Automation of a Multi-Station Rotary Bending Fatigue Test Machine with PLC Control System

Rotating bending fatigue tests are crucial for assessing material fatigue strength in both industrial and academic contexts. While standards such as the AISI and ISO define test methodologies, automation and control mechanisms have not been sufficiently investigated. This study presents the automation of a 22-station fatigue testing system with PLC control. Inductive sensors detect real-time specimen fractures, transmitting signals to the PLC, which autonomously tracks cycles, identifies failures, and terminates tests. A rotary encoder (40 pulses/rev) refines cycle monitoring, whereas an HMI panel enables real-time visualization and parameter adjustments. This automation system significantly improves test accuracy, reliability, and repeatability, offering substantial advantages for material fatigue assessments in industrial and academic applications.