Construction Machinery Test Data Acquisition Solution
A complete data acquisition solution for durability testing, hydraulic system monitoring, structural stress analysis, and performance validation of construction machinery such as excavators, cranes, loaders, and bulldozers. The device features IP67 protection and 100g shock resistance, designed to withstand harsh environments like mines and construction sites with high dust and temperature levels.
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Construction Machinery Test Data Acquisition Solution
A comprehensive data acquisition solution for durability testing, hydraulic system monitoring, structural stress analysis, and performance validation of construction machinery such as excavators, cranes, loaders, and bulldozers. The device features IP67 protection and 100g shock resistance, designed to withstand harsh environments like mines and construction sites with high dust and temperature levels.
4 Major Test Challenge
- Extreme Impact Loads:Heavy machinery generates intense vibration and shock during operation, causing standard sensors and acquisition equipment to fail or break down.
- Hydraulic Transient Capture:Hydraulic system pressure pulsations exhibit high frequency and rapid variation; conventional sampling rates cannot accurately capture transient processes.
- Harsh working conditions:Mining and construction sites are often shrouded in dust, with high temperatures and humidity. Equipment must meet extremely stringent protection standards.
- Multi-condition Continuity:The device must seamlessly switch between operating conditions such as digging, swinging, and traveling to ensure continuous and complete data integrity.
4 core test scenarios
1. Structural Strength Test
Perform stress and strain testing on key structural components, including the boom, stick, bucket, chassis, and upper structure. Utilize waterproof strain gauges and high-protection data acquisition modules to measure structural loads under real-world operating conditions. Validate design strength and assess fatigue life and safety factors using finite element analysis.
2. NVH Vibration Test
Monitor vibration and noise levels in the cab, engine compartment, hydraulic pump, and other key areas. Use synchronized data from accelerometers and microphones to analyze vibration transmission paths and identify noise sources. Evaluate operator comfort according to ISO 2631 standards to guide vibration and noise reduction design optimization.
3. Hydraulic system test
High-frequency acquisition of pressure, flow, and temperature parameters for hydraulic components such as main pumps, multi-way valves, and cylinders. 256kS/s sampling rate precisely captures pressure spikes and flow fluctuations during spool valve switching to evaluate the hydraulic system's dynamic response characteristics and energy losses. Supports reading control signals from electro-hydraulic systems via CAN bus.
4. CAN Bus Test
Integrate with construction machinery standard bus protocols such as J1939/CANopen to read engine parameters including RPM, throttle position, and gear status. Synchronize data recording with physical quantity acquisition to establish correlations between operator actions and structural responses, enabling condition identification and load spectrum generation.
FIDES Product Portfolio
The FIDES series offers modular options including UNI16 universal acquisition, ACC16 dedicated acceleration, and IMU01 inertial measurement. Modules can be flexibly combined to meet test requirements. All modules share a unified mechanical interface and electrical specification, supporting hot-swapping and automatic detection to simplify on-site configuration and maintenance.
Technical Advantages
- Shock-resistant design withstands peak acceleration of 100g without damage, suitable for high-impact applications such as breakers and rock drills.
- IP67 rating fully seals out dust and water, ensuring reliable operation in heavy rain and muddy environments.
- Smart trigger mechanism automatically starts and stops recording based on thresholds to reduce invalid data storage and extend continuous operation time.
- Remote monitoring supports 4G/WiFi data transmission for real-time data upload from construction sites and fault alerts.
Solution Overview
Complete data acquisition solutions for durability testing, hydraulic system monitoring, structural stress analysis, and performance verification of construction machinery such as excavators, cranes, loaders, and bulldozers. The equipment features IP67 protection and 100g shock resistance, designed to withstand harsh environments like mines and construction sites with high dust and temperature levels.
Use Cases
- •Stress-strain fatigue testing of excavator working equipment
- •Strength and Fatigue Life Assessment of Crane Boom Structures
- •Verification of hydraulic system pressure and flow performance for loaders
- •Durability test for bulldozer undercarriage transmission system
Industry Pain Points and Challenges
Gain deep insights into industry testing challenges and receive tailored solutions.
Heavy machinery experiences extreme vibration and impact loads, which can easily damage standard sensors.
High-frequency pressure pulsation in the hydraulic system exceeds the capture capability of conventional sampling rates.
Field operations involve high dust and temperature; equipment requires a high protection rating.
Frequent switching across multiple operating conditions compromises the continuity of data collection.
High-priority response time required for equipment failure alerts; costly downtime losses.
Key Advantages
Advanced technology driving superior test and measurement experiences
Shock-resistant design withstands up to 100g peak acceleration without damage.
High-frequency sampling at 256kS/s precisely captures hydraulic transients.
IP7 rating withstands dust, muddy water, and high temperatures.
Smart trigger mechanism reduces invalid data storage and extends recording duration
Remote monitoring supports real-time fault diagnosis and predictive maintenance.
Complies with ISO 13849 mechanical safety and ISO 61672 sound level meter standards
Typical Use Cases
Covers core industry testing requirements to support the entire R&D and production lifecycle.
Stress-strain fatigue testing of excavator working equipment
Strength and Fatigue Life Assessment of Crane Boom Structures
Verification of hydraulic system pressure and flow performance for loaders
Durability test for bulldozer undercarriage transmission system
Monitoring Compaction Performance and Ground Response of Vibratory Rollers
Safety Performance and Reliability Testing of Mining Machinery
Technical Specifications
High-performance parameters for demanding test environments.
Customer Success Stories
Real-world success stories that help customers succeed
Fatigue testing of work attachments for a leading excavator manufacturer
Top 3 Domestic Construction Machinery Manufacturers
The new 50-ton excavator requires work attachment fatigue life validation, with a test cycle lasting up to 3 months. Due to severe dust at the construction site, previously used imported data acquisition devices repeatedly failed due to dust ingress.
Equipped with the FIDES-UNI16 data acquisition module and an IP67 fully sealed design, it effectively prevents dust intrusion. 48 strain gauges are installed at critical weld seams on the boom and arm to record stress history for each excavation cycle at a sampling rate of 256kS/s. The intelligent trigger function records only during operation, improving storage utilization by 60%.
Completed 2000 hours of equivalent fatigue testing with zero equipment failures and 100% data integrity. Optimized structural design based on measured load spectra, increasing the working device's fatigue life by 30%.
Strength verification of crane boom structure
Large Crawler Crane Manufacturer
The boom of a 1,000-ton crawler crane exceeds 100 meters in length, resulting in complex stress distribution during lifting operations. The high-altitude environment features strong winds and vibrations, making sensor installation and data collection challenging.
Combine the FIDES-ACC16 accelerometer module with the strain acquisition module, powered via PoE to reduce cabling at height. The wireless transmission module sends data in real time to the ground station, eliminating long-distance cables affected by wind sway.
Successfully acquired full-arm stress distribution data under the fully loaded lifting condition, validating the finite element model's accuracy and providing a reliable basis for lightweight design of the new machine.
Performance Optimization of a Loader's Hydraulic System
Leading loader manufacturing enterprise
The hydraulic response of the new electro-hydraulic loader falls short of expectations. Analysis is required to quantify pressure losses and flow distribution characteristics during multi-directional valve switching. Due to the rapid nature of hydraulic transients, conventional equipment cannot capture these details.
Deploy DM-M4-PRO collector to synchronize acquisition of main pump outlet, pre-valve, post-valve, and cylinder chamber pressures via 4 channels at a sampling rate of 256kS/s. Synchronously record valve spool displacement command signals from the CAN bus to establish the control-response relationship.
The spool transition zone accounts for 35% of total throttling losses. Optimizing the valve port shape reduced hydraulic response time by 20%, improving overall machine efficiency by 8%.
Safety Performance Testing for Mining Machinery
Large-scale open-pit mining operations
Under heavy downhill loads, mining dump trucks place extreme stress on braking systems, requiring regular performance checks to ensure safety. The rough terrain of mine roads subjects test equipment to continuous high-intensity vibration.
Uses the DM-M4-PRO collector with a built-in tri-axis accelerometer to monitor device vibration and ensure data integrity. The 10 0g shock-resistant design handles harsh mining site conditions, while IP67 protection guards against dust and rain.
Established a baseline database for braking performance, inspected 50 vehicle units, identified brake degradation risks in 3 vehicles, and prevented safety incidents.
Need a custom solution?
Our technical experts will provide a tailored data collection solution based on your specific needs, offering full support from requirements analysis to system deployment.