DR-6 Workstation Air Pump Performance Testing 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

A. Pressure test: Start the air pump, and the system monitors whether the specified pressure value can be reached, outputting the inflation time. It includes two types of tests: 2L and 12L.

B. High-pressure leakage test: After the 2L and 10L tests are completed, a high-pressure leakage test is conducted.

C. Inflation duration test: Mainly tests how long it takes to inflate to the set maximum air pressure. If it falls within the set time range, it is considered qualified; if it exceeds the set time range, it is considered unqualified.

D. Supports barcode scanning, local saving, and simultaneously opens data for our company's MES system to read at any time. 

Instrument parameters

Core Technology Highlights and Functional Design

✅ 6-Station Independent Control: Flexible Adaptation to Batch Testing and Multi-Model Comparison

✦ High-Density Station Layout:

6 independent test modules operate in parallel (station spacing 200mm, no mutual interference in operation), with a single station test time of ≤2 minutes (production line version) or ≤10 minutes (laboratory version). A single machine can complete 180 tests per hour (production line) or 36 tests per hour (laboratory), meeting the dual demands of "production line batch full inspection" (average daily testing of 1500 units) and "laboratory multi-scheme verification" (average daily testing of 300 units);

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

✦ Independent Parameter Settings:

Each station group can independently set "test item combinations" (e.g., station 1 tests no-load + load, station 2 tests high-voltage start + leakage), "target parameter thresholds" (e.g., pressure upper limit 80kPa), and supports "multi-model testing on the same machine" (e.g., testing A/B/C three types of air pumps simultaneously), improving the efficiency of multi-scheme comparison in the R&D stage by 50% (traditional equipment requires multiple tests). 

✅ Production Line Version VS Laboratory Version: Dual Versions Precisely Adapt to Scene Requirements 

✅ Comprehensive test project coverage: from basic performance to extreme validation

✦ No-load test

Simulates the operation of the air pump without load, collecting basic parameters such as "no-load current (≤0.5A)", "no-load speed (3000–5000rpm)", and "no-load noise (≤50dB)", to assess motor efficiency and operational stability (traditional equipment only measures current, missing noise anomalies).

✦ Load test

Connects adjustable loads (pressure 0–100kPa, flow rate 5–50L/min), simultaneously monitoring "load current (0.8–2A)", "output pressure stability (fluctuation ≤±1kPa)", and "flow rate decay rate (≤5%)", to verify the output capability of the air pump in real gas usage scenarios.

✦ High-pressure start test:

Simulates "air pump start under high pressure" (such as restarting when the gas storage tank is not depressurized), setting the start pressure (e.g., 60kPa), and detecting "start current peak (≤3A)" and "start time (≤0.2 seconds)", to prevent "stall burnout" and other faults (traditional equipment only measures normal pressure start, ignoring high-pressure risks).

✦ High-pressure leakage test:

Closes the air pump output valve, maintains pressure for 30 seconds, and uses a pressure sensor (accuracy ±0.1kPa) to monitor "pressure drop rate (≤0.5kPa/min)", to determine the internal sealing performance of the air pump (such as seal ring aging, pipeline interface leakage);

The laboratory version can add "temperature compensation" (simulating a 50°C high-temperature environment) to more realistically reproduce the aging leakage scenario after long-term use.

✦ Maximum current test:

Gradually increases the load until the air pump stalls, recording "maximum operating current (≤2.5A)" to assess the motor's overload capacity;

Triggers "overcurrent protection" (stops within 0.5 seconds when current exceeds threshold) to prevent damage to the air pump during the test (traditional equipment lacks protection mechanisms, with a test loss rate >5%).

✦ Maximum pressure test:

Closes the gas outlet, gradually increases the air pump's output pressure, and records "maximum pressure tolerance (≤120kPa)" and "pressure peak duration (≥10 seconds)" to verify the air pump's extreme performance (suitable for industrial high-pressure air pump R&D). 

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

✦ Real-time Synchronous Multi-parameter Acquisition:

Equipped with an 8-channel data acquisition card (supporting 8 types of parameters including current, voltage, air pressure, flow rate, temperature, rotational speed, noise, and vibration), with a synchronization rate of less than 0.001 seconds, eliminating the "parameter time difference" that causes analysis errors;

The laboratory version supports "waveform superimposition display" (such as simultaneously displaying current and pressure curves), intuitively presenting causal relationships like "current surge → pressure drop" (traditional equipment only displays separately, making correlation analysis difficult).

✦ Intelligent Abnormal Diagnosis and Early Warning:

Built-in AI algorithm model (trained on 100,000 sets of historical data), automatically identifying hidden defects such as "abnormal pressure fluctuations" (e.g., high-frequency jitter with a frequency > 10Hz) and "current spikes" (e.g., a 1A current rise within 0.1 seconds);

The production line version triggers "audio-visual alarms" (red light + buzzer) and locks the workstation, while the laboratory version generates "abnormal feature reports" (e.g., "Workstation 3 experienced 3 current spikes during load testing"), assisting in rapid problem location. 

Application scenarios and customer value

✅ Full inspection on production lines: Dual improvement in efficiency and yield rate

✦ Adaptability to production lines:

Seamlessly integrated with the "welding-sealing-testing" process of the air pump assembly line, with a single machine daily output of ≥1,200 units (based on 10 hours of operation), meeting the large-scale production demand of "10,000 air pumps per day";

The performance qualification rate of air pumps has increased from 85% (manual spot checks) to 99%, saving an annual repair cost of 500,000 yuan (based on an annual output of 100,000 units). 

✅ R&D Performance Optimization: Accelerate Product Iteration

✦ Multi-scheme Comparative Testing

Simultaneously test six different designs of air pumps (such as different motors, sealing rings, and airway structures);

The laboratory version outputs a "design parameter - performance" correlation matrix (such as "the leakage rate of copper sealing rings is 30% lower than that of silicone"), assisting the R&D team in quickly identifying the optimal solution (traditionally requiring three separate tests, now the time is reduced by 60%). 

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

✦ Compliance Support:

Compliant with global mainstream standards such as ISO 13485 (Medical Device Standard), GB/T 13928 (National Standard for Micro Air Pumps), UL 60730 (Safety Certification), etc.

The laboratory version of the test report includes original waveform diagrams and environmental parameter records, which can be directly used for product export certification (such as EU CE, US FCC). 

Reliability and Maintenance

✅ Structural Durability:

✦ The gas path interface uses stainless steel quick-connect fittings (with a durability of 100,000 insertions and removals), preventing "gas leakage caused by frequent model changes";

✦ The sensor lifespan is ≥ 500,000 tests (equivalent to continuous operation for 5 years, with an average of 300 tests per day). 

✅ Easy-to-maintain design:

✦ The test module supports "snap-on disassembly" (no tools required, replacement completed within 5 minutes);

✦ Annual calibration takes only 1 hour (original factory pressure/flow/current standard parts are provided);

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

Operation Process (Differences between Production Line Version and Laboratory Version)

✅ Production Line Version: 4-step simplified operation, suitable for high-speed production lines

✦ Loading and Clamping → The operator places the pump to be tested into the fixture at the workstation (magnetic positioning, automatically aligning the airway interface);

✦ Mode Selection → Select "Production Line Full Inspection Mode" on the touch screen (default tests no-load + load + high-pressure start);

✦ Start Testing → Click the "Start" button, and the equipment automatically completes the test (real-time display of the status of each workstation: green for OK / red for NG);

✦ Unloading and Sorting → OK products flow into the packaging line, and NG products (such as air leakage / current exceeding the limit) are placed in the defective product box by the mechanical arm.

✅ Laboratory Version: 5-step in-depth analysis, supporting R&D optimization

✦ Parameter Configuration → Import the test plan (such as "High-Pressure Start + Air Leakage Test"), and customize pressure/flow threshold values and sampling frequency;

✦ Clamping and Debugging → Connect the pump and manually calibrate the sensors (such as zero-point correction, pressure calibration);

✦ Pre-test Verification → Execute "Single-step Debugging" (such as only testing no-load) to confirm normal parameter collection;

✦ Full Process Testing → Click the "Start" button, and the equipment synchronously collects 8 types of parameters and generates dynamic curves;

✦ Report Generation → After the test is completed, automatically output a "Performance Analysis Report" (including waveform diagrams, abnormal point annotations, and improvement suggestions).