Fatigue Life Tested Power Steps

-- Steady & Reliable Manufacturer --

Simulated Endurance and Accelerated Life Testing

Our power steps are validated through a rigorous Accelerated Life Testing (ALT) protocol in our dedicated performance center. This process goes beyond simple cycle counting by subjecting the mechanism to continuous operation under various simulated environmental stresses, including full-rated static load (300 kg) combined with dynamic motion and thermal variation. The objective is to verify a minimum service life of 150,000 deployment and retraction cycles, which statistically correlates to over 10 years of typical heavy daily use (approximately 30 cycles per day).

The testing regime incorporates Frequency Sweep Testing to identify natural mechanical resonance frequencies and ensure the design prevents self-destructive vibration during high-speed travel. Continuous monitoring of motor current draw, noise levels, and linkage deflection throughout the 150,000 cycles ensures that all components maintain performance specifications without significant degradation.

Guaranteeing Long-Term Reliability Through Validation

Fatigue failure—the weakening of material under repeated stress—is the most common cause of component breakdown. By rigorously testing our power steps for fatigue life, we provide quantitative assurance of long-term reliability that is essential for both distributors and end-users. This investment in advanced testing reflects our commitment to superior engineering over cost-cutting.

Bohai Auto Technology operates its own full performance testing laboratory, equipped with specialized hydraulic and electronic cycle testing rigs. Our focus on ISO 16750 (Road Vehicles - Environmental conditions and testing) standards for mechanical and electrical durability ensures that the stress applied in the lab accurately simulates the most demanding real-world usage scenarios, cementing our reputation for delivering highly reliable products.

Key Application Areas

Extended Warranty Programs: Preferred by distributors and vehicle manufacturers offering extended warranty coverage (e.g., 5-7 years) who require certified component longevity.
High-Use Commercial Fleets: Businesses (e.g., delivery, transport, security) where the steps may cycle hundreds of times daily, demanding exceptional durability.
Extreme Climate Deployment: Vehicles exposed to frequent temperature cycling (freezing/thawing) and high vibration stress, which accelerate material fatigue.
Quality-Focused Consumer Base: Appealing to customers who view long service life as a critical measure of product quality and total cost of ownership.

Technical Parameters

Validated Cycle Life	Minimum 150,000 Deployment/Retraction Cycles
Testing Standard	Based on ISO 16750-3 (Mechanical Loads) and ISO 16750-4 (Climatic Loads)
Test Load Condition	Full Rated Static Load + Dynamic Cycling
Bearing/Bushing Wear Rate	Measured to limit deflection change to <2 mm post 150k cycles
Component Material Hardness	Rockwell Hardness Tested (e.g., HRC 40-50 for critical pins)

FAQ: Fatigue Life and Longevity Testing

Q: How do you correlate 150,000 cycles to real-world usage?
A: We assume a high-use average of 30 cycles (15 open/15 close) per day. 150,000/30 cycles/day=5,000 days, or approximately 13.7 years. We conservatively guarantee a minimum of 10 years of heavy use based on this data.

Q: What is the primary failure mode you test against in the fatigue protocol?
A: The primary failure mode tested is premature bearing/bushing wear and linkage cracking. The test rig is programmed to halt and flag the cycle count if excessive noise, deflection, or a failure to reach the fully deployed position occurs.

Q: Are the test results independently verified?
A: While the testing is conducted in-house, the methodology adheres to established international standards (ISO/SAE). For large OEM or export clients, we can arrange for third-party lab verification (e.g., TUV, SGS) of the fatigue life results upon request.

Q: Does the warranty cover wear and tear?
A: The structural warranty covers failure due to material or manufacturing defects (e.g., cracking, motor failure) up to the specified cycle/time limit. Normal wear of tread surfaces or cosmetic fading is generally not covered.

Longevity-Focused Engineering Details

Optimized Linkage Geometry: The linkage design is engineered to minimize the angular range of motion required by the motor, reducing stress and wear on the gear assembly over the life cycle.
Micro-Polished Pivot Pins: Critical pivot pins are micro-polished and coated to reduce the coefficient of friction, minimizing wear rate on the bushings and preventing the build-up of abrasive material.
Closed-Loop Motor Control: The ECU utilizes closed-loop feedback to precisely control motor torque and speed during the cycle, preventing unnecessary mechanical stress from hard starts or stops.
Finite Element Analysis (FEA) Verification: Before physical testing, all critical stress points are validated via FEA simulations to predict and eliminate potential fatigue fracture locations in the CAD model.
Thermal Cycling Test Integration: The fatigue cycle is paused periodically for temperature extremes (e.g., exposure to −40∘C and +85∘C) to assess the impact of thermal shock on material integrity and seal performance.

Production Data and Process Control

Data tracking is essential for continuous process improvement and fatigue life extension.

Statistical Process Control (SPC):

Component Batch Traceability: Every critical component (motor, ECU, main linkage) is traced back to its raw material supplier and production batch via the ERP system, allowing for rapid identification and analysis should any fatigue-related field failures occur.
Design for Six Sigma (DFSS): Our R&D process utilizes DFSS methodologies, focusing on reducing variability in the design and manufacturing stages to inherently improve the fatigue performance margin.
Motor Efficiency Measurement: Motors are tested upon receipt to verify their power output and efficiency, ensuring the required torque is maintained throughout the full temperature range, thereby reducing electrical stress.

Material Selection for Anti-Fatigue Performance

Components must possess high endurance limits to resist cyclical stress.

Critical Pivot Pins: Machined from 4140 Chromoly Steel, which is heat-treated to maximize core strength and surface hardness, offering superior fatigue and shear resistance.
Linkage Material: High-purity 6061 or 7075 Aluminum Alloy is used for the linkage arms (where feasible) due to its high fatigue endurance limit relative to its weight.
Lubrication: Critical gear boxes are packed with Synthetic Lithium Complex Grease formulated for extreme pressure (EP) resistance and a wide operating temperature range, maintaining lubrication integrity throughout the fatigue life.
Fasteners: All structural bolts use Self-Locking Nuts or Patch-Locking Coatings (Nylon or similar) to ensure they do not loosen under continuous vibration and cyclical stress.

about Bohai

R&D and manufacturing of mid-to-high-end SUV electric pedals.

Bohai Automotive Technology (Zhejiang Huzhou) Co., Ltd. was established in 2014. It is a technology-based enterprise specializing in R&D China Fatigue Life Tested Power Steps Manufacturers and Wholesale Fatigue Life Tested Power Steps Suppliers The company is located on the southern bank of the beautiful Taihu Lake in the hinterland of the Yangtze River Golden Triangle-Changxing County, Huzhou City, Zhejiang Province. It is about 150 kilometers away from Shanghai, Hangzhou, Nanjing, Ningbo, Suzhou, Wuxi and other large and medium cities.

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