Glass lifter performance durability test bench

1、 Overview
Equipment usage:
The test bench is mainly used for testing manual and electric glass lifters of cars, SUVs, MPVs and other models
Performance and durability tests under vehicle door conditions, applicable to various types of side door glass lifters and commercial vehicle sliding doors
The comprehensive performance and various aspects of the cross arm and rope wheel type glass lifter, glass, door and other assemblies of vehicles of the same type
Durability test under different environmental conditions (room temperature, -45 ° C, 90 ° C). Through experiments, check the intersection of car side doors
The functional quality of mechanisms and fasteners such as arm and rope wheel glass lifters, glass, door seals, etc.
Equipment function:
It can achieve upward, downward, stopping, and blocking rotation of glass. Measure technical parameters such as rise and fall time, current characteristics, locking force, and torque of the elevator handle. Different test parameters such as test frequency, test frequency, travel, and point detection time can be set according to the test requirements.
Test scope:
Test vehicle types: passenger cars (two/three box, MPV, SUV, etc.).
Test system: Real car door (including door sheet metal parts and door accessories, with two types of glass lifters: electric and manual).
The equipment refers to the durability and performance tests for door glass lifting and lowering conducted by FAW Car Co., Ltd
Request to conduct experiments, namely:
Q/CAF01 0300 T-49-2009 "Test Method for Real Vehicle Durability of Car Glass Elevators"
QC T636-2000 "Test Standard for Glass Elevators"
Q/CAF01 P-M6-059-1-2006 "Car Electric Glass Regulator"
Q/CAF01 0300 T-35-2008 "Inspection Standard for Manual Glass Elevators in Sedans"
GB/T 2423.1 Test A: Low temperature test method
GB/T 2423.2 Test B: High temperature test method

Glass lifter performance durability test bench

2、 Main experimental projects
1. Manual glass lifter testing items (actual vehicle):
Performance test: Handle torque detection, operation intensity detection
Durability test;
2. Electric glass lifter testing items (actual vehicle):
Performance test: Heavy load strength, current characteristic testing, closing force testing, anti pinch performance, upper
Speed detection for ascending and descending operation, ascending and descending time detection, self-locking detection, overvoltage resistance detection
Durability tests for overvoltage detection and thermal protection detection.

3、 Equipment composition and structure
3.1 Composition of the test bench
1) The test bench consists of a computer control system (1 set) and a manual glass lifting durability test bench for real car doors (1 set)
One door (1 set), actual door electric glass lifting durability test bench (4 doors tested simultaneously, 2
Fixed stand, one controller (1 set), high and low temperature box (-45 ℃~90 ℃), testing equipment
The calibration device and other auxiliary equipment are composed of compact structures and reasonable layouts,
The human-computer interaction interface is good.
2) Part of the boxes are treated with surface spraying, and the appearance color is in accordance with industrial design requirements.
3) Cooperate with the actual car door durability test bench, manual glass lifter durability drive system, and high and low temperature test chamber
Realize durability tests under different temperature environments (customized opening sizes are required for high and low temperature test chambers).
4) Each device completes its own function, realizing the detection of various functions of the glass lifter, and the overall appearance is large
Fang, easy to operate.

3. 2 Test bench structure
1) The test bench can fix doors of different sizes of vehicle models, ranging from 500mm to 1500mm in length and height
1000mm~1500mm）， The frame structure adopts aluminum alloy profiles, the fixtures are made of aluminum magnesium alloy, and the electrical appliances
Separate the control part from the test bench; The computer console is also a frame structure made of aluminum alloy profiles, which can
It is easy to separate from the test bench, has a beautiful and elegant overall appearance, and is easy to operate.
2) The test bench can be moved as a whole, and the bottom of the test bench is equipped with universal casters with movable and locking devices,
The material is polyurethane. In addition, the strength of the casters should be able to withstand the weight of the platform and load, and be able to move freely
Without deformation or damage. During the experiment, the universal casters on the test bench were locked stably and reliably.
3) The test bench can operate in an environmental chamber between -45 ℃ and 90 ℃.
4) The requirement for spraying dust in the durability test of the test bench is automatic spraying.

4、 Detailed description of the experiment
4. 1. Performance testing items for the electric window regulator of the actual car door:
1) Heavy load strength:
Under heavy load, the output of the motor is operated by applying an 18 volt voltage to the motor terminals to move the bracket up and down
The total itinerary has been moved 5 times. After operation, inspect each component for any abnormalities, including those visible to the naked eye
Deformation and cracks have occurred.
2) Current performance testing:
Measure the starting current, working current, and locked rotor current of the motor separately, and plot the time current curve,
The horizontal axis represents the running time of the motor, and the vertical axis represents the working current and blockage of the motor when the elevator rises and falls
Current conversion;
3) Detection of rise and fall time and running speed:
Test the rise and fall time. Detecting the operation of the glass lifter between the upper and lower stops
Traveling and descending time;
The computer control system monitors the running time of the upper and lower limit positions of the car glass, and converts it into glass lift
The average speed of the descent device;
4) Closing force and anti pinch detection:
The closing force and anti pinch detection on the actual car door are completed through the closing force and anti pinch detection testing module installed on the platform, which can detect the magnitude of the closing force and anti pinch performance.
Detection of closing force: When the elevator reaches the upper limit during the upward movement, the force sensor measures the force required to detect the moment of motor stalling, which is the closing force.

5) Locking force detection:
Install the elevator onto the testing equipment and use a force sensor to measure the closing force 10 times,
Use this method to obtain the mean and variance. The self-locking detection on the actual car door is installed on the platform
The force application mechanism of the cylinder is completed, and the connection of the cylinder is connected with fixtures and glass.
6) Thermal protection detection:
Install the glass lifter on the test bench, block the motor, and measure the first opening of the thermal protector
Time, recovery time.
4. 2. Performance testing items for manual glass lifters on real car doors:
1) Handle torque detection
When performing handle torque on the actual car door test bench, connect the handle torque detection module to the manual glass lifter actual car door durability test bench to control the handle speed and rotation angle. The stroke of the handle torque curve is calculated by converting the number of rotations.

2) Operation intensity detection
When conducting operational intensity testing on the actual car door platform, the drive detection module and manual glass lifter should be tested
The car door durability test bench is connected, and the control handle applies a torque of 14.7N. m. Visually inspect each part
Whether there are any abnormal phenomena such as deformation or cracking.

4. 3. Durability test of electric glass lifter on the actual car door:
The durability cycle is illustrated as follows, with one cycle lasting 20 seconds.

1) Rising and falling running speed detection: monitoring the up and down travel positions of the car glass through current sensors
The average speed of the glass lifter is calculated by converting the running time into the running time.
2) Working current and locked rotor current detection: collected by a current sensor and displayed by a computer.
3) Upper and lower stop position monitoring: By using photoelectric sensors to detect certain points on the car glass, monitor the car glass
Whether the glass has reached the upper and lower travel limit positions can also be determined by detecting the locked rotor current through a current sensor
Detection of upper and lower travel limit positions.
4) During the durability test, the time and current curves can be displayed in real time, with the horizontal axis representing the motor operating time and the vertical axis representing the rising and falling working currents and locked rotor currents.
5) The motor of the electric glass lifter can be cooled with compressed air source on the test bench;
6) The connection and disassembly of sensors, accessories, and wires on the car door are convenient and movable.
7) The detection data in the experiment is stored in real-time at intervals, and the complete data such as the number of experiments during this period is saved according to the interval storage settings (if set to be stored every time, the test data will not be lost in case of power failure). The parameters are automatically recorded and saved for easy next call.

4. 4. Conduct durability test on manual glass lifter on the actual car door:
1) The detection of ascending and descending running speed is set by the program, with a working speed of 80-100mm/s.
2) Upper and lower stop position monitoring: By using photoelectric sensors to detect certain points on the car glass, monitor the car glass
Has the glass reached the upper and lower travel limit positions. A torque limiter is installed on the drive mechanism, which outputs
When the driving force of the mechanism is too large, the torque limiter limits the output of torque.
3) During the durability test, the time and torque curves can be displayed in real-time, with the horizontal axis representing the motor operating time,
The vertical axis represents the working torque for rising and falling.
4) The manual glass lifter durability drive system is movable, making it easy to connect with high and low temperature test chambers for testing.
5) The detection data in the experiment is stored in real-time at intervals, and according to the interval storage settings, it is fully saved during this period
The number of experiments and other data (if set to be stored every time, the test data will not be lost in case of power failure),
Set parameters to automatically record and save for easy next call.
6) Apply a cutoff torque of 6.664N. m for 1 second to the upper and lower ends of the actual stroke in the first half of the first cycle
Apply a cutoff torque of 4.116N. m for 1 second in the second half of the cycle.

4. 5 Spray dust system:
Before the experiment, spray 5cm3 onto the glass guide groove, door frame decorative strip, and door trim sealing strip
Water and dust, then every 5000 times, seal the glass guide groove, door frame decorative strip, and door trim
Spray 3cm3 of water and dust on the seal.
① For the window spray system, the spatial position and distance of the nozzle can be adjusted freely within the range of 5-500mm, the height can be adjusted freely within 600-1300mm, and the spray volume can be adjusted between 1-8 cm3 (the material of the nozzle inserted into the temperature box and nearby nozzles work normally at -40 to 80 ℃)
② For the nozzle of the sandblasting device: Two pipes (with an inner diameter of 4mm) are installed inside the car door, each with 5 holes and a spacing of 30mm. The dust conveying pipeline uses foam pipes with an inner diameter of φ 4, and the nozzle and nozzle that extend into the temperature box are made of corresponding materials. The pressure of ash spraying can be adjusted according to the needs of the experiment, and the amount of ash spraying can be adjusted between 1-8 cm3. (The number of pipes, number of openings, spacing between holes, and pipe diameter can be customized according to customer requirements)
③ Each nozzle can work independently, and the system controls the time and interval between water spray and dust (adjusted in units of the number of cycles of the elevator).
④ The system has 4 sets of nozzles to facilitate the elevator test of 4 actual car doors.

4. 6 Other requirements
For all vehicle models, the entire testing system test layout must be able to meet the requirements of the environmental chamber.
The structural components of the entire testing system must have complete corrosion resistance.
The equipment structure should have good maintainability, and various component replacements should be able to be completed without disassembling unrelated equipment structures.
The equipment structure has good rigidity and can maintain good accuracy for a long time under actual working stress.
Voltage adjustment range: 5-30V, DC output ripple voltage (peak to peak) value ≤ 100mv.
Voltage display resolution is 0.1V, current display resolution is 0.1A.
The equipment structure should have a certain degree of waterproofing.
The components of the test bench have temperature resistance requirements and will not fail due to long-term operation in high and low temperature environments.

4、 Control system
4.1 Control System Hardware
1) Computer system configuration: 1 set
Dual core CPU, with a CPU of 2GB or more, 2GB of RAM, and 320GB of hard drive;
1G (dual video port output) graphics card;
DVD/CD-RW and keyboard and mouse;
19  Wide screen flat panel LCD display;
Pre installed Windows XP Chinese operating system and genuine antivirus software.
2) 1 set of control board and circuit
3) 1 set of 500N force sensor and transmitter
4) 1 set of 20NM torque sensor
5) 4 sets of up and down speed detection
6) 4 sets of voltage and current sensors
7) 1 set of high-speed and high-precision A/D detection card
8) 1 set of high-speed and high-precision D/A detection card
9) Motor drive system
10) 1 set of computer control cabinet (including electrical control)
4.2 Control and Data Processing Software
WINDOWS2000/XP operating platform, Chinese and English interface, easy to operate, can set various detection parameters (according to detection standards), standardized test report format, including detection data output, standardization, and accuracy.

4.2.1 Model Expansion Module:
You can add a product model of a glass lifter or delete a certain glass lifter;
The experimental management program is divided into two levels: tester and administrator. Testers can only perform related operations and are responsible for management
Managers can modify and confirm product models, product parameters, durability times, and other parameters.
4.2.2 Test parameter module:
Experimental action editing, which can edit parameters such as pause time and action process,
Combine different experimental actions to set handle speed, rise and fall, running speed, and stalling time
Test parameters such as interval and pause time are suitable for basic performance testing of various glass lifters.

4.2.3 Test Function Module:
Handle torque function, operation intensity detection function, electric glass lifter current characteristic detection function
Turn off force detection function, up and down stroke detection function, running speed detection function, running
Time detection function, self-locking detection function;
4.2.4 System functional modules:
Divided into system management module, printing module, modifiable content of relevant test reports, and printing test
Report. The data during the experimental process can be automatically saved and imported into Excel. There is a database,
The measured data can be stored in a database for easy querying.

4.2.5 The software has an expandable design, which facilitates the addition of test items in the future, and the test results can be presented as curves
The method is displayed on the screen and can be stored and printed offline. Each experiment record form is flexible, and all
The experimental parameters can be set according to different product requirements.
4. 3 test power supplies (1 unit)
Relative temperature: -5 ℃ -+40 ℃;
Input voltage: AC 220V ± 10%, 50Hz;
The output voltage adjustment range of the load power supply is 0~30V, and the voltage is automatically adjusted by the computer
◇ Maximum output current of 120 A.
4. Self protection function of the test bench:
1. Abnormal stop function:
During the durability test, if the set time has passed, the equipment will automatically stop working.
During the durability test, the glass lifter cannot reach the upper or lower stop position within the set time
Set. The device automatically stops working.
2. During the performance test of the glass lifter, monitor that the output torque is not overloaded.
3. Power overload and short circuit protection; Grounding protection;
4. Alarm sound prompt.
5. System protection: Various working voltages, currents, force values, and torques can be set for protection limits, including over limit values
Automatic shutdown and alarm of the system; Automatic shutdown alarm when the test piece fails; System emergency stop button
Button.
4.5 Safety and reliability
4.5.1 The test bench has self diagnostic and alarm functions. When the system malfunctions, it will sound an alarm and automatically
Parking, automatically indicating the type of malfunction; At the beginning of the experiment, confirm whether the initial position of the test bench is correct
If it is correct or incorrect, provide a prompt message; When a hardware error occurs on the data acquisition card, a prompt will be given
Information.
4.5.2 When the test program is interrupted, stopped, or closed, it can automatically record working parameters, test times, and other parameters,
The default parameters for restarting the test program are the parameters of the last stop time point, the number of tests, etc.
4.5.3 The test bench has the ability to suppress electromagnetic interference, power interference, inductive load interference, etc. Equipment's
Strong grounding and weak grounding for signal processing must be separated; Interference caused by serial input of input and output interfaces
Effective isolation of signals; Test bench sensor power supply and actuator power supply are isolated to prevent damage transmission
Sensor and interference signal acquisition.
4.5.4 Shielded cables are used for various sensor cables.
4.5.5 System grounding and signal grounding shall be isolated.
4.5.6 Electrical grounding must comply with national standards, and control cabinets must have anti electric shock signs. Complete electrical identification with plugs
The seat should have a leakage protection device.
4.5.7 The computer system uses UPS power supply, with a backup time of not less than 20 minutes.
Party B shall provide one set of dedicated calibration device to meet the on-site calibration requirements.

5、 Technical indicators of the test bench
5. 1 Work environment
Power supply: AC 380-10%~+15% VAC frequency: 50 ± 2% HZ, grounding wire.
◇ Environmental temperature: -45 ℃~90 ℃.
Relative humidity:<90%.
Area: 5m in length, 4.8m in width, and 4.2m in height (this area includes a manual glass lifting durability test bench, an electric glass lifting durability test bench, and a high and low temperature box).
5. 2 Technical parameters
5. 2.1 Electric lifting system
Durability test frequency: 1~99999 times
Action: Up, down, stop, top and bottom dead center blockage function;
◇ Detection range for rise and fall time: 1-10 seconds, indication accuracy: ± 0.5% FS; display accuracy: 0.1 seconds;
The measurement range for closing force is 10-500N, with an indication accuracy of ± 0.5% FS and a display accuracy of 1N
Accuracy of running speed detection: 30-500mm/S, ± 1% FS;
Current detection range: 0~30A, detection accuracy: ± 1% FS, display accuracy: ± 0.01A
5. 2. Manual lifting system
Durability test action frequency: 1-10 times/minute (obtained by adjusting the movement speed, deadline, and pause time).
Durability test frequency: 1~99999 times
◇ Actions: Upward, downward, stop, stall;
◇ Torque detection range: 0~20N. m, indication accuracy ± 0.5%, display accuracy: 0.01N. m;
◇ Setting range for rise and fall time: 1-10 seconds, resolution: 0.1 seconds;
◇ Setting range for rise and fall deadlines: 1 to 10 seconds, resolution: 0.1 seconds
◇ The minimum time for rising/falling can be set arbitrarily within 0-60 seconds, with a resolution of 0.1 seconds.