1、 Project Background

As an enterprise dedicated to the research and production of industrial equipment, Kexun Industrial Manufacturing (Shenzhen) Co., Ltd. has always regarded product quality and reliability as the core of its development. With the continuous expansion of its business scope, the company has put forward higher requirements for the adaptability of its products to vibration environments. To simulate the complex vibration conditions that products may encounter during transportation and use, and verify their structural strength and functional stability, Kexun Industry has decided to introduce a high-precision electromagnetic vibration test bench. After multiple rounds of market research and technical comparison, the company ultimately selected Guangdong Aipei Testing Equipment Co., Ltd. (hereinafter referred to as "Aipei Technology") for its customized electromagnetic vibration test bench, with a table size of 55cm × 55cm, to meet its specific testing needs.

2、 Requirement analysis

（1） Test object and operating conditions

The main products of Kexun Industry include industrial controllers, sensors, and precision mechanical components, which need to withstand complex working conditions such as road bumps and mechanical vibrations during transportation. At the same time, during the operation phase of the equipment, continuous vibration will also occur in the motor starting, mechanical transmission and other links. Therefore, the test bench needs to have a wide frequency modulation range (5-600Hz), high acceleration (20g), and multi axis vibration capability to fully cover the vibration scenarios throughout the product lifecycle.

（2） Customized requirements

The table size of a standard electromagnetic vibration test bench is usually 50cm × 50cm or 75cm × 75cm, but the test sample size of Kexun Industry is relatively large (such as the industrial controller housing size of 52cm × 52cm), and a customized 55cm × 55cm table is required to ensure sufficient testing space. In addition, the company requires the test bench to have three-axis synchronous vibration function (X/Y/Z axis) to simulate the multi-directional vibration superposition effect in real environments.

3、 Aipei Technology Solution

（1） Technical parameter matching

Aipei Technology has customized the AP-DC-55 electromagnetic vibration test bench according to the needs of Kexun Industry, with the following core parameters:

Table size: 55cm × 55cm (made of hard alloy aluminum plate, precision machined to ensure table flatness ≤ 0.05mm);

Vibration direction: three-axis synchronous vibration (independent control of X/Y/Z axes, adjustable phase difference);

Frequency range: 5-600Hz (resolution accuracy 0.01Hz);

Acceleration: 20g (acceleration stability ± 0.1g at frequencies of 60-600Hz);

Amplitude: 0-5mm (electronic amplitude modulation, stepless adjustment);

Load capacity: 100kg (suitable for heavy samples such as industrial controllers and sensors);

Control mode: 7-inch color industrial touch screen, supporting 15 testing modes including fixed frequency, sweep frequency, multiplier, program, logarithmic, random, etc;

Security protection: overvoltage/undervoltage protection of the power grid, output overcurrent protection, module overheating protection, platform overheating protection, and over displacement protection.

（2） Customized design highlights

Non standard tabletop expansion: By optimizing the tabletop support structure and exciter layout, while maintaining the standard model volume (1500mm × 1000mm × 1080mm), the tabletop size is expanded to 55cm × 55cm, balancing testing space and equipment stability.

Anti interference circuit upgrade: In response to the strong electromagnetic interference in industrial environments, Aipei Technology uses composite shielding materials and an independent grounding system to control the table leakage magnetic field to ≤ 1mT, avoiding interference with precision electronic components (such as sensors).

Modular design: The control box and platform adopt a split design, which is convenient for transportation and installation; The core modules such as vibration waveform generator and power amplifier support hot plugging, reducing maintenance costs in the later stage.

4、 Project implementation and acceptance

（1） Delivery cycle

After the contract is signed, Aipei Technology will complete the equipment production, debugging, and factory inspection within 5 calendar days, and transport it to the Shenzhen factory of Kexun Industry by special vehicle. The installation team will complete the equipment positioning, horizontal calibration, and electrical connection within 2 working days to ensure that the test bench meets the requirements of ISO 2247 "Low frequency Vibration Test for Transport Packaging and Unit Cargo Fixed with Full Packaging" and other standards.

（2） Acceptance testing

Function verification: Verify the uniformity of the table vibration through frequency sweep testing (5-600Hz), and use a laser displacement sensor to measure the amplitude deviation of the four corners of the table ≤ 0.1mm;

Performance test: Under a load of 100kg, conduct a continuous 48 hour durability test with an acceleration of 20g and a frequency of 600Hz. The equipment operates with a temperature rise of ≤ 5 ℃;

Multi axis synchronous verification: Through three-axis vibration superposition testing, simulate multi-directional vibration during transportation to verify the fatigue resistance of product welding points and structural components.

5、 Collaboration achievements and feedback

（1） Test efficiency improvement

After introducing the Aipei electromagnetic vibration test bench, Kexun Industry has shortened the product vibration testing cycle by 40%, upgrading from traditional manual testing (requiring multiple adjustments of vibration direction) to automated three-axis synchronous testing. A single test can cover X/Y/Z three-axis vibration data acquisition.

（2） Product quality optimization

By simulating real vibration conditions, Kexun Industry has discovered and resolved three potential design defects:

Excessive spacing between reinforcement ribs on the casing of industrial controllers leads to resonance;

There is a risk of virtual soldering in the soldering process of sensor pins;

Insufficient pre tightening force of mechanical component fastening bolts.

After optimization, the product transportation damage rate decreased by 65% and the customer complaint rate decreased by 50%.

（3） Customer reviews

Aipei Technology's customized services exceeded expectations, from table size expansion to anti-interference design, all of which accurately matched our testing needs. The equipment runs stably and the after-sales service responds quickly, providing strong support for the reliability upgrade of our products

——Li Ming, R&D Director of Kexun Industrial Manufacturing (Shenzhen) Co., Ltd

6、 Industry application value

This case provides reference for the selection and customization of electromagnetic vibration test benches for industrial equipment manufacturing enterprises:

Non standard requirement handling: By optimizing the table structure and exciter layout, the table size can be expanded without significantly increasing the equipment volume;

Anti interference design: using composite shielding materials and independent grounding systems can effectively solve electromagnetic interference problems in industrial environments;

Multi axis vibration simulation: The three-axis synchronous vibration function can more realistically reproduce the actual working conditions of the product, improving the reliability of test data.

Aipei Technology has become the preferred partner in the field of industrial vibration testing due to its modular design, fast response customization capabilities, and full lifecycle services.