What was the challenge or problem to be solved?
A client wanted to evaluate some electrical conductors from a supplier, so we designed and manufactured a setup for a customised elongation test.
Our Forensic Engineering team worked on the design and execution of an elongation test for electrical conductors, with the aim of validating their ability to withstand demanding continuous use conditions. The client needed to ensure that the conductors could withstand more than two million load cycles without failure, a key aspect for the safety and performance of their applications.
The main challenge was to develop a test system tailored to the frequency, load and distance specifications, capable of accurately replicating the actual conditions of use. This setup had to be able to simulate the real conditions that the drivers would be subjected to, rigorously following the standards that the customer indicated.
How was it approached or what was the solution?
he development of this project started with a detailed analysis of the conditions and regulations required by the customer. The product development and forensic engineering teams worked together to review the applicable regulations and design the necessary drawings for the construction of the test setup. This design had to be functional and, at the same time, ensure that the tests could be performed without altering the results.
Once the design was defined, the setup and customised testing was carried out. Using control electronics and compressed air installation, a prototype was set up in an isolated room to avoid external interference that could affect the accuracy of the test. The equipment incorporated electronic modules to precisely control the frequency and travel length of a pneumatic cylinder, plus an analogue module for cycle counting, ensuring reliable results.
The success of the project was reflected in both the accuracy of the setup and the performance of the drivers, which exceeded the number of cycles initially set. This result allowed the customer to validate the quality of the supplier’s materials, giving them objective technical arguments to help them in their decision making and purchasing process.
This project highlighted INFINITIA’s ability to transform complex challenges into effective, tailor-made solutions. Once again, we proved that when it comes to bespoke projects, we don’t just meet expectations, we go one step further.
