Heating element failures found only through complaints? 4-station heating-cycle life system runs 2000 cycles straight to failure

The problem

Heating element failures surface as field complaints; third-party 2000-cycle tests cost weeks and stop at pass, leaving true end-of-life unknown. This system runs to failure and records the count.

Capability

4 independent parallel stations; cycle: fill 40-100ml ambient water (default 60ml) -> DC12V heating to 92-93C -> drain 5s -> natural cooling + fan assist (<30C) -> 3min dwell; base cycles >=2000 settable; extended mode keeps running until element open-circuit, recording final failure count with alarm; cold-resistance measurement every 100 cycles; V/A/power/resistance/water temp logged to SD card, CSV export via USB; alarms for water shortage, over-temperature, open circuit, communication failure; Siemens S7-1214C PLC + HMI (MODBUS), manual/auto.

Key specifications

• 测试工位：4工位并行独立运行，单工位单循环独立判定
• 测试对象：手持微型咖啡机发热片（发热板），DC12V供电加热
• 循环流程：注入常温纯净水（40-100ml，默认60ml）→加热至92～93℃→排热水5s→冷却至<30℃→静置3分钟
• 基础循环：不少于2000次（次数可设定）
• 极限测试：2000次后不停机继续运行，直至发热片断路（电阻归零），自动记录最终失效循环次数并报警
• 冷阻测量：每100次循环触发一次冷态电阻测量（断电后立即读取初始电压电流）
• 冷却判定：实时判断水温<30℃且静置3分钟，防止提前进入下一循环；风扇辅助散热
• 数据采集：电压/电流/功率/电阻/水温全参数记录；按循环数存档
• 数据输出：SD卡存储，USB导出CSV（Cycle_Count/Station/Voltage/Current/Power/Resistance/Temp/Timestamp），可导入Excel分析
• 报警保护：缺水、超温、断路、通信失败自动停机报警

Applications

Incoming inspection and life verification of handheld coffee machine heating elements; supplier batch audit; R&D reliability testing of small-appliance heating parts

About the manufacturer

Guangdong Endurance Electronic Equipment Co., Ltd provides non-standard customization, drawing confirmation, factory acceptance, on-site installation and commissioning, operation training and lifetime technical service; 12-month warranty and lifetime spare parts supply. Tel: 0760-88500902 / 13416787649. Web: en.zsnaili.com.