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Measurement and Testing Equipment

Measurement and Testing Equipment

If one looks back on the history of Klotz GmbH, then the entry into the measurement and testing technology field in 1982 is one of the most important moments in the company’s history. Since then, we have developed a comprehensive range of know-how through the design, development and construction of many and highly varied solutions. The focus is on the function testing aspect: Solutions for engines, transmissions, steering systems, axial joints and clutches, for example. We have also made a name for ourselves with many test benches to determine service life, performance and leak tightness. In addition, we have developed test benches for special measurement and testing tasks, such as ultrasonic and diameter checking systems for pistons, radiation sensors for radioactive barrels and surface tension testers for enamel, which have been improved on continuously for 30 years.
Now the name Klotz stands for a particularly high level of competency in the field of test bench software. These days a team of computer scientists is working on a permanent and project-independent basis to develop the most technically demanding software solutions, which are a prerequisite for today’s testing requirements: individually adapted solutions from a single source.

End-of-Line test station for electric power steering systems (EPS/EPAS)

100 % testing of EPAS systems, integrated in the assembly line. In addition to the function tests, the test bench also performs an acoustic test on every steering gear.

The new generation of Klotz steering gear test benches are based on many years of practical experience as well as the results of research and development studies. Computer-controlled function tests can be performed on mechanical and electromechanical rack-and-pinion steering gears. The scope of delivery also includes implementation of the external bus simulation (CAN/Flexray).

The test bay integrated in final assembly generally consists of several autonomous test benches, each equipped with a hydraulic unit for the clamping functions.

Every test bench primarily consists of:

  • Base with base frame and pinion drive frame
  • Electro-mechanical or hydraulic load units on the left and right
  • Docking unit for vehicle points on the left and right
  • Drive unit input shaft with centring gripper as well as torque and angle sensors
  • Units for docking the power and bus connection to the steering column
  • Safety systems
  • Control cabinet, PC and control panel
  • Flexible and expandable test bench software, with all quality data saved to a central location

 

 

 

 

Test bench for pedal assemblies and brake boosters

Testing of pedal assemblies and the individual pedals, brake boosters, wheel brakes and clutch control systems in combination with various loads such as volume transducer brake systems, wheel brakes, clutch slave cylinder and transmission case test devices with clutch and clutch slave cylinder.

Specifications: Testing under extreme temperature conditions (possible in the temperature-controlled chamber)

 

Durability Test Bench for Rack and Pinion Steering Gears

This test bench is used to carry out durability tests of manual and power-assisted rack and pinion steering gears. Static and dynamic tests up to 30 Hz tie rod load run computer-controlled. The drive unit can be adjusted in 4 axes, the load input unit in 2 axes. By TCP/IP interface, the status of the current tests can be queried by any computer concerned.

Test Bench for Single and Continuous Tests of Axial Joints

The axial joint test bench subjects different axial joints to severe single and continuous load tests. Duty cycles, angular movements, temperature and air humidity can be preselected freely. Failure criterion is the axial play that develops or the breakage of the axial joint.

Technical brief description:

The test bench allows the simultaneous test of a maximum of 4 axial joints.
The axial load for each joint and the angular movement for all joints together are applied by servo-type hydraulic cylinders. The control of axial load and angular movement is optionally linear or sinusoidal.
Each test location has a separate support and individual test adapters. This allows simultaneous test of different axial joints.
The axial play is determined by measuring the movement between housing and joint bar at a given load on the axial joint. If a joint is defective, the corresponding cylinder is cut off. Time of failure, number of cycles and development of axial play are recorded.

Power Steering Test Bench for 100 % Testing in Assembly Line

The test bench carries out fully automatic functional testing of hydraulic rack and pinion steering gears. Due to the automatic identification of the steering gear types, the test bench adapts virtually automatically to different steering models. So only few, or ideally no, manual operations are required when model change is carried out.

The integrated tool magazine minimizes the non-productive times and the work to be performed by the operator during tool change or resetting. This increases productivity and efficiency significantly. Because of the short resetting times, even small batch sizes can be made economically.

End-of-Line Test Station for Commercial Vehicle Steering

Durability Test Bench for Axial Joints

Test Bench for Single and Continuous Tests of Axial Joints

The axial joint test bench subjects different axial joints to severe single and continuous load tests. Duty cycles, angular movements, temperature and air humidity can be preselected freely. Failure criterion is the axial play that develops or the breakage of the axial joint.

Technical brief description:

  • The test bench allows the simultaneous test of a maximum of 4 axial joints.
  • The axial load for each joint and the angular movement for all joints together are applied by servo-type hydraulic cylinders. The control of axial load and angular movement is optionally linear or sinusoidal.
  • Each test location has a separate support and individual test adapters. This allows simultaneous test of different axial joints.
  • The axial play is determined by measuring the movement between housing and joint bar at a given load on the axial joint. If a joint is defective, the corresponding cylinder is cut off. Time of failure, number of cycles and development of axial play are recorded.

 

Durability Test Bench for Rack and Pinion Steering Gears

This test bench is used to carry out durability tests of manual and power-assisted rack and pinion steering gears. Static and dynamic tests up to 30 Hz tie rod load run computer-controlled. The drive unit can be adjusted in 4 axes, the load input unit in 2 axes. By TCP/IP interface, the status of the current tests can be queried by any computer concerned.

 

Transmission Test Bench

The test bench serves to determine and test the control characteristic of automatic transmissions with hydraulic and electronic control.
The tests are carried out on steplessly variable automatic transmissions as well as on automatic multi-step transmissions for front-wheel drive and rear-wheel drive and on special transmissions.

Static and dynamic test operation

In the static modes of operation, the test bench can be operated with torque regulation and speed regulation at both the input and output.
In the “road simulation” mode, motor torques are fed to the drive system by the host computer. The parameters for the output system (rolling resistance, air resistance, acceleration resistance, climbing resistance, additional static resistance) are processed by the road-simulation computer.
The test bench supplies the test piece with road and environmental data in the form of speed and torque values. Thus reproducible tests with simulated up- and downhill drive, kick-down acceleration, shift cycles at different transmission temperatures etc. can be carried out on the test bench, avoiding the installation of the test piece on a passenger car for the otherwise necessary road test.
To protect the test piece against damage, the test bench is additionally equipped with a starting and a stopping routine.

Radiation Measuring Unit for Barrels with Nuclear Waste

Laser Measuring Station

Task: 

A measuring station must be provided for checking the current production of cylindrical shafts. The following demands are placed on measurement:

  • diameter range from 4 to 120 mm
  • lengths from 5 to 700 mm
  • extremely mearuring times
  • easy handling
  • subsequent automation of the mearuring procedure must be possible
  • measurement results must be automatically recorded and evaluated
  • measurement accuracy in � range

The following measurements must be made:

  • diameter
  • concentrcity
  • cylindricity
  • length

Description of laser measuring unit

The basis is a laser scanner centered on a helium/neon tube emitting a parallel-aligned pencil-thin laser beam.

This permits rapid and high-precision measurements to be made on the workpiece without the need for any adjustment.

The diameter and the edges are measured, and bevel, curve and roundness measurements are possible as an option.

Specification of standard version

Measuring ranges:
Diameter: 4 to 120 mm
Length: 5 to 700 mm
Measuring time:
Diameter: > 1 sec.
Length: > 10 secs.
Measuring accuracy:
Diameter: 0.005 mm
Length: 0.05 mm

 

Solution:

A slide is located on a solid base frame with drawers for various measuring equipment and tools.
Holders for the test pieces are provided on the slide, which is moved past a laser by a variable-speed motor.
The travel is measured with an accuracy of �m using a glass scale and the exact position is displayed digitally.

Adjustable cantilevers on hardened and ground shafts hold the test pieces.
The these cantilevers are two work-holding centres to hold the shafts being tested between the centres.
In order to measure shafts without centres too, roller supports are provided in addition to the work-holding centres and roller supports are connected by a toothed-belt system and are driven by a variable-speed motor for concentricity measurement.

V-Belt Durability Test Bench