The equipment owned by customer did not allow testing the minimum number of products and did non fullfill the requirements of expected reliability level set by the O.E.M. in the given project timeline.
The testing process was additionally extended by the need of changeovers due to the previous equipment temperature limits.
We designed and built a tester performing the test sequence on 16 valves at the same time (allowing testing of 4 different variants) in the chamber in 95% humidity conditions and a temperature range from -40 * C to + 100 * C.
We provided 60 million activation with a frequency of 11 Hz (10 million per one test) - simulation of road unevenness. Rotational speed control of electric motors and Pneumatic cylinder stroke control
Through a program based on the SIEMENS PLC controller - we have enabled the selection of a test sequence suitable for the tested variant through a simple interface on the HMI panel"
In addition, a step-by-step procedure has been introduced. Our tester design allows quick conversion and testing of other types of valves
As part of the transfer of production between plants, the customer needed modernization of testers. The modernized construction had to deal with Industry 4.0 standards and design capacity assumptions.
We have modernized two testers for vacuum pumps.
We have analyzed the solutions used by the customer:
We have introduced modern control systems that allow for precise control of set parameters such as rotation speed and pressure
We have expanded the functionality by introducing additional sensors to measure the speed of the electric motor, measurement of atmospheric pressure, integration of the label printer (date, product number, production location). In addition, we introduced the automation of the testing process by adding a pump detection sensor, thanks to which the label automatically prints).
In order to ensure full control of the tester, it was necessary to add the NI card and integrate LabView software:
The client asked about the functional valve testing stand. The tester consisted of 60 pneumatic operated valves. The tested valve is responsible for air preparation in trucks.
According to the assumptions, the stand was to map the actual pneumatic system to enable analysis of the valve operation in the conditions of the end customer application.
A series of tests of various valves was performed, selecting those that met the client's specification. The valve with the best price and delivery time was chosen from them, which significantly reduced the final cost of the tester.
The main assumption of the project was the design and construction of the ball valve leak test stand with LabView software.
The project assumed the greatest automation of the test, with continuous control of flow parameters, pressure and temperature of the working medium. In addition, client procedures required the possibility of validation and calibration of the tester using specially made gauges.
The frame is made of ITEM aluminum profiles divided into