Testing2018-11-13T09:53:43+00:00

Measuring systems are becoming ever more complex. A vehicle-friendly test environment with application-oriented measurement technology offers the best prerequisite for efficient solution finding. With our know-how in testing and our modal test environment, we can adapt to a wide range of requirements quickly and flexibly.

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in the electric drive train

Through the experience of our employees with all types of modern drive systems, we can test and optimize individual components in detail. Specific solutions and tailor-made concepts improve the development process of components and reduce the testing effort in the overall system.

A number of highly specialized test benches are available for testing and measuring hydraulic components, such as valves, oil pumps, etc. These elements are used in transmissions, transmission controls, but also internal combustion engines/valve trains.

For the validation of the calculated gear design, the manufactured parts are geometrically measured and specific tests are carried out to determine the contact pattern, the acoustic running behavior (for example gear whine) and the gear breakage (mechanical impulses with defined force until fatigue break).

Electrical machines and power electronics are measured and tested on dynamometers regarding electrical performance, mechanical design, and thermal design.

The performance of transmission components such as synchronizers and clutches are determined, for example, in continuous switching tests. The actuation and evaluation are automated; the vehicle mass is simulated by flywheel masses.

Elastic bearing elements are the link between the powertrain and the vehicle, and their vibrational transmission behavior is measured using vibration excitation, measuring the part according to the requirements.

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Aggregate testing

In the aggregate test, individual components in the composite must fulfill their task. When testing aggregates, we rely on a wide range of test benches, special measurement technology, and software, as well as our experts who use customized and flexible solutions to meet your requirements for optimum results.

Critical operating parameters of the oil system such as operation in the cold, operation with minimum and maximum oil level, operation in the inclined position are tested and measured before use in the vehicle. Transparent housings, inspection windows, temperature and flow measurements give us important insights into the oil behavior and performance oil distribution in the unit.

Precisely defined dirt is introduced into the oil system of the unit, to ensure the long-term stability. Thus, wear over time, filter efficiency, etc. are analyzed.

At the engine test bench, the combustion engine is examined with regard to its primary data such as power, torque, consumption, its mechanical properties and its thermodynamics. Considering the engine peripherals like intake and exhaust system as well as the charge is decisive as well.

We use powerful test blocks and proven procedures for the measurement (performance, temperatures, efficiency) and the testing of complete electrical drives and electric axes. The electrical motors can be operated either with the original power electronics as well as with the power electronics of the test bench. The engine coolant is conditioned externally over a wide temperature range.

The functional software used in the powertrain, e.g., for the control of automatic transmissions, is created by numerical models. The testing of this software already takes place in the model-in-the-loop (Mil), on test computers in software-in-the-loop (Sil) and by the target controller in the Hardware-in-the-loop (Hil). After successful completion, the control unit is put into operation and tested with the new functions on the unit test bench or a vehicle roll.

Measurements and tests about noise and vibration require not only our unique test bench setups but also particular measuring technology for the analysis of airborne and structure-borne noise, for the determination of power by the torque measuring flanges and various strain gage applications. The signals are evaluated in the time and frequency domain. Transfer functions and emission characteristics are measured and compared with the calculated values.

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Vehicle testing

The ultimate testing goal is the positive validation of all functions and durability in the vehicle. Therefore, our employees are familiar with the operation of a wide range of vehicles, from motorcycles, tractors, and trucks to cars and supercars.

The experience of a large number of different projects enables us to correctly evaluate the measured data by comparing measurement data from the various phases of development projects, from the demonstrator vehicle to the end-of-line data at the end of production.

The driving impression of the vehicle is mostly determined by the calibration of the various parameters in the functional software. The deep understanding of the mechanical and electrical processes in the powertrain, as well as the knowledge of the function and software development, allows us a fast and safe calibration of the relevant parameters. The calibration is supported by the close cooperation between the numerical simulation of the vehicle and the applicators in the vehicle. The evaluation of the calibration takes place by measured key figures but substantially also by subjective assessment, which is always adjusted to the customer.

In powertrains with gearboxes, shifting comfort contributes significantly to the overall impression, not just for manual transmissions but even more so for vehicles with automated gearshifts. We deliberately improve shifting comfort by looking at the powertrain mechanics with its stiffnesses, inertia, handling and gearboxes, the control of the shift and the shift strategy. These measurements and analyzes can be done in the vehicle on the road, but also on the chassis dynamometer. In the course of the further automation of driving functions, the shifting comfort will continue to gain in importance.

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Battery testing

The testing of vehicle batteries is a central task of the development towards electromobility. In our battery test field, a battery goes through the complete life cycle of the vehicle batteries with thermal load, charge and discharge cycles, thereby determining compatible battery and aging parameters.

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Custom-made test blocks and procedures

We offer a variety of specialized test blocks for your testing field. In the past, we built and delivered test rigs for testing pedal systems, from hydraulic components to end-of-line testing at the end of the production line. As well as offering the mechanical structure, but also the control of the test bench and the required documents, e.g., CE marking.

Our experience from many projects, numerical calculations and simulations are the basis for significant load and test collectives, even in new applications.

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