druck- und temperaturmesstechnik testing procedure mh-2 mobile hydraulic testing procedure 1...

Druck- und Temperaturmesstechnik

Testing Procedure MH-2

Mobile HydraulicTesting Procedure

1

Pressure Transmitter MH-2



Mobile Hydraulic Testing Procedure

2

passing fields & sites dirt

hydraulics, engine vibration moisture water holes, rain, cleaning operations

cavitation, micro diesel effects internal stresses pressure peaks, changing loads

shock ground waves

weather conditions, hydraulics temperature

electromagnetic interference EMI

Mobile Hydraulic Conditions

Product is extensively tested for mobile hydraulic




Qualification tests

Load cycles

Shock

Vibration

Temperature

EMC

Ingress Protection

…

3

Verify specifications

80 Mio.

500 g

20 g

- 40 … 125 ºC Tamb

CE - Conformity

IP 67 / IP 69K

…




simulate operating conditions

Pressure Transmitter goes through a sequence of tests

3 sequences of mechanical tests

7 sequences of environmental tests

2 sequences of electrical tests

Market specific tests

4




Market Specific Testing Procedure 80 test objects initial test

functionality test

mechanical tests environmental tests electrical tests

10 test objects 5 test objects 5 test objects 5 test objects 5 test objects 10 test objects 10 test objects 10 test objects 5 test objects 5 test objects 5 test objects 5 test objects

connector accuracy

housing stability

impact resistance

transport / storage

load change test

ice-water testvibration duration

UV resistance

freezing test dry heat testreset

behaviourradiates

fields

connector insertion cycles

functionality test

functionality test

functionality test

humid heatfunctionality

testfunctionality

testfunctionality

testfunctionality

testfunctionality

testovervoltage resistance

functionality test

broad-band

noisefunctionality

testvibration

short time

rapid change of

temperature load dump

torque housing

functionality

test

functionality test

dewing test slow load

dump

torque connector

continuous

shocks

resistance to chemicals

freefall

functionality test

functionality

test

functionality test

functionality

test

single shock high pressure cleaner test

functionality

test

functionality test

salt spray

test

functionality

test

5



Mechanical Tests

Connector accuracy

for connectors with connection thread

Insertion cycles

for mating connectors

Torque housing

(torque < 6 Nm)

Torque connector

(torque < 2,5 Nm)

Housing stability – shear test

Impact resistance

6

Market Specific Tests



Environmental tests- Temperature tests

Temperature shock test

Dry heat test

Dewing test

Humid heat test

Rapid change of temperature

Freezing test

7

Environmental Tests

transmitter at ice water (0 ºC) into boiling water (100 ºC C) 10 cycles

21 h at 100 ºC

-10 … 60 ºC, 80 … 95 % rel. humidity

500 h at 45 ºC and 85% rel. humidity

90 min at -40 ºC -> 90 min at 100 ºC, 30 cycles

transmitter being sprayed with water at -4 ºC -> cooling down to -5 ºC, duration 22 h, 10 cycles



Shock and Vibration

Vibration tests

Broad-band noise including temperature superposition

(10 … 2000 Hz, -40 … 85 ºC, 6 g, 32 h, 3 axis)

Vibration short time (20 … 2000 Hz, 20 g, 2 h, 3 axis)

Vibration duration (10 … 300 … 10 Hz, 10g , 150 h, 3 axis)

Shock test

Continuous shock (40 g, 6 ms, 50 times)

Single shock (100 g, 11 ms, 10 times)

Drop test (2 m free fall; 2 times per axis)

8

Environmental Tests



Load cycles

Pressure cycles at nominal pressure

9

P [bar]

t [s]

Tamb = 20 ºC, > 8 mio cycles

Tamb = -40 ºC, >1 mio cycles

Tamb = 120 ºC, >1 mio cycles

Environmental Tests



Ingress protection

IP69K:

High pressure cleaner

Pressure: 150bar, Distance: 10cm, Duration: 10sec

IP67:

Water resistance

(Submerging in 1 m deep water; duration 30 min)

10

Environmental Tests



Resistance

Salt spray test

(Test solution = 5% NaCl, at 35°C, duration = 96h)

Chemical resistance test

(Hydraulic oil; Petrol; Diesel; Brake fluid;

Ethyleneglycol solution (50/50); Phosphatising material)

UV resistance test

(5h of dry phase, 1h of irrigation; 50°C +/- 3°C; Humidity =

10%)

11

Environmental Tests




Noise resistance test (Fields 100V/m 80…1000MHz / 60V/m 1000…2000 MHz)

Overvoltage resistance

(Supply voltage: 48 V; test duration: 10 min)

Reset behavior

(20 supply voltage drops 95 % … 0 % VDDmin)

Load dump

(Voltage impulse: 46.5V and 66.5V; 400 ms; 5 impulses)

Slow load dump

(reduce VDDmax to 0% and then increase again to 100%.

Change speed 0.5V/min; VDDmax = maximal supply

voltage)

Electrical tests

12



Environmental test sequence

80 test objects

initial test

functionality test

mechanical tests environmental tests electrical tests

10 test objects 5 test objects 5 test objects 5 test objects 5 test objects 10 test objects 10 test objects 10 test objects 5 test objects 5 test objects 5 test objects 5 test objects

connector accuracy

housing stability

impact resistance

transport / storage

load change test

ice-water testvibration duration

UV resistance freezing test dry heat testreset

behaviourradiates fields

connector insertion cycles

functionality test functionality testfunctionality

testhumid heat

functionality test

functionality test

functionality test

functionality test

functionality test

overvoltage resistance

functionality test broad-band

noisefunctionality

testvibration short

time

rapid change of temperature

load dump

torque housing functionality

test

functionality test

dewing test slow load

dump

torque connector

continuous

shocks


freefall

functionality test functionality

test

functionality test

functionality

test

single shock high pressure cleaner test

functionality

test

functionality test

salt spray test

functionality

test

13

Market Specific Testing Procedure



ExampleEnvironmental test sequence

14

Initial test Ice water test Functionalitytest

Vibration test

Functionalitytest

Chemical resistance testFunctionalitytest

High pressure cleaner test

Functionalitytest




Initial Test

3 h at 125 ºC

48 h at 110 ºC

24 h at -40 ºC

2 h at 20 ºC

15

initial testfunctionality

test

ice-water test

functionality test

vibration short time

functionality test


functionality test

high pressure cleaner testfunctionality

test




Ice-Water Test

Temperature shock test

Immersion in ice water (0 ºC) for 5 min

Immersion in boiling water (100 ºC) for 5 min

10 cycles

16


test

ice-water test

functionality test


functionality test


functionality test


test




Vibration short time

Frequency range = 20 .. 2000 Hz

Acceleration = 20g

Test duration per axis = 2h

Axes = 3

17


test

ice-water test

functionality test


functionality test


functionality test


test




Resistance to Chemicals

hydraulic oil

Fuel

Diesel

brake fluid

…

Test duration: 3 days

18

Initial testfunctionality

test

ice-water test

functionality test


functionality test


functionality test


test

Environment Test Example



High pressure cleaner test

Spray angle = 0°, 30°, 60°, 90°

Water pressure = 150bar

Water temperature = 60 ºC

Test duration = 10s from all directions

19


test

ice-water test

functionality test


functionality test


functionality test


test


druck- und temperaturmesstechnik testing procedure mh-2 mobile hydraulic testing procedure 1...

Documents

test objects5 test objects

testdry heat test

mobile hydraulic slide

sequence of tests

sequences of mechanical

pressure transmitter

cycles transmitter

nm torque connector