Test benches
Looking at the history of Klotz GmbH, the entry into the Measurement technology and Testing technology in 1982 was one of the decisive moments in the company's history. Since then, we have built up extensive expertise in the design, development and construction of a wide range of different solutions. One focus is on functional testing: for example, solutions for engines, transmissions, steering systems, axial joints and clutches. We have also made a name for ourselves with numerous durability, performance and leak test benches and Test benches for special measuring and testing tasks, such as ultrasonic and diameter testing systems for pistons, radiation measuring devices for radioactive barrels and surface tension testing devices for enamel, which have been under constant development for 30 years and more.
Klotz now stands for a particularly high level of expertise in the field of test bench software. Today, a team of computer scientists is constantly developing the most sophisticated technical software solutions independently of projects, which are a basic prerequisite for today's testing requirements: individually tailored solutions from a single source.
End-of-line test bench for car steering systems
These fully automated end-of-line (EOL) test benches for electromechanical car steering systems enable efficient, precise and flexible end-of-line testing and adjustment. This solution integrates testing and adjustment processes in one system and ensures high accuracy and efficiency. The test bench can set up and contact fully automatically, perform vibration analyses and enable customer-specific adjustments. The EOL test benches offer a cost-effective solution to the challenges of modern car steering production.
1982 until today
Final test bench for commercial vehicle steering systems
The final test bench for commercial vehicle steering systems carries out a comprehensive 100 % test of commercial vehicle steering systems at the end of an assembly line, including checking friction torque, efficiency, reverse torque, valve characteristics and internal leakage, as well as adjusting and testing final limiting valves.
1996 until today
End-of-line testing for high-performance electric motors
Special test benches for high-performance electric motors enable fully automatic set-up, contacting, leakage and performance tests and autonomous operation. They offer flashing, residual bus simulation, customer-specific software installation as well as vacuum and overpressure leakage tests. With robotic or manual loading, high flexibility and efficiency with cycle times under 20 seconds.
2008 until today
End-of-line testing for electric power steering systems (EPS/EPAS)
The end-of-line test for EPS/EPAS steering gears ensures a 100% test, including functional and acoustic testing. Modern Klotz steering gear test benches enable precise computer-controlled function tests for mechanical and electromechanical steering gears. Integrated residual bus simulation (CAN/Flexray) and equipment with robust structures, load units, docking units for vehicle points, torque measurement and user-friendly operating console ensure the highest quality standards.
2008 until today
Vibration friction wear test rig
The oscillating friction wear test bench, also known as a tribology test bench, investigates the wear conditions of piston rings and cylinder segments. With variable loads, temperatures and precise dosing of media, it enables comprehensive simulation of demanding test conditions. The data collected can contribute to the optimization of engine components, which in the long term leads to a reduction in downtime and operating costs and improves overall efficiency in the area of engine development.
2018
Test stand for carrying out individual and endurance tests on axial joints
The axial joint test stand carries out individual and endurance tests on various axial joints, whereby load spectra, angular movements, temperature and humidity can be variably adjusted. The test stand can test up to 4 axial joints simultaneously and uses hydraulic cylinders to apply axial force and angular movement. Each test station has individual test adapters for simultaneous testing of different axial joints. Axial play is measured and, in the event of defects, the corresponding cylinder is switched off, with downtime and other data being logged.
2001
Radiation measuring device for drums with radioactive waste: Precise and safe
The radiation measuring device was specially developed for the precise inspection of 200-liter drums with radioactive waste and enables a thorough measurement of dose radiation. It can be used flexibly for drums with different diameters and can be transported through a 900 mm wide door. The device has a robust design, is easy to load and has 12 gamma sensors that can detect and record the dose rate during a complete rotation.
1997 until today
Service life test bench for rack and pinion steering systems with integrated web server
1992
Power steering test bench for 100 % test in assembly line
The power steering test bench carries out automatic functional tests on hydraulic steering gears in rack and pinion design. It automatically recognizes the steering types and enables efficient model changes with minimal manual effort, thereby increasing productivity.
1992
Rack and pinion steering test bench for endurance tests
This rack and pinion steering test bench enables service life tests on manual and servo-assisted rack and pinion steering systems with static and dynamic tests up to 30 Hz rack load. The tests are computer-controlled and the status can be queried from any computer via a TCP/IP interface.
1992
Power steering test stand for 100 % tests in production lines
The power steering test bench enables 100 % testing of rack and pinion power steering systems in production lines by automatically feeding, docking and testing the test specimens, storing the test results on data carriers and network servers and allowing model changes without manual intervention.
1991
Friction power test bench - dynamometer for testing the friction power of engine components
Two dynamometers have been developed to investigate the effects of various engine component design features on engine friction performance. These test benches can test individual components or complete 6-cylinder engine blocks and are equipped with torque measurement, speed control and data acquisition. The systems have an output of 47 kW and an oil supply unit that supports temperatures from 20 °C to 135 °C. The test benches are designed for three-shift operation and offer a wide range of measurement and control options.
1990
Camshaft test bench
The camshaft test bench is used to test engine components, in particular the camshaft drive, for their friction performance and enables tests of individual parts or complete 6-cylinder engine blocks at various speeds up to 8000/15000 rpm, whereby torque and speed can be measured and controlled. The test bench has a 34 kW drive motor and an oil supply unit for temperature control, and the mounting plate is height-adjustable and complies with DIN 876, grade 3.
1989
Efficient transmission test bench for automatic transmissions
The transmission test bench is used to test and determine the control characteristics of automatic transmissions with hydraulic and electronic control. Continuously variable automatic transmissions, automatic stepped transmissions and special transmissions can be tested. The test bench enables static and dynamic operating modes as well as a driving simulation without having to install the test specimen in a vehicle. The drive and output units are equipped with safety devices and the measurement is carried out with high speed and torque dynamics with low mass inertia.
1988
Inspection system for round parts, stud measuring device (dimension and surface)
The inspection system for round bolts with a diameter of 45-75 mm and a length of 40-130 mm enables the inspection of surface defects and dimensional deviations using a CCD camera and ultrasonic and eddy current technology, with cycle times of 2.5-5 seconds per part depending on size.
1988
Testing system for round parts, bolt measuring device (dimension)
The semi-automatic testing system for studs with a diameter of 10-35 mm and a length of 15-70 mm enables dimensional testing of the outer diameter, crowning, taper and length with high precision and cycle times of 1.5-2.5 seconds per part, depending on the size.
1988
Bolt measuring device, round parts measuring system (ultrasound and eddy current)
The fully automatic stud measuring device enables the inspection of studs with a diameter of 10-35 mm and a length of 15-70 mm for surface cracks, dimensions (outside diameter, crowning, taper), and enables multiple sorting by size with cycle times of 1.5-2.5 seconds per part depending on size.
1988
Laser measuring station for cylindrical shaft monitoring in production
A laser measuring station was developed to monitor cylindrical shafts during production. The requirements include a diameter range from 4 mm to 120 mm, lengths from 5 mm to 700 mm, short measuring times, easy handling and the possibility of subsequent automation. The laser measuring device uses a helium-neon laser beam for precise measurements of diameter, concentricity, cylindricity and lengths. It achieves high measurement accuracy in the micro range and requires no complex adjustment. A sliding carriage, cantilever arms and roller blocks allow the test specimens to be positioned for various measurements.
1987
Hydraulic positioning unit
A hydraulic positioning unit was developed to enable a linear feed with electrically limited minimum and maximum adjustment travel, infinitely adjustable feed speed and monitoring of the position over the entire feed range, whereby the tensile and compressive force can be freely selected and monitored.
1987
Stud measuring device (surface)
The semi-automatic stud measuring device enables the inspection of studs with a diameter of 10-35 mm and a length of 15-70 mm with regard to their surface quality, outer diameter, crowning, taper and length with high precision and cycle times of 1.5-2.5 seconds per part, depending on size.
1987
Measured value acquisition computer for gears and crankshafts
A computer with analog-digital card was used to perform measurements of gears and crankshafts on involute and gear testing machines as well as roller testing machines semi-automatically, whereby the measurement results are displayed in diagrams on the screen or printer and can be archived on data carriers for quarterly evaluations and statistics. The parameters to be evaluated include flank shape, flank direction, surface line (only for crankshafts) and rolling test.
1987
Steering gear test bench with double drive shaft
The steering gear test bench with double drive shaft enables manual and computer-controlled function tests on mechanical and hydraulic steering gears, including rack and pinion and recirculating ball steering systems. The clamping fixtures and docking units offer flexibility for model changes. The test bench is equipped with two measuring lines to measure torques ranging from 0.5 Nm to 750 Nm and enables a variety of functional tests, including steering angle, pressure, leakage oil loss and strength tests.
1986
Test device for handlebars
The test stand is used to examine the wear of steering rods and enables testing via the angle of rotation or torque, whereby the drive and load unit is fixed in the desired position.
1986
Synchronization test bench
The synchronization test bench was developed to test transmission components and complete transmissions under different ambient temperatures and to determine the torque, shifting force and speed of the input and output. The test bench uses a swiveling mounting table on which the transmission types can be mounted. It comprises a drivetrain with torque measuring point and flywheel mass, an oil supply unit, a gear shifting unit with separate hydraulic supply, an air circulation temperature control unit, an insulated test chamber and a test box. The measurement data is recorded and evaluated by a computer and the system is designed for three-shift operation.
1985
Power steering test bench for development
This power steering test bench enables fast and efficient testing of various rack-and-pinion steering systems with short changeover times and is specially designed for steering system development.
1984
V-belt test bench
The V-belt test bench was developed to test narrow V-belts used in the automotive industry for auxiliary units on vehicle engines. The tester is based on the principle of power breakdown by introducing slip. It uses the energy cycle system with mechanical energy feedback to minimize energy loss. The speed at the measuring spindle is 6000 rpm, and the transmission ratio can be adjusted to produce the desired slip. The test bench enables the measurement of torque, power and clamping force and can detect V-belt and timing belt breakage.
1983
Power steering and power pump test bench
The power steering and power pump test bench enables functional tests to be carried out on mechanical and hydraulic rack-and-pinion steering systems. Various tests can be carried out, including characteristic curve tests, leakage tests and efficiency measurements. Testing is computer-controlled and the system is designed for 3-shift operation. It offers comprehensive data acquisition and evaluation as well as the option of adjusting the filter characteristics.
1983
Steering gear test bench
The steering gear test bench enables manual and computer-controlled function tests on mechanical and hydraulic steering gears in both rack and pinion and recirculating ball bearing designs. The test equipment consists of mechanical and hydraulic components as well as an electrical control unit. Various function tests can be carried out, including characteristic curve determination, friction torque characteristic curve, pressure-steering wheel torque characteristic curve and more. The measurement results are recorded and evaluated to check the quality of the steering gears.
1982
Manually operated steering test bench
A hand-operated steering test bench was developed to sporadically check steering systems in incoming goods. The test bench measures parameters such as steering smoothness, noise, torque and valve function and records the data on a multi-channel recorder. The system consists of a basic structure with a clamping device, a control cabinet with a built-in recorder and measuring electronics as well as a hydraulic unit for supplying oil to the steering system. Various tests such as the displacement force, noise development, torque test and valve characteristic curve can be carried out.
1981
Mobile engine test bench for finished vehicles: versatility and precision
A mobile engine test bench has been developed to test automotive engines up to 150 kW, with the ability to quickly change 15 different engine types. The design includes a square tubular frame resting on either locking spindles or rubber rollers, a clever coupling solution, support device and comprehensive measurement technology for power and consumption measurements and efficiency analysis. This solution meets the demanding test requirements for vehicle engines.
1981
Clutch test bench
The clutch test stand enables the service life of four clutches to be tested simultaneously, switches off automatically in the event of a fault and counts the load cycles, supported by an electronic control system for various registrations.
1981
Test device for torsion bars
The fatigue strength test of torsion spring bars with a length of up to 1500 mm and a torque of 4000 Nm is carried out using a test stand that enables an adjustable preload of up to 2000 Nm and an alternating load of ±2000 Nm with a test frequency of up to 10 Hz, whereby the torques occurring are recorded and monitored.
1981
