Technical Proposal

1. Product Overview

The TPJ-20 mechanical spring fatigue testing machine is mainly used for fatigue life testing of various helical springs and cylindrical shock absorbers used in automobiles, motorcycles, and other motor vehicles. Special fixtures can also be manufactured to accommodate fatigue testing of special specimens. A force sensor can be added to monitor spring force in real time and the maximum force attenuation. When the spring force attenuates to less than the set force, the testing machine automatically stops and records the current number of tests. The machine will automatically stop if the shock absorber fails during the test. Easy to use

The testing machine has a fully enclosed structure, an attractive appearance, and safe operation. See the image below for the actual product.

3. System Description

The TPJ-20 mechanical spring fatigue testing machine consists of a main unit and a measurement and control system. The main unit provides the test loading, while the measurement and control system performs real-time measurement, processing, and display of the number of tests, and monitors the test process.

3.1 Main Unit

The main unit mainly consists of four parts: a frame, a mechanical loading mechanism, a transmission mechanism, and fixtures. The frame is a closed frame formed by four columns connecting the worktable and the upper crossbeam. The lower part of the frame is the worktable, and the upper part is the upper crossbeam. The loading crossbeam is located in the middle of the frame and is driven by the transmission mechanism to perform reciprocating motion to achieve compression (or tensile) fatigue testing of the shock absorber. A lifting platform is mounted on the upper crossbeam, and a guide plate is installed at the end of the lifting platform. The fixtures are installed below the guide plate. To meet the fatigue testing requirements of springs of different lengths, the test space can be automatically adjusted. By changing the special fixtures, the requirements of specimens with different installation methods can be met.

The transmission mechanism consists of a speed-regulating motor and a flywheel. By adjusting the motor speed, the test frequency can be arbitrarily adjusted within the range of 1-5Hz.

The loading mechanism is a mechanical structure, mainly composed of a crank-connecting rod mechanism, which converts the rotational motion of the motor into vertical linear reciprocating motion. The amplitude adjustment device adjusts the distance of the linear reciprocating motion by adjusting the eccentricity of the slider, achieving the required test stroke for the test piece.

The main unit is equipped with a safety cover.

The entire mechanical system features a reasonable, simple, and reliable structure; accurate and convenient adjustment of the test space and test stroke; convenient and reliable specimen clamping; stable operation; and ease of maintenance.

3.2 Control System

The measurement and control system, using a touchscreen + PLC configuration, is the central hub of the testing apparatus. On one hand, it processes various signals collected from force sensors and displays various status parameters such as test frequency and current test count. On the other hand, it sets control parameters according to control requirements, such as setting the number of tests for automatic shutdown and setting the test force for automatic shutdown based on stress decrease. Control signals are sent to the high-voltage control box, which in turn controls the main motor, performing functions such as motor start-up, motor speed adjustment, and automatic shutdown according to computer-issued instructions.

The manual control unit is located on the control cabinet of the testing machine and has up and down control buttons for adjusting the test space.

3.4 Main Features

Freely settable test frequency;

Arbitrarily settable number of tests;

Automatic shutdown at test completion;

Automatic shutdown in case of damper failure, recording the number of stops, and restarting for sequential testing;

Designed with specialized fixtures for testing dampers of different structures;

Manually stopable during testing, recording the number of stops, and restarting for sequential testing;

Automatically saves test counts;

High degree of automation, can be operated unattended;

Test results can be printed.

Main technical specifications of the testing machine:

NO. Name Technical Parameter

1 Maximum test force 20000N(20kN)

2 Effective force measurement range 1%-100% of full scale

3 Number of simultaneous test stations 2 (maximum force 10000N per station)

4 Test frequency 1-5Hz

5 Maximum test stroke 100mm

6 Display method Touchscreen

7 Maximum measurable shock absorber diameter 200mm

8 Maximum measurable shock absorber length 500mm (length can be customized)

9 Power supply voltage (three-wire four-phase) 380VAC 50Hz

10 Motor power 22kW (equivalent)

11 Electric lift loading 25 kN

12 protection Fully enclosed enclosure. Should comply with GB/T2611-2006 “General Technical Requirements for Testing Machines”.

13 The quality of the electrical equipment, assembly quality, and appearance of the testing machine. 500mm (length can be customized)

14 Overall dimensions of the machine 1400L*1000W*2000H

15 Overall weight of the machine 1900kg

5. Configuration of the testing machine

NO. Item name Spec. Qty

1 Mainframe Homemade One unit

2 Touchscreen Kunlun Tongtai One set

3 PLC Dechengtai One set

4 Fixture Homemade One set

5 Space adjustment motor 2.5-ton lifting motor One set

7 Inverter Maikaino One set

8 Main loading motor Luchen Multiple sets

9 Main bearing NSK One unit