Drivetrain Test Systems

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2 Drivetrain Test Systems Developing a drivetrain to meet today s expectations is a formidable task. Comfort and performance are critical factors in determining the success of today s vehicles. Car and truck buyers expect durable, quiet, vibration-free, smooth vehicles with brisk acceleration and solid, confident handling. Add to these requirements the continuing need to increase vehicle efficiency while delivering more horsepower, and you have significant engineering challenges. I N T R O D U C T I O N The industry is changing as consumers increase their acceptance of fuel-saving powertrains with technologies as diverse as diesel, ethanol, hydrogen, gas-electric, and plug-in electric. Demand for these systems is growing, and the competition to provide technology with a high level of durability and refinement is becoming fierce. T o o l s f o r i m p r o v i n g d r i v e t r a i n p e r f o r m a n c e a n d d u r a b i l i t y To meet these demands, you need tools that can help you build performance into your products without compromising quality. These tools must have the capability to help you quickly determine the effectiveness of your components, and must provide your designers and product managers with feedback on the areas that need improvement. 3

3 be certain. I N T R O D U C T I O N MTS has been providing chassis development systems to the automotive community since We understand the challenges drivetrain customers face and we know how to work with you to address the needs of your ever-changing marketplace. In more than four decades of serving the automotive industry, MTS has developed a set of tools that provide valuable information to product managers and engineers. These tools include standard turn-key systems, custom systems built to meet a specific need, and system components that you can integrate into your laboratory. Only MTS can provide the full range of testing solutions, including: servo-hydraulic actuators, electric dynamometers, and mechanical fixtures developed specifically for drivetrain applications. Industry standard MTS controllers and software provide the interface to reproduce real-time events such as engine cylinder firing pulses and other torque transients. Trust MTS to provide the testing expertise necessary to help you deliver drivetrain systems that meet your customers expectations. 5

4 Drivetrain Dynamometers MTS has developed permanent magnet dynamometers and modular vector control drive components specifically designed for transmission and transaxle manufacturers. Based on advanced technology first developed for Formula 1 racing gearbox testing, these Drivetrain Dynamometers feature the low inertia and dynamic performance required to accurately reproduce the loading from an internal combustion engine or hybrid powertrain during transmission development. The Drivetrain Dynamometers are compact in size, enabling Drivetrain Dynamometers from MTS are also exceptionally the dynamometer to be directly connected to the test subject, clean and quiet. Due to a unique design that does not eliminating unnecessary shafting and joints that cause require messy oil or noisy fans to keep the rotor cool, torque errors during the test. They have been designed to these dynamometers are capable of being used in anechoic accommodate a wide range of drivetrain architectures, such environments to study the noise, vibration and harshness as transverse mount front-wheel drive (FWD), all wheel drive (NVH) properties of drivetrain components and systems. (AWD), and hybrid electric. MTS Drivetrain Dynamometers can be coupled to test These dynamometers can come equipped with engine systems for a wide range of applications and are the most torque pulse simulation capability for realistic transmission adaptable dynamometer component available today. They development in the laboratory. Their low inertia and extremely are particularly well suited for transaxles and transfer case high power allow you to simulate the actual cylinder firing development due to their very compact size, and are the torque during each revolution, adding a new level of fidelity perfect choice for the evolving world of drivetrain alternatives. to drivetrain performance testing. 7 T R A N S M I S S I O N & T R A N S A X L E T E S T I N G

5 AWD Systems Development MTS Drivetrain Dynamometers are a good choice for active torque transfer devices common in many modern AWD vehicles. The compact size, power, and ability to use for NVH testing make them particularly attractive solutions for performance characterization, tuning, and early development of transfer cases and power take-off units (PTUs). MTS also offers traditional AC dynamometers and drives. These dynamometers are practical alternatives where low inertia and high dynamics are not required for the test, such as in simple durability testing. T R A N S M I S S I O N & T R A N S A X L E T E S T I N G MTS offers the integration of various technologies in a complete system, including input and output dynamometers for different test applications such as transmission only, or complete driveline testing, in 2WD or AWD configurations. Servo-hydraulic, traditional AC dynamometers, and MTS proprietary permanent magnet technology can be seamlessly combined to meet your application needs. 9

6 MTS 839 Sprague Clutch System MTS has developed a test system to address the unique set of challenges presented by sprague clutches. The design utilizes a low speed motor to rotate the inner race of the specimen at up to 20 rpm with respect to the outer race. The system s hydraulic actuator and lever assembly then ratchet the outer race equal to the inner race rotation speed. This ratcheting lock-ups the clutch in order to duplicate the sometimes punishing conditions that occur in actual service. An optional automatic transmission fluid conditioning system is available, allowing you to achieve accurate simulation of real service environments. T R A N S M I S S I O N & T R A N S A X L E T E S T I N G A unique peak load detector helps ensure that the maximum specified torque is applied to your specimen on every cycle. Running on the industry-standard MTS FlexTest test control platform using simple block programming, it coordinates control of the DC drive motor and hydraulic stroke so the Model 839 will apply full torque cycles to your specimen at up to 20 Hz. Data acquisition channels provide for simultaneous measurement of torque, ATF temperature, number of torque cycles, frequency, time, and position. 11

7 MTS 814 Clutch Test System The performance of clutches and couplings changes with speed. The applied centrifugal force changes the dynamic behavior of components such as springs as they deflect. Couplings designed to slip have isolation properties that must be evaluated under realistic conditions. The need to realistically simulate speed and torque led engaged condition. For slipping clutch applications, it is MTS to develop the Model 814 Spinning Torsion system. possible for you to run the system at the slip speed and It features a rotary hydraulic actuator driven with a motor react the transmission side of the clutch to ground. (either hydraulic or electric). Hydraulic slip-rings provide oil flow from the servovalve to the torque actuator. The MTS Spinning Torsion system can also be configured to allow testing of wet clutches with engage and disengage A unique high-precision shear-beam torque cell with cycles under controlled environmental conditions. integrated angular accelerometer is connected through slip rings to provide feedback for test control. MTS also offers transducers to measure angular displacement and speed. T R A N S M I S S I O N & T R A N S A X L E T E S T I N G High-frequency torque fluctuations may be simulated with spinning torsional systems to reproduce the dynamics of a running engine with speeds up to 7000 rpm. For clutch testing, the primary objective is to test the clutch s damper section. Testing the damper simulates the clutch in an 13

8 Transmission Component Test Benches MTS supplies rotary actuator components, and test bench design expertise to configure a test system for any budget. Using proven actuator designs along with many other standard products (servovalves, transducers, and controllers), MTS can configure test stands for many components used in today s vehicle drivetrains. With MTS rotary actuators and test heads you can measure static and dynamic hysteresis, deflection of the clutch plate, and fatigue due to cyclic torque and/ or engage-disengage cycles. T R A N S M I S S I O N & T R A N S A X L E T E S T I N G 15

9 MTS 813 Four Square System MTS 813 Four Square systems are used to test axle and drive shafts with their joint assemblies under realistic inservice conditions. Using our advanced test system controller technology, the MTS Four Square can be used to reproduce, in real time, the actual torque, speed, jounce, steer and plunge inputs to your components with speeds up to 8000 rpm. You can closely simulate the environment of the shaft joints by monitoring and controlling temperature with optical pyrometers, or by introducing air flow, mud, dirt, or moisture. The result is a highly effective laboratory simulation you can use to quickly evaluate your joints, drive shafts and propeller shafts. A X L E & D R I V E S H A F T T E S T I N G The Four Square principle creates a highly efficient test system. Using a unique gearbox with integral spinning torsional actuators, the torque is recirculated in the system by creating a continuous mechanical loop. Gearboxes placed at each end of the system link the test articles together, and the torque is reacted among the shafts under test. MTS uses two high-performance spinning torsion actuators and two electric drive motors placed at the four corners. The result is a highly responsive system with evenly distributed torque in each of the specimens. The system may be configured to test two or four specimens at a time. An optional power ball-screw gearbox positioner provides you with the ability to change specimens faster and with greater ease. Environmental chambers, temperature probes, pyrometers, and other sensors can be purchased as options or upgrades later. 17

10 Dynamometer-based Testing MTS offers a wide range of AC-dynamometers that are perfect for more demanding axle and prop shaft testing. These systems can be equipped with mud and salt slurry environmental chambers to meet the most grueling tests required by some OEMs. Dynamometer systems from MTS recycle the power electrically, providing a system that is economical to operate and still possesses the high power necessary for applications such as off-highway, heavy and medium truck testing. MTS has vast experience in providing extremely large dynamometer systems for specialized testing purposes. A X L E & D R I V E S H A F T T E S T I N G 19

11 Torsion Tests Rotary actuators are the critical component in axle, drive, and propeller shafts test benches. These simple systems provide you with the ability to quickly assess fatigue life by applying cyclic or dynamic torque in an easy-to-configure test. A long-lasting, high performance actuator is critical in the design of such a test bench. A X L E & D R I V E S H A F T T E S T I N G MTS offers the following features in its industry-leading rotary actuators: Model 215: Dynamic torque ratings from 226 N-m to 11,000 N-m Model 216: Dynamic torque ratings from 22,000 N-m to 82,000 N-m Dynamic rotation of 90 degrees (+/- 45 degrees) Heavy-duty roller bearings to withstand the high radial loads associated with rotational testing while providing low friction and long life A precision-machined, fatigue-rated design with one piece rotor bearings that reduce friction and eliminate backlash that can cause load spikes and disturb loading rates Hydrostatic thrust bearings and precision matched rotor-cylinder sets to reduce friction and wave form distortion Fatigue rating for cyclic use and extended service life Hydraulic cushions to protect the actuator when maximum displacement conditions occur 21

12 Spinning Torsion Tests MTS Model 217 Spinning Rotary Actuators are used to provide torque pulses in a rotating environment. They can be driven with either an electric or hydraulic motor, and have the following features: Model 217: Dynamic torque ratings from 500 N-m to 4,000 N-m Maximum rotation speed of 6000 rpm Optional high-speed balancing for up to 20,000 rpm operation (1000 N-m dynamic torque) Heavy-duty roller bearings to withstand the high radial loads associated with rotational testing while providing low friction and long life A precision-machined, fatigue-rated design with specially fitted rotor bearings that reduce friction and eliminate backlash that can cause load spikes and disturb loading rates Hydrostatic thrust bearings and precision matched rotor-cylinder sets to reduce friction and wave form distortion Fatigue rating for cyclic use and extended service life A X L E & D R I V E S H A F T T E S T I N G The MTS Spinning Rotary Actuator can be used to build torque loop test systems for durability testing of shafts and joints. These components can also be used to develop transmission test stands that reproduce the dynamic loads associated with engine torque pulses. 23

13 Structural Testing MTS has a broad range of tools for structural testing of your products. We can supply actuators and load frames to test structures including: axle housings, crank shafts, con rods, and engine blocks. We can either build a system for you, or provide you with the components to do it yourself. No matter what test system you build or buy, MTS offers you a broad range of controller options. You can choose from a set of building blocks to configure a fully integrated solution for your entire laboratory. Engine Torsional Damper Testing A D D I T I O N A L D R I V E T R A I N A P P L I C AT I O N S Many of today s gas and diesel engines would cease to function after several minutes without a crankshaft torsional damper; the shaft would fracture, venting the engine. The ultimate, smooth drivetrain is often developed by adding a torsional damper. The characteristics of this non-linear, elastomeric device are critical to providing the optimal damping properties at the required frequency without adversely affecting other aspects of driveline performance. To provide you with the tools you need, MTS has engineered a variety of elastomer characterization systems. These high-performance, sophisticated testing tools have been designed with control and analysis software that will generate a great deal of information on your torsional damper. MTS elastomer test systems are able to apply loads at up to 1000 Hz. We developed the first ever multi-axial system for evaluating elastomers under tri-axial conditions, and today we can build a system to measure both the torsional and axial properties of your elastomeric dampers. 25

14 Modular Solutions We recognize that your mechanical testing needs are as unique and specific as your products, so MTS has developed modular solutions that allow you to engineer a test system that meets your immediate needs, and can accommodate your changing requirements. MTS TestLine components are the same as those integrated into the most advanced MTS custom test systems. They are precision engineered to the highest quality and designed for seamless integration. Every TestLine component ships with a published specification that it will meet or exceed. MTS engineers work directly with you throughout the ordering and specifying process, integrating the components of each order and checking their performance before they are shipped. A D D I T I O N A L D R I V E T R A I N A P P L I C AT I O N S 27

15 RPC Software s u p e r i o r a c c u r a c y f o r b e t t e r i n f o r m a t i o n Remote Parameter Control (RPC) software provides the ultimate in test accuracy. RPC Pro is the latest evolution of the world s leading software suite for data validation, analysis, laboratory simulation and test monitoring. S O F T W A R E & C O N T R O L L E R S The advantage of RPC is that rather than developing a test based on desired actuator inputs, you develop your test using field measured responses responses from transducers mounted on or around the test article. These transducers may be remote from the actuators themselves. Once the desired response has been developed, the RPC software measures a dynamic model of the system and through an iterative process develops an actuator drive signal that reproduces the desired response. The RPC software is then able to provide sophisticated online data analysis to help ensure that the test maintains its accuracy and to detect any changes to the specimen as the test progresses. 29

16 MTS Controller Family The MTS controller family provides a complete range of powerful and scalable digital controllers, designed to address material testing applications including component, sub-system, and full system testing. f l e x t e s t s e c o n t r o l l e r S O F T W A R E & C O N T R O L L E R S The FlexTest SE digital controller offers real-time closedloop control of single-channel and two-channel tests. The FlexTest SE has front panel system controls for use without a computer, facilitating convenient test monitoring and specimen handling. You may further expand functionality by using a computer to access FlexTest software applications. The FlexTest VME-based hardware includes a processor, a two-stage or three-stage valve driver, digital universal conditioners, and analog input channel, three analog output channels, four pairs of digital I/O, a multi-position handle, and a 100mbps ethernet port. FlexTest SE controllers can also be linked to run multi-channel tests. This portable controller can be conveniently positioned on or near a load frame. 31

17 MTS Controller Family f l e x t e s t G t c o n t r o l l e r The FlexTest GT is a proven control solution for performing complex drivetrain component testing. This flexible controller delivers high-speed, real-time closedloop control, data acquisition, function generation, and transducer conditioning. S O F T W A R E & C O N T R O L L E R S Easily reconfigure your FlexTest GT controller as your needs change. By adding hardware and software modules, you can readily expand your system s capabilities and customize it for a wide range of tests. Designed for multi-channel, multi-station configurations, one FlextTest GT controller can drive several test systems. Capable of supporting up to eight channels and multiple stations, the FlexTest GT enhances productivity by allowing you to manage several stations from one PC screen. Or, if you prefer, the PC-per-station option enables you to employ additional PCs so different operators can run their respective test stations without having to share a PC. This option also makes it possible to support test stations in different locations. The FlexTest GT runs with MTS 793 software and a multitasking Windows operating system, allowing you to take advantage of the full array of proven MTS test application software. 29

18 MTS Controller Family a d v a n c e d d y n a m o m t e r c o n t r o l l e r ( a d c ) The MTS Advanced Dynamometer Controller (ADC) is an expandable, flexible, fully digital control system designed for a wide range of test applications. The ADC controller uses Windows multi-tasking operating system, and allows you to define new tests or analyze results of prior and current tests while the current test is running. The MTS ADC is used for simulating test conditions including torque-speed, speedtorque, speed-speed (unlocked specimen), road load, and inertia simulation. A flexible data acquisition system is also included for analysis. The MTS ADC, based on industry leading MTS controller hardware, is an efficient and powerful platform for drivetrain testing. This controller provides a Windows-based graphical interface to your dynamometer system, allowing you to use predefined templates to change test configurations quickly. It also uses a scripting language that gives you the power to create high levels of automation. This controller features a direct connection to an embedded disk, which provides high speed sustained data play out and data acquisition of either time history or telemetry data. The embedded real-time processors are used for all closed loop control, transformations and other processing that requires very high update rates. To enable high speed interfaces to ECUs and other third party devices, PMC modules have been integrated into the system providing various standard interfaces such as CANOpen and reflective memory. S O F T W A R E & C O N T R O L L E R S 35

19 Experienced Professionals MTS mechanical, electrical, software, and systems engineers represent the best in the business. Our engineers work directly with you so that they are able to understand your issues, concerns, and constraints. When you place an order with MTS, your order is assigned to a professional Project Manager who ensures that your system is built to meet the agreed-upon specifications with predictable delivery and high quality. The Project Manager is your representative in the factory, a focal point at MTS who always knows the status of your order and is able to find answers to your questions. C O N S U LT I N G, S E R V I C E & S U P P O R T T e s t c o n s u l t i n g MTS understands how test systems are used. When you purchase a simulation system from MTS, a test consultant will work with you as you commission the system. The consultant will help you design your tests, select vehicle transducers, collect road data, edit and analyze results, and, through the process, perform training. Our main interest is in transferring the technology to you so that you may be more productive. Once your system has been in operation for a while, you may decide you need more in-depth training, or you may find that you need help on a specific test. These are the times when MTS test consultants are of especially high value. 37

20 People dedicated to supporting you and your system s e r v i c e a n d s u p p o r t MTS has a comprehensive network of sales and service offices around the world, so you can be sure that, no matter where you are, we re close by. We work hard to ensure that our representatives are technically competent and well-equipped to meet your needs. A variety of service support contracts are available, all of which guarantee the availability of fully qualified, trained field service engineers. C O N S U LT I N G, S E R V I C E & S U P P O R T e a r n i n g y o u r c o n f i d e n c e When you invest in MTS technology, you can feel confident that our years of experience, our global network of support, and our integrated product line will combine to give you exactly what you need. No matter how your needs change in the future, MTS will be there with you. We believe it is our job to help you develop your products better and faster, yet with the consistent, high quality you expect. If the drivetrain test technology in this brochure is of interest to you, we welcome your technical discussion. Please contact your MTS sales engineer to take the first step toward improving your tests. 39

21 l MTS Systems Corporation Technology Drive Eden Prairie, MN USA ISO 9001 Certified. MTS, RPC, and FlexTest are registered trademarks of MTS Systems Corporation. TestLine is a trademark of MTS Systems Corporation. Microsoft Windows is a registered trademark of Microsoft Corporation MTS SYSTEMS CORPORATION DrivetrainTestSystems01. PRINTED IN U.S.A 03/07 Regional Business Centers The Americas MTS Systems Corporation Technology Drive Eden Prairie, MN USA Toll Free Fax: info@mts.com Internet: Europe MTS Systems France BAT EXA 16 16/18 rue Eugène Dupuis Créteil Cedex France Telephone: Fax: contact.france@mts.com MTS Systems GmbH Hohentwielsteig Berlin Germany Telephone: Fax: euroinfo@mts.com MTS Systems S.R.L. socio unico Corso Cincinnato, 228/b Torino Italy Telephone: sel. pass. Fax: mtstorino@mts.com MTS Systems Norden AB Södra Långebergsgatan 16 SE Västra Frölunda Sweden Telephone: Fax: norden@mts.com MTS Systems Ltd. UK Brook House Somerford Court Somerford Road Cirencester GL7 1TW Glos. -United Kingdom Telephone: Fax: mtsuksales@mts.com ASIA/Pacific MTS Japan Ltd. ArcaCentral Bldg. 8F Kinshi. Sumida-ku Tokyo , Japan Telephone: Fax: mtsj-info@mts.com MTS Korea Inc. 5th Floor, Core Building 8-1 Sunae-Dong, Bundang-Gu Seongnam City, Gyeonggi-Do , Korea Telephone: Fax: mtsk-info@mts.com MTS Systems (China) Co., Ltd. Building 23, No.481, Guiping Road Shanghai , P.R.China Telephone: Fax: info@mtschina.com