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Testbeds

Our testing stations are individually adapted to the customer specifications. We cooperate with well-known standard suppliers of drive engineering and measuring equipment. Through the modular design we can offer our testing systems with a high degree of flexibility. We respond to our customers special wishes for the selection of components and for the configuration.

Types of Testbeds:

  • Development testbeds
  • Prototype testbeds
  • EOL (End of line) - testbed

The test beds are adapted to the requirements. The offer range goes from variably designed prototype test beds, to adjustable development test beds to EOL test beds with a fix test sequence.

Key Data:

  • up to 200 Nm at 7000 rpm
  • up to 3000 Nm at 50 rpm

Core Competences:

  • Function testbeds
  • Noise testbeds
  • Clutch testbeds

Feeding the System:

  • System operator
  • Handling
  • Transfer systems
  • Robots

Applications:

  • Gear boxes and gear box components
  • AWD gear boxes
  • Differential gear boxes
  • Bevel gear boxes
  • Clutches
  • Axles
  • Oil pumps
  • Component testbed
  • Water pumps
  • Lubrificant testing

Construction:
The system can be established as semi-automatic machine with an operator right up to a fully automated system with handling / transfer system / robots. Depending on the specifications various systems may also be combined.

Connection:
The processing of data can be flexibly adapted to the requirements. The communication to the unit under tests is established by pneumatically advanced contacts. In doing so all relevant data is acquired and recorded in the data base.

Data communication to the unit under test:
Vehicle control devices
Bus systems (CAN, Flexray or LIN)

Types of Tests:

  • Vibration measurement
  • Noise recording via laser
  • Torque measuring
  • Speed measurement
  • Shifting times
  • Gear ratio measurement (high / low)
  • Pressures
  • Temperatures

Vibration measurement / Speed measurement
With the signal processor two speed signals and four A/D channels with 20 bit resolution may be processed at a sample rate of 50 kHz. The processor can process signals from sensors for airborne noise or from sensors for solid-borne noise. In parallel the current speed(s) are acquired with a fork light barrier and a braker plate and the rotation synchronous sampling is performed. Additionally the measurements can be digitally recorded and replayed via a sound card.

Torque measuring
A torque shaft measures static and dynamic torques and speeds or rotational angle of turning or stationary machine parts.

Evaluation:

  • OK/NOK - Evaluation
  • Torque
  • Speed
  • Vibration behavior over time
  • Visualization of test ramp, speed, torque over time

 

Variations:
On our test beds, depending on the requirements, identically constructed gear boxes may be tested with different control systems by simply retooling the test bed. For greater changes of the geometry a special universal test bed is available. It is specially designed constructed for changing gear box types.

Examples:
Clutch testbed
The testbed is modularly designed. A mounting angle is assembled to a processed ground plate with a vibration-isolated concrete base. The driving motors are arranged on a separate base in order to remove unwanted influences. The drive shaft is contacted pneumatically via a proven system of shafts and cardan joints. The parts are hydraulically clamped to fasten the gear box and to avoid moving of the parts during the test. At the infeed a torque is applied at the outfeed a counter torque is generated. A load cell determines the necessary break away torque. The test bed is equipped with all necessary monitoring and recording units, which comprise: e.g. speed monitoring and torque monitoring.

NVH  testbed
The noise test bed is constructed as modular as the clutch test bed. The clamping is done the same way as already described. The generation of noise is recorded with an applied acoustic element.