DR - Three-ton Casters Travel Test Machine (Computer Version)

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 to 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. During the test, real-time curves are drawn, and the test report can be exported to a USB flash drive. 

Test items

1. Dynamic test: The drum can be set to rotate forward or backward, with the option to set 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 test: The running time and mileage can be set. The machine will stop when the preset time or mileage is reached.

3. Static load test: The equipment is equipped with a 3-ton hydraulic cylinder to apply load when the drum is stationary.

4. Castor explosion-proof test: 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 test: Obstacle blocks are added to the drum to simulate the bumps when the castor travels over obstacles. 

Main technical parameters

Core Technology Principles and Test Logic

✅ Three-scenario test coverage: dynamic/long-distance/static, simulating real working conditions. The equipment is centered around the "large drum drive wheel" and precisely simulates the force scenarios throughout the life cycle of casters through "mode switching + parameter setting":

✦ Dynamic test:

Simulates complex conditions such as "uneven roads, sudden stops and turns", by presetting "wave patterns" on the drum surface (depth adjustable from 2 to 5mm), combined with "sudden speed change function" (instant acceleration/deceleration from 0 to 5km/h), to test the "wheel body impact resistance", "bearing wear resistance", and "bracket torsion resistance" of the caster (for example, after 100,000 bounces, a 3-ton caster shows no cracking on the wheel surface and no jamming in the bearing);

Supports "load superposition" (additional loading of 0 to 3 tons), to verify the performance under the dual pressure of "heavy load + bounces" (traditional equipment only tests dynamic conditions without load).

✦ Long-distance walking test:

Test distance 0 to 100,000km (adjustable), simulating "high-frequency usage scenarios" (for example, a warehouse logistics vehicle travels 50km per day, equivalent to 2,000 days of testing);

Walking speed 0.5 to 5km/h (adjustable), covering multiple scenarios such as "low-speed handling (0.5km/h)", "medium-speed transfer (2km/h)", and "high-speed movement (5km/h)";

Supports "alternating forward/reverse testing" (automatically switches direction every 500km), simulating "round-trip handling" conditions, avoiding test deviations caused by one-way wear (traditional equipment only tests in one direction).

✦ Static load test:

Maximum static load 3 tons (accuracy ±1%), simulating the "long-term static load-bearing" scenario (such as when the equipment is parked and the caster is continuously under pressure);

Test duration 1 to 168 hours (adjustable), monitoring "wheel body deformation rate" (for example, under a 3-ton load for 24 hours, the wheel surface compression is ≤2mm), and "bracket stress distribution" (data collected through built-in strain gauges), to evaluate the "long-term load-bearing stability" of the caster (traditional equipment only measures instantaneous load-bearing). 

✅ Instrument-grade intelligent control: Parameter visualization, zero-threshold operation. The equipment adopts a full computer control system (10-inch industrial-grade touch screen), integrating functions such as "speed adjustment, distance setting, time management, and forward/reverse rotation switching", to achieve "one-click" testing:

✦ Real-time multi-parameter display:

The screen synchronously displays "current speed (km/h), cumulative walking distance (km), forward/reverse walking time (h), stop time (h)", with data update frequency of 1 second per time (traditional equipment updates only once every 5 minutes);

Supports "over-limit alarm" (such as speed exceeding the set value by 5 km/h, distance exceeding 100,000 km), automatically stops within 0.5 seconds and prompts the fault code (such as "E01: Abnormal speed").

✦ Real-time curve drawing and analysis:

Equipped with a dynamic data acquisition module (sampling frequency 10Hz), it generates "speed-time curve", "distance-wear curve", "load-deformation curve" in real time, intuitively presenting the "performance attenuation trend" of the casters (such as "wear rate starts to accelerate after 10,000 km");

Supports "historical curve comparison" (superimposition of curves of the same caster under different batches and different loads), assisting in locating "material defects" or "process improvement points" (traditional only stores discrete values). 

✅ Data Management and Compliance Support: Traceable Reports, More Efficient Certification

✦ Intelligent Generation of Test Reports:

Built-in templates for EN12527/GB/T 146888 standards, automatically matching thresholds such as "no cracks on the dynamic test wheel surface", "temperature rise of the long-distance test bearing ≤ 30℃", "static test deformation ≤ 2mm", etc., and outputting "pass/fail" judgments;

Reports can be exported to a USB drive (formats: PDF/Excel), including "test parameters, curve screenshots, compliance conclusions", and can be directly used for "ISO 9001 quality certification", "EU CE certification", etc. (Traditionally, reports need to be manually compiled, taking more than 2 hours).

✦ Cloud Synchronization of Data (Optional):

Supports "Wi-Fi/4G network connection", test data is uploaded in real time to the enterprise cloud platform, allowing remote monitoring of information such as "today's test pass rate of production line No. 1 machine is 98%" and "the long-distance wear rate of No. 2 casters in R&D exceeds the standard", achieving "cross-regional quality control management" (suitable for group production enterprises). 

Application scenarios and customer value

1. Casters Manufacturer: 70% increase in production line quality control efficiency

✦ Production line compatibility:

Seamlessly integrated with the caster production line's "forming - assembly - quality inspection" process, capable of testing 20-30 sets of casters (each set contains 4 casters) per day per machine, meeting the production demand of "2,000 sets per month" for large-scale production;

The pass rate has increased from 85% (manual spot checks) to 99%, saving an estimated 500,000 yuan in annual after-sales maintenance costs (based on an annual production of 24,000 sets).

2. Logistics Equipment Company: More precise selection of matching casters

✦ Selection support:

Through "long-distance walking tests" to compare the wear rates of casters from different suppliers (e.g., Brand A has a 5% wear rate at 100,000 km, while Brand B has an 8% wear rate at 100,000 km), select "high durability" casters to reduce equipment maintenance frequency (actual feedback shows that the maintenance cycle of logistics vehicles has been extended from 3 months to 6 months);

Through "static load tests" to verify that the deformation of casters under the weight of a 3-ton device is ≤ 2mm, avoiding customer complaints such as "ground indentations caused by long-term static placement".

3. Third-party Testing Institution: The "golden certificate" for authoritative certification

✦ Compliance support:

The equipment is certified by the CNAS laboratory (China National Accreditation Service for Conformity Assessment), and the test reports comply with international and national standards such as EN12527 and GB/T 146888;

It has assisted a testing institution in providing a caster test report for "warehousing equipment exported to the EU", ensuring its CE certification (avoiding a return loss of approximately 2 million yuan). 

Reliability and Maintenance

Structural Durability:

- The large roller drive wheel is made of 45# steel with surface quenching treatment (hardness HRC50–55), ensuring a wear-resistant lifespan of ≥500,000 km;

- The servo motor has a lifespan of ≥100,000 hours (equivalent to continuous testing for 11 years, with an average of 8 hours of testing per day).

Operational Safety:

- The equipment is equipped with an "emergency stop button" (power cut-off within 0.1 seconds), "overload protection" (automatic unloading when the load exceeds 3.3 tons), and "hand protection guards" (fully enclosed roller area), meeting the ISO 13849 mechanical safety standards;

- The test chamber is treated with anti-static powder coating (surface resistance ≤10^9Ω), reducing the risk of "static electricity ignition in a dusty environment" (suitable for special industries such as chemical and building materials). 

Precision tracking and dual-dimensional verification - using data-driven testing to ensure that every core component of each wheelset becomes a "reliable quality commitment". Redefining the quality inspection standards for electric bicycles. Whether it is to ensure the safety of users' rides or to break through the technical bottlenecks of high-performance motors, this equipment, with its industrial-grade precision, intelligent diagnosis, and all-round compliance, helps enterprises create high-quality products and gain global market competitiveness.