RELIABILITY TESTBENCH
The goal for this project was to develop a system that provided automated testing and data acquisition of three varying components in parallel. The system had to accommodate a defined capacity for each differing component, run test sequencing depending on which component, and monitor varying parameters while under test. Testing consisted of cycling a custom pneumatic assembly, rotation at varying speeds of rotary unions under fluid load, and rotation at varying speeds of slip rings under high voltage load.These tests would provide the necessary data to determine reliability and the expected life cycle of each component.
My scope of work for this project was the complete mechanical, electrical, and software design of the system.
Test fixture accommodated a maximum of 3 pneumatic lift assemblies, 4 rotary unions, and 6 slip rings
System layout was properly sectioned with fluids supplied and routed away from electrical/HV components.
A custom designed 6U power distribution unit was utilized to power all the devices for the system.
400W & 50W servo motors, coupled with a 28:1 & 12:1 gearbox respectively, were specified and used to meet application requirements
Fluid distribution was properly controlled to allow testing of rotary unions when not at full capacity
Software was developed to provide independent control for auto sequencing of all tests in parallel. Data is then acquired, analyzed, and graphed. Exporting of data was in csv format
Data acquisition of a multiaxis accelerometer was used to monitor cycling for the pneumatic lift. Sample rate was set to 1KHz
Rotary stations monitored critical data at a 1 second poll time
