The power-off brake lever fatigue testing machine is a high-precision safety inspection device specifically designed for the braking systems of electric scooters, balance bikes, electric bikes, etc. B ...
The power-off brake lever fatigue testing machine is a high-precision safety inspection device specifically designed for the braking systems of electric scooters, balance bikes, electric bikes, etc. By simulating the high-frequency operation and extreme conditions of the brake lever under power-off conditions, it comprehensively verifies the mechanical life, signal response reliability, power-off protection function, and material durability of the power-off brake lever. This equipment is widely used in manufacturing, quality inspection centers, R&D laboratories, and certification institutions to ensure that products comply with international safety standards such as ISO 26262, GB/T 36972, and EN 15194, thereby reducing user safety risks caused by brake failure.
Application scope
It is used to simulate the fatigue test of the brake lever of electric scooters under power-off conditions.
Core functional modules
Disconnection Condition Simulation Test
High-frequency Fatigue Test: Simulate continuous pressing of the brake pedal (frequency 1-20 times/second), with a cycle count of ≥100,000 times, to detect spring fatigue, contact wear, and abnormal reset.
Disconnection Protection Verification: Automatically cut off power after triggering the brake signal, verify the brake system's disconnection response time (≤0.1 seconds) and the reliability of mechanical interlocks.
Environmental Coupling Test
Temperature and Humidity Simulation: Optional high and low-temperature chamber (-40°C to +85°C, humidity 10% to 95% RH) to verify brake failure caused by plastic brittleness or metal oxidation in extreme environments.
Vibration and Shock Test: Superimpose random vibration (5-200Hz, acceleration 10g) and mechanical shock (30g, half-sine wave) to detect structural loosening or solder joint cracking.
Intelligent Monitoring and Diagnosis
Multi-parameter Synchronous Acquisition: Real-time monitoring of pressing force (0-500N, accuracy ±0.5% FS), displacement (±0.01mm), electrical signals (voltage/resistance), and temperature changes, generating performance degradation curves.
Failure Warning: AI algorithm analyzes signal jumps (such as Hall sensor drift, poor contact of contacts), automatically stops the machine and generates a fault report.
Data Traceability: Each device is bound to a unique QR code, storing test data, supporting MES system integration and cloud backup.
Core technologies and configurations
| Item | Parameter Range |
|---|---|
| Test Stations | 2 groups (controlled separately) |
| Max Pressing Force | 500 N (expandable to 1000 N) |
| Test Frequency | 1–20 Hz (sine wave / random wave) |
| Temperature Control Range | -40℃ ~ +85℃ (optional) |
| Power-off Response Time | ≤0.1 s (accuracy ±1 ms) |
| Data Sampling Frequency | 1000 Hz (dynamic parameters) / 100 Hz (full parameters) |
| Features | Action and speed adjustable; brake lever movement recordable |
| Overall Dimensions (LWH) | 550×550×450 mm |
| Power Supply | AC 220 V, 50 Hz, 3 A, 1000 W (or as specified) |
Product advantages
Technical Highlights
High-precision control: Servo motor closed-loop drive, force value resolution of 0.01N, displacement repeatability accuracy of ±0.005mm.
Modular design: Quick fixture replacement (compatible with mechanical brake levers, electronic brake levers, and wire control systems), compatible with wheel diameters of 4 to 12 inches.
Safety protection: Fully enclosed explosion-proof cabin, overload protection, emergency stop, meeting ISO 13849 (PLc level) mechanical safety standards.
Energy-efficient and high-performance: Energy feedback technology recovers 30% of the energy during testing, standby power consumption < 100W.
Equipment Advantages
High efficiency and accuracy: 100,000 cycle tests can be completed within 72 hours, with data repeatability error < ±1%.
Comprehensive coverage: Supports mechanical durability, electrical performance, and environmental coupling composite testing.
Cost optimization: Early exposure of design defects, reducing recall risks and after-sales costs.
Standard compliance: Built-in ISO 26262 functional safety testing process, directly generating certification reports.
Application scenarios and industry value
Production quality inspection: Batch fatigue testing of brake handles before leaving the factory to screen out potential hazards such as spring deformation and contact oxidation.
Research and development verification: Optimization of the design of the power-off protection circuit, the fatigue strength of metal parts, and the weather resistance of plastic handles.
Certification testing: Mandatory testing items for power-off protection in certifications such as CE, UL, and GB/T.
After-sales analysis: Reproducing defects and improving processes for user feedback issues such as brake failure and signal delay.
After-sales service
Warranty Policy: Most manufacturers offer a one-year full machine warranty, and support remote fault diagnosis and operation training.
Customization Service: Customization based on requirements, including custom fixtures and software functions according to test standards (such as JIS/CNS) to meet special needs.
After-sales Service: One-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 test standards and relevant parameters.
Plan Confirmation: The supplier provides 3D drawings and parameter lists.
Production and Delivery: 15-20 days for standard models, 30-45 days for non-standard custom models.
Acceptance and Training: Engineers will install and debug on-site and provide on-site training.
