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2 Journal of Achievements in Materials and Manufacturing Engineering

2 2008

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Temperature control strategy for a seal fatigue tester

Czop P., Sławik D., Wszołek G., Związek M.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 29, nr 2

155-158

Purpose: The aim of the paper is optimization of a control strategy used in a seal fatigue tester. Design/methodology/approach: Analytical approach has been applied to get an understanding of a heat exchange process. It is required to optimize the control process algorithm. Findings: The initial control algorithm has been improved regarding numerous tests under different operating conditions. The final version of the control program allows to maintain the temperature according to the on-off strategy minimizing the temperature oscillations and potential overshoots. Research limitations/implications: It should be considered a new control strategy based on PID controller. Practical implications: The major component of the tester is the heat exchanger. It consists of a tube and embedded pipe circuit feeding with the external heating or cooling medium. The tube is a cylindrical housing where the seals are assembled at both sides. Two main pumps circulate the medium at a specified flow rate and pressure. The temperature is maintained to hold it almost constant during heating and cooling phases. Two thermocouples are placed close to the seals, and the one in the middle of the heat exchanger tube. The tester is equipped with a control system consisting of a PLC controller and LabView data acquisition application. It is possible to control the device remotely through LAN/WAN networks. The LabView application communicates with the controller via software with the use of PPI (Point-To-Point Interface) protocol. A new control algorithm has allowed to perform tests according to testing specification without significant overshoots. Originality/value: On-off control algorithm has been proposed for a combined heating-cooling installation rarely using in the industrial solutions.

Design and development of seal components fatigue tester

Czop P., Sławik D., Wszołek G., Związek M.

Journal of Achievements in Materials and Manufacturing Engineering

2008

Vol. 30, nr 1

67-74

Purpose: The aim of the paper is research and development concerning a fatigue tester of shock absorber seal systems. Design/methodology/approach: Analytical approach has been applied to get an understanding of a heat exchange process. The mathematical model has been formulated and validated based on the available measurements. Numerical simulation has been carried out to illustrate a heat exchange process performance. Findings: It is possible to control a seal temperature and mechanical friction related to the rod movement into the seal at the specified velocity. The model accuracy is sufficient to perform sensitivity analysis and optimize the design. Research limitations/implications: The components of a fatigue tester have to withstand the significant temperature differences in the range ~30;+140*C, e. g. hydraulic hoses, fittings, and pumps. Practical implications: We combine the analytical and experimental approach to provide customized and reliable engineering solution in the area of damper component seal development. A typical seal has a lip-like design protecting the moving parts against the leakage. It can be tested in a shock absorber or externally with use of a customized test rigs. Seal tests inside a shock absorber have numerous disadvantages. A shock absorber temperature rises during longer tests and cooling phase is required. This dramatically increases tests duration performed with the use of an expensive general-purpose hydraulic testing machinery. A compressed air or water jacket is used to accelerate the cooling process. Nevertheless, there are limitations related to the physics behind the cooling process. A seal component fatigue tester allows to perform the seal component tests out of the shock absorber. Originality/value: A new testing method provides possibility to quantify the main contributors of seal usage.