NEW NEW TecSA S.r.l. 1/31

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1 TecSA S.r.l. has twenty years experience in the field of brake-system testing laboratories. The company s activity includes both the construction of new machines, and the overhauling/updating of existing equipment. We have supplied complete research laboratories to leading companies, such as, for example: Brembo, ITT-Galfer, Federal Mogul Operations Italy, Remsa (Spain TRW Group). Over the years, TecSA products have been the subject of continual evolution and updating, reaching high standards of performance together with ease of use and high production yields. The level of automation allows for the machines to work continuously in conditions of safety, even in the absence of operators. The tests, therefore, can also be carried out at night or at weekends. Thanks to the relationship of close collaboration that it has established with its Customers, TecSA has developed procedures that satisfy both international regulations (including official approval) and research needs, with high flexibility and the possibility of customising the tests. Various machines have been supplied for quality control and for product development. Apart from the construction of new machines, overhauling of existing machines is also carried, involving action at various levels: mechanical: maintenance/repair and modernisation, with the addition of new functions; electro-technical: updating of control panels; electronic and software: automation. In the case of manually operated dynamometers, it is possible to add just the electronic module and software, thus achieving control of the braking even in deceleration (constant moment), the acquisition of all the braking data and the automatic processing of the results. TecSA Srl can also execute third-parties tests, with many test procedures, on its brake test bench. TecSA Products Automotive: brake dynamometer for passenger car and racing sector; Truck: brake dynamometer for transport sector; TecNAS: noise and vibration acquisition and analysis system; SST: Shear Test Machines, for measuring the shear stress of friction materials; FQT: Friction Quality Tests, for quality control and/or development of the after market; NEW Automation: brake test bench automation system; NEW MiniDyno: friction quality test machine with variable speed; Third-parties test execution Clutch dynamometer 1/31

2 AUTOMOTIVE brake dynamometer The flywheels, together with the contribution from the motor driven in inertia simulation, reproduce the real-world conditions that the brake is subjected to when stopping the vehicle. The flywheels are set in rotation by the electric motor at the required speed for the start of braking. Subsequently action is taken on the brake with either pressure or torque (deceleration) control and the braking characteristics are assessed: braking time, braking distance, friction coefficient, temperatures reached, wear on brake parts, evolution of the pressure or braking torque, etc. Testing Machine for complete brake units (calliper, disc, pad, drum, shoe, parking brake) for passenger cars, racing cars and light commercial vehicles 2/31

3 Technical characteristics Model Standard High performance DC Motor 183 kw 285 kw Basic Inertia 10 kgm 2 10 kgm 2 Flywheels inertia 20, 40, 80 kgm 2 20, 50, 100 kgm 2 Overall mechanical inertia 150 kgm kgm 2 Inertia range, with simulation From 5 to 200 kgm 2 From 5 to 260 kgm 2 Maximum speed 2800 rpm 2800 rpm Maximum braking torque 5 knm 7 knm Maximum braking pressure 200 bar 200 bar Features and Options Reading of four temperatures on brake rotating parts. Parking brake test system with maximum force of 5000 N, maximum stroke of 50 mm. Auxiliary drive for tests at slow speed (from 0 to 20 rpm) with possibility of torque actuation up to 5000 Nm. Static Friction test, Hill Hold tests, Creep Groan tests. Modulated ventilation for brake cooling. Air flow modulated according to the vehicle speed. Modulated fumes intake, with slight predominance as to the brake cooling instantaneous ventilation rate of flow. Measurement of oil volume absorbed by the calliper by means VSE volumetric measuring device. Automatic sprinkling of the brake (also with salt water). Disk DTV strain measurement system. Soundproof cabin for flywheels zone and brake zone. Electro-mechanical brake actuator Maximum pressure: 250 bar Pressure increment: 1000 bar/sec Micrometric stroke measurement 3/31

4 Test report 4/31

5 Conditioning system option Brake zone with climatic characteristics. Stainless steel internal. Double panel system: 100 mm of climatic insulation and soundproof panel of 50 mm. Conditioning system: Recirculation air up to 2000 m 3 /h Temperature range: -20 C / +50 C Refrigerating power: 20 kw Heating power: 15 kw Humidity range: 10-90% (over 5 C), 2% accuracy Noise analysis system options 8 vibro-acoustic channels, 24 bit resolution, 45 khz alias-free bandwidth, ICP-IEPE signal conditioning programmable FFT size (e.g. 1024, 2048, 4096 points) programmable noise threshold online FFT, peak-hold, Leq calculation automatic report generation audio file acquisition sound output for loudspeaker waterfall post-elaboration 5/31

6 TRUCK brake dynamometer Field of application The dynamometer covers all transport sector: from light commercial vans to heavy trucks (including buses). The dynamometer has inertia, braking torque and speed characteristics that are able to also cover rolling stock up to 250 km/h. Testing Machine of complete brake units for trucks 6/31

7 Technical characteristics DC Motor: 400 kw. Basic inertia: 140 kgm 2. Inertia flywheels: 200, 400, 800 and 870 kgm 2. Overall mechanical inertia: 2410 kgm 2. Inertia range, with simulation: from 100 to 2700 kgm 2. Maximum speed: 1500 rpm. Maximum brake Torque: Nm. Pneumatic braking system with 14 bar maximum pressure. Hydraulic braking system with 200 bar maximum pressure. 7/31

8 Truck brake dynamometer Complete wheel assembly 8/31

9 Test reports 9/31

10 NVH acquisition system Hardware 8 analog input vibro-acustic channels 24 bit resolution 110 db dynamic range ks/s max 45 khz alias-free bandwidth IEPE/ICP conditioning software configurable Software acquisition of pressure, torque, temperature, speed signals (100 Hz) different FFT length (1024, 2048, 4096) FFT, noise / vibration, peak / frequency online calculation programmable threshold automatic report generation audio file acquisition sound output for loudspeaker waterfall postelaboration 10/31

11 User interface Test report 11/31

12 Measures the strength of adhesion (shearing load) of the friction material and the metallic plate to which it is bonded Tests as per ISO 6312 Road vehicles Brake linings Shear test procedure for disc brake pad 12/31

13 Test procedure overview The sample is fitted into a special fixture designed to allow the application of a load on the friction material face by means of a vertical pressing cylinder. Another cylinder applies an increasing shearing load sideways by means of a blade. The control system identifies the exact load applied when the friction material shears from the backing support. Features and Options Fixtures are easy to construct. Blades have a rapid insertion device to allow a fast and easy change of type. Automatic calculation of the shearing strength (ratio between the load at the moment of separation and the surface of the sample). Possibility of carrying out tests including several measures, with automatic calculation of the minimum, maximum and average values of the load at the moment of separation and of the shearing strength. Automatic output of graphic reports. Management of database of test descriptions. Automatic updating of a database of the tests results. Offline analysis of the tests results stored in the database. Technical characteristics Brake pads from 8 to 100 cm 2 with maximum width of 200 mm. Maximum length of blade approach stroke: 50 mm. Maximum shearing force: 100 kn. Load of the vertical pressing cylinder: 50 N/cm 2. Incremental rate of shearing force: 4500 N/sec. 13/31

14 Test reports 14/31

15 User interface 15/31

16 Constant Pressure / Torque braking applications Four temperatures acquisition (two inside the rotating part of the brake) Pressure, Torque and Residual torque measurement Fumes extraction system Cooling air system Real-scale brake testing machine at constant speed 16/31

17 Technical characteristics Model AC Motor 75 kw 110 kw 160 kw Maximum braking torque 1000 Nm 1500 Nm 2300 Nm Maximum braking pressure 200 bar 200 bar 200 bar Options Parking brake test system Completely automatic handling Dedicated control mechanism Constant Force / Torque braking applications Force and stroke measurement Maximum pull force: 5000 N Maximum stroke: 50 mm Automatic sprinkling of the disk Watertight stainless steel hood Water draining system Two solutions available: Pressurised reservoir for small quantities of water (10-20 ml/min) Tank with pump for large quantities of water (1-5 l/min) Auxiliary drive for tests at slow speed (from 0 to 20 rpm) This option allows the following types of tests to be carried out: Statis friction tests Sticking tests Hill Hold tests 17/31

20 Bench Control System Are you unsatisfied with your old brake dynamometer? Upgrade its control system at a very low cost! Automation system including top level software and electrical cabinet with PC, UPS, real-time control and transducers interface Automation system that can be added to an existing brake bench dynamometer or a friction quality test machine to obtain high-performance and capabilities. Technical characteristics 32 analog input:14-bit resolution; 8 analog output: 14-bit resolution; 16 digital input: 24 V DC; 16 digital output: 24 V DC; 2 counter channels; Real time activity (acquisition, programmable filters, elaborated channels, PID processing, decisional choices and output) managed at a frequency of 1 khz; Inertia simulation algorithm; Software PI servo-valve control; PLC Siemens S7 interface; Open rack to add others cards; 20/31

21 Software capabilities Description of every normed test procedure (AK Master, ECE R90-R13, Eurospec, AK Noise Matrix, SAE J2521, ) Simplest user-configurable brake application parameters Automatic test report generation with user configurable template Acquisition parameters configuration (frequency, filter, acquisition instant) Result calculation configuration (friction values, min-max-avg values, MFDD, braking distance, ) User configurable formulas 21/31

22 MINI-DYNO automotive brake dynamometer Are you looking for a brake dynamometer at a low cost? MiniDyno is a valid solution! At a price slightly higher than that of a Friction Quality Test machine, you can get: A high performance Friction Quality Test machine A bedding machine A brake dynamometer with software and automation system at the top level The performances of the MiniDyno are reduced if compared to those of a modern brake dynamometer just in terms of maximum speed and inertia simulation range. MiniDyno is the best solution for normal tests that don't need a high performance brake dynamometer. MiniDyno is a valid alternative to a common second hand brake dynamometer of old design (conceived for cars of old generation) Two families: MINI-DYNO: for quality and performance test MINI-DYNO-COMFORT: with extension for reduced comfort test Two models for each family: Model AC Vector Speed Motor Maximum drag torque 190 kw 260 kw 1820 Nm 2480 Nm Maximum speed 2000 rpm 2000 rpm Inertia simulation (wheel radius 0.3m) up to: rpm 1500 rpm rpm 0 0 J sim [Kg*m2] Dec [m/sec2] J sim [Kg*m2] Dec [m/sec2] 22/31

23 Performance as Friction Quality Test machine: Constant speed of 660 rpm Constant pressure / torque application Four temperatures acquisition (two inside the rotating part of the brake) Pressure and torque measurement Fumes extraction and cooling air system Sprinkling of the brake (option) Performance as MiniDyno: Variable speed up to 2000 rpm Inertia simulation Modulated pressure / torque control Static friction test Fumes extraction and modulated cooling air system Sprinkling of the brake (option) Noise analysis (option for MiniDyno-Comfort families only) Climatization (option for MiniDyno-Comfort families only) Brake cabinet (MiniDyno) Brake mounting (MiniDyno) 23/31

24 MiniDyno structure 24/31

25 MiniDyno-Comfort structure 25/31

26 THIRD PARTIES tests execution Customer service by our brake dynamometer Execution of tests on discs, callipers, pads, drums, shoes and parking brake for automotive and light vehicle applications sector Features of our test bench A 195 kw constant power DC motor Maximum speed: 1950 rpm Drag torque: 1100 Nm Maximum inertia of 220 kgm² (190 kgm² mechanical inertia + 30 kgm² of inertia simulation) Maximum braking moment: 5000 Nm Maximum braking pressure: 250 bar Maximum pump oil volume: 15 cm 3 Residual torque measurement system with overload mechanical protection (200 Nm of end scale) Parking brake system actuation: maximum force 5000 N maximum stroke 50 mm Cooling with maximum air flow of 4000 m3/h Auxiliary transducers two thermocouples inside the disk (slip ring) oil volume transducer (VSE) 2 disk deformation sensors (one for each face) 26/31

27 Test procedures AK Master AK1 AK 2 ECE R-90 Auto Moto Sport DTV EFFICIENCY THERMAL DEFLECTION GREEN DISCK CRACKING THERMAL SHOCK FADE (fading service offered to the Customer) WEAR test 7-H Fiat procedure (partial and/or total) TSR 5151G procedure Wear Test Bosch (partial and/or total) Other procedures (supplied and agreed according to the Customer) Standard FFSS (Dry & Wet test) Other tests are available upon demand. The referring procedures and the international rules must be showed by the Customer (according to the maximum bench performances) Results analysis Test report generation Wear measurement Cracks measurement FFT analysis (for DTV measurement) Customer s defined test report and analysis 27/31

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30 CLUTCH dynamometer Clutch dynamometer for car and light commercial vehicle sector Features of our test bench Push and pull clutch control; Preload management; Driven disc blocked or rotating; Different engagement control: Torque; Clamp load; Release load; Release travel; Plate and flywheel temperature measurement; 30/31

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