Kistler 9289A113 Owner's manual

Instruction

Manual

RoaDyn S220

Measuring hub for

tire test stands

Type 9289A103



9289A_002-494e-07.21

Foreword

9289A_002-494e-07.21 Page 1

Foreword

Thank you for choosing a Kistler quality product

characterized by technical innovation, precision and long

life.

Information in this document is subject to change without

notice. Kistler reserves the right to change or improve its

products and make changes in the content without

obligation to notify any person or organization of such

changes or improvements.

as expressly provided herein, no part of this manual may

be reproduced for any purpose without the express prior

written consent of Kistler Group.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

[email protected]

Kistler Instrumente GmbH

Umberto-Nobile-Str. 14

71963 Sindelfingen

Deutschland

Tel. +49 7031 3090 0

info.de@kistler.com

www.kistler.com

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 2 9289A_002-494e-07.21

Content

1.Introduction .................................................................................................................................. 4

2.Important notes ........................................................................................................................... 5

2.1For your safety .................................................................................................................... 5

2.2Warnings ............................................................................................................................. 7

2.3How to treat the instrument ................................................................................................. 8

2.4What happens after modifications? ..................................................................................... 8

2.5Disposal instructions for electrical and electronic equipment ............................................. 8

2.6Software upgrades and updates ......................................................................................... 8

3.General description of the instrument ...................................................................................... 9

3.1Field of application of a multi-component measuring hub S220 ......................................... 9

3.2RoaDyn S220 measuring chain digital and analog ........................................................... 10

3.3Technical data ................................................................................................................... 11

3.4Additional Documents ....................................................................................................... 11

4.Installation .................................................................................................................................. 12

4.1Preparation and tools ........................................................................................................ 12

4.2Preparation for mounting the measuring hub on the test bench ....................................... 13

4.2.1Measuring hub mounting location ........................................................................ 14

4.2.2Mounting on the test stand ................................................................................... 15

4.3Preparation of oil connection ............................................................................................ 16

4.3.1Connection of RoaDyn S220 with digital electronics KiRoad TT Type 9820A... .. 17

4.3.2Connection of RoaDyn S220 with analog electronics Type 5633A ..................... 17

5.Oil lubrication ............................................................................................................................ 19

5.1Oil connection ................................................................................................................... 19

5.2Oil circulating lubrications ................................................................................................. 20

5.3Oil lubrication system ........................................................................................................ 21

5.4Mounting oil hoses from the rear side of the test stand .................................................... 22

5.4.1Plug in the 5 oil hoses into the oil lubrication unit according Fig. 10 ................... 25

5.5Run the system ................................................................................................................. 26

5.5.1Oil lubrication ........................................................................................................ 26

5.5.2Final check ........................................................................................................... 26

5.5.3Mount adapter onto the RoaDyn S220 (if needed) .............................................. 26

5.5.4Mount the wheel ................................................................................................... 27

5.5.5Set Measuring values to zero ............................................................................... 27

6.Operation .................................................................................................................................... 28

6.1Permissible loads on the measuring hub .......................................................................... 28

6.2Service life of bearings ...................................................................................................... 28

6.3Setup DAQ ........................................................................................................................ 29

6.3.1With digital electronics Type 9820A… ................................................................. 29

6.3.2With analog electronics Type 5633A1 .................................................................. 29

6.4Run the system ................................................................................................................. 30

7.Maintenance ............................................................................................................................... 31

7.1On-side Fx calibration by the use of dead weights ............................................................ 31

7.1.1Preparation of Equipment .................................................................................... 31

7.1.2Deadweight calibration procedure ........................................................................ 32

7.2Checking calibration, function test and recalibration ........................................................ 37

Content

9289A_002-494e-07.21 Page 3

7.2.1Checking calibration and function test .................................................................. 37

7.2.2Recalibrating the measuring hub .......................................................................... 37

7.3Maintenance work .............................................................................................................. 37

7.3.1General ................................................................................................................. 37

8.Troubleshooting ......................................................................................................................... 38

8.1Fault location and rectification ........................................................................................... 38

8.2Technical support ............................................................................................................... 39

9.Appendix ..................................................................................................................................... 40

Total pages: 43

Introduction

9289A_002-494e-07.21 Page 4

1. Introduction

Please take the time to thoroughly read this instruction

manual. It will help you with the installation, maintenance,

and use of this product.

To the extent permitted by law, Kistler does not accept

any liability if this instruction manual is not followed or

products other than those listed under Accessories are

used.

Kistler offers a wide range of products for use in

measuring technology:

 Piezoelectric sensors for measuring force, torque,

strain, pressure, acceleration, shock, vibration and

acoustic emission

 Strain gage sensor systems for measuring force and

torque

 Piezoresistive pressure sensors and transmitters

 Signal conditioners, indicators and calibrators

 Electronic control and monitoring systems as well as

software for specific measurement applications

 Data transmission modules (telemetry)

Kistler also develops and produces measuring solutions

for the application fields of engines, vehicles, manufac-

turing, plastics and biomechanics sectors.

Our product and application brochures will provide you

with an overview of our product range. Detailed data

sheets are available for almost all products.

If you need additional help beyond what can be found

either on-line or in this manual, please contact Kistler's

extensive support organization.

Page 4 9289A_002-494e-01.12

Important notes

9289A_002-494e-07.21 Page 5

2. Important notes

It is essential for you to study the following information,

compliance with which is for your personal safety during

use and will ensure long, fault-free operation of the

instrument.

2.1 For your safety

This product has been manufactured in compliance with

current valid safety regulations. It has been thoroughly

tested, leaving the factory in a perfect, safe condition. In

order to maintain this condition and ensure safe

operation, compliance is required with the instructions

and warning notes contained within this manual.

Compliance with local safety regulations, which apply to

the use of power line operated electrical and electronic

equipment, is strongly recommended.

Compliance with the following precautionary

measures is vital to ensure safe and reliable

operation.

 The measuring hub must be installed, operated and

serviced only by qualified persons who are familiar

with this kind of instruments

 If there is evidence that safe operation is no longer

possible, the instrument must be powered off and

rendered safe against accidental start-up. Safe

operation is no longer possible when the product:

 shows visible signs of damage

 is no longer operating

 has been subjected to prolonged storage under

unsuitable conditions

 has been subject to rough transit conditions

 When utilizing an external AC/DC power adapter, be

certain to use the proper input line voltage and proper

output DC voltage prior to power-up

 Never expose the instrument to contamination or oil

mist

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 6 9289A_002-494e-07.21

 Never operate or store the instrument outside the

specified temperature range

 Never exceed the maximum stated voltage

 Connect the instrument only to equipment for which it

was designed to be used

 Never allow the product to drop

 The environment should be as dry, clean and free

from vibrations as possible

 Never operate the instrument if there are visible signs

of damage

For wheel force measurements, secure the

measuring hub to the test bench correctly!

Secure all parts mounted on the shaft according to

the anticipated forces!

Important notes

9289A_002-494e-07.21 Page 7

2.2 Warnings

The measuring hub is designed and manufactured by

Kistler Instrumente AG according to the best enginee-

ring knowledge and the latest state of technology.

These components, however, are not designed for

indefinite use. They are highly stressed high-perfor-

mance products and as such have a limited life, since

they are subjected to wear and tear and in extreme

cases to fatigue stress.

For this reason, the following safety measures must be

strictly observed:

 The loading for the measuring hub and its accessories

must basically not exceed the overload ranges

specified in the Type 9289A data sheet

 If the user has reason to believe that these overload

ranges have been exceeded, he must have the parts

tested (according to the situation, for example: visual

inspection, crack analysis etc.)

 All parts must be subjected to a visual inspection on

each occasion before use

 As soon as any signs of damage (crack, deformations

etc.) are visible, further use is prohibited

 Strict compliance is required with the operating

instructions during mounting, in particular concerning

tightening torques for screws, the correct fitting of

parts, adequate clearance for the fixation arms and

safe cable installation

 A crack test must be carried out after the first 100

hours operating time

 After 500 hours operating time, the instrument wheel

and the accessories must be subjected to a crack test

periodically

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 8 9289A_002-494e-07.21

2.3 How to treat the instrument

 The measuring hub may only be used under specified

environmental and operating conditions

 Protect the signal output of the instrument against

contamination and do not touch it with your fingers. Fit

the cover supplied when the connection is not used

 Protect the measuring hub while it is not in use by

keeping it in the transport and storage box supplied

2.4 What happens after modifications?

Modifications to instruments result in alterations of the

operating instructions as a rule. In such cases, enquire at

your Kistler distributor about the possibilities of updating

your documentation.

2.5 Disposal instructions for electrical and electronic equipment

Do not discard old electronic instruments in municipal

trash. For disposal at end of life, please return this

product to an authorized local electronic waste

disposal service or contact the nearest Kistler

Instrument sales office for return instructions.

2.6 Software upgrades and updates

Kistler may occasionally supply upgrades or updates for

embedded software. Such upgrades or updates must

always be installed.

Kistler declines any liability whatsoever for any direct or

consequential damage caused by products running on

embedded software which has not been upgraded or

updated with the latest available software.

General description of the instrument

9289A_002-494e-07.21 Page 9

3. General description of the instrument

3.1 Field of application of a multi-component measuring hub S220

The RoaDyn S220 measuring hub is used for rolling

resistance measurements according the commonly used

global regulations (ISO 28580, SAE J1269, ECE R117)

for passenger car tires up to tire load index 121.

Therefore, two of the orthogonal components (Fx and Fz)

which are acting on the shaft respectively on the tire

patch will be measured.

The measuring hub has a high accuracy with lowest

crosstalk and thus the ability to measure smallest

longitudinal forces (Fx) while a high normal force (Fz) acts

simultaneously. As a result of the ability to measure Fz,

the measuring hub is perfectly suited also to be used for

the test-stand controlling. It mea measures the active

wheel force independently of its point of application. Both

the average force and dynamic force changes can be

measured. The useful frequency range depends mainly

on the resonant frequency of the entire test rig.

The main application of use for the multi-component

measuring hub is:

 Rolling resistance measurement

As a result of the specific construction, lowest longi-

tudinal forces (Fx) applied on the tire patch could be

precisely measured at a high nominal force (Fz).

Fig. 1: Measuring hub Type 9289A103

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 10 9289A_002-494e-07.21

3.2 RoaDyn S220 measuring chain digital and analog

Below are the measuring chains with single

measuring hub and digital and analog electronics.

Fig. 2: Digital measuring chain RoaDyn S220

Fig. 3: Analog measuring chain RoaDyn S220

In case any problems occur during the setup, please

contact your local Kistler office.

Measuring Hub

RoaDyn S220

Type 9289A103

Analog

Electronic

Type 5633A1

DAQ

Fz UAFxi (i= a...c)

UAFzi (i= a...c)

AD-converter

10 channels

±10V

Cable L= 4m

Type 1795A14

Cable

Lmax= 25m

DC 10...36V

(5...10W)

UAFyi (i= a...c) Calculation algorithms

according specifications

A

D

Fx

Fz

Temp

D

A

Supplied by customer

T

General description of the instrument

9289A_002-494e-07.21 Page 11

3.3 Technical data

Specifications

Measuring range Fx

Fz

N

–400 … 400

15 000

Instrumentation accuracy Fx

Fz

N 1)

or

% 1)

N 1)

or

% 1)

±0,5

±10

±0,5

Max. Load Fx

Fy

Fz

N

±1 500

±500

0 … 20 000

Calibrated range Fx

Fz

N

0 … 400

0 … 15 000

Operating temperature range °C 5 … 80

Degree of protection (cable mounted) DIN40050 IP65

1) dependent upon which value is higher

For detailed specifications please refer to data sheet

9289A_000-761e. The actual document is available on

the Kistler website: www.kistler.com

3.4 Additional Documents

 Calibration data sheet

 Data sheet 000-761e

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 12 9289A_002-494e-07.21

4. Installation

4.1 Preparation and tools

The work surface must be clean and dry. Use appropriate

storage surfaces and lifting gear.

The measuring hub must be fitted only by trained

personnel. Make sure screws and bolts are never

over-tightened beyond their specified torques.

Use suitable lifting gear when fitting a measuring hub.

Support the measuring hub at all times to prevent it

from dropping.

Make sure that it is never exposed to any hard

strokes! The force of such shocks may exceed the

measuring range of the instrument and cause

permanent deformations.

Do not use inappropriate tools like, for example, a

hammer to position the rim adapter (hammer strokes

may cause deformation of the bearings or rim).

Use health and safety equipment (wear safety shoes

and gloves).

In the following chapters, you will find information on

installing the measuring hub and basic details for

setting up the test rig.

Installation

9289A_002-494e-07.21 Page 13

4.2 Preparation for mounting the measuring hub on the test bench

Please comply with the following notes for correct

mounting of the measuring hub:

 The measuring hub must only be installed by persons

who are familiar with the instrument and are

adequately qualified for this work

 Before connecting the cable to the measuring hub

clean both sides of the connector (measuring hub and

cable) with the cleaning and insulation spray Type

1003. Check orientation by bringing the mark on the

connector of the cable in line with the hole of the

metal sheet (Fig. 2). Plug in the cable until a proper

contact is made

 Before mounting the measuring hub on a test bench

or another test device also connect the oil hoses as

explained in chapter 5.1

 Before mounting the measuring hub on a test bench

or another test device, check that the mounting

surface is flat and clean. Uneven and dirty contact

surfaces cause internal distortions, which will expose

the individual force sensors to additional high shear

stresses and can increase crosstalk

Fig. 4: Connection

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 14 9289A_002-494e-07.21

4.2.1 Measuring hub mounting location

The measuring hub could be mounted either on the left or

the right side of the drum (Fig. 6).

Fig. 5: Horizontal drum axle with different positions of

the measuring hub

As the coordinates are in fixed relation to the measuring

hub, they remain for all positions the same:

Fx: Longitudinal force (rolling resistance)

Fz: Normal force

To avoid overload on the X direction, ensure that the

measuring hub is mounted in the correct orientation.

The measuring hub is provided with oil lubrication. It must

be performed with the specific oil-supply related

to the mounting position as described in Fig. 6.

Installation

9289A_002-494e-07.21 Page 15

4.2.2 Mounting on the test stand

Depending on the design of the tire test stand it is

recommended to mount all equipment on the rear side

(e.g. resolver, slip ring, oil hoses, etc.) before mounting

the RoaDyn S220 onto the tire test stand.

Standard mounting of the measuring hub by using six

M16x60 mm screws on pitch circle diameter of 280 mm.

Screws must be tightened with a torque of

180 … 190 Nꞏm.

The positioning is given by two 10 mm pins which are

also located on the pitch circle diameter 280 mm. These

positioning pins allow accurate mounting and remounting

of the measuring hub. Therefore, adjustment of position

according the regulations is recommended to be done on

a second layer.

Fig. 6: Measuring hub with wheel mounted on the tire

test stand

 Ensure that the measuring hub makes absolutely flat

contact. Even the slightest gap will produce unwanted

elasticity and cause a reduction in the resonant fre-

quency of the measuring arrangement. Therefore,

examine all structures also for vibration

 Wherever possible, the connecting cable should

remain permanently connected to the measuring hub

 Fit the connecting cable and the oil tubes so that it

cannot shear off or be ripped out during operation

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 16 9289A_002-494e-07.21

4.3 Preparation of oil connection

The following instructions will give you a stepwise

explanation about the mounting of the RoaDyn S220 onto

the tire test stand.

To avoid any shunt-force measurement due to a strong

contact to the test stand, we strongly recommend taking

out the oil hoses at the rear side as shown in the

following picture. Therefore, the straight oil connectors

are already mounted.

Fig. 7: Check if sealing is correctly done by connecting

to oil lubrication system according instructions in

chapter 5.1

Installation

9289A_002-494e-07.21 Page 17

4.3.1 Connection of RoaDyn S220 with digital electronics KiRoad TT Type

9820A...

Fig. 8: Connection with digital electronics

4.3.2 Connection of RoaDyn S220 with analog electronics Type 5633A

Fig. 9: Connection with analog electronics

RoaDyn S220 Measuring hub for tire test stands Type 9289A103

Page 18 9289A_002-494e-07.21

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