Case Study

Fatigue Durability Test Rig Upgrade

Customer Challenge

The existing test machine was unable to fully meet the customer's requirements for test accuracy, load control, and flexible test profiles. A complete hardware replacement would have involved modifying the existing control panel, wiring, and data acquisition system.

PROLABS Solution

PROLABS developed a new LabVIEW-based test automation and machine control software to upgrade the existing test rig.

The first application developed was a Fatigue Durability Test, capable of applying alternating loads of up to 50 kN to the Unit Under Test (UUT).

The software was designed to generate and execute multiple load profiles, including:

• Sine wave

• Square wave

• Sawtooth wave

• Triangular wave

• Custom user-defined profiles

The operator can create or select the required load profile and run the test with precise control and monitoring.

The Technical Challenge

The key challenge was achieving accurate profile generation and load control while continuing to use the machine's existing control panel, electrical wiring, actuators, and NI DAQ hardware.

PROLABS developed the control algorithms and LabVIEW software to communicate with and control the existing hardware, eliminating the need for a complete machine rebuild.

Key Benefits

✓ No major hardware replacement
✓ Existing control panel retained
✓ Existing wiring retained
✓ Existing NI DAQ hardware retained
✓ Up to 50 kN alternating load testing
✓ Multiple standard waveform profiles
✓ Custom load profile capability
✓ Improved test accuracy and flexibility
✓ LabVIEW-based test automation
✓ Cost-effective machine modernization

The Results

The upgraded machine can now execute different customer-defined load profiles with high accuracy and repeatability, while retaining the existing hardware infrastructure.