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Transmission test bench

Performance analysis of vehicle transmissions

The core of automotive innovation can only pass through test benches and experimentation. In case of single transmission testing, Control Sistem offers the design, construction and commissioning of test benches and test cells used to perform any type of test on transmissions for light-duty or heavy-duty vehicles.

The traction that can be tested on Control Sistem Transmission Test Benches can be classic (endothermic engines), full electric or hybrid. The transmission unit tested can be either transverse or longitudinal (gearbox + differential) or a differential only. In addition, the test bench is able to handle both manual and automatic transmissions.

Depending on the case, the test bench is mainly composed of two, three or five electric motors. In case of testing a 2WD transmission, two electric motors are in charge of simulating vehicular inertia, while the third is responsible for simulating the vehicle internal combustion engine. Similarly, in the case of testing a 4WD transmission, there are four electric motors in charge of simulating vehicular inertia, while the fifth eventually deals with the simulation of the combustion engine.

Features

  • Dynamometric brakes: the right coupling between the electric motors (or dynamo) and the drive panel guarantees high regulation accuracy and therefore allows an accurate evaluation of the performance of the transmission in all conditions.
  • Transmission chain: to ensure the necessary mechanical connection between each motor brake and the transmission under test, Control Sistem designs and assembles a telescopic transmission chain for each motor of the test bench. Each transmission chain is equipped with a torque flange with a customizable scale and able to communicate with the automation system either in analog or in EtherCAT, if necessary.
  • Electric motor movement system: in order to adapt the bench to the transmission under test, the motor units can be easily moved by means of a lifting system that uses the factory's compressed air and anchored to the floor by means of electromagnets.
  • Measurement instrumentation: the test benches are equipped with sensors useful for ensuring both good regulation (such as encoders, torque transducers, etc.), and measurement and evaluation of the performance tested on the bench.
  • Automation system: transmission test bench automation systems simplify and optimize the testing process for the maximum operational efficiency. In addition, it allows the operator to carry out the several phases of preparation and testing of the transmission in a simple, automatic and intuitive way.
  • Automatic gear change systems: in the case of testing transmissions with manual transmissions, it is necessary to equip the test bench with a system capable of automatically varying the gear to be engaged. This system consists of an anthropomorphic robot capable of acting on the gear lever and an actuator capable of acting on the transmission clutch.
  • Test Cells: in addition to test benches, Control Sistem is able to design and build the cells that house the test benches themselves. As a General Contractor, many Control System projects start from the ground or floor and go all up the way to the realization of a turnkey project.

Products

Transmission test bench for light vehicles

Control Sistem aim to meet this need by providing a controlled and accurate environment to test and optimise light duty transmissions.

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Transmission test bench for heavy vehicles

Heavy-duty transmissions are the heart of vehicles such as cars, vans, SUVs, etc.

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TRICEX

Automation system for transmission test benches

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Automatic gear change and pedal management system

Gear lever and clutch management system for transmission test cells

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Why Choose Control Sistem

  • Engineering: test benches are specifically engineered and designed for the requirements of the vehicles or motorbikes to be tested.
  • Customising: for Control Sistem there are no real standard catalogue products, but any solution can be engineered to meet customer specifications.
  • Precision: every component is carefully designed to ensure precision and reliability.
  • Experience: thanks to a long history in the automotive industry, Control Sistem expertise is a guarantee for the provision of a safe and reliable system.

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