Endurance test stand for vehicle components
Application of stress to vehicle components in continuous operation, through to their destruction, product life cycle simulation
In our endurance test stands, we realistically simulate the mechanical and thermic stress situations to which vehicle components are subjected. The test series are carried out in fast motion, and the use of further measuring sensors makes it possible to detect developing damage, and thus calculate the service life of the test object.
The following vehicle components can be tested:
- Wheel bearing
- Electro-mechanical actuators
- Drive belts
Endurance test stand for wheel bearings
Inspection task
Endurance testing, used to calculate service life, plays an important role in the development and validation of wheel bearings. A suitable test stand must be capable of the following:
- Realistic simulation of the load on the wheel bearing
- Checking the wheel bearing in continuous operation, to provoke wear and tear
- Impending damage to bearings can be recognised by:
- analysing bearing noise
- monitoring bearing temperature
Test bench set-up
The wheel bearing in its original wheel suspension is fixed in the test stand with rubber/metal bushes, to reproduce the wear behaviour as realistically as possible.
To ensure that the bearing undergoes the same wear and tear as it would in real vehicle operation, it isspeed controlled.
The static and dynamic forces which affect the wheel bearing in real vehicle operation are simulated in the test stand.
- Power is input via a hydrostatic or conventional test stand bearing which is mounted in place of the wheel and suspended so as to be mobile in the test stand portal.
- Creation of dynamic forces in 3 directions with hydraulic cylinders
- Possible adjustment of centre offset and dynamic wheel radius
The test stand is equipped with measuring technology which enables it to spot any impending failure of the bearings in good time.
- Acceleration sensors close to the bearing observe the structure-borne sound spectrum.
- Bearing temperatures are monitored by temperature sensors close to the bearing.
Any changes in the structure-borne sound spectrum or temperature are signs that the bearing is about to fail.
Benefits
- Realistic simulation of the load on the bearing and therefore realistic results
- Sensitive approach to the point of total failure of a bearing
Endurance test stand for electro-mechanical actuators
Inspection task
The motor is tested in an electronically controlled electro-mechanical adjusting unit in the vehicle.
Whilst it is being continuously run, speed torque cycles are run under thermic conditions.
Test bench set-up
Two test objects are tested at the same time, one on each of the independent test stands.
The test object runs in the climatic chamber, under climatic conditions, whilst the test stand is set up outside of the chamber.
Both the test object and the test stand, including the climatic chamber, are electronically controlled by means of a control computer via modern interfaces:
- CAN bus
- Flexray
- Digital IN / OUT
The convenient user interfaces are designed for manual and automatic operation.
The operating status is being continually monitored by measuring technology for speed, torque, voltage, current, temperature testing and temperature in the chamber.
Testing process
The testing process is defined in a cycle file and a stress cycle file. The test object is torque controlled, and the load unit speed controlled. The test cycles are worked through automatically.
- Example of a stress cycle
CONTACT
Your partner for more information on Test Engineering:
Thomas Schuster
Sales Test Engineering
Tel.: +49 2361 58201-90
Email