High-Performance Fatigue Stimulation, Measurement & Analysis for Custom Test Rigs

Our fatigue testing environment enables highly efficient cycle accumulation through resonance stimulation, precise dynamic control and stepped sine excitation. Continuous resonance tracking ensures the structure is always excited at its true resonant frequency, allowing significantly faster stress cycling. Fast sampling and regulation loops provide stable excitation at higher frequencies, integrated directly into customer-provided fatigue rigs without requiring modifications to the mechanical setup.

Our platform continuously follows the specimen’s resonance using phase-tracking, amplification-tracking or peak-response tracking. The excitation frequency adjusts automatically in real time to match the specimen’s changing resonance. This maintains consistent stress input and high efficiency during resonance fatigue testing, dynamic fatigue test procedures and accelerated fatigue testing, ensuring that fatigue behaviour is stimulated precisely throughout the test duration.

Our system supports synchronized multi-sensor acquisition with high resolution and flexible channel configurations. Strain can be measured using quarter-, half-, full-bridge and rosette arrangements via VibRunner’s strain gauge modules. Force, displacement, rotational angle, torque, velocity and acceleration can be recorded at the same time and can also be used as control variables. This enables high-quality mechanical fatigue tests, axial fatigue tests, torsion fatigue tests, and rotary fatigue testing, all integrated within the customer’s existing rig.

Our solutions continuously record load cycles, excitation frequency, phase shift, amplification levels and response magnitude. All parameters are logged over time and exported directly into Excel for fatigue testing analysis, fatigue strength test evaluation and damage analysis. This time-resolved data enables detection of resonance drift, stiffness reduction and behaviour characteristic of fatigue failure.

Engineers can configure excitation profiles in which amplitude increases smoothly at a constant frequency, enabling the identification of nonlinearities without interruptions or resets. This reveals damage onset, loss of stiffness, hysteresis effects and other nonlinear phenomena. Combined with multi-sensor data, this provides strong insight for structural fatigue analysis and mechanical integrity testing.

High-rate time-domain data can be recorded in parallel with the closed-loop control system. These recordings can be imported directly into the m+p Analyzer for frequency-domain analysis, orbit plots, operational load simulation and advanced fatigue testing analysis. Dual Y-axes, flexible cursor tools and detailed visualizations enable precise interpretation of dynamic and evolving fatigue behaviour.

Stepped Sine excitation allows engineers to define linear or logarithmic frequency steps and specify dwell durations at each step. This provides controlled cyclic loading at multiple frequencies and stress levels, supporting cyclic fatigue test procedures, low cycle fatigue tests, high cycle fatigue testing and accelerated fatigue testing with consistent and repeatable excitation profiles.

Our fatigue testing environment integrates smoothly into any external rig. CODA or the Analyzer can monitor external systems such as hydraulic actuators, rotating shafts, torque sensors, climate chambers or additional load equipment. Key variables including torque, angle, strain or auxiliary temperatures can be captured and synchronized with the excitation. This makes our platform a powerful measurement and analysis hub for operational load simulation, rotary fatigue testing and tailored mechanical fatigue test setups.