DR - Single-station Casters Life Test Machine (Disc)

This equipment is mainly designed in accordance with the European standard EN12527 and the national standard GB/T14688. It uses a large circular disc as the driving wheel to drive the tested casters. The disc with obstacles can conduct tests such as "obstacle crossing test", "long-distance walking life test", and "load-bearing test". It is microcomputer-controlled and can set different operation modes for distance and obstacles, such as running forward for 2 minutes, stopping for 2 minutes, then reversing for 2 minutes, stopping for 2 minutes, or running for 3 minutes, stopping for 1 minute, and then continuing. The load application adopts a stackable weight direct pressure method, which more realistically simulates the test environment and conditions. It is controlled by a touch screen, making the setting and operation very convenient. It can display the walking time and distance in real time and is suitable for testing the wheels of suitcases, roller skates, office furniture wheels, trolleys, and industrial casters, etc. 

Function Description

1) Dynamic Experiment: The disc can be set to rotate forward or backward, with the option to specify the duration of forward and backward rotation. Up to ten consecutive change processes can be set, and the total process can be cycled up to 9,999 times.

2) Long-Distance Travel Experiment: The running time and distance can be set. The machine will stop when the preset time and distance are reached.

3) Static Load Experiment: The equipment is equipped with weight holes with a diameter of 50mm. There are six 20KG weights, six 10KG weights, and four 5KG weights, totaling 200KG. The load is applied when the drum is stationary.

4) Castor Explosion Prevention Experiment: A photoelectric switch is installed at the castor mounting position to detect any breakage or damage. If damage is detected, the machine will stop.

5) Bump Simulation Experiment: Obstacle blocks are added to the drum to simulate the bumps encountered by the castor during travel.

6) Curve Analysis: Curves can be plotted to visually analyze the trend of changes. Mileage, time, and speed are recorded and support the generation of reports. 

Relevant parameters

Core Functions

Disc-type cyclic fatigue testing

High-frequency rolling simulation:

1. Disc diameter 1-2m (customizable), rotational speed 10-150rpm (stepless speed regulation), simulating continuous rolling of casters (equivalent to 80 kilometers per day).

2. Load range 0-1 ton (expandable to 3 tons), precisely controlling vertical pressure and lateral torque.

Multi-directional impact testing: Adjustable bumps (height 5-30mm) can be installed on the disc surface to simulate the impact of bumpy roads, testing the wheel's resistance to deformation and bearing life.

Environmental coupling testing (optional)

Temperature and humidity cycling: Temperature range -40°C to +80°C, humidity 10% to 95% RH, verifying material thermal aging, low-temperature brittleness and metal corrosion risks.

Salt spray/dust testing: Salt spray or dust is sprayed according to ASTM B117 standards to evaluate the sealing protection performance (IP65/IP67).

Intelligent monitoring and diagnosis

Real-time multi-parameter collection:

1. Load force (accuracy ±0.5% FS), rolling resistance (±0.1N), wheel temperature rise (infrared thermal imager ±1°C), vibration spectrum (5-2000Hz).

2. 3D laser scanning (optional) for real-time monitoring of wheel surface wear depth (±0.01mm), generating wear cloud maps.

AI failure warning: Machine learning algorithms analyze data trends (such as abnormal noise frequency, sudden temperature changes) to predict the risk of bearing jamming or wheel cracking, automatically stopping the machine and generating reports.

Data traceability: Automatically export PDF/Excel reports (including fatigue curves, thermal imaging maps), supporting integration with MES systems. 

Technical Highlights

High-Precision Disk Drive:

1. Servo motor closed-loop control, rotational speed accuracy ±0.1rpm, torque fluctuation < ±0.5%, suitable for long-term continuous operation.

2. Modular disk design, quick replacement of different diameters and bump layouts, compatible with wheel diameters of 80 to 400mm casters.

Safety and Energy Efficiency:

1. Fully enclosed protective cover (pressure resistance ≥ 2MPa), emergency stop, overload protection, meeting ISO 13849 (PLc level) safety standards.

2. Energy feedback technology recovers 30% of the energy during testing, standby power consumption < 100W.

Equipment Advantages

High Efficiency and Precision:

1. 72-hour continuous testing is equivalent to 4,000 kilometers of actual rolling, with data repeatability error < ±0.5%.

2. Supports custom test scripts (such as step loading, random shock), adaptable to diverse testing requirements.

Flexible Adaptability:

1. Compatible with swivel casters, fixed casters, and models with brakes, load range 50kg to 1 ton (expandable to 3 tons).

2. Optional vertical static load crush test module (maximum pressure 5 tons).

Cost Optimization:

1. Laboratory testing replaces outdoor road tests, reducing overall costs by 50%.

2. Through early defect interception, reduces after-sales maintenance costs by over 60%.

Standard Compliance: Built-in 20+ test procedures including ISO, GB, DIN, etc., one-click generation of global certification reports. 

Application scenarios and industry value

Production quality inspection: Fatigue life screening of casters before leaving the factory to quickly identify material defects or poor assembly.

Research and development verification: Optimization of wheel body materials (polyurethane, nylon, rubber) and bearing structure design.

Medical equipment: Life verification of silent and low-resistance casters for hospital beds and operating tables.

Certification testing: Compulsory testing items such as ISO 22883 cycle life and DIN 15106 rolling resistance. 

The single-station castor life testing machine (disc) upgrades the fatigue life test of castors from "experience-driven" to "data-driven" through high-precision cyclic loading and intelligent data analysis, helping enterprises precisely control product quality and reduce market risks. Whether it is to enhance the durability of industrial castors or ensure the silent and safe operation of medical equipment, this device can serve as a core tool for the research and development and production of castors, safeguarding brand competitiveness and user trust.

If you need to customize a test plan or obtain a technical demonstration, please contact our engineering team! 

Related Services

Warranty Policy: Most manufacturers offer a 1-year full machine warranty, supporting 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: 1-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.

Spare Parts Supply: Quick replacement service for consumable parts (fixtures, hydraulic seals).

Ordering Process

Requirement Communication: Provide test standards and relevant parameters.

Solution Confirmation: Supplier provides 3D drawings and parameter lists.

Production and Delivery: 15-20 days for standard models, 30-45 days for non-standard customized models.

Acceptance and Training: Engineers install and debug on-site and provide on-site training.