Measurement and Testing Equipment

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

End-of-Line-Prüfstand für Elektrolenkungen

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)

Funktionsprüfstand für Fußhebelwerk und Bremskraftverstärker

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.

Lebensdauer Prüfstand für Zahnstangen Lenkungen

Lebensdauer Prüfstand für Zahnstangen Lenkungen

Lebensdauer Prüfstand für Zahnstangen Lenkungen

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.

Laser measuring station

Laser measuring station

Laser measuring station

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.

Prüfstand für Dauerbelastungstests von Axialgelenken

Prüfstand für Dauerbelastungstests von Axialgelenken

Prüfstand für Dauerbelastungstests von Axialgelenken

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.

Power steering test bench for 100 % testing in assembly line

Power steering test bench for 100 % testing in assembly line

Vollautomatischer Servolenkungsprüfstand

End-of-Line Test Station for Commercial Vehicle Steering

End-of-line test station for commercial vehicle steering

End-of-line test station for commercial vehicle steering

End-of-line test station for commercial vehicle steering

V-Belt Durability Test Bench

V-belt durability test bench

V-belt durability test bench

V-belt durability test bench

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.

Prüfstand für Dauerbelastungstests von Axialgelenken

Prüfstand für Dauerbelastungstests von Axialgelenken

Prüfstand für Dauerbelastungstests von Axialgelenken

Radiation Measuring Unit for Barrels with Nuclear Waste

Radiation Measuring Unit for Barrels with Nuclear Waste, complete with measuring slide and PC (see also drum measuring instrument and measuring slide)

Task:

For storage purposes, contaminated material is filled in 200 l barrels. To determine the dose radiation of the single barrels, these must be checked all around. The barrels weigh up to 1000 kg. It must be possible to use two locating diameters. For carrying out the measurement, the barrel must perform one rotation. The unit must be movable and fit through a 900 mm wide door.

Solution:

The measuring set-up and the rotation mechanism of the barrel meter is installed on a 42 mm thick steel plate. In the movable condition, the dimensions of the meter are (width x length x height) 850 x 1300 x 1600 mm.
The rotation mechanism consists of a locating ring with 5-bearing system. Drive is by a toothed belt around the locating ring. The direct-current motor permits a continuously adjustable rotation time of 200 – 2000 sec. An intermediate ring inside the locating ring allows 2 different barrel diameters. Loading can be done by means of a crane or a lift truck.

For dose measurement, there are 12 differently arranged gamma sensors on the meter. During the measurement, the dose rate is determined and recorded every 5°.

Radiation measuring unit for barrels with nuclear waste

Radiation measuring unit for barrels with nuclear waste

Radiation measuring unit for barrels with nuclear waste

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.

Task:

Test stand serves to discover and test control characteristic of automatic transmissions with hydraulic and electronic control.

To achieve this test gears are sped up in ambient temperature -40 to +50 C under part-load and run through dynamically defined ranges of total control resp. shift field provided in test programs, to analyse function of transmission control.

Test is carried out with steplessly variable automatic transmissions as well as with automatic multi-step transmissions for front and rear drive and with special-type transmissions.

Following operations of test stand are required:

• manual operation
• static automatic operation
• dynamic automatic operation
• road simulation

Solution:

Drive unit

To achieve high speed/torque dynamics with low mass inertia, drive is equipped with secondary hydromotors.

Hydromotor speed is geared up to required test stand speed by high-performance, play-free chain transmission.

Power take-off unit

Construction is roughly the same as with drive unit, maximal take-off torque is however 360 Nm. To balance offset of driven shafts for different transmissions power take-off unit is mounted on stable lift platform with cross slide. For quick cut-out of test stand in case of EM-OUT or test piece fault safety denture clutch is integrated in drive chain. Drive moment is measured with torque-measuring shaft, type T32 (make HBM). To achieve maximal rigidity with low mass inertia of drive, connection between drive unit and test piece is made with carbon-fibre reinforced plastic pipe. To test front-wheel driven test pieces side shafts are guided back over intermediate transmission to common take-off shaft and from there to take-off chain.

Road simulation

With “road simulation” programme motor torque’s are fed to drive system by master computer. Drive system parameters are processed by road-simulation computer ECB Z80. Parameters for road simulation:

• rolling resistance
• air resistance
• speed-up resistance
• slope resistance
• static additional resistance

Speed moment and torque acquired from control board and road and ambient data acquired from master computer with cycle rate 12 Hertz are converted into resistance data. On test stand reproducible tests with simulated up- and downhill drive, kick-down speed up, switch variants with different gear temperatures etc. may be carried out replacing prescribed road test with integration of test piece into motor car.

Selector regulation:

With selector regulation selector positions may be set from central control room resp. by computer (automatic programs). Selector positions are only released by test stand control when safe selection for test stand and test piece has been checked by corresponding programme routine (e.g. switching from “D” to “R” under load). Regulation is made with power and position control.

Interface test stand/master computer:

25 analogous true values from test stand resp. piece
15 analogous set-point values for test stand control
20 digital I/O signals for transmission/test stand control

Technical data

Test piece drive:

speed 0 – 6000 r.p.m.
torque max. 150 Nm
speed alternation – max. 3000 r.p.m./1 sec.
inertia moment at drive shaft 0.1 kgm2

Test piece power take-off:

speed 0 – 6000 r.p.m.
torque max. 360 Nm/1000 r.p.m.
torque max. 60 Nm/6000 r.p.m.
speed alternation max. 1000 r.p.m./1 sec.

selector regulation:

regulating distance: 100 mm
regulating speed: 200 mm/sec.
actuating power: 150 Nm
accuracy: +/- 0.1 mm

air-conditioning:

Separate control board (19″ slide-in) includes temperature control with digital set-point selector and all control elements needed for the function.

Dimensions assembly:

height: appr. 2055 mm
width: appr. 800 mm
depth: appr. 2090 mm

overall dimensions:

height: appr. 1200 mm
width: appr. 1960 mm
depth: appr. 1200 mm

Test chamber volume appr. 1700 l

Temperature range: 40 C to + 50 C

temperature constancy: +/- 0.1 mm

Bowden-pull regulation:

regulating distance: 100 mm
regulating speed: 50 – 1000 mm/sec.
actuating power: 150 Nm
accuracy: +/- 0.1 mm

Transmission-oil cooler: -40 to 150 °C

coolant: water

Transmission test bench

Transmission test bench

Transmission test bench