LightCarbon Road and Mountain Bike Carbon Frame Test

All LIGHTCARBON products will be tested strictly in accordance with EN or ISO4210, and will also be sent to an External Organization for SGS testing upon guest's request. All new products will be tested 10% more strictly in the development phase on the basis of EN or ISO4210, to ensure the safety of all products.

The process for LightCarbon Test as follows:

Rigid Test-disc brake seat fatigue test-head Tube fatigue test-seat Tube fatigue test-BB fatigue test-frame Front back test-frame back test-frame head Tube impact test-head Tube strength test-seat tube strength test-frame vibration failure test Development of any new product must be strictly in accordance with the above process test and pass, even if one above test item failed then need to do a new test until pass all test item. Quality control in the mass production stage according to the proportion of 1-2% sampling test to ensure the quality of mass production products.

As the following figure rigid test, equipment for universal machine test and automatic recording. F 1 is the test head tube rigidity, F 2 is the test BB rigidity, F3 and F4 is the Test dropout of single side and double side rigidity. The rigidity of the head tube is a fixed BB and seat tube, and the center of the head tube is 250 mm above the head tube and 51 kgf is applied, The test speed is 50mm/min, and the deformation of the head tube should be ≥100N / MM. The rigidity of the BB is 260mm in the center of the BB, and 36kgf is applied. The test speed is 50mm/min, and the deformation of the BB should be ≥120 n/mm.

In order to test the rigidity of single side and double side, first fix the BB and seat tube, test the right side of the dropout and apply 16 kgf to the center of the dropout. The test speed is 50mm/min, and the deformation of single side should be ≥14 n/mm. To test the bilateral rigidity of the dropout, first fix the BB and the seat tube, then lock the dropout on the left and right sides with the hub and apply 16 kgf to the center of the dropout. The test speed is 50mm/min, and the bilateral deformation should be ≥20 n/mm.

As shown in figure F5, the frame brake seat fatigue test, the frame is fixed on a special test machine, the dropout is placed in the seat of the disc brake fixture, tightening the screws at various parts, testing frequency 2HZ, testing force 1000n, Torque 340 mm, testing times 25, 000 without fracture or obvious crack is qualified.

As shown in figure F6, the fatigue test of the head and seat of the frame is carried out. The frame is fixed on a special test machine. When the test head is tired, the front fork is applied to the horizontal force and moves freely in front and back direction. The Applied Force is + 1470 /-600N, the frequency is 3hz, test 100,000 times without fracture or apparent crack as qualified.

The front fork is fixed when the test tube is fatigued, the inner diameter fixture is inserted into the seat tube 75mm deep, the seat Tube Bundle is fixed at h: 250mm, the downward force is 1470N at 70mm, the frequency is 3HZ, the test 1000000 times without fracture or obvious crack is qualified. If F7 is a BB fatigue test, fix the frame on the test fixture, keep the force arm vertical to the machine table, the two feet pedal at 4-5 degrees.

As shown in figure 8, front impact test of frame, fixed dropout, front fork of head tube fitting. The weight of middle pipe is 30 kg, the weight of BB is 50 kg, the weight of head pipe is 10 kg, and the front fork is raised 220 mm. Any part of the frame must not appear broken or obvious crack is qualified.

For example, F9 is the reverse impact test after frame, after fixing the head tube, the weight of the seat tube is 30kg, the weight of the BB is 50kg, the weight of the head tube is 10kg, the weight of the two sides of the dropout is 20kg, the height of the dropout is raised 200mm and 220mm after each test. Any part of the frame must not appear broken or obvious crack is qualified.

As shown in F10 was the impact test of frame head Tube, fixed dropout, head tube fitted with front fork. Weight of 22.6 kg, test height of 380 mm. Any part of the frame must not appear broken or obvious crack is qualified.

As shown in F 11, Strength Failure Test for frame head tube, universal machine test and automatic recording, fixed dropout, head tube fitting front fork. The pressure point is on the same vertical line with the dropout of the frame, and the front fork lock which is the same as the geometry of the frame is selected and tested on the frame. The test speed is 30mm / Min, the test value is over 300kgf, no fracture or obvious crack in the head tube area is qualified.

As shown in figure F12 for the strength of the frame seat tube failure test, equipment for universal testing and automatic recording, fixed dropout and BB, so that the center line of the fixture and the center line of the seat tube before and after at the same level. The length from the center of the riser to the pressure point is 140 mm, the pressure point is perpendicular to the center of the three-point pressure fixture, the test speed is 30 mm / Min, the test value is over 300 KGF, the seat tube area must not appear the fracture or the obvious crack is qualified.

For example, F13 is the frame vibration damage test, fix the frame on the special machine, install the weight of each part according to the test force, tighten the screws of each part, test force BB counterweight about 20 kg each, head pipe counterweight 10 kg, seat pipe counterweight 50 kg, the test frequency is 5 HZ, the test frequency is 20,000 times without fracture or obvious crack is qualified, this test is not in the scope of EN and Iso4210, it is the strict test equipment in the factory, Simulate Mountain Riding Test.

Lightcarbon Comonents(fork and handlebar) Test

FK01 FK02 is the front fork rigidity test, equipment for universal testing and automatic recording. FK01 is used to test the lateral rigidity of the front fork, F2 is used to test the forward rigidity of the front fork, the vertical pipe of the front fork is fixed on the fixture, the universal machine is applied to the center of the side dropout of the front fork and 35kgf is applied, the test speed is 50mm / Min, and the deformation of the front fork should be ≥40N/MM. The forward rigidity is that the universal machine applies force to the center of the hub and applies 63.3 KGF, the test speed is 50 MM / Min, and the deformation of the front fork should be ≥100 N/MM.

FK03 diagram is the front fork disc brake test, the front fork is fixed on the special test machine and fixed the front fork vertical pipe, the fixing tool is mounted on the disc brake seat to simulate the actual riding condition and the force is applied 63.3 Kgf, the force is the up and down free movement test, the test frequency is 3 Hz, test frequency 20,000 without fracture or apparent crack is qualified. FK04 is used as the front fork fatigue test, the front fork is fixed on the special test machine and the front fork vertical pipe is fixed, and the force of 620N is applied to the center of the front fork false flower drum and is tested up and down freely, the test frequency is 3 HZ, the test frequency is 100, 000 without fracture or obvious crack is qualified.

FK05 shows the static bending test of the front fork. The front fork is fixed on a special test machine and the front fork vertical pipe is fixed. The static pre-load force of 100N is applied to the roller perpendicular to the pipe shaft, remove the force and repeat the load until a common reading is obtained. The static force was increased to 1200 N and maintained for 1 minute, then the force was reduced to 100 n and the related permanent deformation was recorded. After testing, no crack or obvious break should be found in any part of the front fork, and the permanent deformation is not more than 5mm. FK06 picture shows the impact test of the front fork. The front fork is fixed on the Special Test Bench and the Front Fork Vertical Tube is fixed. The false flower drum is fixed in the front fork Hook Claw. The weight of the test bench is 22.5 KGF, the height of the test bench is 670 mm and the free fall test is carried out in the center of the Flower Drum, after the second test, no fracture or obvious crack can be found in any part of the front fork. After the test, the deformation can not slide down more than 20mm. FK07 diagram is the strength test of the front fork, the equipment is universal machine test and automatic record, fix the vertical tube of the front fork and let the false flower drum of the front fork at the center of the force point, the test speed is 25.4 mm / Min, the front fork must pass over 200 kgf.

Handlbar Test

Fig. HB01 for the handle fatigue test, the handle is fixed on the special test machine, the position is locked, the force is applied to the handle left and right to hold the inverted end, the test is divided into two test categories. Test: Apply Force + /-364N, Test Frequency 3 HZ, test times 100,000 times. Test in the same direction: + /-520N, Test Frequency 3 HZ, test times 100,000 times.

The handlebar shall not break or crack after the test and the deformation shall not exceed 20% of the initial value as qualified. Fig. HB02 for the impact test of the handle, the handle is fixed on the impact machine, the weight of the handle is 10kg, the test height is 300mm, 400mm, no fracture or obvious crack is qualified. Figure HB03 is a single-side tension test of the brake handle, the angle of the driver's grip end is 22 and the locking force of the vertical lock is 12n. M, keep the center of the bushing and the center of the force on the same line, and put 12 brake handles on the driver, when applying force to 100kgf, the handlebar is not broken or cracked Figure HB04 for the brake handle single side pressure test, the driver grip angle of 22, the Vertical Lock Locking Force 12n. M, keep the center of the bushing and the center of the force on the same line, and put 12 brake handles on the driver, when applying force to 120kgf, the handlebar is not broken or cracked.

Figure HB05 is the single side tension test of the grip, the grip end should be at the same angle as the driver's natural droop. Locking force on a vertical lock. M, keep the center of the ring and the center of the force on the same line during the test. The ring should be placed 90 times on the driver. When applying force to 120kgf, the handlebar is not broken or cracked.

Figure HB06 is the single-side compression test of the grip. The grip end should be at the same angle as when the driver is naturally drooping. Locking force on a vertical lock. M, keep the center of the ring and the center of the force on the same line during the test. The ring should be placed 90 times on the driver. When applying force to 200kgf, the handlebar is qualified without fracture or crack.

Test Video