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03/11/2021 - 04/11/2021

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Dynamic test of vehicle systems

Dynamic test of vehicle systems

Bringing cars to market faster requires compressed development and testing times. For example, vehicle functions, such as the frequent opening and closing of the door, must be tested quickly and precisely so that any necessary optimisations can be performed on short order. Powerful drive solutions are required that can be integrated into test systems easily, work reliably and are easy to operate.

Kübrich Ingenieurgesellschaft develops and manufactures test systems for checking and ensuring the functionality and quality of complex mechatronic units. Its new μAct actuator is a typical example, and is used in the testing of sun visors, door handles, various unlocking devices, and more.

The compact combination of a complete drive in a robust housing, a flexible mechanical interface for coupling, control electronics, bus interface and a hub for connection additional sensor systems is vibration and moisture resistant, which is important for dynamic component testing under climatic conditions. The actuator is available in two versions, because different applications require different forces. 

Thanks to an integrated processor, the systems can carry out the movement processes independently in combination with the relevant test software (TiS). Considerable demands are made of the actuator when this takes place. Up to one million test cycles may be necessary depending on the application; this means that reliable functionality in continuous operation over several weeks is mandatory. The components that are used must therefore meet high expectations, be as durable as possible, reliable, and do their job without needing maintenance.

Brushless DC-servomotors are the driving force behind the micro-actuator, with Kübrich choosing microdrives from the Faulhaber product range, available in the UK from EMS. These are provided as functional drive systems consisting of a motor, gearhead, brake and encoder. The individual drive components are optimally matched to one another, work perfectly together and thus achieve a very high level of efficiency.

A brushless DC-servomotor lasts significantly longer in comparison to mechanically commutated electric motors. It consists of fewer individual components, and the dynamically balanced rotor provides quiet, cogging-free operation, also important in this application.

Kübrich has two different types of use for these servomotors depending on the purpose of the test and the torque that is required. For the smaller version of the μAct, the choice fell on the brushless DC-servomotor of model series 2250 BX4. It has a diameter of 22mm and is a mere 52mm in length, offering up to 32mNm of continuous torque. The bigger testing device is also equipped with a four-pole DC-servomotor from model series 3268 BX4 or 3242 BX4. With a diameter of 32mm and length of 68mm or 42mm, these motors achieve torque of 96 mNm or 53 mNm.

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