This equipment is mainly designed in accordance with the European standard EN12527 and the national standard GB/T-146888. It uses a large roller as the driving wheel to drive the tested casters and ca ...
This equipment is mainly designed in accordance with the European standard EN12527 and the national standard GB/T-146888. It uses a large roller as the driving wheel to drive the tested casters and can conduct "dynamic tests", "long-distance walking tests", and "static load tests". It is controlled by an instrument and features adjustable speed, speed display, walking distance, walking time (forward walking time, reverse walking time, 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 9,999 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 3-ton hydraulic cylinder to apply load when the drum is stationary.
4) Castor Explosion-proof Experiment: There is a photoelectric switch at the castor installation position to detect whether it is broken or damaged. The machine will stop when damage is detected.
5) Bump Simulation Experiment: Obstacle blocks are added to the drum to simulate the bumps when the castor travels over obstacles.
Curve Analysis: Curves can be plotted for intuitive analysis of the changing trends. Mileage, time, and speed are recorded and support the generation of reports.
Core technologies and configurations
| Item | Parameter Range |
|---|---|
| Test Station | Single station |
| Display & Control Mode | Touch screen + PLC with custom program |
| Drum Diameter | 600 mm |
| Test Caster Specification | Φ50 mm – Φ450 mm (fixtures customized per sample) |
| Load | 30000±1 kg (applied by hydraulic cylinder) |
| Speed | 0–15±0.01 km/h, forward & reverse supported (speed adjustable) |
| Drum Power Source | 3.7 KW gear motor |
| Travel Distance | 1–99999 km (programmable) |
| Number of Obstacles | 1–99999 pcs (programmable) |
| Obstacle Height | 3 mm, 5 mm (customizable) |
| Obstacle Installation | Installed at 45° to drum surface (forward & reverse) |
| Obstacle Spacing | 0.5–2 m per piece |
| Equipment Dimensions (LWH) | 2215×860×1250 mm |
| Equipment Weight | Approx. 800 kg |
| Power Supply Voltage | 380 V±10% |
| Configuration | Inverter + 3.7 KW motor + gearbox set |
| Max Load | 3 tons per station (expandable to 10 tons) |
| Travel Speed Range | 0~15 km/h (stepless speed regulation) |
| Steering Frequency | 1~15 Hz (sine wave / random wave) |
| Test Track Type | Steel plate, gravel, ramp, step (4 standard types) |
| Data Sampling Frequency | 1000 Hz (dynamic parameters) / 100 Hz (full parameters) |
| Power Supply | AC 380 V/50 Hz (peak power ≤ 50 kW) |
Core Functions
Extreme Load Dynamic Testing
High Load Travel Simulation:
1. Maximum test load 3 tons per station (expandable to 5 tons), travel speed 0~15 km/h (stepless speed regulation), simulating the daily operation scenarios of heavy-duty forklifts and port lifting equipment.
2. Steering frequency 1~15 Hz, testing the shock resistance and wear life of universal joints and bearings.
Complex Terrain Simulation: Replaceable test track modules (steel plates, gravel, slopes, steps) to simulate the friction and impact characteristics of factory, dock, and outdoor rough roads.
Environmental Coupling Testing (Optional)
Temperature and Humidity Cycling: Temperature range -40°C to +80°C, humidity 10% to 95% RH, verifying the thermal aging of wheel materials, rusting of metal parts, and low-temperature brittleness risks.
Salt Spray/Dust Intrusion Testing: Simulating high salt spray environments according to ASTM B117 standards to test anti-corrosion performance (IP68 certified).
Intelligent Monitoring and Diagnosis
Real-time Multi-parameter Collection:
1. Load force (accuracy ±0.5% FS), rolling resistance (±1N), wheel temperature rise (infrared thermal imager ±1°C), vibration spectrum (5~2000Hz).
2. 3D laser scanning (optional) captures wheel surface wear depth and structural deformation (accuracy ±0.01mm).
Failure Warning System: AI algorithm analyzes data anomalies (such as abnormal bearing sounds, wheel 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. Utilizes a high-strength alloy steel frame + hydraulic servo system, with rigidity ≥ 1.5×10¹⁰ N/m, ensuring no deformation or resonance under a 3-ton load.
2. Modular track design, supporting rapid switching between sand and gravel, ramps, steps, and other test scenarios.
Precise Control and Energy Saving
1. Servo motor closed-loop drive, with speed control accuracy ±0.1 km/h, and energy feedback technology saving ≥ 30% energy.
2. Optional dual-station parallel testing (efficiency increase of 200%), with independent station control and no interference.
Safety Protection:
1. Explosion-proof test chamber (pressure resistance ≥ 5 MPa), mechanical limit stops, and emergency stop buttons, meeting ISO 13849 (PLe level) safety certification.
2. Automatic fire suppression system (inert gas/dry powder), addressing fire risks caused by high-load friction.
Equipment Advantages
High Efficiency and Precision:
1. 72-hour continuous testing is equivalent to 10,000 kilometers of actual operation, with data repeatability error < ±0.5%.
2. Supports multi-station expansion (optional 2-4 stations), suitable for synchronous testing of different load grades.
Comprehensive Coverage:
1. Compatible with industrial casters with wheel diameters of 200-800mm, load range of 0.5-3 tons (expandable to 10 tons).
2. Optional static load crush test (vertical pressure test) and EMC interference test modules.
Cost Optimization:
1. Laboratory testing replaces outdoor high-intensity operation verification, reducing overall costs by 60%.
2. Through early defect interception, reduces after-sales maintenance and recall losses by over 70%.
Standard Compliance: Built-in 30+ test procedures including ISO, GB, DIN, etc., one-click generation of global certification reports.
Application scenarios and industry value
Heavy-duty industrial casters: Batch testing of port cranes, heavy-duty forklifts, and construction machinery casters before leaving the factory.
Warehousing and logistics equipment: High-load durability verification of AGV carts and automated shelving casters.
Research and development laboratories: Optimization of wheel body materials (ultra-high molecular weight polyethylene, cast iron), bearing structure, and dust-proof design.
Certification testing: Compulsory inspection items such as ISO 22883 dynamic load and DIN 15106 rolling resistance.
The three-ton castor walking test machine, through laboratory-level extreme load simulation and intelligent data analysis, transforms the traditional experience-based heavy-duty castor testing into a standardized and traceable scientific verification process, helping enterprises overcome the challenges of lifespan and safety in high-load scenarios. Whether it is ensuring the all-weather operation of port equipment or enhancing the operational efficiency of heavy logistics, this device can serve as a core tool for castor quality control, providing a solid guarantee for product competitiveness and brand value.
