Pulse Generator Test Bench: Precision Platform for Verifying Critical Pulser Component Performance
The Challenge of Unverified Pulser Components
Lack of systematic testing for pulse generator components leads to:
⚠️ Insufficient pump displacement, causing weak or unstable pulse signals
⚠️ Inaccurate control valve response, affecting pulse encoding precision
⚠️ Deviations in main valve actuation time, leading to abnormal data transmission rates
⚠️ Inconsistent overall tool performance, increasing field failure risks
Our Test Bench Delivers:
✅ Integrated performance testing and debugging for pumps, main valves, and control valves
✅ Precisely controllable hydraulic environment simulation (adjustable flow, pressure, differential pressure)
✅ Automated data acquisition with Pass/Fail determination
✅ Standardized testing procedures ensuring consistent performance for every pulser
Design Features & Working Principle
Integrated Hydraulic & Electrical Test Platform
| Test Module | Testing Principle | Functional Benefit |
|---|---|---|
| Pump Test Module | Applies constant backpressure, measures output flow | Verifies pump displacement stability at rated pressure |
| Control Valve Test Module | Applies stepped voltage signals, monitors spool position & oil flow blockage | Calibrates the electro-mechanical response of the control valve |
| Main Valve Test Module | Records time for fixed oil volume to pass under set differential pressure | Ensures main valve throttling characteristics meet pulse timing requirements |
| Data Acquisition System | High-precision sensors + PLC, real-time logging of flow, pressure, time, voltage | Generates detailed test reports, supports data traceability and analysis |
Technical Specifications
| Parameter | Specification |
|---|---|
| Flow Range | 0 – 15 L/min |
| Pressure Range | 0 – 6 MPa |
| Differential Pressure Range | 0 – 16 bar |
| Tank Volume | 40 – 50 L |
| Dimensions (LxWxH) | 1080 x 800 x 1800 mm |
| Power Supply | 220VAC / 50Hz (or customized per client) |
| Control Method | Touchscreen HMI + PLC Automatic Control |
| Test Medium | Mineral oil or specified hydraulic oil |
Testing Standards & Qualification Criteria
Pump Test Pass Criteria
- After adjustment to specified pressure, pump displacement must be > 1.45 L/min.
Control Valve Test Pass Criteria
- At 9V, the valve must OPEN and block oil flow.
- At 14V, the valve must CLOSE and block oil flow.
- Response and state transition must be clear and stable.
Main Valve Test Pass Criteria
- Under set conditions, time to pass 50 mL of oil must be 6 – 10 seconds.
- Under set conditions, time to pass 1 L of oil must be 14 – 21 seconds.
Core Advantages
Enhanced Product Quality & Consistency
- Identifies and rejects substandard components prior to final assembly.
- Ensures highly consistent performance parameters for each pulse generator through precise calibration.
- Significantly reduces field failure rates caused by component performance variance.
Improved Production Efficiency & Traceability
- Automated testing process reduces reliance on highly skilled technicians.
- Automatically generates and stores complete test reports for each component.
- Supports historical data query by serial number for full lifecycle quality traceability.
Supports R&D & Failure Analysis
- Provides a reliable platform for component selection and performance verification of new pulser models.
- Can replicate field failure modes to aid precise root cause analysis.
Application Scenarios & Workflow
Typical Application Scenarios
- Pulse Generator Manufacturing: Serves as the final critical step in factory acceptance testing (FAT).
- MWD Service Company Workshop: Used for performance verification and recalibration of returned components.
- R&D Laboratory: Tests the performance limits and reliability of newly designed valves and pump bodies.
Standard Testing Workflow
- Connection: Connect the component under test to the corresponding interface on the test bench.
- Setup: Select the test program (Pump / Control Valve / Main Valve Test) on the HMI.
- Execution: Start the test. The system automatically applies pressure, voltage, and collects data.
- Judgment: The system automatically determines the result (Pass/Fail) based on preset tolerance ranges.
- Reporting: Print or export a test certificate containing all key data points.
