1. Product Overview
The RS-8100 is an industrial-grade plug bending and wire flex testing machine engineered to evaluate the fatigue resistance and bending life of power cords, plug leads, DC cables, and flexible cord assemblies. Fully compliant with international safety standards including UL 817, this system is widely utilized by cable manufacturers and quality inspection departments worldwide.
During operation, cable samples are secured within specialized fixtures and tensioned via adjustable deadweights. The machine drives the samples through repeated bending cycles at a defined angle and speed. Equipped with an advanced PLC and touch screen, the system monitors electrical continuity in real time; if any internal core wire fractures or power delivery fails, the tester automatically stops the corresponding station and locks in the precise cycle count.
2. Engineering and Motion Highlights
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Compliance with Global Standards: Engineered to satisfy UL 817 and related safety requirements for cord sets and power supply cords.
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Efficient 6-Station Batch Testing: Features 6 fully operational testing stations with dedicated signal detection lines, allowing simultaneous multi-sample testing.
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Precise Servo Drive System: Powered by a premium servo motor for exceptionally smooth travel, minimal angular deviation, and low operational noise.
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Fully Customizable Bending Profile: Angles can be set arbitrarily from 0 to 180 degrees (±90°) directly via the touch screen interface, eliminating mechanical limits.
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Smart Touch Screen Control: An intuitive PLC touchscreen streamlines parameter input, allowing operators to configure speeds from 10 to 60 rpm and target cycles up to 999,999.
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Non-Marring Anti-Slip Clamps: Fixture jaws are lined with anti-slip rubber padding to guarantee a secure grip without pinching or damaging the wire insulation jacket.
3. Test Methodology and Execution
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Sample Setup: One end of the cable or headphone cord is secured in the main fixture. The sample is fixed to the clamp and tensioned with a specified counterweight.
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Standard Test Profile: The system drives the wire back and forth within the preset bending angle range and speed. A full set of weights is included to fit different cable sizes.
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Automated Interruption: If any internal core wires break or conductivity fails during the continuous swinging, the loop circuit opens, and the machine automatically stops to preserve the exact cycle count at failure.
4. Technical Specifications
| Item |
Specification |
| Model |
RS-8100 |
| Control Architecture |
PLC Control with Color Touch Screen Interface |
| Testing Capacity |
6 Stations running concurrently |
| Bending Angle Range |
0 to 180° (±90°) fully adjustable via touch panel |
| Testing Speed |
10 to 60 rpm adjustable via touch panel |
| Pre-set Cycle Counter |
0 to 999,999 cycles with auto-stop function |
| Tension Deadweights |
6 full sets included (50g, 100g, 200g, 300g, 500g weights) |
| Drive System |
High-precision Servo Motor |
| Equipment Dimensions |
Approximate 850 x 660 x 1230 mm |
| Equipment Weight |
Approximate 120 kg |
| Power Supply |
Single-phase AC 220V, 50Hz, 0.4KW |
5. Primary Applications
This plug bending tester is essential for component-level reliability testing and quality verification of:
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Power supply cords and flexible cord sets
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AC/DC power lines and appliance plug leads
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Consumer electronics charging cables and connection wires
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Automotive internal wiring harnesses
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Third-party testing laboratories and factory QC inspection
6. FAQ
Q: Can the bending angle be set to non-standard increments like 65 or 120 degrees?
A: Yes. Unlike traditional mechanical systems restricted to fixed presets, the RS-8100 uses servo control linked to a PLC touch panel. You can enter any precise angle between 0 and 180 degrees depending on your custom testing criteria.
Q: Does the machine stop automatically when a wire breaks?
A: Yes. Each of the 6 stations features dedicated continuity detection. If internal core wires fracture or electrical conductivity is lost during the continuous swinging, the machine stops running and retains the total finished cycle count for that sample.
Q: How does the system prevent thin-jacketed cables from slipping out or getting crushed?
A: The testing fixtures are specifically lined with a high-friction anti-slip rubber coating. This design firmly holds the wire at the pivot point during long-term flexing while distributing clamping pressure evenly to prevent surface damage.
7. Contact ITM-LAB
For technical specifications, custom fixture configurations, or a formal quote:
