At the Slovenian Institute of Quality and Metrology, mechanical durability tests are performed on various electronic and mechanical components, including in-ground street lights and batteries for electric bicycles. The street lights, embedded in the road surface, must withstand repeated loads caused by passing vehicles. Likewise, lithium-ion batteries for e-bikes must endure compressive forces in the event of an accident in which they are run over, without posing a risk of thermal runaway that could result in fire or explosion. This thesis addresses the development of a universal device capable of performing the tests prescribed by Slovenian standards to demonstrate the safety and reliability of the lights and batteries under the aforementioned conditions.
Following a technical analysis of several possible solutions, a hydraulic press was identified as the optimal choice, as it enables controlled and repeatable loading of test samples with high forces. Within the scope of this thesis, we designed the entire system—from the mechanical structure to the control architecture. The press was first modeled in three dimensions, and its structural integrity and operation were evaluated using numerical simulations. We then fabricated the mechanical components, designed and assembled the hydraulic system, and developed the control electronics required for precise regulation of pressure and operating speed. Additionally, we programmed a graphical user interface that enables safe and user-friendly operation of the device, as well as the recording and storage of test results.
The test results demonstrated that the system operates reliably and accurately and meets the technical requirements for both testing procedures.
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