ZF Versuch Englisch.qxd 14.02.

2006 16:31 Uhr Seite 1

ZF Test Services for

Vehicles and Vehicle Components
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Extensive Group Know how
-- Highly Flexible Divisions
Only testing makes
technology safe for people.
Our trust in the world of tech-
nology is strong, causing
thoughts of potential danger to
be pushed far into the back-
ground. While this is a tribute
to progress, it also reflects gra-
tifying developments. After all,
being able to trust the experi-
ence of others in many areas
of our lives makes us freer and
Josef Thuringer more independent. Indeed, it
Senior Manager
ZF Test Service is the sole reason why we are
able to trust and use modern
transportation taking us to the
most far-flung corners of the
earth -- at increasing speeds
and rising levels of safety. We
trust that experts have paved
the way, putting technologies
on the test bench, researching
and testing what is technically
possible and proving reliabili-
ty. It is thanks to these com-
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mitted efforts that we can all feel safe. It is
reassuring to be able to place trust. In turn,
such trust is also an obligation and entails
responsibility that must be fully met.
Performance, durability, economic efficiency,
safety and comfort are the essential bench-
marks we measure up to. The work performed
at ZF Test Service is geared to optimizing and
safeguarding the functionality of components
and systems.
In view of shorter developmental cycles and
worldwide pressures on costs, powerful testing
systems and efficient methods and procedures
are becoming increasingly indispensable. Here,
state of the art, virtual world development tools
enter the picture in performing powerful calcu-
lation procedures and flexible simulations.
All these developments, however, are conclu-
ded their verification through experiments on
test systems taking the stringent demands
made on technology into account and genera-
ting the necessary trust in all the technologies
involved.
Josef Thuringer
The ZF Test Centre, with its test and circular
course hall, spreads out over a total of 37,000
square meters, and also offers sufficient space
for field tests.
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Functional and
Component Testing 4

Structural Testing 6

Driveline Testing 8

Acoustics Testing 10

Communication plays a significant New ways and concepts arise Circular Course Test and
role at all levels of ZFs progressive in co-operation with experts Vehicle Measurement 12
management culture. from a wide and varied range
of disciplines. Technical Calculations 14

There is an optimum solution for

all testing tasks -- and we have them all!

We are bringing roads and streets into the laboratory --
with test systems that simulate the desired test condi-
tions in a realistic way. We create laboratory conditions
that are exactly reproducible as well as cost efficient.
Backed by in-depth technology competence and experi-
ence culled from countless projects, the ZF specialists
will assist you in your planning. You will benefit from
the extensive knowledge and skills of an independent
partner.
From design and drafting all the way through to realiza-
tion, our planning teams will focus their entire experi-
ence on your projects and infuse them
with fresh ideas from the drafting to their
final realization.
Professional project management in the
realization phase safeguards the smooth
progress and success of demanding pro-
jects. In this way, coordination input and
time will be reduced, potential conflicts
averted, thereby ensuring smooth techni-
cal handling within the prescribed time
and cost frameworks.

Sensors, transducers and measuring equipment

catering to the most wide and diverse physical
dimensions are calibrated at the companys own
calibrating laboratory. A closed chain of traceability
is achieved through a comparison with working
standards that are calibrated in DKD laboratories
or directly by the manufacturer.

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Functional and
Component Testing
Simulating real life situations.
The starting point for all additional test.
A perfect unit is always
the sum of perfect individual parts.
Realistic no-load operational
conditions delivering valuable
information on unit behavi-
our patterns, are created
during functional tests. The
establishment of the maxi-
mum steady-state tempera-
ture as well as dissipated
energy are the key focus of
these investigations. Here,
test facilities with rotations
of up to 10,000 rotations per
minute are available.
During component testing,
individual components are
tested in terms of their dura-
bility and functionality under
realistic utilization conditi-
Functional test bench
determining steady-state
temperature and dissipated
energy
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ons. The main emphasis lies on the testing
of steering systems and the examination
of different sealing concepts in complete
vehicle axles.
Steering system test benches enable the
transfer of the steering system-specific po-
pulation load established in vehicles from
the roads to the laboratory. Impermeability,
functioning and life expectancy are all tes-
ted at the same time.
A specially developed, computer-controlled
servo-hydraulics regulates all parameters in
real time or a test-time compression popula-
tion.
Mud water test benches serve to test the
seals in complete axles, axle systems and
transmissions. Forward and backward dri-
ving, steering system or spring deflections
are among the possible test parameters. In
addition, the simulation of driving through
water with subsequent drying processes is
possible. Modern automation systems gua-
rantee smooth program sequences.
The supply of lubrication oil is
investigated precisely within the
framework of the functional test.
Specially installed viewing win-
dows allow the visual checking
of flow conditions.
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Cold chamber testing
Axles and transmissions are frozen
in a refrigerating box to test functi-
ons at extremely low temperatures.
In this test, temperatures as low as
-40 C are standard parameters.
Incline test bench (above left)
The incline test bench is suitable for
general investigations on axles, axle
components and transmissions. The
test bench can be inclined up to 45
in two levels with the help of a central
hub mechanism.
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Functional test benches
34 kW / 55 kW / 65 kW
Incline test benches
20 / 65 kW
45 angle of inclination
Cold test chamber
160 kW
Steering system test bench
The test bench checks the Steering system test benches
impermeability, functioning and for complete axles
life expectancy of steering sys-
tem components of every type Mud water test benches
of complete vehicle axles. for complete axles
Mud water test bench (above) Real utilization conditions
Complete axles or transmissions with are simulated and the life-
different sealing concepts are tested time of seals in axles are
for impermeability in continuous realis- tested at the same time.
tic operation or -- for test-time com-
pression -- in a particularly aggressive
mixture of sludge.
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Structural Testing
The safe operating behaviour of products is a major
demand made on development activities. Structural
testing ensures that these demands are reliably met.

Service life, economy and safety

-- structural testing at ZF Test Service

In view of ever increasing Whether dynamic or statistical structu-

time and cost pressures, deve-
lopment tasks in the vehicle
and automotive supplier
industry necessitate efficient,
innovative solutions. This
holds especially true against
the background of the extre-
me increase in testing task
complexity. This entails achie-
ving precise results in conti-
nuously shorter cycles and at
lower costs. These challenges
can only be met by concentra-
ting on the essentials and
deploying the right tools.
ral testing, ZF Test Service has the right
test facilities for every application. The
Hydropuls test bench comprises over
20 linear cylinders for forces from 63 to
400 kN and two rotating cylinders intro-
ducing torques up to 32 kNm. All the
test cylinders can be operated indivi-
dually or in co-operation. The two multi-
channel plants for multi-axis tests form
the core of this test field. Computer-con-
trolled real time fatigue tests or synthetic
population loads can be tested on these
facilities. The modular design of this
comprehensive mechanical equipment
guarantees a high degree of flexibility.

A consistent, comprehensive software

system and associated data processing
deliver statements on the lifetime and
the necessary dimensioning of the test
object in a relatively short period of
time.

Hydropuls test benches

The tests provide information
on the lifetime and the neces-
sary dimensioning of the test
object. Real time fatigue tests
are also possible here, apart
from synthetic load populations.

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Hydropuls test bench

with torsional and longitu-
dinal cylinders (16/32 kNm
and 63-400 kN)

Test objects team up with sensors Torsion cylinder

Test objects fitted with measuring For combined driveline
technology supply information on and structural testing
stretching and therefore on loads
at specially defined points. This
enables direct comparisons with
calculations.

Multi-axis structural testing Operation room

The Hydropuls testing facility forms A consistent, comprehensive soft-
the core the structural test. Among ware system enables the recording
other processes, it is possible to and processing of measuring data
simulate a computer-controlled and their provision for calculation
multi-axle spectrum of loads here. and simulation, all the way through
to generation of test programs.

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Driveline Testing
The torque loading at axles and drive units are tested during drive
unit line tests. The control system is capable of simulating realistic
conditions as fully automatic operations around the clock.

Rotations up to 11,000 rpm? Torques

up to 120,000 Nm? No problem for us!

ZF shifts road testing to the
laboratory, thereby trimming
development times and dis-
pensing with expensive dri-
ving tests. Our precisely
adjusted simulation and auto-
mation technology are the
decisive factors ensuring suc-
cessful laboratory tests. All
parts of the entire vehicle,
driver and street system can
be simulated in different com-
binations on the test benches.
Automatic test sequences gua-
rantee the high reproducibili-
ty of the test conditions and
thereby the comparability of
results. You can rely on our many years of
experience in the sector of simulation test
technology. Flexible solutions meeting a
wide range of individual requirements are
one of our key strengths.
The drive line test field comprises approxi-
mately a dozen test benches of varying de-
sign and construction types. A host of drive
unit variants can be reproduced, from a
simple dual inline operation through triple
machine T operation to 4-machine all-
wheel drive units.
The range of services also includes loaded
runs, differential and contact pattern inves-
tigation on axles, differentials and transmis-
sions for automobiles, freight vehicles,
coaches as well as for agricultural and con-
struction machines or special applications.
Our testing facilities are available 24 hours
a day, 365 days a year. Our in-depth know-
how and the resulting technology lead gua-
rantee the continuous availability of inno-
vative and high-quality testing.

Measuring and operational room

All test facilities are automated
and equipped with control and
measuring computers. The test
processes are tracked and moni-
tored by measuring terminals.
Four-machine load test bench
Universal test bench with four
electrical drive units performing
loaded runs, differentials, wheel
heads, distributor transmissions
and special drive units.

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Load test benches

in T arrangement 270-450 kW

Four-machine load test bench

200 kW

Inline test benches

80-300 kW

Disassembly-free, endoscope video High-precision measuring

inspection system establishing degree
of effect

Modern multi-machine test bench Load test bench

Testing loads of drive unit inline Loaded runs, differential and
components up to complete drive contact pattern investigations
unit inline systems with high torque loads

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Acoustics Testing
Reduced noise limits and the significantly increased customer
awareness of comfort are pushing acoustic development increa-
singly into the foreground. You can count on our expert support
as your reliable, competent partner.

Perfect units down to the last detail

-- call on our acoustics competence!

The acoustic characteristics of tional vibration and impact measurements.

a product represent a decisive
competitive factor. We at your
service as a strong, reliable
partner, enabling you to keep
in step with the rising require-
ments in the area of acoustics
and vibration technology.
We command all the necessary
knowledge and skills, as well
as the sophisticated tools and
facilities to cope with all rele-
vant tasks. The range of ser-
vices of our acoustics specia-
lists includes the multi-chan-
nel recording of the air-borne
sound and structure-borne
sound, in addition to complex
analyses of rotation and opera-
At ZF Test Service, there is a differentiation
between the focus areas of test bench work
and vehicle acoustics.
Investigations at the test bench guarantee
high reproducibility, allow direct compari-
sons and can be carried out in a time effi-
cient way. Two test benches, which are
equipped with large, low noise-reflexion
acoustics measuring spaces, are available
for these tasks.
Vehicle measurements have the advantage
that they concern typical product utilization
cases on the one hand, while specific or
critical operational states can be investiga-
ted on the other.
Apart from conventional methods of sound
measuring technology, modern measuring
systems, which can record sound in a cor-
rect and faithful manner in terms of acous-
tics, are available for driving tests. All data
are promptly analyzed, processed and simu-
lated in the acoustics laboratory.

One of the core skills of ZF is the

manufacture of bevel gear sets. Their
running noise is a significant quality
characteristic here. It is possible to
comprehensively evaluate noise beha-
viour by means of acoustic testing.

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Acoustic test benches

T arrangement 272 kW,
360 kW (low reflexion test
chambers)

Comprehensive vehicle measure- Data obtained from vehicle

ments are carried out to verify the measurements are immediately
test bed measuring results in analyzed and evaluated online.
practical applications.

Acoustic test benches Leading-edge measuring

The acoustics tests are performed in the low equipment and instruments
reflexion test chambers. The course of the enable a comprehensive
tests can take place in a T arrangement, or investigation of the data at
inline or individual machine operation. the test bench and in the
vehicle.

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Circular Course Test and
Vehicle Measurement
Driver-less driving tests are carried out under realistic working conditi-
ons in our own circular course hall. Vehicle measurements create the
data basis for all further testing.
We transform
roads and streets into test beds!
Reproducibility independent
of weather conditions and
operation without drivers on
the circular course represent
an attractive, cost efficient
alternative to durability tests
on the road. The bump ob-
stacle test is the most impor-
tant test procedure on the
circular course with a 50 m
radius. Structural parts such
as axle bracket, steering
knuckles, suspensions and
spring systems or steering
system components are tested
for load-bearing capacity and
life expectancy.
Measuring wheel
Prior to testing, vehicles are
equipped with sophisticated
sensors
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Here, the test object is pulled across ob-
stacles of different geometries and arrange-
ments by a lane-guided vehicle in a suitable,
padded test device. Vertical impact loads
are achieved in this manner.
Stress tests that have been passed -- some-
times beyond actual requirements -- guaran-
tee the unlimited everyday capability of
the components or the complete vehicles.
Measurements in the vehicle provide infor-
mation on component loads in everyday
conditions. Values acquired serve as the
basis for additional investigations or as the
validation of the model for technical calcu-
lations.
The measuring equipment available at ZF
Test Service covers the entire product
range, from automobiles through to com-
mercial vehicles and on to machines. The
establishment of load populations, stress
analyses and the synchronous video analy-
sis of measurements are only a small part
of our comprehensive range of services.
Tires test
In addition to axle loading,
tires and wheels can also be
subjected to continuous load
testing.
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Circular course testing

Tires test
Bump obstacle test for
structural testing
Lane-guided vehicle
testing

Vehicle measurement
On-road and off-road
Drive test Synchronous recording testing
Vehicle tests are carried out at our of measuring data and Load cycle recording
own driving yard or on defined video images Noise level testing
routes within a radius of 200 km.

Circular course Vehicle measurement

24-hour fatigue testing without driver and A wide range of diverse
closely simulating actual conditions are measurements on vehicles
advantages of the circular course testing of are also conducted at our
load-bearing capacity and life expectancy. testing site.

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Technical Calculations
In components calculation, customer requirements are
implemented in a targeted manner in the dimensioning
of new products.

Competent partners
in the development process

As a service provider in cross- methods we are able to shape and deter-

sector development, we are
available as an innovative
and competent partner in the
technical calculation and the
CAE/PDM user service. In
supporting the product gene-
ration process, we draw on
leading-edge, process oriented
methods, combined with a
high degree of flexibility. We
are committed to the aims of
shortening development cyc-
les, minimizing costs and con-
tinuously improving quality.
By utilizing state of the art
CAD/CAE software and
advanced, latest generation
mine the development process in a deci-
sive manner.
Before the first prototype actually exists, it
can already be investigated on the virtual
simulation model, enabling weak points to
be recognized at an early stage and the
optimum variant filtered out from different
drafts.
Different cases of loading -- derived from
simulations or measurements -- can be eva-
luated accompanying development. The
influence of the components on durability
is established at an early stage through
fatigue strength analyses. The depiction
of the realistic simulation model is conti-
nuously improved through the permanent
ongoing adjustment and balancing of the
load and boundary conditions with testing.
In this way, it is possible to reduce testing
on actual prototypes to the necessary
levels. This saves time and makes a deci-
sive contribution to competitive strength.

Optimization
Innovative lightweight
structures arise because
of the targeted application
of optimization methods.

Analysis of eigenvalues
Rising demands on noise
behaviour necessitate timely
investigation of dynamic
behaviour

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Design methods
Finding concepts
Development accompanying
calculations

System behaviour
Kinematics
Component analysis Analysis of structural
Vibration
Implementation of detailed FE ana- components
lyses on system components FE model of automobile Strength
differential Stiffness
Optimization
Verification
Durability

Complex Structures Durability calculation

Implementation of complex Analysis of fatigue life during the
FE analyses of entire sys- development process results in
tem, taking into account products dimensioned to ensure
the adjacent structures operational reliability.

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ZF Passau GmbH
Test Service
D-94030 Passau
Telefon +49 851 494-5613
Telefax +49 851 494-5638
www.zf.com
sales.art@zf.com

A-RT / TEST SERVICE 06E / Design: Graswald & Heiligtag, Passau / Druck: Ostler-Druck, Passau

Driveline and Chassis Technology