GIANT Options

Dynamic Blower System for Cooling and Dust Filtering

The dynamic ventilation system serves for cooling the test brake and removal of the brake lining abrasion (brake dust). The ventilation system is a complete and independent module of the dynamometer. It must be set up at a suitable place, as close as possible to the dynamometer. The fresh air is taken from out of doors, via a protective wire grid and a light-duty intake filter. The air is collected by a powerful ventilator and supplied to the dynamometer via ductwork.

Climatic System for "Cooling Air Conditioning - 20°.... + 50°C"

The climatic system assists with brake testing under the influence of different environmental conditions. For this purpose a separate ventilation unit is available for heating, cooling and humidifying the complete Test Chamber. The system enables climatization of a constant supply air flow of 3 200 m3.The temperature control range is -15 °C up to + 50°C, within accuracy of ~ + - 1°C.

DTV & Deflection Measuring System

For the basic measuring of the thickness of the rotating brake disk, the test station will be equipped with a distance measuring system using capacity sensors. The adaptation of the sensors are connected with a plug connection including an evaluation unit. The measuring values can then be recorded with the test stand automation. Thus it will feed the actual DTV-VALUE at creeping speed directly to the x-brake measured data acquisition.

Road Dust Injector

For testing the brake performance under the influence of severe road dust pollution, a road dust injector unit is available. This injector is powered by compressed air. The road dust [will be provided by customer] is stored in a 2 Ltr. container. A pneumatic value controlled via x-brake allows the dust injector to be switched ON/OFF. The injector nozzle will be focused on the test brake.

Prepared Test Programs

In order to allow the customer a rapid start up with the entire automation system, and to achieve replicable test results, x-brake will be delivered with pre-installed projects comprizing: test program - measuring definitions - limited data fields - function generators matching the standard test procedure as per specification AK I / II, AK III, AK-Master, AMS-Fade, HMC-CV Wear, VW TL 110. This test program includes all parameters, command signals, switches and data acquisition needed for a fully automatic test run. A 24 hour and weekend test are possible.

Auxiliary Drive for "Static Brake Test / Creep & Groan Investigation"

The system for static brake test serves to determine the static brake torque / static friction coefficient of the test brake (either service brake or parking brake). For generating the necessary torque load at speed zero, a special drive unit is used. This drive unit is coupled at the rear end of the main-motor, via a shiftable remote-controlled coupling. In order to perform the static brake test, the coupling is actuated by the automation system.

Water Spraying Device for "Wet Test @ 1 - 10 Ltr./min"

This device allows for automatic brake tests under the influence of humidity. Two spraying nozzles are fed via a pipeline with an integrated water filter, a throttle valve for manual settings, and a water flow meter. A solenoid valve allows activation of the spraying nozzles by means of an electric command from the dynamometer automation system. Thus the wet test may be a part of any automatic test cycle. The actual spraying rate can be monitored at the flow meter.

Adaption System for Customer Brake (Stator & Rotor)

At the brake dynamometer for performance and wear investigations, the friction material along with the brake rotor (disc) and brake stator (calliper) serve as a test sample. These parts must be adapted to the rotating and static test flange at the dynamometer. The adaptable parts are designed to fit an individual brake unit - either disc or drum brake - which will be provided by the customer.

Calibration Tool Kit

For regular recheck and calibration of the basic analogue measuring system, which can change during longer time periods, the optional "Calibration Tool Kit" is available.

GIF Inline Torque Meter System

The rotating GIF torque measuring flange allows tests at half axle resp. wheel suspensions. The testing of brakes installed at half axles resp. complete wheel suspension systems serve primarily for NVH testing a are always achieved using a homokinetic drive shaft and the torsional vibration damper (e.g. a Küsel coupling). Torque measuring via tail stock is not applicable. This rotating GIF torque measuring flange is demounted during the performance-/wear- testing procedures. These test procedures will be performed with the tail stock and a load cell system.

Telemetry for 4 Rotating Temperatures

The rotating temperature of the brake is measured at various measuring points by means of thermocouples Typ K - NiCrNi. The thermoelectric voltages are transmitted from the rotating test brake to the amplifiers by means of a telemetry system with 4 channels. We will use a "DATATEL" time multiplex system.

The testing station can be opened for the loading of Brake Assembly

For easy loading and unloading of the test brakes. The NVH - testing chamber can be moved aside using a "Sliding Hood".

Clamping Angle for Adaptation of suspension systems

As the test station is equipped with a demountable designed tail stock, this can be exchanged by a clamping angle, which is also mountable / demountable. Therefore the customer can mount a complete wheel suspension system to the clamping angle e.g. for a Mc-Pherson damper or a half axle. If required it can be shifted within the T-Slot rail. The variable axial position allows the adjustment of the installation room to different test samples and guarantees a simple installation of the test sample.

STAC "Event Scan" NVH-Measuring System

EventScan allows for localization of vibration- and/or sound phenomenons arising under certain operational conditions. For instance, under certain speeds- and load conditions - and also additionally at certain temperatures and other parameters.

Thermographic System

We supply a Thermocamera System "Thermographic Brake" for Thermographic Images of Brake Discs. The High speed IR-line-camera performs 160 measuring points per line and a measuring rate of 1000 lines per second. This is a special and has been - already proven in several brake inertia dynamometers - for fast contactless temperature measurement at rotating parts of brake-discs. This system - as per the design - supports the extreme conditions and the mechanical conditions in the brake testing station during hundreds of brake applications, especially at high temperatures, with brake dust and wind, with reflecting surfaces and with no direct view to front and back side disc surface.

Direct Measuring System for Brake Fluid - Displacement

This device allows for the measuring of the brake fluid flow into the test brake. The volumetric sensor is a flow quantity measuring unit for liquids and works according to the gear wheel principle. The measuring unit consists of a pair of gearwheels which are inserted into the housing very precisely. The rotation of the measuring unit is picked up by a signal system tooth by tooth, with each tooth generating a pulse.

Air Suspension for perfect Vibration Isolation

An air suspension is a suspension that rides on air. The air is contained in an air spring or an air cylinder. The adjustability of an air suspension system is its greatest advantage over other options.

IR Pyrometer

The pyrometer ensures remote temperature recording of objects moving with velocity up to 250 km/h. Mapping of measurement data of the one-dimensional scanning pyrometer onto the Brake surface.


Software

Function Generator "Braking Pressure"

During normal brake-performance and wear test the command value for the braking pressure set within the automation system test program is a constant value, e.g. 5/10 bar valid. For special investigations, e.g. for NVH-work it is helpful to modulate the actual braking pressure during a stop.

Function Generator "Braking Torque"

During normal brake-performance and wear test the command value for the braking torque set within the automation system test program is a constant value, e.g. 100 / 200 / 500 / 1000 Nm, valid for the entire stop.

Function Generator "Cooling Air Flow"

During normal brake-performance and wear test the command value for the entire braking and subsequent cooling period set within the automation system test program is a constant value, e.g. it may be 2000 m3/h or 10 m/s continuously.