Carroll A. Campbell Jr. Graduate Engineering Center Automotive Testing Equipment

1. Renk Labeco 4-Wheel 500 HP Chassis Dyno and Faist Semi-Anechoic Chamber

The Renk system is a low-noise chassis dynamometer housed in a semi-anechoic chamber, making it able to perform driveline noise studies, mileage assessments, sound measurements and all other chassis dynamometer and sound room-related test activities.

Renk Labeco Chassis Dyno Features and Specifications:

  • Special noise reduced machine design
  • Overhanging roller design with inspection walkway
  • Capable of testing of vehicles having FWD, RWD and 4WD
  • ABS/ASR car systems do not affect testing procedure
  • Includes compensation during test operation for mechanical losses
  • Dynamometer drive with speed-and torque-controlled AC-motor (4-Q operation)
  • Road load function is fully implemented
  • Noise and vibration optimized design
  • Temperature range inside test chamber: 10°C (winter) to 40 °C (summer)
  • Max front axle weight of test vehicle: 3000 kg
  • Max rear axle weight of test vehicle: 2400kg
  • Max. total ehicle weight: 5000kg
  • Vehicle drive configurations: FWD, RWD, 4WD
  • Noise emission 1m above roller at 100km/h: 50 dB(A)
  • Max. speed: 200 kph
  • Max. power per roller: 95 KW (127 hp)
  • Max. total power: 380 KW (510 hp)
  • Number of rolls: 4
  • Roll diameter: 1274 mm
  • Roll width: 650 mm
  • Axle base of vehicles under test: 2,100-3,500 mm
  • Max outer wheel distance: 2330 mm
  • Max inner wheel distance: 1185 mm
  • Max. traction force per roll: 4000 N
  • Max. roller speed: 850 rpm
  • Equivalent base inertia of roller set: 1560 kg
  • Roll surface: Smooth machined steel
  • Friction coefficient steel to rubber: approx. 0.7 – 0.8
  • Balancing quality: (VDI 2060)Q 2.5
  • Vehicle cooling airflow: 600 to 30580 m3/hr
  • Exhaust suction airflow: 600 to 4080 m3/hr

Faist Sound Room:

  • Broad band compact absorber design (no wedges, 350 mm thick)
  • Conforms to ISO 3745
  • Frequency range 50 – 10,000 Hz
  • Room size: 9350 mm long by 8230 mm wide by 4570 mm high
  • Door size: 3480 mm wide by 3000 mm high

2. MTS 320 Tire Coupled Road Simulator and Weiss Climate Test Chamber

This system consists of an MTS 320 road simulator with 4 vertical servo-hydraulic actuators to simulate vertical road inputs, coupled with 3 down force actuators to simulate aerodynamic forces, roll moments, and pitch moments. The Weiss climate chamber is capable of -40C to +85C operation and a relative humidity range of 15% – 95%. This equipment also includes an MTS SWIFT wheel force transducer, a SoMat in-vehicle data acquisition system, and MTS RPC-Pro software, all of which will be used to develop real time test inputs based on actual on-road or proving ground measurements. This test facility will support activities such as squeak & rattle testing, vibration testing, structural durability testing, suspension characterization testing, and fastener testing. Having the road simulator in an environmental chamber allows for many unique testing possibilities.

MTS 320 Road Simulator Features and Specifications:

  • Maximum total vehicle weight:  5000 kg
  • 35 KN actuators, 250 mm stroke, 340 L/min flow rate servo-valves
  • Moveable floor and actuators accommodate wheel bases of 2,450 mm to 3,300 mm (Mini-Cooper to Humvee)
  • Maximum velocity of 3,500 mm/s and maximum acceleration of 17 G
  • Drive-on system (actuators located in a pit)
  • FlexTestIIm control system
  • Adaptrac adaptive control software
  • RPCPro drive file creation and editing software
  • SWIFT 30T Wheel Force Transducer System for measuring road inputs
  • On-vehicle data acquisition system (Somat EDAQ)

 

Weiss Environmental Chamber Features and specifications:

  • Climate chamber dimensions: 8,750 mm, 6,475 mm and 3,350 mm
  • Door opening: 3,023 mm wide by 2,438 mm high
  • Temperature range: -40 C to 85 C
  • Humidity range: 15 percent to 95 percent
  • Heating rate (average): 1.3 C/minute with 3,000 kg vehicle in the chamber
  • Cooling rate (average): 0.9 C/minute with 3,000 kg vehicle in the chamber

3. FEV 500 HP Engine Dyno Test Cell

A containerized and expandable facility, this system accommodates testing of performance, engine durability and components, emissions, fuel, catalysts, and engine mapping and calibration.

Features and specifications:

  • Containerized test facility
  • Test cell management system for data acquisition and control
  • Rated Power: 428 kw (580HP)
  • Rated Torque: 950 N-M
  • Rated Speed: 4,300 rpm
  • Maximum Speed: 9,000 rpm
  • Inertia: 0.81 kg m2
  • Speed Gradient: 9,000 rpm/sec
  • Ultra low vibration and noise
  • Transient cycle capability (HDDT, FTP 75)
  • Integration of Dyno drive, throttle actuator and torque flange
  • Quick change pallet
  • Entire measurement equipment on pallet (including ECU)
  • Standardized connections to drive shaft, exhaust system
  • Manual quick connectors for media, measurement equipment, electrical
  • Capability of commissioning outside test cell

 

Modular design 19-inch Rack Mount Instrumentation Package including:

  • 16 Analog voltage inputs, 16 outputs
  • 16 “J” Type thermocouple inputs
  • 16 “K” Type thermocouple inputs
  • 16 pressure transducers
  • 32 Digital inputs
  • 32 Digital outputs
  • 12 Frequency inputs
  • High transmission reliability
  • CANopen Interface
  • High flexibility
  • Expandability

4. ETS Lindgren Electromagnetic Compatibility Chamber

An ETS Lindgren FACT-3-2.0 PREMIUM high-performance, RF-shielded, 3 meter semi-anechoic chamber for EMC testing supports FCC and CISPR radiated emissions tests as well as electromagnetic immunity testing up to 100V/m.

Features and specifications:

  • Chamber size: 8,530 mm x 6,100 mm x 5,490 mm
  • ANSI C63.4 (2003) acceptance tested
  • CISPR 25 conducted and radiated EMC testing
  • FCC Part 15 EMI testing
  • IEC 61967-2, 3, 4 Integrated Circuit EMC testing
  • Most MIL-STD 461 EMC measurements
  • Power bus transient testing
  • Electrostatic Discharge Susceptibility testing
  • Antenna impedance and pattern measurements
  • Electromagnetic model validation

5. MTS Model 891-00-25 Vibration Table with Additional Fixed Reaction Load Frame:

Features and specifications:

  • Frequency range of 0.1 to 100 Hz
  • Can perform inertial reaction vibration testing or fixed reaction load/fatigue testing
  • 48” square aluminum table
  • Table natural frequency is greater than 200 Hz
  • 12,000 lb reaction mass with air suspension
  • MTS 40 KN (9 KIP) hydraulic actuator (model 248)
  • 30 gpm hydraulic oil supply
  • MTS 407 Servo-controller
  • Data Physics SignalStar Vector Vibration Controller
  • Sine, random, mixed mode, resonance search and dwell, classis shock, SRS, transient, and time wave replication control modes.

6. Machine Shop

A well equipped machine shop with turning, milling, drilling, sawing, welding and plasma cutting capabilities is located within the Campbell Center.

Machine Shop Equipment

  • ACRA FEL 1640 CNC Lathe (16” X 40” / CNC or manual operation)
  • ACER 3VKH E-Mill (3 Axis / CNC or manual operation)
  • Lincoln Pro-Cut 55 Plasma Cutter with 5’X5’ Plasma Cam CNC Table
  • Lincoln 300 MIG Welder
  • Wilton 7040 Horizontal Band Saw
  • Parma-Dake 20” Vertical Band Saw
  • Wilton 2221VS 20” Floor Drill Press
  • Wilton 2530 15” Bench Drill Press
  • Dake 25 Ton H-Frame Hydraulic press
  • Wilton 4200A Belt and Disc Finishing Machine
  • Bench Grinders
  • Sand Blaster

7. Data Acquisition and Instrumentation Services

The Campbell Center is equipped with a full range of instrumentation and portable data acquisition tools for the collection of engineering data on the road, in the field, and in the laboratory. The staff includes one engineer and three technicians with extensive industry experience. Capabilities and resources are outlined below and include the following:

Data Acquisition Equipment:

  • Two SoMat EDAQ multi-purpose data acquisition systems with a total of 88 measurement channels including 40 strain gage/bridge channels and 8 thermocouple inputs.
  • Mueller MKII 28-channel data acquisition and analysis system with PAK software for NVH measurement and analysis projects.
  • Miscellaneous National Instruments equipment and instrumentation
  • dSpace microautoboxes and HIL simulator platform

 

Sensors and Measurement Capabilities:

  • Full capabilities to instrument vehicles for on and off road measurements
  • Complete strain gage installation and measurement services
  • DC and modal accelerometers
  • Impact hammers for modal analysis
  • Type I microphones (7) and Larson Davis 831 sound level meter.
  • Custom strain gage based load cell design, fabrication, and calibration capabilities
  • Miscellaneous displacement transducers, gear tooth sensors, optical tachometers, thermocouples, angular rate sensors, DC current transducers, etc.
  • Vehicle bus and GPS measurements

 

Data Analysis Software

  • Matlab
  • Dadisp
  • SoMat Infield
  • MTS RPC Pro
  • Mueller BBM PAK 5.5
  • University of Cincinnati XModal
  • Data Physics SignalCalc Mobilyzer Dynamic Signal Analyzer

 

8. General Purpose Lab

The laboratory has a large general purpose high bay area with a 5 ton overhead crane and two Rotary vehicle lifts. One is a two-arm 10,000 lb capacity lift and the other is a four-post 14,000 capacity alignment lift.

9. Support Staff

The technical support staff consists of a research engineer with over 20 years of on and off-road automotive test and measurement experience and three technicians with 60+ years of combined industry experience. The technical staff skill-set includes machining, mechanics, electronics, instrumentation, servo-hydraulics, measurements, and testing.