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Dynamic Wheel Endurance Test Machine |
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Caster Concepts engineers have developed a state of the art, fully automated testing machine to simulate real world use of their products in a laboratory setting. Shown on the right, the Dynamic Wheel Endurance Test Machine (DWETM) is what CCI engineers delivered. The DWETM is fully computer controlled (PC Based) and able to run 24/7 entirely unattended. It is able to automatically and programmatically change its testing conditions, the load, the speed and the test duration. The DWETM is able to simulate static and dynamic loads up to 10,000lbs and speeds up to 20 MPH. The DWETM is capable of automatically stopping the testing session when it senses
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any one of the various failure conditions. The DWETM is instrumented with a force load cell, to measure load on the test product, a torque and speed sensor, to measure the speed of the wheel and the torque being exerted onto the test wheel, an infrared temperature sensor, to measure wheel temperature, and an accelerometer to measure machine vibration. All data is fed directly into the PC based controller and can be reviewed and analyzed using custom written software programmed in LabView.
The DWETM was designed, built and tested entirely by CCI's RapidType engineering team. All software and electronics was written and designed by this engineering team. Major components were manufactured by Caster Concepts or sourced to local vendors.
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Portable, Continuous Ergonomic Pull Tester (PCEPT) |
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Caster Concepts engineers have developed a portable ergonomic pull tester (PCEPT) that could continuously acquire and record data with a high degree of accuracy and repeatability. Prior to the development of the PCEPT, Caster
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Concepts used an electronic, hand held scale to measure the pull force needed to roll its caster products. The data was displayed on a small LCD readout but testers were unable to be record the data to allow it to be reviewed and analyzed after testing. Data from this method of testing proved to be inconsistent and unreliable.
CCI engineers delivered a semi-automated, portable testing machine capable of simultaneously measuring, displaying and recording pull force data and pull speed data.
The PC base data acquisition system records all incoming data and custom written LabView software allows the data to be retrieved and analyzed. An open loop motor controller ensures that run conditions remain constant between different test sessions, resulting in very repeatable and consistent measurements.
The PCEPT was design and manufactured entirely in-house by CCI engineers. CCI engineers also built all of the electronics and wrote all of the control and data acquisition software.
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Multi-functional Static Condition Caster Test Machine |
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Caster Concepts engineers have developed a multifunctional Static Condition Caster Test Machine. This test machine was built in order to verify and quantify the static characteristics of CCI’s current and future product line. Specifically, the static tester has the capabilities of continuously measuring
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the stiffness profile of spring loaded and other shock absorption casters along their entire travel length. It can also be used to determine tread bond strength and quality of elastomer treaded wheels. Additionally, the static tester can continuously measure the resulting footprint of a wheel with respect to the load applied thus capturing the change in footprint area as the load applied to the wheel is varied.
Our aim was to create a low cost multi-functional machine capable of generating useful data for a wide range of products. In order to reduce the cost and maintain flexibility, much of the machine is un-automated. Since operation and testing time of each specimen is relatively short, an operator is required to be present at all times. The operator duties in running the test machine include loading and unloading specimens, initiating of the data acquisition software and controlling the force actuation mechanism.
The machine is capable of generating and measuring 20,000 pounds of force though its hydraulic cylinder and S beam load cell. The cylinder has 10 inches of travel measured through a linear encoder. Its plunging height can be further adjusted to accommodate various caster sizes with the addition of 6” extension rods.
All data is recorded through a laptop data acquisition system and customer written software. The static tester is built around an aluminum structure, which allowed it to be easily and cost effectively constructed. All electronics and software were developed by Caster Concepts engineers.
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