Implementation of a Hydraulic Test Bench Controlled by a Programmable Logic Controller

Sammanfattning

This thesis presents the design and implementation of an automated hydraulic and pneumatic test bench for fatigue testing of hydraulic components. The primary objective was to develop a PLC-controlled system to enable in-house testing, reducing reliance on external consultants for parameter adjustments. The system applies cyclic loading to simulate real-world stress on components, monitoring for failure indicators such as pressure drops and leaks. Two key experiments were conducted to evaluate the system: Usability Testing for Sensor Accuracy and Stability Testing for System Performance. In the usability tests, pressure, temperature, and motor speed sensors were validated, with accuracy levels meeting the specified thresholds for most parameters, although challenges were noted at set low-pressure ranges. Stability testing demonstrated the system’s ability to apply consistent cyclic hydraulic pressures, maintaining uniform pressure peaks and confirming the system's functionality through a brief evaluation of the setup. The results confirm that the system fulfills its objectives, improving testing efficiency while enabling accurate monitoring of hydraulic component performance. Future work includes integrating flow sensors, enhancing low-pressure sensor accuracy, and automating test analysis reporting. This work provides a reliable foundation for fatigue testing in industrial settings.