Motorcycle and Private Vehicle Roller - Projects Automotive Industry

Power Train, Research & Development · Vehicle test rigs

Motorcycle and private vehicle roller test rig
for acoustic tests

A roller test rig for motorcycles and private vehicles in the school of "Acoustic and Vibration Technology" of the BMW AG Research and Engineering Center

A roller test rig for motorcycles and private vehicles was installed in the school of "Acoustic and Vibration Technology" of the BMW AG Research and Engineering Center. Since the test rig is used for acoustic tests, special attention needed to be paid to low-noise design of the electrical and mechanical components.

Test rig design

The test rig basically comprises a set of rollers with 2 crown rollers (1060 mm in diameter) driven by a DC generator. The air/water cooler for dissipating machine losses is fastened elastically to the ceiling of the floor below. The brake, torque measuring flange and overload safety clutch are integrated in the shaft chain. The unused roller is covered when testing motorcycles. Calibration of the measuring flange can take place from the test room with a lever and weights. An LC filter circuit was integrated in the armature circuit to reduce the magnetic noise of the thyristor-fed DC generator.

Technical Data

Maximum braking performance (continuous operation) per machine	222 kW
Rated tractive force	6150 N
Maximum speed	250 km/h
Maximum possible acceleration	1,7 g
Maximum axle load	2500 kg
Roller diameter	1060 mm
Roller width	500 mm
Noise emission 38 dB(A) at 52 dB(A) at 69 dB(A) at	0-30 km/h 100 km/h 200 km/h

Control types

Speed control
Tractive force control
Drive simulation (road resistance including gradient, vehicle mass)
Calibration
Coast down

Operation

The test rig has a WINDOWS user interface that also supports mouse-free operation.

Software system CATSNT
Operating system WINDOWS NT
PC version SIMATIC plug and play card

The plug and play card PC with CATSNT is integrated in a common SIMATIC frame with the digital control and the process I/O. Information is exchanged through an internal bus system by short, interference-free routes.

Division of the user interface

operation of the test data
test preparations
test execution
system setting
password protection

The setpoints can be set optionally:

by the PC keyboard or the mouse
from the drive profile stored on the PC
via sockets by a master system

As well as in the online mask, all analog variables can be parameterized in an additional measured value display (display with limit value monitoring).