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Electric Plug / Cord Bending Tester QualiPlugBend100

Electric Plug / Cord Bending Tester
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Semiconductor and Electronics Reliability Testing Equipment
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Electric Plug / Cord Bending Tester - QualiPlugBend™ 100

The QualiPlugBend™ 100 power cord bending tester measures how many flex cycles a plug lead, power cord, or insulated wire survives before its internal conductor breaks. Appliance makers, cable producers, and electronics manufacturers use it to verify cord durability during design validation and incoming inspection. Six independent stations swing samples back and forth under a hanging load. Each station watches its own circuit and logs the exact cycle count at the moment of conductor failure. That number becomes the endurance index for the sample.

Qualitest built the Electric Plug / Cord Bending Tester for labs that need repeatable flex data without constant supervision. Operators set the swing angle, speed, and target cycles, then let the machine run. A 2.8-inch color touchscreen shows completed cycles, preset cycles, and the estimated time remaining. The tester stops on conductor breakage, on reaching the preset count, or on demand through the emergency stop. Six counters plus a master counter keep each result separate.

The adjustable swing range of ±30° to ±90° and speeds from 10 to 120 cycles per minute let one machine cover gentle service conditions as well as aggressive accelerated aging. Four counterweight sizes from 100 g to 500 g set the tension on the cord during flexing. A wide 100 to 240 V input lets the QualiPlugBend™ 100 operate on North American and international power without a transformer. Its 710 × 620 mm footprint fits most lab floors.

Electric Plug / Cord Bending Tester - QualiPlugBend™ 100 Applications

Cord flex testing reveals weak strain reliefs, poor conductor stranding, and brittle insulation before products reach customers. The QualiPlugBend™ 100 serves manufacturers and labs that build, buy, or certify flexible electrical cords.

  • Household Appliance Manufacturing: evaluates power cords on kettles, irons, vacuums, and hair dryers that bend daily at the plug and appliance entry
  • Wire and Cable Production: compares conductor stranding, insulation compounds, and jacket materials for flex life during product development
  • Plug and Cord Set Assembly: checks molded plug strain reliefs to confirm they spread bending stress away from the conductor exit point
  • Consumer Electronics: tests charger leads, adapter cables, and DC power cords that users repeatedly coil and bend
  • Power Tool and Hand Lamp Production: measures cord endurance on portable equipment that moves constantly during use
  • Incoming Quality Inspection: screens cord batches from suppliers and flags lots that fail below a target cycle count
  • Third-Party Testing Laboratories: runs multi-sample flex tests for clients who need comparative durability data

Electric Plug / Cord Bending Tester - QualiPlugBend™ 100 Key Features

The QualiPlugBend™ 100 combines six-station throughput with automatic failure detection, so labs gather more flex data per shift with less operator time.

  • Six Independent Test Stations: flex six samples at once, each with its own counter, for faster comparison of materials or production lots
  • Automatic Break Detection: identifies an open circuit the moment a conductor fails and stores the exact cycle count for that sample
  • User-Defined Stop Threshold: stops the run after 1 to 9 sample failures, matching the test plan instead of halting at the first break
  • Five Selectable Swing Angles: adjusts from ±30° to ±90° to reproduce mild service flexing or severe accelerated bending
  • Digital Speed Control: sets flex rate from 10 to 120 cycles per minute with ±2% accuracy for consistent loading between tests
  • Preset Cycle Counter: ends the test automatically at a target count of up to 99,999,999 cycles for pass/fail endurance checks
  • 2.8-Inch Color Touchscreen: shows completed cycles, preset cycles, test speed, and remaining time at a glance
  • Remaining Time Estimate: calculates test duration from speed and preset count so operators can plan lab scheduling
  • Per-Channel Auto-Stop: halts each station individually when it reaches its preset count
  • Multi-Language Interface: switches between English, Chinese, and Japanese menus for global teams
  • Jog Function: fine-adjusts the grip angle during sample loading for accurate alignment
  • Emergency Stop and Pause: lets operators halt or pause the test instantly for safety or sample inspection
  • Universal Power Input: runs on single-phase 100 to 240 V for use in any region

Theory and Method

Repeated bending causes fatigue failure in metal conductors. Each time the clamp swings a cord to one side, the outer strands of the conductor stretch while the inner strands compress. Strain in a single strand rises with strand diameter and falls with bend radius, so thick strands and tight bends fail sooner. Cyclic strain starts microscopic cracks at the strand surface. Those cracks grow with every cycle until individual strands snap and, eventually, the whole conductor separates.

The QualiPlugBend™ 100 recreates this damage under controlled conditions. The operator clamps the plug or cord end in a swinging grip and hangs a counterweight from the free end, which pulls the cord straight and concentrates bending at the clamp exit. The grip oscillates through the selected angle on each side of vertical. An angle indicator panel shows the current test angle, and the jog function lets the operator fine-tune the starting position during setup.

Each station runs a low-voltage continuity circuit through the sample conductor. While the conductor stays intact, current flows and the counter advances. When the conductor breaks and opens the circuit, the controller records the cycle count for that channel. Users can define how many failures, from 1 to 9, the machine tolerates before stopping, so a test can continue until most samples have failed.

Electric Plug / Cord Bending Tester - QualiPlugBend™ 100 Technical Specifications

ParameterSpecification
Swing AngleAdjustable to ±30°, ±45°, ±60°, ±75°, and ±90°, with built-in angle indicator panel
Test Speed10 to 120 cycles per minute (±2%)
Test Stations (Grips)6 sets
Counterweights100 g, 200 g, 300 g, and 500 g (one set of each, 6 pcs per set)
Counters6 individual counters and 1 master counter
Maximum Count99,999,999 cycles
Display2.8-inch color touchscreen
Interface LanguagesEnglish, Chinese, Japanese
Jog FunctionFine angle adjustment during sample setup
Stop ConditionsConductor break detection (stops after 1 to 9 user-defined failures), preset cycle count, manual stop, emergency stop
Dimensions (W × D × H)710 × 620 × 890 mm
Weight122 kg (without counterweights)
VotlageSingle-phase, 100 to 240 V

Standard Accessories

ItemQuantityDescription
100 g Counterweight Set6 pcsHook-type weights for light-gauge cords and leads
200 g Counterweight Set6 pcsHook-type weights for small appliance cords
300 g Counterweight Set6 pcsHook-type weights for medium-gauge cords
500 g Counterweight Set6 pcsHook-type weights for heavy-gauge power cords

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