Testing Technology for. Commercial Vehicles. together for a safe and clean environment. inside. solutions

Size: px

Start display at page:

Download "Testing Technology for. Commercial Vehicles. together for a safe and clean environment. inside. solutions"

Anabel Maxwell
6 years ago
Views:

1 Testing Technology for Commercial Vehicles together for a safe and clean environment solutions inside

Technology and Market Leader in the Field of Motor Vehicle Testing Technology MAHA-AIP MAHA-AIP (Automotive Industry Products) a member of the MAHA Group has been a separate division since 2005

MAHA-AIP designs and supplies individual system solutions to development and production centers of most of the renowned vehicle manufacturers worldwide.

for Function tests, pre-conditioning and end-of-line quality checks (production) R & D Centers Emission, performance, fuel consumption tests, etc.

system solutions are modularly designed and are optimally adaptable to customer requirements. (Vehicle type, budget, time frame, laws, etc.

company with over 1,000 employees. MAHA products and services are offered by 24 regional dealers throughout Germany.

2 Technology and Market Leader in the Field of Motor Vehicle Testing Technology MAHA-AIP MAHA-AIP (Automotive Industry Products) a member of the MAHA Group has been a separate division since 2005 operating independently of the MAHA serial production and enjoying intensive manangement care by the MAHA AIP GmbH & Co. KG. MAHA-AIP designs and supplies individual system solutions to development and production centers of most of the renowned vehicle manufacturers worldwide. In addition, MAHA AIP provides solutions for the automotive supply industry. Special Test Stands for Cars, Trucks, Motorcycles, Tractors, Forklifts, etc. for Function tests, pre-conditioning and end-of-line quality checks (production) R & D Centers Emission, performance, fuel consumption tests, etc. Climate and acoustic chambers Dynamic function tests (DVT) 4-matic, ABS-, ESP-, ASR brake tests Test Stand Accessories Design, Consultation and Execution of Turnkey Projects The comprehensive AIP system solutions are modularly designed and are optimally adaptable to customer requirements. (Vehicle type, budget, time frame, laws, etc.) MAHA Maschinenbau Haldenwang Since its founding as a two-man operation in 1969 in Haldenwang (Southern Germany) MAHA has had continuing success developing into a competent, pioneering high-tech company with over 1,000 employees. MAHA products and services are offered by 24 regional dealers throughout Germany. Excellent customer service is provided by worldwide MAHA subsidiaries and a widespread dealer network in more than 100 countries. MAHA sets standards in workshop technology with a comprehensive spectrum of test systems for cars, trucks, motorcycles, tractors, forklifts, etc. such as: Designing and outfitting vehicle service centers Complete test lanes for TÜV, DEKRA, etc. Function, performance and brake roller test stands Lifts of all types Workshop accessories (Diesel Smoke Meter, Side-slip Tester, Headlight Tester and much more). Table of Contents Commercial vehicle function roller test stand 3 Commercial vehicle ABS roller test stand 4 Commercial vehicle performance roller test stand 5 Wheel loader roller test stand 6 Tractor roller test stand 7 Special stationary test stand 8 Forklift roller test stand 9 Forklift roller test stand, small 10 The highest degree of customer trust and satisfaction is created by motivated and creative employees using state-of-the-art, environmentally friendly production systems consistently developing customer-oriented testing technology. Find detailed information about standard MAHA products for all your vehicle testing systems for your workshop and service center needs at our homepage 2

FRP 8x8 Function Roller Test Stand for Trucks For end-of-line quality and final checkout testing in vehicle production. For performance and component tests in research and development.

of one-axle or 4-wheel drive vehicles Dynamic function tests e.g.

steering wheel position Testing of the emergency steering pump Tempomat test, speed limiter Road simulation with mountain and valley drive Motor brake-, retarder, intarder test Performance

3 FRP 8x8 Function Roller Test Stand for Trucks For end-of-line quality and final checkout testing in vehicle production. For performance and component tests in research and development. The flexibility of the system offers simple driving tests up to special function tests such as ASR or differential locking function. Active Off-Board Diagnostic (communication with the vehicle via k-line or vehicle CAN Bus system). Testing of one-axle or 4-wheel drive vehicles Dynamic function tests e.g.: Warm-up driving under load Function tests for gears, axles, drive shaft ABS, ASR tests Brake test Grinding of vehicle brakes Testing of the axle ratio Differential locking testing Testing of the steering wheel position Testing of the emergency steering pump Tempomat test, speed limiter Road simulation with mountain and valley drive Motor brake-, retarder, intarder test Performance determination Fuel consumption measurements Tachograph test acc. to 57b, 57d Communication with the vehicle via k-line or CAN Fully automatic test stand conditioning 3 station PC system for simultaneous testing, input and evaluation of up to 3 vehicles Additional vehicle fi xing with stoprollers Control of test stand periphery (Hall gates, ambient air, exhaust air, illumination etc.) Optional load device for weight simulation Connection and communication to production control makes a focused vehicle control in the reworking or fi nal inspection possible Design: Roller diameter: Max. axle load.: Axle base: Max. traction force: Max. testable engine performance: Multi-Motor concept possible (each roller pair has its own drive) or with switchon belt connection between the roller pairs with motor/brake support. The 1-, 2-, 3-, 4- or 5 axle test stand 500 mm 7.5 t, 13 t, 16 t infi nitely variable 40 kn 600 kw results are documented on a protocol print out and stored in a test result database. The evaluation is passed on to the production control so that the focus is placed on the vehicle for re-working or the next production step. 3

ABS / EPB / EBS Test Stand LPS / Commercial Vehicle / Truck Performance Test Stand For end-of-line quality tests. For brake effectiveness and component tests in research and development.

4 ABS / EPB / EBS Test Stand LPS / Commercial Vehicle / Truck Performance Test Stand For end-of-line quality tests. For brake effectiveness and component tests in research and development. Function and Performance Roller Test Stand for oscillation inspections on commercial vehicles in the area of vehicle development. Specially developed test routines and optimally adapted test procedures limit the test time to a minimum. Brake tests of service and parking brakes Single wheel tests Axle brake test with display Brake force per wheel and imbalance display Testing of out-of-round Other tests ASR test Differential locking test ABS / EPB / EBS Test of the wheel sensors of the magnet wheels the brake lining wear sensors the valve the dynamic communication with ABS- /EPB- / EBS control device read / delete error memory switch test (e.g. ABS- / ASRswitch off) signal lamp test the pneumatic system the spare pressure the positioning pressures the dynamic pressure build up the air hoses for kinks interchange test the axle module the trailer control valve the pressure reduction redundancy path ABS / EBS test via diagnosis interface (e.g. BOSCH, WABCO, Knorr) 3-, 4-, and 6 channel ABS system (On-Board / Off-Board) Reproducible test processes Manual and automatic test procedures Active communication with the vehicle RPM controlled drives Vehicle databases, automatic selection of the test routines based on vehicle recognition Modular test stand design for various requirements and budgets Highest possible efficiency with small series and multi-shift operation low wear and maintenance system design Cable guidance pressure sensors, trailer pressures at the coupling heads / trailer ABS plug / Options The test stand is designed for brake effectiveness tests and tests of the ABS / EPB / EBS systems of truck / commerical vehicles up to a max. of 13 t axle load. For ABS / EPS /EBS test, the vehicle is connected with the test stand at the diagnostic plug via a moving cable unit. Active Off Board-Diagnostic (communication with the vehicle via k-line or vehicle CAN). The test can be automatically done specially adapted to the end-of-line test. A networking with the company network is possible. (Production control). Automatic user-guided tests. The test stand provides the test cycles, whereby the tester can intervene in the test procedure at any time via the cable-free remote control. Test steps judged by the tester must be positively or negatively acknowledged using the remote control in order to proceed to the next test step. Warm-up driving Function test of gears, axles, drive shaft Performance determination Fuel consumption measurements Oscillation / vibration measurements Determination of the vehicle losses Road simulation (driving resistances, mass simulation and incline) Speed test Speedometer test Freely definable test screens The test stand is a one-axle version. An additional apex roller can be added for vehicles with double axles. Two eddy current brakes serve as load simulation. Complex measurement value acquisition for recording of additional measurement variables such as engine RPM, oil temperature, etc. Axle load: Roller diameter: Roller coating: Traction: Brake performance: Highest speed: Load device: Tire cooling fan Automatic tie down device Load device to avoid slip between rollers and tires Visualization via a large color monitor in the test hall and a VGA color monitor in the control room Measurement box for recording of: Engine RPM Oil temperature Air temperature Air pressure Intake pressure Exhaust pressure Emission temperature Air speed fan Test stand control via PC with databases (measurement values, target values) Print out of test protocol on color printer Diesel emission tester (testing of smoke gas turbidity under engine load, recording of the turbidity in % in relation to engine RPM) Diesel fuel consumption measurement device (recording of the consumption in g/kwh in relation to engine RPM) max. 16 t 500 mm CrNiMo- Steel, flame-sprayed max. 30 kn max. 600 kw max. 120 km/h up to approx. 3,200 kg Cable guidance data line / diagnostic line / pressure sensors Power- / Operation control cabinet Test Attendant Power- / Operation control cabinet Printer (test protocol) Printer (test protocol) Monitor #1 (short wheel bases) Monitor #2 (long wheel bases) Monitor Measurement box Air speed fan (Light barrier Emergency Off) 4 Service Pit (Light barrier Emergency Off) (Light barrier Emergency Off) 5 Service Pit (optional)

Specially developed test routines and optimally adapted test procedures limit the test time to a minimum.

5 ABS / EPB / EBS Test Stand LPS / Commercial Vehicle / Truck Performance Test Stand For end-of-line quality tests. For brake effectiveness and component tests in research and development. Function and Performance Roller Test Stand for oscillation inspections on commercial vehicles in the area of vehicle development. Specially developed test routines and optimally adapted test procedures limit the test time to a minimum. Brake tests of service and parking brakes Single wheel tests Axle brake test with display Brake force per wheel and imbalance display Testing of out-of-round Other tests ASR test Differential locking test ABS / EPB / EBS Test of the wheel sensors of the magnet wheels the brake lining wear sensors the valve the dynamic communication with ABS- /EPB- / EBS control device read / delete error memory switch test (e.g. ABS- / ASRswitch off) signal lamp test the pneumatic system the spare pressure the positioning pressures the dynamic pressure build up the air hoses for kinks interchange test the axle module the trailer control valve the pressure reduction redundancy path ABS / EBS test via diagnosis interface (e.g. BOSCH, WABCO, Knorr) 3-, 4-, and 6 channel ABS system (On-Board / Off-Board) Reproducible test processes Manual and automatic test procedures Active communication with the vehicle RPM controlled drives Vehicle databases, automatic selection of the test routines based on vehicle recognition Modular test stand design for various requirements and budgets Highest possible efficiency with small series and multi-shift operation low wear and maintenance system design Cable guidance pressure sensors, trailer pressures at the coupling heads / trailer ABS plug / Options The test stand is designed for brake effectiveness tests and tests of the ABS / EPB / EBS systems of truck / commerical vehicles up to a max. of 13 t axle load. For ABS / EPS /EBS test, the vehicle is connected with the test stand at the diagnostic plug via a moving cable unit. Active Off Board-Diagnostic (communication with the vehicle via k-line or vehicle CAN). The test can be automatically done specially adapted to the end-of-line test. A networking with the company network is possible. (Production control). Automatic user-guided tests. The test stand provides the test cycles, whereby the tester can intervene in the test procedure at any time via the cable-free remote control. Test steps judged by the tester must be positively or negatively acknowledged using the remote control in order to proceed to the next test step. Warm-up driving Function test of gears, axles, drive shaft Performance determination Fuel consumption measurements Oscillation / vibration measurements Determination of the vehicle losses Road simulation (driving resistances, mass simulation and incline) Speed test Speedometer test Freely definable test screens The test stand is a one-axle version. An additional apex roller can be added for vehicles with double axles. Two eddy current brakes serve as load simulation. Complex measurement value acquisition for recording of additional measurement variables such as engine RPM, oil temperature, etc. Axle load: Roller diameter: Roller coating: Traction: Brake performance: Highest speed: Load device: Tire cooling fan Automatic tie down device Load device to avoid slip between rollers and tires Visualization via a large color monitor in the test hall and a VGA color monitor in the control room Measurement box for recording of: Engine RPM Oil temperature Air temperature Air pressure Intake pressure Exhaust pressure Emission temperature Air speed fan Test stand control via PC with databases (measurement values, target values) Print out of test protocol on color printer Diesel emission tester (testing of smoke gas turbidity under engine load, recording of the turbidity in % in relation to engine RPM) Diesel fuel consumption measurement device (recording of the consumption in g/kwh in relation to engine RPM) max. 16 t 500 mm CrNiMo- Steel, flame-sprayed max. 30 kn max. 600 kw max. 120 km/h up to approx. 3,200 kg Cable guidance data line / diagnostic line / pressure sensors Power- / Operation control cabinet Test Attendant Power- / Operation control cabinet Printer (test protocol) Printer (test protocol) Monitor #1 (short wheel bases) Monitor #2 (long wheel bases) Monitor Measurement box Air speed fan (Light barrier Emergency Off) 4 Service Pit (Light barrier Emergency Off) (Light barrier Emergency Off) 5 Service Pit (optional)

BHY Wheel Loader Test Stand Testing of construction machinery and special purpose vehicles in the area of research and development and quality control.

of the hydrostatic brake effectiveness Special, easy-to-use test routines for hydrostatic drives Determination of driving resistances in consideration of driving pressures Road simulation (driving

consideration of driving pressures Target value curves can be loaded in the background for comparison Determination of the controller action of the hydrostatic driving mechanism Import possibility

6 BHY Wheel Loader Test Stand Testing of construction machinery and special purpose vehicles in the area of research and development and quality control. Traction determination with increasing / decreasing load Determination of the traction hysteresis with load change Determination of the start-up traction Determination of the vehicle losses Testing of the hydrostatic brake effectiveness Special, easy-to-use test routines for hydrostatic drives Determination of driving resistances in consideration of driving pressures Road simulation (driving resistance, mass simulation and incline) ABS test ASR test Speed test Driving pressure recording possible with each test Freely defi nable test screens Determination of driving resistances in consideration of driving pressures Target value curves can be loaded in the background for comparison Determination of the controller action of the hydrostatic driving mechanism Import possibility for target values Export of test data The roller set halves of the front and rear axle are each equipped with a drive brake motor. (Four motor principle). The test stand rollers are solely electronically synchronized with a corresponding synchronization control. The energy absorbed (load simulation) in brake operation is delivered to the tracking wheels and fed back into the power supply. The test stand s energy balance is optimised and the operating costs minimized. The hydraulic steel cable control at the front and rear of the construction machinery secures the vehicle on the rollers sets. Weight load can be simulated using a hydraulic load device. Test speed: Axle load: Total- drive-, brake power: Traction-, brake forces: Total traction: Overload operation short term: Total traction short term: Roller diameter: Wheel base: Traction load device: max. 80 km/h max. 13 t 250 kw 4 x N N 4 x N N 500 mm infi nitely variable max N 6

FRP / BPS Tractor Test Stand Designed for end-of-line quality and final checkout tests or performance and component tests in research and development.

differential lock automatic under load as well as thrust operation Testing of the cut-off RPM Testing of the standstill RPM Testing of the idle RPM Hydraulic function test Front axle brake test (4

7 FRP / BPS Tractor Test Stand Designed for end-of-line quality and final checkout tests or performance and component tests in research and development. Application Function tests Shifting through all gear levels Testing of reverse gear or reverse switch Testing of the power shift steps Testing of the front axle lead Testing of the 4 wheel drive and differential lock automatic under load as well as thrust operation Testing of the cut-off RPM Testing of the standstill RPM Testing of the idle RPM Hydraulic function test Front axle brake test (4 wheel brake system) Rear axle brake test (4 and 2 wheel brake system) Testing of the steering brake function Driving simulation Acceleration measurements Hoisting power measurement on three-point rod optional The AIP-FRP/BPS test lane for tractors is designed for end-of-line quality and final checkout tests. Two vehicles can be tested simultaneously on the combination two axle function and brake roller test stand. The automatic test program accesses the vehicle database of the production control. All testing-relevant target data and outfitting features of the respective vehicle are downloaded from the database. The test stand can be operated as a stand-alone unit or within a networked system. The test results are documented on a protocol print out and stored in a database. The evaluation is passed on to the production control either for re-working or end-of-line control. Automatic user-guided procedure Automatic fixing device with integrated hoisting power measurement on the three-point rod alternatively: cable line tie down system Automatic hydraulic support roller on the brake tester for vehicle fixing during the brake test Axle load: Test speed: Wheel base: Vehicle mass simulation: Roller diameter front axle: Roller diameter rear axle: Mechanical flywheel mass: max. 15 t max. 80 km/h infinitely variable based on drive outfitting 318 mm 500 mm optional 7

LPS ST2AC Stationary Torque Shaft Test Stand Combination brake and performance test stand for various type, function and quality tests of special purpose vehicles such as combine harvester, wheel

Application Brake tests of service brakes, parking brakes Single wheel tests Axle brake test with display of brake force per wheel and imbalance display Test of the hydrostatic brake effectiveness

8 LPS ST2AC Stationary Torque Shaft Test Stand Combination brake and performance test stand for various type, function and quality tests of special purpose vehicles such as combine harvester, wheel tank etc. for end-of-line, research and development. Application Brake tests of service brakes, parking brakes Single wheel tests Axle brake test with display of brake force per wheel and imbalance display Test of the hydrostatic brake effectiveness Performance, traction tests in driving mode (speed, traction) in standstill (measurement of the starting torque) Measurement variables: speed, traction with force direction, wheel power, driving direction, optionally driving pressures, oil temperature, engine RPM, driven RPM Road simulation allowing for driving resistances vehicle mass inclines and slopes Load simulation constant traction constant speed Cycles Fixed settings of road profiles with changing inclines The test stand essentially consists of two self-aligning AC motor units. Each motor unit can actively drive or brake and is connected via a gear and cardan shaft to the wheel hub of the driven vehicle axle. No friction burden on the tire surface Absolute non-slip measurement system Easy vehicle adaption with special quick coupling flanges Optimally suited for steady load testing no tire wear and tear no slip Absorbed energy is fed back into the power supply network 8

BHY Forklift Test Stand Combination brake and performance test stand for various type, function and quality tests on three and four wheel forklifts and small wheel loaders in research and

Traction determination with increasing/ decreasing load Determination of the traction hysteresis with load change Determination of vehicle losses Determination of the starting traction

simulation (driving resistances, mass simulation and inclines) ABS test ASR test Speed test Recording of driving pressures with each test Freely definable test screens The roller set halves

The energy absorbed in braking operation (load simulation) is fed back into the power supply. The test stand power balance is thereby optimized and the operating costs lowered.

9 BHY Forklift Test Stand Combination brake and performance test stand for various type, function and quality tests on three and four wheel forklifts and small wheel loaders in research and development. Traction determination with increasing/ decreasing load Determination of the traction hysteresis with load change Determination of vehicle losses Determination of the starting traction Testing of the hydrostatic brake effectiveness Special easy handling test routines for hydrostatic drives Determination of the driving resistances in consideration of driving pressures Road simulation (driving resistances, mass simulation and inclines) ABS test ASR test Speed test Recording of driving pressures with each test Freely definable test screens The roller set halves of the front axle are each equipped with a drive brake motor. The test stand roller synchronisation is totally electronic with appropriate synchronisation control. The energy absorbed in braking operation (load simulation) is fed back into the power supply. The test stand power balance is thereby optimized and the operating costs lowered. A combined holding and load device is used for vehicle fixing on the roller set, whereby weight load can be additionally simulated. Roller geometry: Roller diameter: Test speed: Axle load: Absorbable vehicle power: Traction per wheel: Traction total: Overload operation Traction per wheel Traction: total asymmetric 200, 265 or 318 mm max. 45 km/h max. 6,000 kg max. 80 kw max. 15 kn max. 30 kn max. 20 kn max. 40 kn 9

BL Forklift Test Stand Combination brake and performance test stand for various type, function and quality tests at end-of-line for three and four wheel forklifts Brake tests of service brakes,

Performance Tests in driving operation (speed, traction) in standstill (measurement of the starting torque) Measurement variables: speed, traction with force direction, wheel power, driving direction

Documentation of measurement values per protocol print out and in a database Easy-to-read, clearly structured display of the test procedure on the monitor Double roller set in asymmetrical

Lifting bar between the rollers with integrated sensor roller for slip recognition.

10 BL Forklift Test Stand Combination brake and performance test stand for various type, function and quality tests at end-of-line for three and four wheel forklifts Brake tests of service brakes, parking brakes Single wheel tests Axle brake test with display brake force per wheel and imbalance display Roller resistance, pedal force left / right, etc. Performance Tests in driving operation (speed, traction) in standstill (measurement of the starting torque) Measurement variables: speed, traction with force direction, wheel power, driving direction with electro-forklift display of traction current, hoisting power, etc. with fuel driven forklifts display of engine RPM, driving pressure, hoisting power, etc. Documentation of measurement values per protocol print out and in a database Easy-to-read, clearly structured display of the test procedure on the monitor Double roller set in asymmetrical arrangement for three- and four wheel forklift load units possible as disc brakes, eddy current brakes or asynchronous engines. Lifting bar between the rollers with integrated sensor roller for slip recognition. Automatic roller covering optimum safeguard Weight simulator with integrated hoisting power measurement Pull-down unit to simulate the battery weight (adjustable load) Current measuring tongs PC with test result database for test result filing Can be combined with emission testers Worldwide proved and established testing technology for cars, trucks, motorcycles, tractors, forklifts etc. Roller brake testers Roller performance testers Function roller test stands Air speed fans Production installation test stands Special lifting technology for rail and wheel vehicles MAHA workshop outfitting e.g. complete test lanes for TÜV, DEKRA, etc. Lifting technology and roller test stands of various kinds MAHA-AIP GmbH & Co. KG Automotive Industry Products Hoyen 20 D Haldenwang (Allgäu) / Germany Phone: +49 (0) Fax: +49 (0) aip@maha.de Danvers Drive SE Kentwood, MI Phone Fax

Roller Dynamometer Performance and Function Tester for cars, trucks and motorcycles Model: LPS 3000

Roller Dynamometer Performance and Function Tester for cars, trucks and motorcycles Model: LPS 3000 Continuous measurement Discrete measurement Load simulation Elasticity measurement Speedometer test Graphics