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PLC Servo-Driven Six-Station Endurance Cycling Tester 5000 Insertion Withdrawal Cycles IEC60884-1 Clause 20 21 220V

Brand Name:	HongCe
Model Number:	HC-PST001
MOQ:	1 Set
Price:	Negotiation
Payment Terms:	T/T,L/C
Supply Ability:	1 Sets per 2 Months

Detail Information

Product Description

Detail Information

Place of Origin:

Guangdong, China

Certification:

Calibration Certificate(cost additional)

Number Of Stations:

Servo Motor Power:

200W

Positioning Accuracy:

±0.1mm

Stroke Range:

0-100mm

Linear Speed:

50-300 Mm/s

Cycle Rate:

30 Cycles/min

Contact Resistance Range:

0-200.0 MΩ

Noise Level:

≤65 DB(A)

Packaging Details:

Export-grade plywood case with high-density foam insert, vacuum-sealed moisture barrier, reinforced steel strapping

Highlight:

IEC60884-1 Endurance Cycling Tester

Six-Station Endurance Cycling Tester

PLC Endurance Cycling Tester

Product Description

PLC Servo-Driven Six-Station Endurance Cycling Tester

Product Overview

The PLC Controlled Six-Station Plug Socket Endurance Life Cycle Testing System represents HongCe's 15+ years of expertise in automated electrical safety testing systems. This precision testing system is engineered to satisfy every requirement of IEC 60884-1 Clauses 20 (Breaking Capacity) and 21 (Normal Operation), IEC 60669-1 Clauses 19 (Normal Operation) and 20 (Making and Breaking Capacity), and corresponding national standards including GB/T 2099.1, VDE 0620-1, BS 1363-1, and EN 60669-1.

The system's closed-loop AC servo motor drive architecture with absolute encoder feedback distinguishes it from lower-tier endurance testers using open-loop stepper motors, ensuring test results that withstand certification body scrutiny.

Key Features

Six Independent Test Stations

Each station operates with complete independence—different stroke lengths, speeds, cycle count targets, ON/OFF timing parameters, and failure detection thresholds can be configured simultaneously.

Industrial PLC Control

Industrial-grade PLC with 7-inch color HMI touch screen provides deterministic real-time control with intuitive, icon-driven user interface requiring no programming knowledge.

Closed-Loop Servo Drive

200W AC servo motors with 17-bit absolute encoders (131,072 counts per revolution) provide precise positioning accuracy of ±0.1mm, continuously verified at 1 kHz update rate.

Universal Quick-Change Fixtures

Patented modular fixture system with kinematic coupling interfaces enables tool-free fixture changeover in under 2 minutes per station, compatible with 15+ international plug/socket form factors.

Comprehensive Failure Detection

Five independent detection modes per station: contact resistance exceedance, mechanical overload, electrical continuity monitoring, position deviation, and cycle rate anomaly detection.

Multi-Layer Safety Architecture

Four independent protection layers: per-station safety shields with magnetic interlocks, central emergency halt, electrical protection, and thermal protection systems.

Technical Specifications

Parameter	Specification
Number of Test Stations	6 stations, each independently controlled
Control Architecture	Industrial PLC with 7-inch TFT color HMI touch screen
Drive System (per Station)	200W AC servo motor, 17-bit absolute encoder, C5-grade precision ball screw
Positioning Accuracy	±0.1mm (continuously verified at 1 kHz)
Stroke Range	0-100mm per station, programmable in 0.1mm increments
Linear Speed Range	50-300 mm/s per station, programmable in 1 mm/s increments
Maximum Cycle Rate	30 cycles per minute (one cycle = full insertion + withdrawal)
Cycle Counter	6-digit electronic counter (0-999,999 cycles) with non-volatile memory
Test Load Voltage & Current	30A/300V AC per station, solid-state relay switching
Contact Resistance Measurement	4-wire Kelvin measurement, 1.000A DC ±0.5%, 0-200.0 mΩ range
Power Supply Input	AC 220V ±10%, 50Hz ±1Hz, single-phase, maximum 2.5 kW
Noise Level	≤65 dB(A) at 1 meter distance
Overall Dimensions	Approximately 1800 × 900 × 1700 mm (W×D×H)
Net Weight	Approximately 480 kg

Supported International Standards

Standard	Clause / Reference	Test Description
IEC 60884-1:2013	Clause 20, Figure 16	Breaking capacity test for plugs and socket-outlets - 50 operating cycles at 1.1× rated voltage
IEC 60884-1:2013	Clause 21, Figure 16, Table 18	Normal operation endurance test - 5,000 cycles for ≤16A/250V, 2,500 cycles for >16A to 32A
IEC 60669-1:2017	Clause 19, Figure 12	Normal operation for switches - 40,000 operating cycles (≤16A/250V), 20,000 cycles (>16A)
IEC 60669-1:2017	Clause 20, Tables 9-10	Making and breaking capacity for switches - 200 operating cycles at 1.1× rated voltage
IEC 61058-1:2016	Clause 17	Mechanical endurance for appliance switches - without electrical load
GB/T 2099.1-2008	Clause 20, 21	Chinese national standard - breaking capacity and normal operation requirements
VDE 0620-1:2021	Clause 20, 21	German standard - endurance, breaking capacity, and temperature rise requirements
BS 1363-1:2023	Clause 19, 20	British Standard - UK-specific endurance and breaking capacity requirements

Core Technology Advantages

Closed-Loop Servo Positioning with Absolute Encoding

Eliminates the root cause of invalid endurance test data by providing continuous position verification. Unlike open-loop stepper systems that can experience step loss under varying loads, the closed-loop servo architecture ensures every cycle is performed with the plug fully inserted and properly positioned.

Four-Wire Kelvin Contact Resistance Measurement

Detects contact degradation before failure using precision 4-wire Kelvin measurement that eliminates parasitic resistance errors. Provides milliohm-level accuracy for trending analysis and early detection of contact wear.

Modular Kinematic Fixture System

Maximizes versatility and minimizes changeover time with tool-free fixture replacement in under 2 minutes per station. Maintains positioning repeatability within ±0.02mm after every fixture change.

Test Object Compatibility

Household and similar-purpose plugs (all international form factors within mechanical capacity)
Fixed socket-outlets (flush and surface mounted, single-gang and double-gang configurations)
Portable socket-outlets and multi-socket adapters
Appliance couplers (IEC 60320 series: C13/C14, C15/C16, C19/C20, C5/C6, C7/C8)
Industrial plugs and socket-outlets (IEC 60309-1/-2, rated 16A and 32A)
Switches for household and similar fixed electrical installations (IEC 60669-1)
Shaver socket-outlets (BS 4573)
Smart sockets and IoT enabled socket-outlets
USB charging socket-outlets
Rewirable and non-rewirable plugs

Manufacturing Quality Control

QC Stage	Inspection Activities	Acceptance Criteria
Stage 1: Incoming Material	Chemical composition verification, hardness testing, dimensional verification	SUS304 composition per ASTM A240, hardness within ±2 HRC, surface finish Ra ≤1.6μm
Stage 2: In-Process	First-article inspection, dimensional verification, weld integrity inspection	Gauge element tolerance: ±0.005mm, structural component tolerance: ±0.1mm
Stage 3: Assembly	Mechanical fit verification, electrical panel wiring, safety interlock testing	Insulation resistance ≥100 MΩ, all interlocks functional, no abnormal heat generation
Stage 4: Functional Testing	48-hour continuous burn-in, calibration verification, safety systems testing	No failures during 48-hour burn-in, calibration within tolerance, noise ≤65 dB(A)
Stage 5: Pre-Shipment	Final visual inspection, documentation completeness, packaging verification	No cosmetic defects, all accessories present, packaging intact per standards

After-Sales Service Commitment

12-Month Full Warranty: Comprehensive coverage including replacement parts, remote diagnostic support, and return-to-factory repair
Lifetime Free Technical Support: Permanent commitment to ensuring equipment performance with multiple support channels
On-Site Commissioning & Training: Optional hands-on assistance with setup and operator qualification
48-Hour Response Service Level: Acknowledgment within 24 hours, technical assessment within 48 hours
5-Year Spare Parts Availability: Critical spare parts maintained in inventory for minimum 5 years
Calibration & Recertification: Annual factory recalibration, on-site calibration, and compliance maintenance services

Frequently Asked Questions

Is HongCe a genuine manufacturer with its own factory?

HongCe is a genuine source factory manufacturer. We own and operate our production facility in Guangdong, China, where we perform CNC machining, heat treatment, precision grinding, electrical panel assembly, and final system integration under one roof.

What are the key differences between servo motor drive and stepper motor drive?

Servo motors operate in closed-loop with continuous position feedback, eliminating step loss that can occur in open-loop stepper systems. This ensures position accuracy across the entire speed and load range, critical for tests with varying insertion forces over thousands of cycles.

Can the equipment be integrated with our Laboratory Information Management System (LIMS)?

Yes. All PLC-controlled instruments feature standard communication interfaces including USB 2.0 for manual data export and RS-232 serial for automated data transfer. Optional RS-485 (Modbus RTU) and Ethernet (Modbus TCP) modules are available for direct LIMS network integration.

What routine maintenance does the equipment require?

Weekly cleaning of linear components, monthly lubrication of bearings, quarterly calibration verification, and annual comprehensive electrical safety testing. Detailed maintenance procedures with step-by-step photographs are provided in the user manual.

How do I ensure test results will be accepted by major certification bodies?

Maintain current calibration, verify equipment configuration matches standard requirements, document measurement traceability, follow written test procedures, retain complete test records, and participate in proficiency testing programs.

Contact Information

For detailed quotations, technical specifications, or custom requirements, please contact our engineering team directly. As a source factory manufacturer, we provide factory-direct pricing and comprehensive technical support.

Tags:

Three-Phase Plug Socket Breaking Capacity & Normal Operation Test System — IEC 60884-1 IEC 60669-1 Integrated RLC Load Testing Platform with PLC Synchronized Control

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products details

PLC Servo-Driven Six-Station Endurance Cycling Tester 5000 Insertion Withdrawal Cycles IEC60884-1 Clause 20 21 220V

PLC Servo-Driven Six-Station Endurance Cycling Tester 5000 Insertion Withdrawal Cycles IEC60884-1 Clause 20 21 220V

IEC60884-1 Endurance Cycling Tester

Six-Station Endurance Cycling Tester

PLC Endurance Cycling Tester