What really matters with sophisticated test benches

• What is test bench construction?

  Test bench construction refers to the development and integration of technical systems that are used to test components or complete systems under defined conditions. The aim is to validate functions, determine load limits and verify the performance, safety and conformity to standards of components and systems.

  Typical challenges in test bench construction
  Typical challenges in test bench construction arise from the increasing complexity of modern products and test requirements. Different test specimen variants, high forces and dynamics, combined loads, sophisticated automation concepts and increasing requirements for functional safety and machine safety place high demands on the design of test systems.

  Our particular strength 
  lies in the development of individual test bench solutions for highly complex systems where standard test benches reach their technical or economic limits.

• What are the key phases of a test bench project?

  The success of a test bench project is often determined in its early stages. That is why we support our customers from the initial concept through to long-term operation.

  A typical test bench project includes the following steps:

  Requirements Analysis and Concept Development
  Joint definition of technical, functional and regulatory requirements, followed by the development of a suitable test bench concept.

  Engineering and System Design
  Design and specification of mechanical, electrical, hydraulic and software-based components.

  Integration and Automation
  Assembly and integration of all subsystems, including control systems, data acquisition and test automation.

  Validation and Commissioning
  Verification of the required functionality and handover of a fully operational test system.

  Operation, Service and Further Development
  Ongoing support during operation, as well as adaptation to new test articles, requirements or standards.

  Through transparent project and risk management, we create planning certainty at an early stage and ensure that technical, economic and organisational requirements are considered equally throughout the project.

• How do we select the right test bench concept?

  Particularly in the case of far-reaching decisions or projects with a high degree of novelty, we first develop several basic solution concepts for your core task based on your requirements. These concepts are elaborated to such an extent that they can be reliably compared with each other in terms of the degree of fulfillment of the technical requirements, feasibility, risks and investment and operating costs.

  The result is a sound basis for decision-making that makes typical conflicts of objectives between performance, costs, flexibility, sustainability and risks transparent and allows them to be weighed up in a comprehensible manner.

  We also show you different options and variants for the implementation of subsystems and functions during the further development of the selected concept and compare them. In this way, we create a reliable basis for a technically viable, economically sensible and long-term sustainable concept decision.

• How do we arrive at a test bench solution that meets the requirements?

  The path to a cost-effective test bench solution that meets requirements does not begin with a hasty technical definition, but with a complete and reliable understanding of the actual requirements and framework conditions. In practice, however, it is often the case that requirements are understood inconsistently, boundary conditions and interfaces are not fully clarified and important stakeholders and life phases of the test system are not sufficiently taken into account.

  With a neutral view from the outside and decades of experience in the construction and operation of complex test systems, we work with you to develop a structured and reliable requirements basis. In this way, we create the basis for a solution that fits technically, is economically viable and proves itself in subsequent operation.

  The result is a set of well-documented, prioritized requirements for your test system - precise, solution-neutral, complete, unambiguous and verifiable.

• How do we make a sound investment decision?

  Investment decisions for testing infrastructure are often associated with high costs, long-term commitments and uncertainties. It is crucial to create an overall picture of requirements, solution options, risks and cost-effectiveness at an early stage so that investments can be reliably evaluated and confidently represented internally.

  This is exactly where we support you. Based on a structured requirements analysis with all relevant stakeholders, we first create the technical basis for a reliable decision. Building on this, we analyse feasibility, technical risks, organizational framework conditions as well as investment and operating costs and compare possible solutions in a manufacturer-independent and comprehensible manner.

  This provides you with a basis for decision-making that transparently combines technical suitability, cost-effectiveness and future viability - and with which you can justify investments in your inspection infrastructure internally and release them in a targeted manner.

• How do we get a reliable specification for our test bench?

  A reliable specification is the basis for ensuring that a test system will later function technically, be economically viable and integrate smoothly into your processes. It plays a decisive role in determining whether offers can be compared, whether the most economically viable offer is selected and whether your test bench can subsequently be implemented and operated on time, within budget and with the required quality. In addition to the technical requirements, this also includes standards, competencies, responsibilities and clear change processes. The following applies: specify as much as necessary, as little as possible.

  We work with you to develop a specification that takes all key aspects into account - from the specific test tasks and test scenarios to functional requirements, interfaces, data and automation concepts, regulatory requirements, acceptance criteria and requirements for operation and expandability.

  Our advantage: We not only develop test benches, but have also been operating, testing and qualifying systems ourselves for decades. As a result, we know from our own experience which requirements are really decisive in real test operation - and which points are often overlooked in early project phases. This results in specifications that are not only convincing on paper, but also ensure efficient tendering, smooth implementation and economical operation.

• Who implements test benches when standard solutions are not sufficient?

  Many testing tasks cannot be covered by standard solutions. Different test specimen variants, complex load cases, high automation requirements, functional safety, individual software logic or special environmental simulations quickly push the limits of systems available on the market. This is when you need a partner who understands your testing task holistically and translates it into a resilient, customer-specific solution.

  This is exactly where we support you. We combine consulting, development and implementation expertise in an integrated engineering approach - from requirements analysis, system design and construction to commissioning, qualification and operational support.

  This results in individual test bench solutions that are technically viable, economically viable and tailored to your specific testing task - even if no standard solution is available on the market.

• How can test benches remain economical, available and future-proof?

  Test specimens, test procedures and regulatory requirements often change faster than a test system is amortized. At the same time, the cost-effectiveness and availability of a test bench are usually not decided at the time of procurement, but during subsequent operation. This is why we develop test benches that not only meet current requirements, but also remain efficient, reliable and adaptable in the long term.

  To achieve this, we rely on modular architectures, open interfaces and standardized hardware and software modules that facilitate subsequent expansions and adaptations. Individual test automation, energy-efficient drive concepts, robust system architectures and automated solutions for the reproducible simulation of environmental influences help to permanently reduce operating costs while increasing availability, reproducibility and process reliability.

  We take maintainability, diagnostic capability, ease of servicing and ergonomic operability into account right from the development stage. Supplemented by fast and pragmatic service support - from spare parts, maintenance and calibrations to software upgrades and modernizations to engineering support and training - we create the conditions for permanently stable and economical operation.

  The result is test systems with high availability, low total cost of ownership and the flexibility to reliably meet future requirements. It is not without reason that many of our endurance test benches have been successfully used by customers for more than 30 years.