Test Rig Four‑Bar Mechanism
Jun 2021 – Aug 2021
Project while working at Multi Parts (MPS). I designed and built a compact four‑bar test machine that exercises throttle‑position and fuel‑sender sensors inside a thermal chamber from −40 °F to 180 °F, enabling repeatable, multi‑million‑rotation endurance testing.
Summary
The goal was to turn a testing need into a reliable pre‑production fixture that runs unattended endurance cycles and produces consistent, reviewable data. Packaging was tight (thermal‑chamber footprint), the mechanism had to support multiple sensor types, and we needed simple angle adjustability to match different test profiles.
Approach
- Created a parametric four‑bar calculator to choose linkage geometry from required angles and stroke, then used it to drive the mechanical design.
- Modeled the rig in SolidWorks, selected off‑the‑shelf hardware where possible, machined the base and crank, and assembled and wired the system.
- Integrated instrumentation checks and fixture alignment steps; authored procedures and run logs and iterated alignment based on early trials.
- Designed the layout to fit the chamber and to support multiple sensors with quick swap‑outs and angle adjustment.
What I built
- A production‑ready four‑bar mechanism with compact packaging for chamber use.
- Endurance test procedures, setup sheets, and quick references so operators could run tests consistently.
- Data‑collection templates and plots for analyzing wear and drift over multi‑million rotations.
Results
- Supported sustained, multi‑million‑rotation endurance runs with repeatable setups.
- Improved reliability of test evidence for design reviews and supplier qualification.