Hose burst simulation testing system for hydraulic machinery

Abstract

A hose burst simulation testing system is disclosed, comprising a controller, a simulation rig, and a height sensor. The system is designed to simulate hose bursts in hydraulic machinery. The controller operates the simulation rig to control the hydraulic valves of a machine, enabling the simulation of a hose burst event. The height sensor is attached to a load of the machine and is configured to measure the height of the load during testing. This configuration allows for the monitoring and verification of hose burst prevention mechanisms while maintaining the stability and accuracy of load measurements. The system can facilitate comprehensive testing by providing real-time data and feedback to the operator, ensuring compliance with safety standards and improving the reliability of hydraulic systems.

Description

Hose Burst Simulation Testing System for Hydraulic MachineryField of the Invention

[0001] This disclosure relates to hydraulic system testing, specifically to systems and methods for simulating hose burst scenarios in earth-moving and construction equipment. The disclosed system is designed to assess the performance, safety, and reliability of hydraulic systems in heavy machinery such as excavators, loaders, and bulldozers, ensuring compliance with industry standards and enhancing operational safety.Background of the Invention

[0002] Hose burst simulation for earth-moving and construction equipment refers to a testing process that assesses the performance and safety of hydraulic systems used in heavy machinery like excavators, loaders, bulldozers, and other construction or mining equipment. These hydraulic systems play a critical role in controlling the lifting and lowering of suspended loads.

[0003] During operation, hydraulic systems are under significant pressure, and a hose failure or burst can lead to catastrophic consequences, including injury to personnel, damage to equipment, and potential environmental hazards. To prevent such incidents, manufacturers and regulatory bodies conduct hose burst simulations to ensure that hydraulic systems are robust and can handle unexpected failures without endangering personnel or equipment and without causing environmental harm.

[0004] The hose burst simulation involves deliberately simulating a hose failure while the equipment is lifting, holding or lowering a suspended load under controlled conditions in a test environment. The test typically includes pressurising the hydraulic system to levels experienced during normal operation and then deliberately simulating a burst or failure in one of the hoses. The equipment's response to the burst is carefully observed and analysed.

[0005] According to the ISO 8643 standard, mobile earthmoving machinery such as excavators and wheeled loaders weighing over 1 ,000 kg and rated according to Australian Standards for lifting suspended loads must be equipped with boomlowering control valves and stick lowering control valves. These valves are necessary to ensure that the machine meets the requirements outlined in AS 1418.5.

[0006] ISO 8643 also provides a testing procedure to assess the load-holding capability of earthmoving machinery when equipped with boom lowering control valves. This testing involves simulating a hose burst while the machine is holding, raising, or lowering a load. According to the standard, during this simulation, the load should not drop more than 100 mm for a minimum of 10 seconds. Complying with ISO 8643 necessitates thorough type testing of the machine and its configuration to verify adherence to the standard.

[0007] The simulation aims to determine how the equipment reacts to hose failure and whether it can safely stop the hydraulic function, prevent oil leakage, and maintain control of the machine. Designers and engineers use the insights gained from these simulations to improve the hydraulic system's safety and reliability, ensuring compliance with industry standards and regulations.

[0008] By conducting hose burst simulations, manufacturers can identify potential weaknesses in their hydraulic systems and make necessary design improvements or valve adjustments to ultimately provide safer and more reliable equipment for operators and workers in the construction and mining industries.

[0009] While hose burst simulations for earth-moving equipment are crucial for ensuring the safety of hydraulic systems, there are some disadvantages associated with these tests. Setting up a comprehensive hose burst simulation test can be expensive and time-consuming, requiring skilled personnel to conduct the tests accurately. The costs involved can be significant, especially for smaller manufacturers with limited resources.

[0010] Furthermore, while engineers strive to recreate realistic conditions, certain nuances may be challenging to reproduce accurately, and human error can lead to limitations in the simulation's accuracy.

[0011] This disclosure seeks to provide a way to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[0012] It is to be understood that if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.Summary of the Disclosure

[0013] This disclosure relates to a hose burst simulation testing system designed to assess the safety and performance of hydraulic systems in heavy machinery such as excavators, loaders, bulldozers and other construction equipment. The system includes a controller, a simulation rig configured to control hydraulic valves, and a height sensor attached to a load of the machine. The height sensor measures the load's height during testing, while the controller manages the simulation rig to simulate hose bursts, allowing for the evaluation of hydraulic system integrity.

[0014] The system facilitates the testing process by employing wireless communication between the controller, the simulation rig, and the height sensor, thereby streamlining setup and operation. An in-cabin display module provides realtime feedback to machine operators, assisting them in maintaining control and ensuring compliance with test parameters. The system's design supports the automation of test procedures, enhancing the accuracy and efficiency of hose burst simulations.

[0015] By simulating hose failures under controlled conditions, the system provides valuable insights into the hydraulic system's response to potential failures. This enables manufacturers, engineers and equipment owners to identify weaknesses, improve design safety, and ensure adherence to industry standards and regulations. The system's capabilities support comprehensive testing, helping to prevent equipment failure and enhance operator safety in the construction and mining industries.

[0016] According to one aspect, there is provided a hose burst simulation testing system that comprises a controller, a simulation rig configured to control hydraulic valves of a machine, and a height sensor attached to a load of the machine. The height sensor measures the height of the load, and the controller manages the simulation rig to simulate a hose burst while the height sensor records the load height.This system provides a comprehensive approach to testing the integrity and safety of hydraulic systems in heavy machinery, ensuring that potential hose failures can be effectively managed.

[0017] Optionally, the controller is configured to control relays that operate solenoids of the simulation rig, enabling precise operation of the hydraulic valves. This feature offers technical advantages in terms of automation and accuracy in simulating hose burst scenarios, enhancing the reliability of the test results.

[0018] The solenoids may be linked to hydraulic lines equipped with bypass or pilot valves that bleed off pressure, triggering the activation of at least one hose burst prevention valve to verify its proper functioning. This optional configuration ensures that the system can assess the responsiveness and effectiveness of safety mechanisms, thus preventing equipment failure and ensuring operator safety.

[0019] The simulation rig may also comprise at least one hydraulic sensor input, with the controller configured to receive hydraulic sensor readings. This feature allows the system to monitor critical parameters such as pressure, temperature, and flow, providing comprehensive data for analysis and improving the diagnostic capabilities of the system.

[0020] In some embodiments, the hydraulic sensor input interfaces with a pressure sensor, which allows for precise monitoring of pressure levels within the hydraulic system. This option enhances the system's ability to detect anomalies and ensure that hydraulic components operate within safe limits.

[0021] Alternatively, the hydraulic sensor input can interface with a temperature sensor, providing data on the thermal state of the hydraulic fluid. This information is crucial for ensuring that temperature-induced changes in fluid dynamics do not compromise system performance.

[0022] Additionally, the hydraulic sensor input may interface with a flow sensor, enabling the detection of variations in fluid flow. This option is particularly useful for conducting balance-line tests, where the solenoids can be controlled to bypass a balance line valve, and the flow sensor confirms the correct flow rate. This ensures the balance line functions safely and accurately.

[0023] The controller may communicate wirelessly with the height sensor and the simulation rig, offering the advantage of a streamlined setup with fewer physical connections, which enhances the flexibility and ease of deployment of the system.

[0024] The system may further comprise an in-cabin display module configured to provide a machine operator with feedback. This feature ensures that operators are continuously informed of the test progress and can make necessary adjustments to maintain safety and compliance with test parameters.

[0025] A control device may be included in the system, configured to control the in cabin display module to indicate a target height for a test and provide feedback on raising or lowering the load to meet this target height. This option aids operators in achieving precise control over load movements, thereby improving the accuracy of the testing process.

[0026] The in-cabin display module may incorporate multiple LEDs or other Visual Display such as an LCD or OLED screen to signify compliance with reaching specific target heights or indicate if the raising or lowering rate is appropriate. This visual feedback enhances operator awareness and ensures that operations are conducted within safe and optimal parameters.

[0027] The control device may be configured to control a test process, communicating with the controller, height sensor, and in-cabin display module. This integration allows for seamless coordination of test activities, enhancing the efficiency and effectiveness of the testing process.

[0028] The system can employ a broadcast method of communication, allowing multiple devices to communicate directly with each other. This method supports efficient data transmission and enhances system responsiveness, enabling real-time feedback and adjustments during testing.

[0029] The height sensor may be configured to broadcast height data to both the incabin display module and the control device, ensuring that all relevant stakeholders receive accurate and timely information regarding load movements.

[0030] Furthermore, the system may utilise the User Data Protocol (UDP) for broadcasting, which facilitates high-speed data exchange between devices,enhancing the system's ability to operate under real-time conditions without data loss. This UDP protocol might be enhanced to include confirmations and retries as required.

[0031] The controller may transmit sensor reading data to the control device, allowing for comprehensive monitoring and decision-making based on real-time feedback from the hydraulic system. This capability ensures that corrective actions can be promptly implemented, thereby enhancing system safety and reliability.

[0032] The height sensor may employ an ultrasonic sensor to measure height, providing accurate and non-contact height measurement capabilities that are crucial for maintaining the integrity of the test environment and ensuring consistent data collection.

[0033] Additionally, height sensing can involve motion sensing, which detects rotation, swing, and angle of the load. This feature offers enhanced stability assessment, ensuring that the load remains secure and balanced during testing, thereby preventing accidents and ensuring the validity of test results.

[0034] Motion sensing may also be used to detect load instability and compensate for measured height, improving the accuracy and reliability of height measurements and ensuring that tests are conducted under controlled and predictable conditions.

[0035] Other aspects of the invention are also disclosed.Brief Description of the Drawings

[0036] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0037] Figure 1 illustrates a hose burst simulation testing system 100, including the wireless system controller 101 , simulation rig 102, wireless height sensor 103, incabin display module 105, and control device 104.

[0038] Figure 2 depicts the simulation rig 102, serving as the mechanical and electrical interface to the machine 109, and enabling simulation of hose burst failures and testing of the balance line for dual-piston loaders.

[0039] Figure 3 shows the control device 104, typically a tablet computer, responsible for managing the test process, including height sensor activation, data streaming, and recording test videos with data overlays.

[0040] Figure 4 illustrates the wireless system controller 101 , which receives control messages from the control device 104 and interfaces with solenoids and sensors to execute and measure the test procedures.

[0041] Figure 5 shows the technical elements of the controller 101 in more detail.

[0042] Figures 6 and 7 display the wireless height sensor 103, which accurately measures the height, rate of ascent or descent, and stability of the load during testing.

[0043] Figures 8 and 9 represent the wireless in-cabin display module 105, providing visual and audio feedback to the machine operator, with RGB LEDs to signify compliance with height targets and rates of ascent or descent, along with internal and external Piezos for notifications and warnings.Description of Embodiments

[0044] Figure 1 shows a hose burst simulation testing system 100 in accordance with a preferred embodiment. The system 100 includes a wireless system controller 101 responsible for controlling relay outputs 106 to operate solenoids 107 of a simulation rig 102, which manage the hydraulic valves of a machine 109. The simulation rig 102 also has sensor inputs 108 to monitor critical pressure, temperature, and / or flow sensors connected to the rig 102.

[0045] The system 100 may incorporate a full-colour in-cabin display module 105, providing the machine operator with visual and audio feedback. To facilitate height measurement, the system 100 utilises a wireless height sensor 103 placed on the test load, allowing the operator to raise and lower it. To manage the entire test process, the system 100 employs a control device 104 (such as a tablet computer) running custom software. This device 104 enables wireless communication with other hardware components of the system 100, allowing the operator to oversee all test steps, record relevant test data, and capture videos of each test with data overlays. Furthermore, completed tests can be sent to the cloud for report generation and data preparation.

[0046] The rig 102 is connected to hose burst prevention valves, enabling hose burst simulation as part of the testing process. Before commencing each stage of the test, following the ISO and Australian Standards for both the loader and bucket, the bucket is replaced with a specialised testing device 1 10 known as a 'Material Handling Arm / Jib'. For the loader stage of the test, the simulation hoses are connected to the existing Hose Burst Protection Valves (HBPV) for the loader on the machine 109, using pilot and bypass valves. Once the loader test stage is complete, the oil is returned to that circuit of the machine, the hoses are disconnected, and then connected to the bucket circuit for the next stage of the test. These simulation hoses are connected to the rig 102, with solenoids 107 on the rig 102 managing their control. The rig solenoids 107, in turn, are controlled by relays 106 controlled by the system controller 101 .

[0047] This connection process involves attaching various hydraulic hoses, bypass, and pilot valves, as well as pressure and temperature sensors and transducers. These components are essential to ensure compliance with test parameters and to accurately determine the success or failure of each test. A notable safety improvement is that personnel conducting the test can now be located inside the vehicle's cabin, significantly enhancing overall safety during the testing process.

[0048] The system 100 preferably employs a broadcast method of communication to allow multiple devices to communicate with each other directly. As such, the system 100 can swiftly stream data in a broadcast fashion. An example of this is the height sensor 103, which, upon activation, rapidly sends height and acceleration data. This data is then received and utilised by various devices, including the in-cabin display module 105 and the control device 104. The system 100 may employ the User Data Protocol (UDP) as it allows broadcasting messages that can be received simultaneously by multiple devices, supporting high transaction rate streaming. To ensure the delivery of critical messages, the system 100 may incorporate an acknowledgment layer that intelligently retries message transmission. For instance, the control device 104 may broadcast a UDP command to the network, prompting the height sensor 103 to turn on and start transmitting height data. This data is used todisplay visible interactions via the colour LEDs on the in-cabin display module 105 and is also streamed to the control device 104 for recording and decision-making. The control device 104 can assess the efficacy of the test, such as the correct rate and stability of the height.

[0049] Similarly, the control device 104 may broadcast messages to the controller 101 , instructing it to turn on a solenoid 107 for opening a bypass valve. The controller101 may read sensor data such as temperature, pressure, and / or flow rate and broadcast this data for the control device 104 to access. The control device 104 can then make intelligent decisions based on the data received. For example, if a drop in pressure is observed, the control device 104, or possibly the controller 101 itself, can take appropriate action, such as turning off the solenoid 107 to close the bypass valve.

[0050] Figure 2 illustrates the simulation rig 102, which serves as the mechanical and electrical interface to the machine 109. Its primary role is to interface hydraulically with each hose burst prevention valve to simulate failures and test the reliable functionality of the balance line for dual-piston loaders. Physically, the simulation rig102 is connected to the wireless system controller 101 , which enables and disables the relays that control the solenoids 107. Additionally, it connects to pressure, temperature, and flow sensors via sensor inputs 108. The rig 102 includes an internal power supply that provides power to its relays 106, attached solenoids 107, sensors, and the controller 101 .

[0051] The solenoids 107 are linked to hydraulic lines equipped with bypass valves and pilot valves. These valves effectively bleed off pressure, triggering the activation of the Hose Burst Prevention Valves (HBPVs) to verify their proper functioning. During the test, these lines are initially connected to the HBPV hydraulic circuit for the machine 109, and then they are disconnected and reconnected to the HBPV hydraulic circuit for the bucket for that particular test. To comply with test requirements, the pressure and temperature sensors are sequentially connected to each hydraulic circuit to ensure the oil is at the correct temperature and the pressures meet the test criteria.

[0052] For the balance-line test, specific solenoids 107 are utilised to bypass the balance line valves, and flow sensors come into play with the boom raised and in a neutral control position (without a load). This process confirms the correct rate of flow, ensuring the balance line functions safely and correctly.

[0053] The control device 104, depicted in Figure 3, plays a central role in managing the test process. While it can be any control device, it is typically a tablet computer. Before each test, the customer and machine details are entered into the device. The system database contains machine parameters that assist with calculations related to stick length and load. Running custom software, the control device 104 takes on the primary responsibility of supporting the test procedures. It connects to the system's private WIFI network and utilises the UDP protocol to control other modules and receive data from them.

[0054] Initially, the height sensor 103 and in-cabin display module 105 are turned off. The control device 104 software initializes both modules, enabling them for the test. As an example of communication supporting the test, the control device 104 informs the in-cabin display 105 of the target height for the test, allowing it to signal the driver when to stop. The in-cabin display automatically provides feedback to the driver on raising and lowering to meet the target height. Once initiated, the control device 104 activates the height sensor 103, which starts streaming height data while internally managing stability. It also records video of the ongoing test. Both the in -cabin display module 105 and the control device 104 receive this streamed data. The in-cabin display provides feedback to the machine operator regarding speed, while the control device 104 evaluates various aspects of the test, such as whether the correct height has been achieved and maintained, and if the lowering rate is appropriate.

[0055] To control the physical test, the control device 104 sends signals to the system controller 101 , which, in turn, releases a bypass valve. The controller 101 provides pressure and temperature feedback used by the software to determine the safety and success or failure of the test. When the appropriate time comes, the control device 104 sends another signal to the controller 101 to close the bypass valve and complete the test. The controller 101 also checks the stability of the load while receiving heightsensor data to ensure compliance. Throughout the test, the control device 104 records video using its camera and overlays the received data onto the video. The software compiles all this data into a report that can be uploaded to the cloud, along with the supporting video data.

[0056] The wireless system controller 101 , depicted in Figure 4, plays a crucial role in the testing process. Its main responsibility is to receive control messages from the control device 104 and interface with the solenoids and sensors that execute and measure the test procedures. The controller 101 performs two main functions. Firstly, it controls relays 106 that are connected to solenoids 107 responsible for operating various valves involved in the test operation, including bypass valves and balance valves. Secondly, it connects to and gathers data from temperature, pressure, and flow meter sensors relevant to the test process.

[0057] Throughout the test, the control device 104 takes command of the controller 101 at different stages, putting the test equipment into specific states. For example, it may activate a solenoid that triggers the pilot and bypass valves for the hose burst simulation test. Concurrently, the controller 101 continuously monitors data from the various sensors and takes appropriate actions based on the values received. These actions are essential for evaluating whether the hose burst simulation test complies with the standard and whether it was successful.

[0058] Figure 5 shows the technical elements of the controller 101 in more detail. The wireless height sensor 103, as shown in Figures 6 and 7, plays a crucial role in the test by ensuring precise measurement of the load's height, its rate of ascent or descent during raising and lowering tests, and most importantly, the load's stability during testing to ensure accuracy. This sensor 103 operates on battery power and contains a CPU with custom firmware and wireless connectivity. It employs a dual ultrasonic sensor 1 11 to measure height and a combination of a gyro, accelerometer, and / or magnetometer 1 12 to measure acceleration, rotation, and orientation.

[0059] Once activated, the height sensor 103 streams height data to other modules in the system and utilises its internal sensors for compensation, ensuring compliance with correct raising and lowering rates for the loads. To support the test process,several key elements are considered around the load, including height of the load, stability of the load during raising and when static and the rate of raising or lowering the load. As shown in Figure 7, the height sensor 103 fulfils these requirements by employing a height measuring device (such as a dual ultrasonic sensor) to measure the load's height off the ground. It also utilises a 9-degree-of-freedom accelerometer, gyro, and magnetometer to determine any rotation, swing, and angle of the sensor and, consequently, the load. This data is used to determine stability and support correction algorithms for height measurements.

[0060] Upon activation through a UDP message to commence reading, the height sensor 103 streams height data to other devices. This data is then utilised to determine compliance with the ongoing test, such as ensuring correct heights and rates of ascent or descent. The wireless in-cabin display module 105 shown in Figures 8 and 9 serves as a graphical interface for the machine operator, assisting them in complying with the test process. This display module 105 incorporates multiple RGB LEDs 1 13, usually arranged in a vertical group, offering valuable visual cues to the machine operator. This interface may be further enhanced using a graphical interface displayed on an LCD, OLED or similar screen.

[0061] For instance, colours can be used to signify compliance with reaching specific target heights, with red, orange, and green representing different levels of compliance. Similarly, colours can indicate adherence to target rates of ascent or descent, enabling the operator to adjust their lever operations accordingly. The ability to 'stripe' LEDs allows the simulation of motion direction, providing clear instructions to the operator, such as LEDs striping downwards or upwards to signify the target direction. Moreover, the module 105 includes an internal Piezo and the capacity to drive a louder external Piezo, serving various notifications and warnings to the operator. The internal, softer Piezo can signify compliance or noncompliance with instructions, while the louder external Piezo is reserved for more urgent warnings or notifications, designed to overcome the noisy environment in which the operator operates.

[0062] As illustrated in Figure 8 and elaborated in Figure 9, the module 105 is equipped with a CPU featuring custom firmware and wireless connectivity. Additionally, it comprises a visual interface, typically incorporating multiple RGB LEDs, and an audio interface with both internal and external Piezos.

[0063] According to an exemplary method of use of using the hose burst simulation testing system 100 to evaluate the effectiveness of hose burst prevention mechanisms in hydraulic machines, the specialised testing device 1 10 is attached in place of the bucket to comply with ISO and Australian Standards for testing.

[0064] Once the machine 109 has been prepared, the simulation rig 102 is connected to the machine's hydraulic circuits, beginning with the loader circuit. The simulation hoses are attached to the High-Pressure Burst Prevention (HBPV) valves using pilot and bypass valves. This setup allows hydraulic flow to be controlled by the simulation rig 102 through solenoids 107, which are managed by relays 106 as directed by the system controller 101.

[0065] Next, the control device 104, as shown in Figure 3, is activated and connected to the system's private WIFI network. This device 104 acts as the central hub for managing the test process, recording data, and communicating with other system components. It must be ensured that the control device 104 is running the custom software necessary for overseeing the test.

[0066] With the control device 104 ready, the test is initiated by activating the wireless height sensor 103, as illustrated in Figures 6 and 7. The height sensor 103 is placed on the test load to monitor its position and stability during the test. Real-time data is streamed from the sensor 103 to both the in-cabin display module 105 and the control device 104, providing feedback on the load's height, rate of ascent or descent, and overall stability.

[0067] During the test, the operator remains in the cabin, and visual and audio cues regarding compliance with test parameters are received through the in-cabin display module 105, depicted in Figures 8 and 9. The RGB LEDs 1 13 on the display module 105 indicate whether the target height and rate of movement are achieved. Auditory signals are provided by the internal and external Piezos for further guidance.

[0068] Throughout the testing process, data from the sensors and system components is continuously monitored by the control device 104. This information is used to make real-time decisions, such as adjusting solenoid 107 positions to open or close bypass valves as needed. Video footage of the test is captured by the device, with relevant data overlaid for documentation purposes.

[0069] After the loader stage is completed, the hoses are disconnected and repositioned to test the bucket circuit. The test procedure is repeated, ensuring all parameters are met for each stage. Upon completion, all test data and video footage are compiled by the control device 104 into a comprehensive report, which can be uploaded to the cloud for further analysis and record-keeping.

[0070] By following these steps, accurate and reliable testing of hydraulic machines' burst prevention mechanisms is ensured by the hose burst simulation testing system 100, enhancing safety and compliance with industry standards.

[0071] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed as obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.

Claims

Claims1 . A hose burst simulation testing system comprising: a controller; a simulation rig configured to control hydraulic valves of a machine; and a height sensor attached to a load of the machine, the height sensor configured to measure height of the load, wherein the controller is configured to control the simulation rig to simulate a hose burst while the height sensor measures the height of the load.

2. The system as claimed in claim 1 , wherein the controller is configured to control relays operating solenoids of the simulation rig to operate the hydraulic valves of the machine.

3. The system as claimed in claim 2, wherein the solenoids are linked to hydraulic lines equipped with bypass or pilot valves which bleed off pressure, triggering the activation of at least one hose burst prevention valve to verify its proper functioning.

4. The system as claimed in claim 1 , wherein the simulation rig comprises at least one hydraulic sensor input, and the controller is configured to receive hydraulic sensor readings from the at least one hydraulic sensor input.

5. The system as claimed in claim 4, wherein the at least one hydraulic sensor input interfaces with a pressure sensor.

6. The system as claimed in claim 4, wherein the at least one hydraulic sensor input interfaces with a temperature sensor.

7. The system as claimed in claim 4, wherein the at least one hydraulic sensor input interfaces with a flow sensor.

8. The system as claimed in claim 7, wherein, for a balance-line test, the solenoids are controlled to bypass a balance line valve, and the flow sensor is used to confirm a correct flow rate.

9. The system as claimed in claim 1 , wherein the controller is configured to communicate wirelessly with the height sensor.

10. The system as claimed in claim 1 , wherein the controller is configured to communicate wirelessly with the simulation rig.1 1 . The system as claimed in claim 1 , further comprising an in-cabin display module configured to provide a machine operator with feedback.

12. The system as claimed in claim 1 1 , further comprising a control device configured to control the in-cabin display module to indicate a target height for a test.

13. The system as claimed in claim 12, wherein the in-cabin display module is configured to provide feedback on raising or lowering the load to meet the target height.

14. The system as claimed in claim 13, wherein the in-cabin display module incorporates multiple LEDs to signify compliance with reaching specific target heights.

15. The system as claimed in claim 1 1 , further comprising a control device configured to control the in-cabin display module to indicate if a raising or lowering rate of the load is appropriate.

16. The system as claimed in claim 15, wherein the in-cabin display module incorporates multiple LEDs to signify if the raising or lowering rate is appropriate.

17. The system as claimed in claim 1 , further comprising a control device configured to control a test process and communicate with at least one of the controller, the height sensor, and the in-cabin display module.

18. The system as claimed in claim 17, wherein the controller is configured to receive operating instructions from the control device for the operation of the hydraulic valves of the machine.

19. The system as claimed in claim 17, wherein the control device is configured to receive sensor readings from the controller.

20. The system as claimed in claim 17, wherein the control device is configured to communicate wirelessly with at least one of the controller, the height sensor, and the in-cabin display module.21 . The system as claimed in claim 17, wherein the control device is configured to at least one of: display test steps, record test data, and capture test videos with data overlays.

22. The system as claimed in claim 21 , wherein the control device is configured to transmit test data to a remote server.

23. The system as claimed in claim 1 , wherein the system employs a broadcast method of communication to allow multiple devices of the system to communicate with each other directly.

24. The system as claimed in claim 23, wherein the height sensor is configured to broadcast height data to an in-cabin display module and a control device.

25. The system as claimed in claim 23, wherein the broadcast method of communication employs User Data Protocol (UDP).

26. The system as claimed in claim 23, wherein the system is configured to retransmit message broadcasts which are not acknowledged.

27. The system as claimed in claim 23, further comprising a control device configured to broadcast a command to the height sensor to turn on and start transmitting height data.

28. The system as claimed in claim 23, wherein the height sensor is configured to broadcast height data to an in-cabin display module.

29. The system as claimed in claim 23, further comprising a control device, wherein the height sensor is configured to broadcast height data to the control device.

30. The system as claimed in claim 23, further comprising a control device configured to broadcast instructions to the controller.

31. The system as claimed in claim 30, wherein the instructions include instructions to operate a solenoid to control a valve.

32. The system as claimed in claim 23, wherein the controller is configured to transmit sensor reading data to a control device.

33. The system as claimed in claim 32, wherein the control device is configured to monitor the sensor reading data to control the controller.

34. The system as claimed in claim 33, wherein the control device is configured to control the controller to close a valve if the sensor reading data indicates a drop in pressure.

35. The system as claimed in claim 1 , wherein the height sensor employs an ultrasonic sensor to measure height.

36. The system as claimed in claim 35, wherein height sensing involves motion sensing.

37. The system as claimed in claim 36, wherein the motion sensing is configured to detect at least one of rotation, swing, and angle of the load.

38. The system as claimed in claim 36, wherein the motion sensing is used to detect load instability.

39. The system as claimed in claim 36, wherein the motion sensing is used to compensate for measured height.

40. The system as claimed in claim 37, wherein motion sensing involves at least one of a gyro, accelerometer, and magnetometer.41 . The system as claimed in claim 1 , wherein the system uses the height sensor to determine movement rate of the load.

42. A method of using the hose burst simulation testing system as defined in claim 1 , the method comprising:connecting the simulation rig to hydraulic valves of a machine; attaching the height sensor to a load of the machine; measuring the height of the load using the height sensor; and controlling the simulation rig with the controller to simulate a hose burst while the height sensor measures the height of the load.

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