when the disc is stationary.
4) Castor Explosion Prevention Experiment: A photoelectric switch is installed at the castor mounting position to detect any breakage or damage. If damage occurs, the machine will stop.
5) Bump Simulation Experiment: Obstacle blocks are added to the roller to simulate the bumps encountered by the castor during travel.
6) Curve Analysis: Curves can be plotted to visually analyze the trend of changes. Mileage, time, and speed are recorded and support the generation of reports.
Core technologies and configurations
| Item | Parameter Range |
|---|---|
| Test Station | Dual stations (500KG load per station) |
| Display & Control Mode | Touch screen + PLC with custom program |
| Test Caster Specification | Φ25mm – Φ400mm (fixtures made according to samples) |
| Load | 500±5KG per side (direct weight loading) |
| Speed | 0–15±0.01km/h, forward & reverse supported (speed adjustable) |
| Main Power Source | 3.7KW gear motor |
| Travel Distance | 1–99999Km, programmable |
| Number of Obstacles | 1–99999 pcs, programmable |
| Disc Diameter | 1200MM |
| Obstacle Height | 3mm, 5mm (customizable) |
| Obstacle Installation | Installed at 45° to drum surface (forward & reverse) |
| Obstacle Spacing | 0.5–2m per piece |
| Equipment Dimensions (LWH) | 1500×1500×2700mm |
| Equipment Weight | Approx. 1600KG |
| Power Supply Voltage | 380V±10%, 4KW |
| Caster Turning Diameter | 1000mm |
| Configuration | Inverter + motor + gearbox set |
| Max Load | 2 tons (expandable to 5 tons) |
| Disc Speed Range | 10~200rpm (accuracy ±0.1rpm) |
| Compatible Wheel Diameter | 100~500mm |
| Temperature Control Range | -40℃~+80℃ (optional) |
| Data Sampling Frequency | 1000Hz (dynamic parameters) / 100Hz (full parameters) |
| Power Supply | AC 380V/50Hz (peak power ≤50kW) |
Core Function
Dual-position disc-type fatigue testing
Cyclic loading system:
1. Disc diameter: 1 - 3m (customizable), rotational speed: 10 - 200 rpm (stepless speed regulation), simulating high-frequency rolling of casters (equivalent to 100 kilometers per day).
2. Dual-position independent control, load range: 0 - 2 tons per position (expandable to 5 tons), supporting differentiated test parameters.
Multi-directional impact simulation: Adjustable bumps (height: 5 - 50mm) are built into the disc to simulate the impact of bumpy roads, testing the anti-deformation ability of the wheel body and the anti-impact capacity of the bearings.
Environmental coupling test (optional)
Temperature and humidity cycling: Temperature range: -40°C to +80°C, humidity: 10% to 95% RH, verifying the risk of thermal aging of plastic wheels and rusting of metal parts.
Salt spray/dust test: Spraying salt spray or dust according to ASTM B117 standard, evaluating the sealing performance and corrosion resistance level (IP67).
Intelligent monitoring and diagnosis
Real-time multi-parameter collection:
1. Load force (accuracy ±0.5% FS), rolling resistance (±0.1N), wheel temperature rise (±1°C), vibration spectrum (5 - 2000Hz).
2. 3D laser scanning (optional) captures the wear depth of the wheel surface (±0.01mm), generating wear cloud maps.
Failure warning system:
1. AI algorithm analyzes data trends (such as abnormal noise frequency, temperature gradient), predicts the risk of bearing wear or wheel cracking, and automatically stops the machine and alarms.
2. Data traceability: Automatically generates PDF/Excel reports (including fatigue curves, thermal imaging maps), supporting integration with MES systems.
Technical Highlights
High-Precision Disk Drive:
1. Servo motor closed-loop control, rotational speed accuracy ±0.1 rpm, torque fluctuation < ±0.5%, suitable for continuous operation under high load.
2. Modular disk design, allowing for quick replacement of disks with different diameters and bump layouts, compatible with casters of 100 to 500 mm in diameter.
Safety and Energy Efficiency:
1. Fully enclosed protective cover (pressure resistance ≥ 3 MPa), emergency stop, overload protection, meeting ISO 13849 (PLd level) safety standards.
2. Energy feedback technology recovers 35% of the energy during testing, with standby power consumption < 150 W.
Equipment Advantages
High Efficiency and Precision:
1. Dual-station synchronous testing, equivalent to 5,000 kilometers of actual rolling in 72 hours, with a 200% increase in efficiency.
2. Data repeatability error < ±0.5%, supports automatic sorting of defective products (optional mechanical arm).
Comprehensive Coverage:
1. Suitable for light (50kg) to super heavy (2 tons) casters, compatible with swivel casters, fixed casters, and models with brakes.
2. Expandable static load crushing test and vertical impact test modules.
Cost Optimization:
1. Laboratory testing replaces outdoor road tests, reducing overall costs by 60%.
2. By intercepting early defects, it reduces after-sales claim losses by more than 50%.
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
Production quality inspection: Batch fatigue testing of casters before leaving the factory to screen out potential hazards such as uneven materials and welding defects.
Research and development verification: Optimization of wheel body materials (polyurethane, nylon, cast iron) and bearing lubrication schemes.
Certification testing: Compulsory testing items such as ISO 22883 cycle life and DIN 15106 rolling resistance.
Heavy industry: High-load durability verification of casters for port cranes and mining vehicles.
The dual-station castor disc-type fatigue testing machine, through an innovative design of dual-station parallel testing and disc-type cyclic loading, has elevated the traditional single-machine detection efficiency to a new level, helping enterprises achieve precise assessment of castor fatigue life and zero-defect delivery. Whether it is to meet strict industrial certifications or optimize product user experience, this equipment can serve as a core tool for castor quality control, safeguarding product reliability and brand competitiveness.
