Conceptual design and realisiation of hardware-in-the-loop simulators and test benches

测试台的方案策划和实施

IABG – Design & realisation of test benches

We configure and implement test facilities at the highest of technical levels. The salient features of our test facilities are safe operation, easy handling, flexible application options, cost-effective maintenance and problem-specific expandability. In this way we ensure cost-efficiency and future proofing.

Design & realisation of test benches
Design & realisation of test benches

Our services

  • Customer support and advice in drafting specifications / design and in implementing test benches
  • Products / standard test benches for axle springs, stabiliser bars, steering systems and wheels
  • Customer-specific / tailor-made special test benches
  • Realisation of large test benches as general contractor.

We offer customers the development, planning, manufacture and commissioning of test benches from a single source: turnkey solutions – with or without customer-specific adaptation – or as new developments according to customer requirements and at the leading edge of technology.

Our portfolio covers the engineering, manufacture and naturally also the servicing and expanding of our test benches. Our test facilities embody our many years of broad experience in dealing with fatigue strength and in the development and fine-tuning of test procedures.


Our portfolio includes the following test benches as standard products:

Our seal stands for the quality of our accredited and certified test house.
Our seal stands for the quality of our accredited and certified test house.

  • Resonance test benches for springs and stabiliser bars
  • Test benches for rotating bending
  • Stone chip simulators
  • Impact simulators for wheels and steering columns
  • Test benches for steering systems
  • HIL simulators and test benches

Contact us for customer-specific adaptations or new developments. We would be glad to advise you personally and find an individual solution for you.

 

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HIL test bench for rear-axle steering systems

Fields of application

  • Function development, optimisation and validation of rear-axle steering systems
  • Analysis of performance and control in a HIL-environment
  • Simulation and validation of rear-axle steering behaviour in failure scenarios
  • Automated HIL road and approval tests

 

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HIL test bench with climatic chamber for rear-axle steering systems

Fields of application

  • Function development, optimisation and validation for rear-axle steering systems
  • Analysis of performance parameters and control quality within the HIL network and under certain climatic conditions
  • Simulation and validation of rear-axle steering behaviour in failure scenarios
  • Automated HIL road and approval tests as well as endurance tests

     

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    HIL test bench for EPS steering systems

    Fields of application

    • Endurance tests for electro-mechanical steering systems (ESP steering systems)
      • Fatigue strength validation
      • Validation of all functions and performance data within the expected service life
    • Real-time fatigue load simulations and standardised tests with synthetic nominal data profiles
    • Determination of steering parameters (e.g. support characteristic, sliding force, …)

     

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    HIL test benches for chassis control systems

    Fields of application

    • System and component development, optimisation and validation
    • Analysis of performance parameters and control quality within the HIL network
    • Endurance and HIL road tests
    • „Simulation and validation of system behaviour in failure scenarios

     

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    Stabilizer Bar Test Machine (STAP)

    The Development and Quality Monitoring of resilient, highly stressed automotive components such as stabilizer bars, requires testing that represents actual vehicle conditions as accurately as possible. There are some essential test areas when determining the quality of spring steel, for example, fatigue strength under realistic load and environmental conditions.

    Based on these requirements, IABG offers a stabilizer bar test machine capable of performing fatigue tests under normal laboratory atmosphere. Thus allowing the determination of stabilizer bar fatigue strength while reducing both time and cost.

     

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    Variable Test Rig for Resilient Components (VTRC)

    The development and quality monitoring of high stressed spring components of vehicles like suspension springs and stabilizer bars demand fatigue tests under near-service conditions. The main quality features to be tested are, for instance, fatigue strength and relaxation behaviour under near to reality load and environmental conditions.

    Based on these requirements IABG offers an energy-efficient test rig for the testing of resilient components under saltwater corrosion, with different temperatures or under laboratory conditions for a time and cost saving determination of fatigue strength.

     

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    Grit Impact Simulator Machine (GISM)

    With the IABG Grit Impact Simulator it is possible to create stone impact damage to components in a defined and reproducible manner. The type and amount of discharge material and impact velocity is  continuously variable, within certain limits. It is guaranteed that every single particle of the selected discharge material – regardless of its shape, size and weight will have the same defi ned speed.

    The two simulators developed by IABG are among other things designed to test suspension springs, stabilizer bars, dampers, axle components, motor vehicle or rail vehicle fronts, car body parts, fuel tanks, transmission housings, oil pans, windscreens and axles. They are also suitable for the simulation of hail fall on wind power rotor blade tips or solar panels.

     

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    Rotating Bending Test Machine (RBTM)

    When using high-strength materials it is very important to consider not only the fatigue strength but also the presence of surface defects when determining the fatigue life of components.

    The IABG Rotating Bending Test Machine allows the time and cost saving determination of the fatigue strength of high-strength materials, such as those used in the manufacture of springs and stabilizer bars.

     

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    Spring Coil Test Machine (SCTM)

    The Development and Quality Monitoring of resilient, highly stressed automotive components such as springs, requires testing that represents actual vehicle conditions as accurately as possible.

    The influences relevant to fatigue strength must therefore be known and the effects therefore determined with the testing of adequate specimens.

    The IABG Spring Coil Test Machine allows the time- and cost-saving determination of the fatigue strength of individual spring coils under corrosion. In this way, it is possible to perform comparative tests to determine the influence of specific factors on the fatigue strength of the test samples.

     

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    Radial Impact Simulators

    The simulator for radial impact is for testing the fatigue strength and failure behaviour of wheels and steering columns under load. This provides manufacturers valuable information about the properties of their products right at the development stage.

     

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    Torsion Bar Test Bench

    Fields of application

    • Testing torsion bars for seat belt restraint systems
      • Measuring and analysing torsion bars‘ rotation angle and torque absorption capacity
      • Measuring and analysing rotational energy absorption
      • Specifying the rotational energies and output speeds for predefined partial/full damage
    • Quality assurance during production
    • Developing and validating specific customer requirements and test specifications

     

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    Endurance test bench for EPS steering systems

    Fields of application

    • Endurance tests for electro-mechanical steering systems (ESP steering systems)
      • Fatigue strength validation
      • Validation of all functions and performance data within the expected service life
    • Real-time fatigue load simulations and standardised tests with synthetic nominal data profiles
    • Determination of steering parameters (e.g. support characteristic, sliding force, …)

     

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    Endurance test bench for vehicle alternators

     Fields of application

    • Validation of the functionality and fatigue strength of four alternators subjected to certain loads and temperatures
    • Definition of application-specific test cycles with predetermined load, torque and temperature collectives
    • Direct comparative tests for multiple test items (operated in parallel) and recording of measured values for analyses