Endurance Test Rigs And Inspection Machines

These are endurance testing equipment. These are custom designed for various applications. These are fully automatic cryogenic test rigs for endurance testing of components for critical applications in cryogenic as well high ambient temperatures. The test rig shown in the picture is a cryogenic endurance test rig for testing gear shifter as well as the gear shifter cables of TATA MOTORS passenger vehicles at cryogenic as well as high temperature.

This cryogenic test rig consists of three chambers which can be maintained at different temperatures with individual temperature controllers. The cables can be tested with a temperature range of     -50 to +160 deg Celsius. Pneumatic cylinders are provided for actuating the shift and select levers as per the designed sequence. The cryogenic temperatures are achieved using liquid nitrogen and controlled by cryogenic valves. All the operations are controlled by a PLC based control panel.

The test rig is custom built to check the tensile strength of the component. This is designed for continuous production lines for 100% production. Hence, ease of operation, minimum loading and unloading time, minimum setting time for change of component are the major factors for design.

This is a sturdy and highly reliable design, user friendly and very precise. Real time graphs are generated and stored in a computer connected to the test rig automatically. The equipment comprises of a rigid assembly of base plate and two side plates fixed to a rigid stand. A hydraulic cylinder and component holding brackets are fixed on either side of the test rig. Tension is given by means of hydraulic cylinder and can go upto 50KN. Load measurement is done by S-type load cell. Displacement is measured by linear scale with DRO. The testing load can be varied manually.

The following are the main specifications of this equipments

• TEST CAPACITY: upto 50,000 N.

• DEFLECTION MEASUREMENT: 5 microns - 120mm max

• DISPLAYS:

  • Set test load

  • Actual load

  • Elongation

  • Counter for no of tests.

  • Component pass condition

  • Component fail condition

• ONLINE GRAPH: force (N) Vs Deflection (Microns)

• OVERLOAD PROTECTION: necessary precautions are taken to protest the test rig for overloading as well as safe working with closed loop controls using a PLC based control panel.

The dynamic test rigs are designed for endurance testing of auto components in simulated dynamic conditions to predict the life of the components.

The picture shows a dynamic test rig to test the TATA MOTORS cables in dynamic condition. A 40 HP motor is connected to achieve the dynamic conditions such as the torque and speed of the gear box. A fly wheel is also connected to the gear box output shaft to provide necessary inertia to the system. The cables are tested for different gear shifting as well selection cycles at different speeds. The test rig is made up of five basic assemblies. The shifter housing assembly, Grommet assembly, Gear box assembly, Motor assembly, Pneumatic assembly, PLC based control panel.

The forward and reverse movements of the lever for gear changing are acquired by actuating the pneumatic cylinders in forward and reverse direction in a particular sequence. Variable speed of the motor is obtained by a 40 HP VFD (variable frequency drive). The control panel is divided into two portions. The upper portion consists of electrical elements. The lower portion acts as a pneumatic control panel with all the valves.The control panel displays the following data: Motor speed, Gear box speed, Gear oil temperature, Ambient temperature, Shift force, Select force, Cycle count.

These are endurance testing equipment. These are custom designed for various applications. These are fully automatic cryogenic test rigs for endurance testing of components for critical applications in cryogenic as well high ambient temperatures. The test rig shown in the picture is a cryogenic endurance test rig for testing gear shifter as well as the gear shifter cables of TATA MOTORS passenger vehicles at cryogenic as well as high temperature.

This cryogenic test rig consists of three chambers which can be maintained at different temperatures with individual temperature controllers. The cables can be tested with a temperature range of     -50 to +160 deg Celsius. Pneumatic cylinders are provided for actuating the shift and select levers as per the designed sequence. The cryogenic temperatures are achieved using liquid nitrogen and controlled by cryogenic valves. All the operations are controlled by a PLC based control panel.