Load Testing vs. Stress Testing — What’s the Difference and Why It Matters for Industrial Applications
You already know that your equipment is tough, but the only way to find out exactly how tough is by testing it. There are plenty of different ways to put your machinery under added strain, but the two most common are stress testing and load testing. Here’s everything you need to know about both of them.
What Is Load Testing?
Load testing measures how well your equipment performs under a specific workload. The process isn’t designed to push the limits of your machinery; instead, it verifies that your equipment can handle typical or expected conditions without degradation in performance.
Key Goals
The main goals of load testing are as follows:
- Evaluating performance under normal and peak loads
- Identifying issues before they impact your operations
- Ensuring compliance with industry safety standards
Let’s look at an example of how you might set up a load test:
Example
Imagine a conveyor belt system in your manufacturing plant. Load testing would involve assessing its performance when handling the maximum weight it’s expected to carry during normal operations.
Can the conveyor system start and stop smoothly? Are there any delays, or does it move goods slower than expected? Load testing is what will answer these critical questions.
What Is Stress Testing?
Stress testing focuses on determining the breaking point of a system. It’s all about intentionally pushing your equipment beyond its normal operating limits to observe how it behaves under extreme conditions. If the continuity of your business hinges on a machine’s durability, you need to make sure it will deliver.
Key Goals
The primary goals of stress testing include the following:
- Identifying the maximum capacity a machine can handle before failure
- Understanding what type of failure occurs so you can establish safety thresholds
- Preparing for unexpected scenarios that may arise (i.e., someone accidentally overloading a machine)
With these details in mind, let’s look at an example of stress testing:
Example
Using the same conveyor belt system example, you now want to figure out the machine’s breaking point. To do so, you will gradually increase its load until the belt either stalls or breaks completely. Make a note of the weight that caused the machine to fail and how it broke, as that information will help your team figure out how far you can push the equipment and what will happen if you do.
Key Differences Between Load vs. Stress Testing
Both load and stress testing aim to improve reliability and safety, but where the former gives you a chance to see how your machines will perform under normal conditions, the latter reveals how your machinery holds up when pushed past its limits.
The purpose of each test varies as well. Normal load testing helps you better understand how reliable and efficient equipment is. Stress tests identify the failure point. The better you understand these differences, the easier it will be to decide when and how to conduct each type of test.
Why Testing Matters for Industrial Applications
You don’t want to cut corners when it comes to your equipment. If you do, you may give rise to any of the following:
- Safety Risks: Malfunctioning equipment can get your team members hurt
- Costly Downtime: Unplanned failures will cost you thousands and lead to many unhappy customers
- Equipment Failure: Your machinery will break down earlier than expected
Through proper testing, you give your maintenance team the information they need to keep your facility safe and productive at all times.
Applications in Weighing Systems and Equipment
Weighing systems should also be stress and load-tested. By performing these types of tests on your weighing equipment, you can confirm that your scales and sensors provide consistent, accurate readings under varying loads. You’ll also be able to determine their upper limits and identify scenarios where they may fail.
Testing these systems also promotes compliance with regulatory standards and can help your business avoid fines related to sending out overweight shipments.
How to Implement Each Type of Testing
You need a structured approach to load and stress testing. Here are some tips to help you achieve meaningful results:
- Define your objectives
- Use actual or simulated operational environments
- Employ modern testing equipment and software so you can gather performance data in real-time
- Look beyond pass/fail metrics to identify potential weak points and areas for improvement
Keep in mind that your demands and the regulations you are subject to evolve over time. With that in mind, perform periodic testing to ensure that you adapt to changing requirements.
Which Type of Testing Should You Use?
Both stress and load testing play a role in promoting business continuity and keeping your team safe. Using these strategies in tandem is what will ultimately set your operations up for success.