The dynamic fatigue testing machine for frame disc brakes is a specialized device designed to simulate the alternating loads caused by the huge braking torque and heat generated by the disc brake syst ...
The dynamic fatigue testing machine for frame disc brakes is a specialized device designed to simulate the alternating loads caused by the huge braking torque and heat generated by the disc brake system on the rear triangle (or front fork disc brake mount) area of bicycles, electric bicycles and motorcycles during riding, especially during continuous downhill or frequent braking. It is used to verify the fatigue strength and structural reliability of the frame (especially the rear dropouts, disc brake mounts and related welds) under long-term braking stress.
Designed in accordance with the testing standards of nine countries including CNS, JIS, DIN, NF, ISO, CPSC, CSA, AS and BS, EN 15194 electric bicycles, ISO4210, EN14781 road racing bikes, EN14766 mountain bikes and EN14764 city bikes.
Technical parameters
| Parameter | Specification |
|---|---|
| Machine Max Frequency | 0–5 Hz |
| Control Method | Computer automatic control, with displacement, force, time and other control modes |
| Load Cell Resolution | 1/10000 |
| Electric Cylinder | Servo-controlled electric cylinder |
| Sensor Capacity | Sensor Capacity |
| Displacement Stroke | 150 mm (±75 mm) |
| Test Cycles | 0–999,999 (programmable) |
| Sampling Frequency | > 200 kHz |
| Data Acquisition | High-speed acquisition card |
| Force Waveform | Sine wave |
Core Technologies and Functions
1. Power System
Servo Electric Cylinder: High-frequency (10Hz), high-precision control, suitable for complex waveform loading (such as sine waves).
Pneumatic System: Low cost, easy maintenance, combined with FESTO cylinders and sensors to achieve smooth loading.
Hydraulic Drive: Suitable for high-load testing (such as construction engineering components), but with relatively high noise.
2. Intelligent Functions
Automatic Shutdown: Immediately stops the test when the sample breaks or exceeds the limit, retaining the data.
Multi-mode Testing: Supports dynamic walking brake, yaw brake, wheel static pressure and other compound condition simulations.
3. Structural Design
Adjustable Fixture: Adaptable to different frame sizes (such as axle sleeve spacing 800-1200mm), patented clamping plate design enhances fixation stability.
Safety Protection: Steel base + leveling feet reduce vibration interference, electrostatic spraying for rust prevention treatment.
Applicable Standards
1. Bicycle Standards:
ISO 4210-6: Bicycles - Safety requirements (Part 6: Test methods for frames and forks) - Explicitly includes the fatigue test method for the rear dropouts of disc brake frames.
GB 3565: Safety Requirements for Bicycles (Chinese National Standard, corresponding to ISO 4210).
2. Electric bicycle standards:
GB 17761-2024: Safety Technical Specification for Electric Bicycles (Requirements for Disc Brake Systems by Reference to Relevant Standards)
EN 15194: European standard for electrically assisted bicycles. Special note: Electrically assisted bicycles are heavier and faster, and have greater inertia when braking. The test load is usually significantly higher than that of ordinary bicycles.
3. Motorcycle Standards:
ISO 8644/ISO 8645: Fatigue test methods for motorcycle frames (including braking load conditions).
Purchasing Suggestions
If you are considering purchasing this type of equipment, the following points need to be given priority consideration:
1. Clearly define the test object and load range:
For ordinary bicycles/mountain bikes, the load is usually within the range of 100 to 250 N·m.
Electric-assisted bicycles/electric motorcycles: It is necessary to confirm the maximum load (which may exceed 500 N·m), and inform the supplier so that they can configure the actuator of the corresponding tonnage.
2. Fixture accuracy and adaptability:
The disc brake mount simulation fixture is the core. You need to provide the supplier with the specifications of the disc brake mounts (IS/Flat Mount, hole spacing, thickness) of your common frames so that a precisely fitting fixture can be designed. The centering accuracy of the fixture directly affects the test results, and any eccentricity will introduce additional stress.
The rear axle fixture needs to be able to precisely simulate the fixing method of the hook claw (quick-release or through-axle), and be adjustable for the opening distance (135/142/148/157mm, etc.).
3. Loading direction and waveform:
Confirm whether the equipment can simultaneously or separately simulate the braking force in both forward and backward directions.
The software should be capable of generating standard waveforms such as sine waves and square waves, and also allow for the customization of load spectra.
4. Automatic Failure Detection:
The software should be capable of automatically stopping the operation when the load drops (specimen breaks, load drops by 20%), displacement exceeds the limit (severe deformation), or the cycle count is reached.
5. Environmental Simulation (Optional):
If the product is intended for harsh environments, it is advisable to consider purchasing models with temperature control boxes or mud and water spray systems for more rigorous testing.
6. Data Collection and Analysis:
It is recommended to choose a system with a high sampling rate to capture the load fluctuations at the moment of crack initiation. The software should be capable of real-time plotting of the load-displacement curve (hysteresis loop), and the degree of internal damage can be determined by the change in the area of the loop.
Ordering Process
1.Requirement Communication: Provide test standards and relevant parameters.
2.Plan Confirmation: The supplier provides 3D drawings and parameter lists.
3.Production and Delivery: 15-20 days for standard models, 30-45 days for non-standard custom models.
4.Acceptance and Training: Engineers install and debug on-site and provide on-site training.
