Custom-Built Solution Automates Complex Testing Sequence
Thanks to a customized solution from All World Machinery Supply, an industrial hydraulic manufacturer transitioned from the laborious manual filling, charging, and testing of a stabilizing device to a fully automated system, minimizing the need for human intervention. In addition to freeing up labor time, it’s also substantially boosted productivity and streamlined the process of accurate data collection.
Addressing a Unique Industry Challenge
Bucher Hydraulics is a global leader in advanced electric and hydraulic drive and control technologies for mobile and industrial hydraulics. In the summer of 2024, Bucher’s Elgin, Illinois, facility contacted All World for help resolving a specific boating and marine industry challenge.
Bucher needed to enhance the efficiency of testing a braking component designed for an anti-roll gyroscopic stabilizer used on boats. This stabilizer, paired with a hydraulic cylinder that acts as a brake when the gyroscope detects excessive movement, effectively eliminates boat roll on vessels 23 feet and larger. However, their manual testing process for the braking component was time-consuming and labor-intensive. To address this challenge, Bucher sought an automated testing system capable of verifying these devices’ quality and leakage rates.
“Nothing like this existed in the market. This was all conceived, created, and engineered to provide a solution for this purpose,” said Kyle Crull, Senior Director of Machine Accessories. “This test stand verifies the operation of the braking unit, performance as required, and pre-charges an onboard accumulator.”
Additionally, Bucher wanted a robust and durable system capable of thousands of testing cycles and the versatility to test different models of braking components for the various gyroscopic stabilizers. The ability to accurately gather data in finite measurements would help them demonstrate the quality of the units being produced.
Designing the Ultimate Testing Solution
With specific test criteria provided by Bucher, All World faced the challenge of determining the most effective way to measure performance, withstand high forces, and collect accurate data. The previous test stand was incapable of handling the required pressure or force. All World’s engineers worked backward, using the testing requirements to design a strong fixture to endure repeated heavy loads while ensuring the efficient loading and unloading of parts.
All World developed a robust 14-foot test stand, weighing 8,000 pounds, equipped with two ARROW Fixture boxes designed for high-performance testing. These fixtures were designed to handle forces of up to 38,000 pounds. With dual fixtures and two operator HMIs, one system can be in testing while the other is being set up for testing.
The system measures movement and pressures under specific operating conditions and evaluates performance, providing precise and reliable results.
To enhance precision, the test stand features analog pressure sensors and laser sensors with a range of up to 13 inches, capable of measuring increments as small as a thousandth of an inch. Designed for versatility, each ARROW Fixture box can support five to six different models thanks to interchangeable blocks, enabling compatibility across Bucher’s product line.
For added safety, the setup includes a front light curtain and protective guarding around the exterior, always ensuring secure operation.
All World designed a user-friendly interface for operators, developed a sequence, and wrote ladder logic to control the automated test cycle and capture sensor data. The process begins when the barcode reader scans the part being tested, allowing the test stand to retrieve specific test requirements for that device. Operators can use the HMI to rotate the fixture forward for ergonomic loading and unloading of parts.
Streamlined Testing Process
The testing process is a structured sequence designed to ensure compliance and reliability. It typically takes 7–10 minutes and includes the following steps:
Filling the Cylinder: Degassed oil fills the test cylinder.
Air Purging: The test unit is purged of all air trapped in the system.
Pressure Switch Test: Verifies the pressure at which the pressure switch contact openings during a pressure loss.
Accumulator Gas Charge Check: Verifies the accumulator's gas pre-charge.
Charging the Accumulator: The accumulator is charged to a pre-determined pressure.
?P Test: Checks the pressure differential between extending and retracting the piston rod.
Drift Test: The system assesses movement in a hydraulically locked state to ensure there is no drift or leakage.
Position Pre-Set: A passed unit’s cylinder rod is pre-positioned for easy of assembly into the final product.
Each cycle, taking 7–10 minutes, evaluates results automatically. If a part meets the set standards, it is approved for removal. Should any discrepancies arise, the system flags these issues and informs the operator of the specific problem. At the completion of the test, all the test results data is available to be transferred to a server for quality tracking and further evaluation.
Driving Innovation Through Expertise
