Portfolio

Structural integrity assessment in wood

The Cubus ramp test program controls this actuator applying ramp test loads with special load target conditions. Additional displacement transducers are integrated into the Control Cube hardware which provides synchronised readings of deflections. This I-joist from Boise Cascade is fabricated from laminated veneer flanges with an oriented strand board web and is one of several examples of composite fabricated wood beams under investigation.

 

8 Actuator FlexMAST simulator rig

Eight Control Cubes are employed on this special rig which replicates tri-axial measured accelerations on the four corners of the vehicle frame. The rig was designed to perform durability simulations on the frames, bodies, body mounting systems and load boxes of body-on-frame light truck vehicles. The rig provides conventional 6-DOF motions in addition to shear and twist on the vehicle frame. Hylec Controls assisted Ford with the design of this rig and supplied all the servo-mechanical and control components

Further details and Engineering Technical Excellence Award

 

Vehicle body on FlexMAST simulator rig

This shows the vehicle body mounted on the FlexMAST rig. The 8 Cubes provide a total of 64 channels of signal conditioning for the actuator displacement control channels, simulation accelerometer response channels and general data for road-load correlation and other purposes. Ford developed special routines which integrate with our QanTiM® simulation software to reproduce a greater level of simulation accuracy compared with the conventional approach. See further details below.

Further details and Engineering Technical Excellence Award

 

Front suspension and steering rig

This is one of 4 QanTiM® Simulation Systems supplied to IABG in Munich. These systems comprise of software and a total of 15 control channels which were supplied in cooperation with Zwick. Three of the supplied systems are integrated into multi-channel test rigs by IABG who also operate these rigs for BMW. These rigs simulate the Nürburgring race track on various sub-systems and components on the vehicle, which include the complete front suspension and steering system, brakes as well as the alloy wheels, as part of their gruelling fatigue test qualification.

 

Truck Axle - Fretting fatigue investigation

QanTiM® simulates realistic measured operational conditions on this heavy duty truck axle. The production process utilises a large press to install the axle stub into the tube housing under an interference fit. Under operational loads, micro movements occur between these parts, which can lead to fretting fatigue. Realistic reproduction of operational loading is the only method of establishing representative fatigue life testing.

 

Four-post Road Simulator

Two dual-channel Control Cubes have been utilised in modernising this four-post road simulator. Vehicles are exposed to various road surfaces under prescribed operational conditions. QanTiM® ensures the accuracy of the simulation. Both durability and rattle and squeak investigations can conveniently be conducted on such rigs.

 

Motor Cycle Road Simulator

This simple dual-actuator motor cycle road simulator provides convenient reproduction of measured operational load conditions. Additional transducers, such as strain gauges, LVDTs and accelerometers can provide useful additional measurements from the test specimen.  In comparison with driving the motor cycle on a test track, an extremely high level of repeatability is achieved with this simulator.

 

Actuator helicopter tail rotor gearbox rig

The Cubus block program applies a simulated duty cycle test on this helicopter tail rotor gearbox. Applied load, casing strains and deflections are controlled and monitored. Signal Cube provides additional synchronised strain gauge conditioning and acquisition as part of the integrated control and monitoring system.

 

Quarter car simulator

Vertical, longitudinal, lateral and brake loading is applied to suspension components by this rig. QanTiM® takes care of any cross-coupling interaction and deals with the inherent geometric relations of all the links in the system. This allows reproducing measured operational conditions on the suspension system under investigation. Specimens are often MacPherson struts and investigations focus on the damper/strut and lower control arm.