DR-4 Station Air Pump Life Test Machine

This equipment is mainly used for the performance testing of air pumps. It can collect and process real-time data such as current, voltage, air pressure and flow rate of the air pump under no-load and load conditions. The test items include no-load test, load test, high-pressure start-up test, high-pressure leakage test, maximum current test, maximum pressure test, etc.

The system is divided into two different versions: the production line version and the laboratory version. The production line version focuses on test efficiency and convenience, while the laboratory version emphasizes the processing and display of test process data, capable of capturing the subtle fluctuations in test process data in real time and comprehensively presenting the performance of the product. Each station of both versions can work independently (setting parameters do not interfere with each other), and can also be started and stopped all at once. 

Test items

1. It can simultaneously test 4 units of production.

2. It can control the product to perform X min ON and X min OFF timed control life tests.

3. It can control the air pump to perform cyclic tests from X pressure point to X pressure point. The solenoid valve automatically releases air, and the air pump can be set to stop working during the air release process. The number of cyclic tests can be set by oneself, and it should at least have the function of recording 500 cycles of test data.

4. All test data are automatically recorded by the computer, with the fastest recording frequency of once per second.

5. If any abnormal situation occurs with the air pump during the test, the computer will automatically control the machine to stop. If the current exceeds the set value or the single cycle time exceeds the set time during the test, the machine will automatically stop.

6. The recorded data include: the number of inflation times, inflation time, and the maximum current during the inflation process.

7. It can control the air pump to perform constant pressure life tests. 

Instrument parameters

Core Technology Highlights and Functional Design

✅ 4-Station Synchronous Testing: Double the Efficiency, Flexible Resource Allocation

✦ Multi-machine Parallel Testing:

4 independent test modules operate simultaneously (with a 200mm distance between stations, ensuring no interference in operation), with a single-station single-test cycle of ≤72 hours (supporting 7×24 continuous operation). A single machine can simultaneously complete comparative tests on 4 different models/parameters of air pumps (traditional single-station equipment requires 4 separate tests, increasing the time by 3 times).

Supports "Single Station Start" (e.g., testing only 1 unit), "Group Start" (e.g., testing 3 units simultaneously), or "Full Station Start" (6 units simultaneously). Mode switching can be completed by selecting the stations on the touch screen (traditional equipment only supports full start/stop, with a resource waste rate > 30%).

✦ Independent Parameter Settings:

Each station can independently set the "timed cycle" (e.g., Station 1: 5min ON/2min OFF, Station 2: 10min ON/3min OFF) and "pressure cycle range" (e.g., Station 3: 20kPa→80kPa, Station 4: 30kPa→60kPa), enabling "multi-condition testing on the same machine". This increases the efficiency of multi-scenario verification during the R&D stage by 60% (traditional equipment only supports tests with the same parameters). 

✅ Multi-mode cycle control: Restore real working conditions, making tests more reliable

Control: Restore real working conditions, making tests more reliable

✦ Timed start-stop cycle:

Set "ON time (1–60min)" and "OFF time (1–60min)" through the PLC controller to simulate real usage scenarios such as "e-cigarette puffing (5min ON/2min OFF)" and "intermittent gas supply for medical equipment (10min ON/3min OFF)";

The response time for start-stop switching is less than 0.1 seconds (relay control), ensuring that the test is highly consistent with the actual working conditions (traditional equipment has a delay of more than 0.5 seconds, affecting the assessment of lifespan).

✦ Pressure cycle test:

Equipped with a high-precision proportional valve and pressure sensor (pressure range 0–100kPa, accuracy ±0.5kPa), it can customize the "start pressure (X) → end pressure (X)" cycle path (e.g., 20kPa → 80kPa → 20kPa);

It is also equipped with an automatic venting function of the solenoid valve (vent rate adjustable), during which the air pump automatically stops (to avoid idle running loss), and the number of cycles can be set (≥500 times), fully simulating the "inflation - pressure holding - venting" full process (traditional equipment only measures constant pressure lifespan, missing the aging of seals caused by pressure fluctuations).

✦ Constant pressure lifespan test:

Supports setting a "fixed pressure value" (e.g., 50kPa), and the air pump runs continuously until the end of its lifespan (flow rate decays to 80% of the initial value or pressure cannot be maintained);

It is suitable for scenarios such as "long-term pressure holding of industrial air pumps" and "continuous gas supply of medical oxygen generators", verifying the durability of the air pump under constant load (traditional equipment does not have this mode and cannot assess long-term operational performance). 

✅ Full-process intelligent data recording: Second-level capture, abnormality second-level warning

✦ High-frequency data collection:

Equipped with an industrial-grade data acquisition card (sampling frequency 1Hz, fastest 1 record per second), it synchronously collects five core parameters: "inflation times, inflation time, maximum current, real-time pressure, and real-time flow";

Data is automatically stored on the computer (supporting a 500GB hard drive, capable of saving 100,000 sets of test records), and supports quick retrieval by "time/workstation/cycle number" (traditional manual recording has a missing rate of over 20%).

✦ Intelligent anomaly detection and protection:

Overcurrent protection: The current sensor monitors in real time (accuracy ±0.02A), and when the current exceeds the set threshold (such as 120% of the rated current), the system automatically stops within 0.5 seconds and marks "motor overload";

Timeout protection: When the single cycle time exceeds the set value (such as inflation time > 10 minutes), it is determined as "airway blockage/seal failure", triggering a sound and light alarm (red light + buzzer, volume 85dB);

Life-end determination: When the inflation time extends to 150% of the initial value (pump efficiency decline) or the cycle number reaches the upper limit (such as 500 times), the test automatically stops and generates a "life termination report". 

✅ Data Visualization and Analysis: Efficient Conversion from Data to Decision-Making

✦ Real-time Dynamic Interface:

Equipped with dedicated test software (compatible with Windows system), the main interface displays "cycle progress of each station, real-time current/pressure curves, and abnormal status alerts" (green: normal; red: abnormal) in real time;

Supports "curve overlay comparison" (such as simultaneously displaying the current curves of station 1 and station 2), intuitively presenting the lifespan differences of different air pumps (traditional equipment only shows values and cannot be compared and analyzed).

✦ Multi-dimensional Report Output:

Automatically generates Excel/CSV reports (including statistics of inflation times, distribution of single inflation time, and maximum current peak table);

The laboratory version can be optionally equipped with an "AI analysis module" (trained based on historical data), outputting "lifespan prediction curves" (such as "the remaining lifespan of this air pump is 30% after 500 cycles"), assisting in advance planning for maintenance or design optimization. 

Application scenarios and customer value

✅ Batch quality control on production lines: Improved yield and reduced costs

✦ Production line compatibility:

Seamlessly integrated with the "assembly - initial inspection - life test" process of the air pump production line, capable of testing 4 air pumps at a time (averaging 96 per day), meeting the needs of medium and small batch production lines with a monthly output of 3,000 units;

The qualified rate of air pump life has increased from 80% (sample testing) to 98%, reducing the number of returns due to insufficient life (traditional sampling missed detection rate > 20%). 

✅ R&D parameter optimization: Accelerate product iteration

✦ Multi-scheme comparison testing:

Simultaneously test 4 different designed air pumps (such as different motors, sealing ring materials);

Output "material-life" and "structure-decay rate" correlation curves to assist the R&D team in quickly locking the optimal solution (traditionally, it would require 4 separate tests, reducing the time by 75%). 

✅ Third-party Testing: The "Golden Certificate" of Authoritative Certification

✦ Compliance Support:

Compliant with global mainstream standards such as ISO 13485 (Medical Device Standard) and GB/T 13928 (National Standard for Micro Air Pumps);

The test report includes original data curves and environmental parameter records, which can be directly used for product export certification (such as EU CE and US FDA). 

Reliability and Maintenance

✅ Structural Durability:

✦ The service life of proportional valves/electromagnetic valves is ≥100,000 adjustments (equivalent to continuous testing for 2 years);

✦ The test chamber is made of 304 stainless steel + anti-corrosion coating (resistant to oil mist/water vapor corrosion, with a service life of ≥10 years). 

✅ Easy-to-maintain design:

✦ The gas path module/sensor supports "clip-on disassembly" (no tools required, replacement completed within 2 minutes);

✦ Annual calibration takes only 30 minutes (original factory pressure/current standard parts provided);

✦ Self-diagnostic function for faults (displaying error codes such as "pressure sensor drift" and "stuck solenoid valve"), guiding quick maintenance. 

Operation Process (4 Simple Steps) ✅ Production Line Version: 4 Simple Steps, Suitable for High-Speed Production Lines

✦ Parameter Setting → Open the test software on the computer, select the test mode (timed start and stop / pressure cycle / constant pressure test), and set parameters such as "ON/OFF time", "pressure range", and "cycle count";

✦ Mounting the Air Pump → The operator connects the air pump to be tested to the workstation air line through a quick-connect fitting (automatically sealed), and secures it in the test chamber (elastic fixture prevents vibration and displacement);

✦ Start Testing → Click the "Start" button, and the equipment automatically executes the entire process of "cycle testing - data collection - anomaly detection", with the computer interface displaying the real-time operation status of each workstation;

✦ Result Output → After the test is completed, a "Life Assessment Report" is automatically generated (including cumulative cycle count, anomaly records, and life endpoint analysis). OK products (meeting life standards) flow into mass production, while NG products (with insufficient life) are returned to R&D for optimization.