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 time for forward and backward rotation, and up to ten consecutive change processes. 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. The static load is applied when the drum stops rotating.
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 bumping when the castor travels over obstacles.
6) High-temperature Explosion-proof Detection: The temperature of the castor is detected by a laser temperature sensor. The machine will stop when the temperature is too high.
7) Temperature Curve Analysis: Curves are drawn to visually analyze the changing trend. Mileage, temperature, 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 | Computer + PLC with custom program |
| Drum Diameter | 1600 mm |
| Test Caster Specification | Φ50 mm – Φ450 mm (fixtures made according to samples) |
| Load | 10000±50 KG (applied by hydraulic cylinder) |
| Speed | 0–15±0.01 km/h, forward & reverse supported (speed adjustable) |
| Drum Power Source | 15 KW variable speed 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 |
| Max Load | 10 tons (expandable to 20 tons) |
| Torque Range | 0~5000 N·m (accuracy ±0.5% FS) |
| Travel Speed Range | 0~30 km/h (stepless speed regulation) |
| Test Track Type | Smooth, sand & gravel, ramp, obstacle (4 standard types) |
| Data Sampling Frequency | 1000 Hz (dynamic parameters) / 100 Hz (full parameters) |
| Equipment Dimensions (LWH) | 3400×1100×2400 mm |
| Equipment Weight | Approx. 3600 KG |
| Power Supply Voltage | 380V±10% |
| Configuration | Inverter + 15 KW motor + gearbox set |
Core Functions
Dynamic Walking Performance Testing
Multi-condition Load Simulation:
1. Load range: 0 to 10 tons (customizable up to 20 tons), torque range: 0 to 5000 N·m (accuracy ±0.5% FS), simulating scenarios such as climbing, acceleration, and heavy-load transportation.
2. Supports constant torque, constant power, and custom load curve modes.
Complex Terrain Simulation:
1. Replaceable test tracks (smooth, gravel, slope, obstacles) to replicate real industrial terrain conditions.
2. Walking speed: 0 to 30 km/h (stepless speed regulation), testing the traction and slip rate of drive wheels at different speeds.
Environmental Coupling and Durability Testing
Temperature and Humidity Cycling Test (optional): Temperature range: -40°C to +80°C, humidity: 10% to 95% RH, verifying material aging and performance degradation of drive wheels under extreme conditions.
Salt Spray/Dust Test (optional): Simulating coastal or factory environments according to ASTM B117 standards, testing the corrosion resistance of metal parts and sealing protection performance (IP68 certified).
Intelligent Monitoring and Diagnosis
Real-time Multi-parameter Collection:
1. Torque, speed (accuracy ±0.1%), motor temperature (infrared thermal imager ±1°C), vibration spectrum (5 to 2000 Hz).
2. Laser displacement sensor detects wheel body deformation (±0.01mm), 3D contour scanning captures tire surface wear.
Failure Warning System: AI algorithm analyzes data anomalies (such as abnormal bearing noise, gear wear, motor overheating), automatically stops the machine and generates a fault report.
Technical Highlights
High Rigidity Structure Design:
1. Utilizes heavy-duty steel frame + hydraulic servo system, with rigidity ≥ 10⁹ N/m, ensuring no resonance deformation under 10-ton load.
2. Modular track system, supporting rapid switching of road conditions (smooth, gravel, slope, etc.).
Precise Control and Energy Saving:
1. Servo motor closed-loop drive, speed control accuracy ±0.1 km/h, energy feedback technology saves energy ≥ 25%.
2. Independent station control, supporting multi-station parallel testing (optional 2-4 stations).
Safety Protection:
1. Explosion-proof test chamber (pressure resistance ≥ 5 MPa), mechanical limit, emergency stop, certified by ISO 13849 (PLe level) safety standard.
2. Automatic fire extinguishing 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 5,000 hours of actual operation, with data repeatability error < ±0.5%.
2. Supports multi-station synchronous testing, increasing efficiency by 200%.
Comprehensive Coverage:
1. Compatible with drive wheels of 200 to 1,000mm in diameter, and load range of 0 to 10 tons (expandable to 20 tons).
2. Optional static load crush test and EMC interference test modules.
Cost Optimization:
1. Reduces after-sales maintenance costs by over 50% through early defect interception.
2. Laboratory testing replaces outdoor operation verification, reducing overall costs by 60%.
Standard Compliance: Built-in over 30 test procedures including ISO, GB, and ANSI, with one-click generation of certification reports.
Application scenarios and industry value
Industrial vehicles: Pre-delivery performance verification of drive wheels for forklifts, AGV carts, and heavy-duty material handling robots.
Logistics and warehousing: Durability testing of drive wheels for automated sorting systems and unmanned material handling vehicles (AMRs).
Construction machinery: High-load fatigue life assessment of drive wheels for excavators and cranes.
Certification testing: Mandatory items such as ISO 12100 mechanical safety and ANSI/ITSDF B56.5 traction performance.
The drive wheel walking test machine, through laboratory-level high-precision working condition simulation and intelligent data analysis, transforms the traditional verification process that relies on actual operations into a standardized and traceable scientific test, helping enterprises overcome core challenges in drive wheel life, efficiency and safety. Whether it is to meet strict industrial certifications or ensure the reliable operation of heavy equipment, this equipment can serve as a core tool for drive wheel quality control, providing a solid guarantee for product competitiveness and brand value.
