The Challenge
What began as a relatively simple question from a client grew into an advanced and complex test setup.
The challenge? Determining the service life and reliability of a brake system within a new design. In this application, a motor continuously moves a weight up and down, with the weight needing to stop accurately at various intermediate positions. The brake plays a crucial role here: any deviation in braking performance directly affects positioning accuracy. A long-term reliability test of the brake was therefore essential.
Our approach
Initially, a simple endurance test seemed sufficient, with the motor cyclically moving and braking over an extended period. It soon became clear, however, that a realistic simulation of the final application required much more. An additional motor was added to replicate the actual counterweight, sensors were integrated to accurately monitor movement and position, and functionality was developed to continuously measure brake wear, also known as slip.
In addition, the setup had to be flexible enough to simulate different usage scenarios and test cycles. All measurement data needed to be reliably recorded, without any risk of data loss in the event of an unexpected system shutdown, for example.
The result
The end result is an advanced test environment in which positioning, data logging, diagnostic functionality and a synchronised movement between the motor and counterweight come together in a single system. A project that began as a simple endurance test, but grew into a highly complex and reliable test setup with which the performance of the brake system can be fully validated under realistic conditions.