Dynamometer Version B

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Dynamometer Version B
Haugweg 24
D-71711 Murr / Murr
Dynamometer Version B for
CV Brakes
SEITE 1
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Single Ended Truck Dyno with Inertia Set
Machine type
:
Open
Description no.
:
3A259-31B01E
First release date
:
08.08.2014
Krauss GmbH
Haugweg 24
D-71711 Murr / Murr
Tel. (+49)7141-788932-20 - Freiberg
Fax. (+49) 7141-788932-19 - Freiberg
[email protected]
www.kraussgmbh.de
Disclaimer :
Information presented in this paper is for informational purposes only. It includes pictures from
July 2014 of the machine sitting in a warehouse near Darmstadt. Krauss Company reserves the
right to make changes, alterations and substitutions to the machines, components or other
information presented in this brochure without prior notice. For the latest information contact
Krauss GmbH.
Equipment pictured in this brochure may be shown from other machines and might be seen with
safety equipment removed or disabled for purposes of illustration. Equipment must never be
operated with safety equipment removed or disabled.
Index
No.
Modifications
1.
New created
Page(s)
1 - 22
Date
08.08.14
Editor
PK
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Haugweg 24
D-71711 Murr / Murr
Dynamometer Version B for
CV Brakes
SEITE 2
Kapitel 03
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Layout
Scope
Function / Use
The dynamometer provides an efficient and tool to be use tool brake performance
testing in R&D of brake pads and brakes of commercial vehicles (CV) as per AKM.
Componets that
can be tested
Disc brakes for CV
Air disc brakes for CV
Brake pads (friction material)
Disc brake rotors for PV
Test fixtures
The fixtures must be designed and manufactured by
KRAUSS. For acceptance test a pneumatic operated disc
brake from ATEGO Truck / Daimler Benz will be used.
The test fixture will be designed in a flexilbe way.
Daimler Benz
ATEGO
Picture – Sample for the adaption of a CV air brake for Daimler Benz ATEGO
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Haugweg 24
D-71711 Murr / Murr
Programmes
Dynamometer Version B for
CV Brakes
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The dyno will be set to the testing of a standard AK-Master only. Other procedures
must be set up by KRAUSS. The following procedures are recommended to be used
•
Performance test as per AK-Master
Test rig mechanics The dyno type version B uses an electric motor driving a gearbox to adopt the
torques to the test station. All tests can be made with constant pressure or constant
torque. For the simulation of the car mass, there are fitted selectable flywheel
masses who can be connected to the main shaft manually. The inertia required for
testing will be simulated bmechanically only. The generation of the brake pressure
will be done using a servo hydraulic supply unit operated with brake fluid DOT4.
The layout of the machine comprises the following units :
Drive modul with main drive (Option : water cooled motor for higher power)
Gear box
Large inertia module with flywheel masses
Small inertia module with flywheel masses
Test station (not good for wet tests – Option)
A/C air cooling system (Option)
DOT4 brake pressure generation unit
Pneumatic air brake pressure system & regulation unit
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Haugweg 24
D-71711 Murr / Murr
Dynamometer Version B for
CV Brakes
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Dynamometer Version B - Features
Layout with tailstock and bracket for brakes. The torque sensing is done using a tail stock with lever ram and
load cell. The test is done with stopping of the masses by the brakes. During the braking, the inertia will be
simulated by the flywheels fixed to the main shaft. The flywheels must be coupled manually prior to test.
The test rig is built using
Test station with tail stock and load cell
Protection doors electrically locked
Test fixture
Hydraulic pressure generation for DOT4
Pneumatic pressure control circuit for air brakes
Separate electric power board with
Main switch
Power supply
4-Quadrants frequency inverter for main drive
Bus-System for control
Elektric distribution of power
Operating panel with on / off switches and lamps
Drawer wit measuring amplifiers
Various inertia fly wheels, safety brake and protection doors
Cooling fan für brake controlled with frequency inverter (A/C unit as an option)
Main drive with and forced air cooling including tacho generator
Must be provided locally
Pipeworks for cooling & extraction of brake dust
Cooling fan & Extraction fan
Filtering system for brake dust
Ducts for cabling
Picture – Possible layout of dynamometer Version B (gear box not fitted)
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Dynamometer Version B for
CV Brakes
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Pictures - Dynamometer Version B
Test station
with protection
doors
Location load cell
Cooling system
with fan and
cooling jet
Tailstock with
bracket
Pressure
generator
The machine supplied can be different from the photo shown here. The pictures are only used to show the
technology existing !
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Haugweg 24
D-71711 Murr / Murr
Dynamometer Version B for
CV Brakes
SEITE 6
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Picture – Emergency stop brake with one of the flywheels
Picture – Large flywheel set
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Dynamometer Version B for
CV Brakes
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Picture – Small flywheel set
Test rig modules
Options
01. Cooling installation with A/C-unit
A local cooling system with A/C systems is recommended to have the
cooling air for the brake conditionned to approx. 15°C. This isnstallation
depends upon the location where the equipment is installed.
02. Additional temperature channels
For the adaption of additional thermo couples there are required measuring
amplifiers and analog inputs at the PC. The thermocouples can be
connected in aconnection box in the test station.
03. Web Cam
In order to view the inside of the test station for a longer period of time a
camera can be fitted. The camera must be protected from the heat and dust
in the test chamber. For recording of the video signal an additional PC is
required.
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Test rig modules
Dynamometer Version B for
CV Brakes
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Accessories
1. Torque calibration
Hydraulic cylinder with reference load cell
2. Temperature calibration
mV - injector for thermo couples NiCr-Ni (Type "K")
3. Pressure calibration
Reference pressure gauge with manufacturers certificate
4. Speed calibration
Digital hand held tachometer
5. Aneometer
For measuring fo the air flow speed a bore in the in / out pipes can be
applied. At these bores the air speed can be measured by the hand held
air speed sensor (withour further data processing).
6. Foot pedal for bleeding
In manual control, the brake easily can be bled by the operator.
Further tools and utilities must be arranged by the customer for operation of
the machine.
Brake cooling
(Standard)
The brakes tested are cooled by the local cooling fan. The air flows from top to
bottom. The brake dust will be extracted from below the brake.
Both, the extraction and the cooling fan speed can be controlled by the PC in a range
of 0 ... 100 %.
Hydraulic pressure The brake pressure will be generated by a hydraulic supply unit fitted in the chassis.
Pressure control will be done by a Schneider servo valve. Pressure and / or torque is
generation
controlled by the PC during the test run. The hydraulic circuit is designd for use f
brakefluid DOT4. No other liquid ma be used in the system. A level detector
shwitches off the unit, if the lower level in the tank has been reached.
In the ciruit is included a pressure sensor which is connected to a measuring
amplifier and an electronic regulating circuit for pressure setting.
Sample electric Schneider - DBV for
setting of the pre-pressure
Servo valve for pressure and torque
regulation
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Haugweg 24
D-71711 Murr / Murr
Dynamometer Version B for
CV Brakes
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Pressure
generation DOT4 –
hydraulic supply
unit
Colours
Standard
Standard-colourss (see picture total view) :
Chassis
Doors
Cover
Sheet metal
Switchboard
Light grey
green
RAL 6011
green
RAL 6011
RAL 6011
RAL 7035
The machine will bre repainted in assembled condition.
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Dynamometer Version B for
CV Brakes
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Electric installation
Power board
A separate located power switch board must be placed as per the room design of
the customer close to the machine. Measuring and control cables as well as the
power cable to the main motor must be laid in separated ducts in order to prevent
electromagnetic influences. The cable enter the switch board from below.
Corresponding cable ducts must be prepared by the customer on site.
Option : Cable trays in order to enter the cables from to into the switchboard
The switch board includes a 4-Quadrant SCR controller for the main drive. In
addtition to this the entire power distribution with breakers and motor protection
relays are installed. A bus system serves as process I/O for the analog an digital
signals.
Switch board
sample
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Haugweg 24
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Dynamometer Version B for
CV Brakes
Electonic drawer Inside view of measuring and control electronic with open door.
with servo
Torque measuring amplifier and
Selection relays
controller for
controller
both hydraulic &
pneumatic brakes
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Driver card for
servo valve
Pressure amplifier and
controller
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Dynamometer Version B for
CV Brakes
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Automation system The control of the dyno is done by a PC with UniTEST Software for control and data
processing and printing of graphs. The PC is connected to the main swithc board
Hardware
with a bus cable.
Picture - PC for control & dataprocessing
Operating panel
(Option)
An operating panel is located below the PC including an emergency stop push button
and other operating elements.
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Dynamometer Version B for
CV Brakes
Haugweg 24
D-71711 Murr / Murr
SEITE 13
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Electronic control In the power switch cabinet there are installed modules with analog and digital
Dataprocessing
I/O. For control, the tester is equipped with a PC computer system using
system
software for data processing and printing of graphs. No recorder is needed
anymore. The computer is connected to the modules by an Ethercat cable .
Picture - Layout of Electronic System for Automation System KRAUSS
DESKJET FARBDRUCKER HP 1200C
VGA VIDEO
MONITOR
DESKJET
Ethercat
INTERBUS
1
2
3
4
5
9
6
8
7
1
Analog inputs
6
Switches
2
Analog outputs
7
Motors and valves
3
Digital inputs
8
Sensors connections
4
Digital outputs
9
Measuring & regulating electronics
5
Sensors
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Automation
system Software
Standard
Dynamometer Version B for
CV Brakes
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For automation of the dynamomater, we use the standard softwarepackage
UniTEST from Fa. Fröhlich & Schade GmbHt. In includes the following features :
Calibration, linearisation aof analog signals
UniTEST includes a powerful tool for calibration, linearisation and evaluation of
analog in/outputs. The entrie measuring chain from sensor to PC via measuring
amplifiers is calibrated and lineraized. The calibration will be documentated.
Monitoring of Test Rig
All relevant signals are monitored continuously. This is how the limitzs during manual
operation are verified and its surpassing avoided.
The supervision also includes the data. E.g. it is expected, that the temperature at
the brake rotor increases during an exisitng speed and when a torque is created.
Or when a speed is monitored and a pressure is used for braking, a certain torque
must come up.
Assistance in manual operation
UniTEST assists the works using any sequences in manual control. With this feature
repeating operations can be automatized in manual mode. These sequences are
also used to store and evaluate data as per given criteria in manual operation as
well.
Administration of test samples
The integrated administraion tool helps to process data of various test samples in
one test even if they are handled separately. The presetting allows a wide range of
specificatins which sample data shall be processed or not. Entries can be covered by
masks or selection lists. The entries also serve for specification of the data paths
and file names.
Data interfaces
UniTEST provides data storage in different file formats such as Excel, Famos,
DIAdem etc.
Automation
All processes run under UniTEPC. UniTEST controls the regulation, data monitoring,
processing, evaluation and storing of test results.
Creation of test procedures
Testprocedures are realized as UniTEST sequences. AK-Master modules serve as a
base for this. The test behaviour with limits, demand values etc. is controlled using
so called process variables. An integrated editor helps create and edit these process
variables.
Inertia simulation
In order to cover the demand of inertia required for testing, the motor power is
controlled by adding or subtracting energy using UniTEPC.
Visualisiation
Display screens can freely be generated. A modification of displays depending upon
relation to the test is not possible. Limits are monitored by a task in the back ground.
Changing of analog display upon reaching a certain limit can not be done.
Data storage
The test data will be stored in various places like harrdisk, network etc. depending
upon the selection of the user. Manipulation of data with UniTEST is nor possible.
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Dynamometer Version B for
CV Brakes
Haugweg 24
D-71711 Murr / Murr
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Measuring & Regulation
Torque measuring
Is done using an in-line torque sensor of messrs. GIF. The sytem includes the torque
sensing system and 3 rotating temperature channels with wireless signal transfer.
Torque and temperatures can be read at the computer screen. The system does not
allow to measure residual drag torques.
Temperature
measuring
(Standard)
The rotor temperature can be mesured using :
Embedded thermo couples. Signal transfer via GIF system (included in scope
of supply).
Thermo couple pins sliding on the friction surface.
(Holder and one element included in scope of supply).
Standard :
As a total there are fitted 6 temperature channels, which can be used as follows :
3 pc. Rotating channels for rotor. One used for control of the test programme.
3 pc. Local channels with connection a box fitted in the test chamber. For
measuring of the temperature of the test chamber in case of fire and
emergency shut off (limit can be set). Others can be used for stationary
temeratures like brake pad or caliper temperatures.
Pressure DOT4
measuring
The brake pressure is measured using a strain gauge pressure transducer fitted
hanging near the brake hydraulic connector. The pressure can be read at the PC
screen.
Pressure transducer
Speed
(rpm)
The speed is measured at the analog output of the 4Q drive electronics. It is sensed
by a tachometer fitted to the drive shaft. The speed can be read at the PC screen.
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Installation
Dynamometer Version B for
CV Brakes
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The PC must be located on a table close to the dynamometer. A table will not
be supplied. Several cables have to be laid from the PC to the machine. It is
recommended to locate the PC in a separate room. A UPS is included in the
scope of supply. In this case data security is given during poewr failure. The
PC must be sut don manually in case of power failure. No automatic data
storge is provided. A web cam is recommended for observation of the test
station by the operator during testing.
The dyno has to be connected to the local power supply by the customer
himself.
A tubing system is requred to connect the brake dust outlet. A filtersysem is
recommended.
For cooling of the brake a The air cooling unit (A/C unit) for the brake
condtionning requires water in and out. An additional draining pressureles
condensate must be avaliable on site to drain the water without pressure e.g.
into a sink.
For operation a compressed air supply with min. 6 bars is essential.
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Dynamometer Version B for
CV Brakes
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Technical Data - Testing & Systems
Mechanics
Drive system
Motor Type
[-]
open
Motor maker
[-]
open
Supplier 4Q SCR
[-]
open
System analog/digital
[-]
Digital
Power
[ kW ]
open
Drive
[-]
gear box
Rated torque main
drive motor
[ Nm ]
open
Test speed
[ min-1 ]
800 / 1.200 depending upon masses
Max. acceleration
[ sec ]
open
Max. acceleration
[ sec ]
open
Sense of operation
[-]
open
Electronic Simulation
[-]
No
Increments
[ kgm² ]
Open
Basic intertia
[ kgm² ]
300 – up to 1.200 / min
Flywheel 1
[ kgm² ]
150 – up to 1.200 / min
Flywheel 2
[ kgm² ]
300 – up to 1.200 / min
Flywheel 3
[ kgm² ]
600 – up to 800 / min
Flywheel 4
[ kgm² ]
1.200 – up to 800 / min
Total
[ kgm² ]
2.550
Inertia set
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Dynamometer Version B for
CV Brakes
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Testing station
Adaption bracket max
travel
[ mm ]
open
Max. Brake diameter
[ mm ]
400 for brake disc
Torque sensing system
[-]
Tailstock with load cell
Measuring range
[ Nm ]
40.000
Residual torque
[ Nm ]
Not measurable
Isolation for temperature
tests
[-]
No
Brake actuator for pneumatic brakes (Option)
Servo valve
[-]
Schneider
Pressure ramp
[ bar/sec ]
0,1
Torque control
[-]
Yes
Fluid
[-]
Non lubricaterd and dry compressed air
Brake Pressure
[ bar ]
1 – 15 depending upon imcoming pressure
Brake pressure generation (DOT4)
Hydraulic circuit
[-]
Brake fluid DOT 4
Pressure generation
[-]
Hydraulic unit
Pressure regulation
[-]
Yes - hardware
Torque regulation DOT4
[ Nm ]
8.000
Max. pressure
[ bar ]
200,0
Smallest pressure rise
time to max pressure
[ msec ]
150 +/- 20
Brake cooling – to be fitted locally preferably with A/C unit
Brake dust extraction – to be fitted locally
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Dynamometer Version B for
CV Brakes
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Safety
Mechanic emergency
brake
[-]
2 spring loaded brakes with brake disc
(pneumaticallly lifted)
Troque limiter
[-]
Yes by computer monitoring
Vibration sensors
[-]
No
Safety switch protection
doors
[-]
Yes – electrically locked. Doory made of
aluminium anodised in nature colour
Cover over interia set
[-]
Yes
Above test station
[-]
Yes with sliding hood
Zero speed detection
[-]
Yes – for door lock & switching of fly wheels
Measuring systems
a) Temperature – On drive shaft side (rotating) for control and monitoring
Qty. Channels
[ Pc. ]
3
Thermo couple type
[-]
„K“ - NiCr-Ni
as per DIN 43 713 und DIN IEC 584
Measuring range
[ °C ]
-20 ... 1.000
Resolution
[%]
As per DIN 50049 - 2.2.
From
Allowed deviation
+/- 3 °C
20° to
400°C
From
Allowed deviation
0,75 %
400°C
to
1.000°C
b) Temperature – Freely applicable. Connection at box in testing station
Qty. Channels
[ Pc. ]
3
(1 x room temperature)
Thermo couple type
[-]
„K“ - NiCr-Ni
Measuring range
[ °C ]
0 - 1.000
Resolution
[%]
From
20° to
400°C
From
400°C
to
1.000°C
As per DIN 50049 - 2.2.
Allowed deviation
Allowed deviation
+/- 3 °C
0,75 %
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Dynamometer Version B for
CV Brakes
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Measuring systems
c) Brake pressure
Range
[ bar ]
100
Sensor type
[-]
Strain gauge
Precision
[%]
0,15
Supplier
[-]
HBM
Qty. Channels
[ Pc. ]
1
Range
[ Nm ]
40.000
Sensor type
[-]
Strain gauge load cell
Measuring system
[-]
open
Precision
[%]
0,1
Supplier
[-]
HBM
Qty. Channels
[ Pc. ]
1
Range
[ min-1 ]
1.500
Sensor type
[-]
Tacho generator
Precision
[%]
Depending upon type
Supplier
[-]
open
d) Brake torque
e) Speed
f) Webcam (Option ) – Not included
Qty. channels
[ Pc. ]
Sensor type
[-]
Meßsystem
[-]
Precision
[%]
Supplier
[-]
No name
T:\3-ANGEB\3A\259-RW-GEBRAUCHT\31 - LKW TRM DARMSTADT\BESCHREIBUNG\259-31B01E-DESCRIPTION.DOC
© Alle Rechte bei Krauss GmbH. Jede Verfügungsbefügnis, wie Kopier- und Weitergaberecht bei uns.
Dynamometer Version B for
CV Brakes
Haugweg 24
D-71711 Murr / Murr
SEITE 21
Kapitel 03
07.Aug.2014
11:50
RW-Vers.B
Connection Data
Physical :
Weights
Total
[kg]
~ open
Acoustic pressure max.
[dB(A)]
≤ 83
Vibrations max.
[g]
x -, y -, z - axis: ± 0,08
Temperature computer
[°C]
20 ... 30
Temperature machine
[°C]
15 ... 40
Relative humidity max.
[%]
60 ... 80
Emissions
Room condtitions
Space requirements
Length X
Basic dimensions machine
[m]
open
Including maintenance routes
[m]
open
Basic
board
[m]
open
dimensions
electric
Width Y
Height Z
Protection calss
Switch board
[-]
IP 66 DIN 40 050
Terminal boxes
[-]
IP 66 DIN 40 050
T:\3-ANGEB\3A\259-RW-GEBRAUCHT\31 - LKW TRM DARMSTADT\BESCHREIBUNG\259-31B01E-DESCRIPTION.DOC
© Alle Rechte bei Krauss GmbH. Jede Verfügungsbefügnis, wie Kopier- und Weitergaberecht bei uns.
Haugweg 24
D-71711 Murr / Murr
Dynamometer Version B for
CV Brakes
Electrical connection
Voltage
SEITE 22
Kapitel 03
07.Aug.2014
11:50
RW-Vers.B
Connection
[V]
400 / 50 Hz threephase
(± 10 %)
Rated current
[A]
open
Power approx.
[KVA]
open
Connection cord min.
[mm²]
open
External fuse
[A]
open
Pneumatic connection
x 5 - cable without
plug
Connection
Compressed air
[bar]
Min. 6
Flow rate
[l / min]
0,001
Connection tube min.
[”]
R¼
Condition of air
Filtered and dry
List of measuring systems installed (standard)
Physical value
Qty
Note
Torque
1
Tailstock with load cell
Temperature rotor
3
Included in drive shaft. One channel used for
control of procedures
Temperature fix
3
For free use. Connector box in test chamber
Speed
1
Main drive
Pressure (pneumatic)
1
Pneumatic pressure 20
Pressure (hydraulic)
1
Hydraulic brake pressure
T:\3-ANGEB\3A\259-RW-GEBRAUCHT\31 - LKW TRM DARMSTADT\BESCHREIBUNG\259-31B01E-DESCRIPTION.DOC
© Alle Rechte bei Krauss GmbH. Jede Verfügungsbefügnis, wie Kopier- und Weitergaberecht bei uns.