Heavy Duty Double Acting Shock Absorber Fatigue Testing Machine for Auto After-Sales Service

• Customization: Available
• After-sales Service: Within 1 Year
• Warranty: 12 Months
• Model NO.: TPJ-W20
• Max Diameter of Workpiece: <500mm
• Mass Scope of Workpiece: <900kg
• Type: Tensile Testing Machine
• Maxcapacity: <1000KN
• Accuracy Grade: 0.5
• Load Way: Mechanical Load
• Loading Method: Dynamic Load
• Display: Digital
• Control: Computer Control
• Weight: 500-1000Kg
• Power Source: AC220V
• Oil Cylinder Position: Under
• Test Force Accuracy: Testing Range 2%-100% Full Scale
• Actuator Amplitude: Standard Configuration±75
• Actuator Structure: Double Rod Double Acting
• Displacement Accuracy: 0.5% Fs
• Optional Fixture Types: Mechanical Tension, Compression, Bending Fixtures
• Frequency Range Hz: 0.001~35 Or0. 1~100 ,T0.001~25(0. 1~60)
• Appliance: Spring, Rubber, Steel, Industrial Production
• Usage 1: Wohler Fatigue Testing Machine
• Transport Package: Container
• Specification: 1200*1200*2100
• Trademark: CJ or OEM ODM
• Origin: Jinan and Others
• HS Code: 9024109000

Product Description

Technical Proposal
Project:TPJ-W20 Shock Absorber Comprehensive Performance Test Bench
Crank and Connecting Rod, Pneumatic Clamping, Online Monitoring             
              

      


          

Product Description

1. Product Overview

The TPJ-W20 universal dynamic and static testing bench for telescopic shock absorbers is mainly used for dynamic and static tests on telescopic shock absorbers used in cars, special vehicles, armored vehicles, electric vehicles, motorcycles, and other motor vehicles, including dynamism, speed, fatigue life, damping, and friction tests. It is a high-performance testing machine with a high cost-performance ratio. The machine 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 easy maintenance.

This shock absorber dynamism tester adopts a motor + crank-connecting rod structure, resulting in fast testing speed and stable performance. The piston rod features pneumatic clamping, allowing for quick and convenient clamping and high testing efficiency. It is specifically designed for online testing of shock absorbers. The dual-station design further improves testing efficiency.

The maximum speed is 1.04 m/s (stroke 100 mm and 50 mm), and speed parameters can be set arbitrarily below this speed.   

2. Solution Description
2-1. Main Unit
The main unit is a dual-station operation with a vertical, double-column structure. It mainly consists of a frame, transmission mechanism, quick-clamping system, and fixtures. The frame comprises columns, a worktable, a pump station, an upper crossbeam, a lifting mechanism (for test space adjustment), and a base. The columns, worktable, lifting mechanism, and upper crossbeam are mounted together and stably on the base. The damper under test is installed between the vibration table and the worktable using fixtures. The amplitude is adjusted to meet the requirements of specimens of different sizes. By changing the fixtures, the requirements of specimens with different installation methods can be met.
2-2. Loading Mechanism
The loading mechanism is a mechanical structure, mainly composed of a crank-connecting rod mechanism. It converts the rotational motion of the motor into linear reciprocating motion in the vertical direction. By adjusting the eccentricity of the slider, the distance of the linear reciprocating motion can be adjusted to achieve the required test stroke for the test specimen. Special tools such as T-sleeves and ratchet wrenches can be used to quickly adjust the amplitude (test stroke) and reduce the test intensity.
2-3. Quick Clamping: The quick clamping system is designed primarily for online testing. It mainly consists of a pneumatic pre-clamp and a guide frame. The pneumatic pre-clamp uses a cylinder to quickly fix the shock absorber onto the guide frame, and the upper pneumatic clamp holds the piston rod for online demonstration testing. It adopts a dual-station, dual-sensor structure with dual-curved display, with each station displaying independently for each test.
The quick clamping system can perform tests at the same pace as the shock absorber production line, achieving integration with the production line and enabling full inspection of the shock absorbers.
2-4. Test Fixture: The test fixture is specially designed and manufactured according to the structure of the sample, i.e., the shock absorber. The piston rod end uses a pneumatic clamp with corresponding threads, automatically holding the sample without gaps and enabling quick clamping, improving work efficiency.
2-5. Sensor: The force sensor is used to monitor the tensile and compressive force values of the workpiece in real time during movement.
5.1 Force Sensor (DC): Range ±20kN, filtration capacity 150%. Placed on the upper end of the shock absorber.
5.2 The sensor was calibrated before leaving the factory.

2-6. Main Features:
6.1 The amplitude and frequency of the vibration damper fatigue test are freely adjustable.
6.2 Digital display of vibration frequency and number of vibrations; generation of sinusoidal force-time curves provides a clear view of force changes.
6.3 Automatic shutdown after preset test cycles; automatic judgment of test results for higher efficiency.
6.4 Fully automatic control for demonstration testing: fully automatic fixtures and one-button fully automatic testing. The test steps are as follows:

1. Place the damper to be tested on the guide frame;
2. Press the test button; the testing machine automatically completes pneumatic fixing → pneumatic clamping → demonstration test → result display (distinguishing between pass and fail);

3. Place the selected dampers in their respective areas for the next damper test.

Because of the dual-station design, two dampers are tested simultaneously, doubling the testing efficiency, increasing the testing cycle time, and reducing testing costs.

Demonstration curves and velocity curves are generated simultaneously. It can test 5 levels of compression force (the number of levels can be freely selected according to test requirements). Each level of compression force can be set automatically or manually via a button, completing the test in one go and generating a diagram and speed curve, making it convenient and fast.
6.5 It has a wide testing range, capable of testing shock absorbers with large strokes (100mm) and long lengths (800mm), as well as those with small strokes (20mm) and short lengths (180mm), meeting the needs of testing at various locations without dead spots.
6.6 Test results are automatically distinguished by color (green for pass, red for fail), making it easy to see and quickly differentiate between pass and fail.
6.7 The controller and software are independently developed and can be customized according to customer requirements, meeting the fast and accurate testing needs of different customers.
6.8 It has both manual and automatic operation modes, and the equipment includes a manual switch to ensure one-button start.
 

Detailed Photos

 

3. Dedicated Digital Controller for Shock Absorbers:

3-1. Main Components of the Digital Controller:
1.1 Computer (Industrial PC, 17" Touchscreen Monitor, Windows Operating System)
1.2 Two-channel signal conditioning unit (test force, displacement, and performance curve)
1.3 Other necessary I/O input/output units
1.4 Dynamic testing software and dedicated data processing software for shock absorber testing
3-2. Main Technical Specifications of the Controller: PCI bus-based digital hydraulic servo controller
2.1 Control method: Force, displacement, and deformation all-digital PID closed-loop control; control modes can be smoothly switched.

2.2 Main test waveform: Sine wave;
2.3 Test signal measurement resolution: ≥1/200000, indication accuracy 0.05FS
3-3. Software Testing System: (Test interface, image reference)

Main test interface
Performance curve and resistance test results
Velocity characteristic curve

3.1 Windows 3.1 Operating system with a fully Chinese user interface;
3.2 Employs high-speed data acquisition technology to achieve high-speed data acquisition across multiple channels;

3.3 The computer screen displays test curves and various test parameters, such as force/displacement-time relationship curves, force-displacement relationship curves (dynamometer diagrams), and peak and valley values of test parameters (force, displacement);
3.4 The system has complete file operation functions for storing test curves and test data; simultaneously, test data can be stored in ASCII format, allowing users to perform secondary data processing using commercial data processing software;
3.5 Supports printing test reports (report format is ECELL, editable);

4. Equipment Manufacturing Process Description:

Install tooling according to product type and adjust stroke according to testing requirements → Turn on main unit and computer power to enter testing program → Load workpiece and press start button → Cylinder clamping device clamps and positions workpiece → Drive mechanism drives workpiece to begin power indication → Display system draws power indication diagrams on the same interface and displays maximum tensile and compressive damping force values; non-conforming parts automatically alarm and are indicated by red and green lights → This process alternates and cycles.

4-1. Change power indication fixtures for different types of workpieces.
4-2. Automatically adjust the initial position of the upper crossbeam for workpieces of different lengths.

4-3. Adjust the eccentric position for workpieces with different strokes. Stroke can be adjusted arbitrarily from 0 to 100 mm.

5. Quality Control Requirements:
5-1. Two load force sensors (each with a total range of 2T), with a repeatability of 1%FS.
5-2. Displacement sensor range: 0-150mm, with a repeatability ≥1%FS.
5-3. Settable upper and lower limits for force values; display on screen for non-compliance and simultaneous color alarm.
5-4. Force detection error: ±1%.

6. Process Equipment Requirements:

6-1. The supplier shall provide the client with one type of tooling and drawings during equipment manufacturing.
6-2. Machine tool performance shall meet the client's drawing requirements.
6-3. Tooling surfaces shall be blackened or chrome-plated for rust prevention.
6-4. Equipment shall have a nameplate.

7. Machine Tool Control and Safety Requirements:

7-1. Equipment shall have an emergency stop button, an added light grating, and manual start-up.
7-2. The electrical control system adopts a controller independently developed by Shijin, with a control voltage of DC24V.
7-3. The rotating parts of the equipment are equipped with fully enclosed protection.
 

Product Parameters

 

8. Main technical specifications of the testing machine:

NO.	Spec.	Technical Parameter
1	Maximum test force (tensile, compressive)	20 kN (10kN per workstation)
2	Fatigue test frequency	0.3~3Hz
3	Maximum test stroke	100mm
4	Maximum linear velocity in demonstration test	1.04m/s
5	Sensor calibration accuracy;	1%FS
6	Counter capacity;	9*10^9
7	Required air source pressure range;	0.4-0.7MPa
8	Maximum outer diameter of specimen;	Φ150mm(Specially designed fixtures are available.)
9	Shock absorber installation position;	2
10	Maximum specimen length;	800mm(Customizable)
11	Power supply voltage (three-wire four-phase);	380VAC 50Hz
12	Motor power;	22kW
13	Cycle time;	The three-point dynamometer detection time at 0.1m/s, 0.3m/s, and 0.6m/s is ≤9~12 seconds; (This time does not include loading and unloading time because it cannot be calculated due to human intervention during loading and unloading).
14	Simultaneous testing points;	Capable of simultaneously detecting more than 5 speed points.
14	Quality of electrical equipment, assembly quality, and appearance of the testing machine.	Should comply with GB/T2611-2006 "General Technical Requirements for Testing Machines"

 

1. Testing machine configuration

NO.	Spec.	Original	Qty
1	Mainframe	Homemade	1 set
2	Main load motor	Lu Chen	2 sets
3	Electrical control box	Aluminum Profiles	1 set
4	Inverter	Maikaino	2 sets
5	Load sensor	Yangda (Shock-resistant type)	2 PCS
6	Shock absorber controller	Independently developed	1 set
7	Shock absorber online software	Independently developed	1 set
8	Computer host	Lenovo	1 set
9	Touch screen monitor	15-inch, embedded	1 set
10	Printer	HP	1 set
11	Displacement sensor	LVDT	2 PCS
12	Pneumatic system	Airtac	4 PCS
13	Swivel boom	Aluminum profile	1 set
14	Quick clamp	Self-made	1 set
15	Common toothed blocks	M10*1.25, M12*1.25	2 sets
16	Random documentation	Instruction manual, certificate of conformity, packing list	Each copy 1

10. Operating Conditions of the Testing Machine

10-1. Ambient temperature: 10°C-35°C; Relative humidity: ≤80%
10-2. Horizontally installed on a stable foundation, with a levelness of 0.2/1000;
10-3. Environment free from vibration, corrosive media, and strong electromagnetic interference.
10-4. Power supply voltage fluctuation: not exceeding 10% of the rated voltage;
10-5. The equipment should be at least 0.8m away from walls on both sides for easy maintenance.

11. Installation, Commissioning, Acceptance, and Personnel Training

11-1. Installation and Commissioning: The supplier is responsible for transporting the equipment, and the cost is borne by the purchaser. Upon arrival, the purchaser is responsible for unloading, unpacking, and positioning the equipment, and the cost is borne by the purchaser. After the purchaser positions the equipment, the supplier is responsible for wiring and commissioning. The purchaser should provide necessary assistance to the supplier's commissioning personnel during the purchaser's commissioning process.

11-2. Equipment Acceptance: Acceptance is based on the packing list.
11-3. Personnel Training: After acceptance, the supplier shall provide free technical training to the buyer's operators and equipment maintenance personnel to ensure they can operate the equipment independently and safely, perform daily maintenance, and troubleshooting. The supplier requires that the aforementioned personnel possess the corresponding qualifications.

12. After-Sales Service and Guarantee

12-1. The supplier shall provide free commissioning and training for the buyer's operators and equipment maintenance personnel for the testing machine. The product warranty period is one year, with lifetime service.
12-2. The equipment's warranty period is one year from the date of delivery. During the warranty period, the supplier shall promptly provide free repair services for all types of equipment malfunctions (excluding human-caused quality accidents). For non-human-caused damage to parts (excluding sensors and jaws), the supplier shall promptly replace them free of charge. Outside the warranty period, if the equipment malfunctions during use, the supplier shall promptly provide on-site service and actively assist the buyer in completing the repair service.

13. Confidentiality of Technical Information and Data

13-1. This technical solution constitutes our company's technical information. The user shall be obligated to maintain the confidentiality of the technical information and data provided by us. This clause shall remain in effect regardless of whether this solution is adopted; we shall also be obligated to maintain the confidentiality of the technical information and data provided by the user.
13-2. Any other matters not covered herein shall be resolved amicably through negotiation between both parties.

14. Miscellaneous

14-1. This agreement is an appendix to the contract and shall come into effect simultaneously with the contract. Any matters not covered herein shall be resolved through negotiation between the supplier and the buyer.
14-2. This technical agreement is made in duplicate, with each party holding one copy.
14-3. This agreement is an appendix to the contract and shall have the same legal effect as the contract.