Kistler 9289A013A1 Owner's manual

Instruction

Manual

RoaDyn S260

Measuring hub for

tire test machines

Type 9289A113

9289A_002-535e-07.21

Foreword

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 S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 2

Content

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

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

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

2.2Warnings ............................................................................................................................. 6

2.3How to treat the instrument ................................................................................................. 7

2.4Hints for using the operating instructions ............................................................................ 7

2.5What happens after modifications? ..................................................................................... 7

3.General description of the instrument ...................................................................................... 8

3.1Field of application for multi-component measuring hub S260 ........................................... 8

3.2RoaDyn S260 measuring chain digital and analog ............................................................. 9

4.Installation ................................................................................................................................... 10

4.1Important Notes ................................................................................................................. 10

4.2Dimensions......................................................................................................................... 10

4.3Preparation for mounting the measuring hub on the test bench ....................................... 11

4.3.1Measuring hub mounting location ..................................................................................... 12

4.3.2Mounting on tire test bench ............................................................................................... 13

4.3.3Mounting oil hoses ............................................................................................................ 14

4.4Connection and cables for the measuring system ............................................................... 16

4.4.1Connection of RoaDyn S260 with digital electronics KiRoad Tire Testing Type 9820A… 17

4.4.2Connection of RoaDyn S260 with analog electronics Type 5633A1 ................................ 17

5.Oil lubrication ............................................................................................................................ 18

5.1Oil connection .................................................................................................................... 18

5.2Oil circulating lubrications ................................................................................................. 19

5.3Oil lubrication system ......................................................................................................... 20

6.Operation .................................................................................................................................... 21

6.1Permissible loads on the measuring hub .......................................................................... 21

6.2Service life of bearings ...................................................................................................... 21

6.3Setup DAQ ........................................................................................................................ 21

6.3.1With digital electronics Type 9820A… .............................................................................. 21

6.3.2With analog electronic Type 5633A1 ................................................................................ 21

6.4Mounting adapter flange ................................................................................................... 23

6.5Run the system ................................................................................................................. 23

7.Maintenance ............................................................................................................................... 24

7.1On-side Fx calibration by the use of deadweights ............................................................. 24

7.1.1Basics .............................................................................................................. 24

7.1.2Preparation of equipment .................................................................................................. 24

7.1.3Deadweight calibration procedure .................................................................................... 25

7.2Checking calibration, function test and recalibration ........................................................ 32

7.2.1Checking calibration and function test .............................................................................. 32

7.2.2Recalibrating the measuring hub ...................................................................................... 32

7.3Maintenance work ............................................................................................................. 32

7.3.1General .............................................................................................................. 32

Content

Page 3

8.Troubleshooting ......................................................................................................................... 33

8.1Fault location and rectification ........................................................................................... 33

8.2Defective measuring hub ................................................................................................... 34

9.Technical data ............................................................................................................................ 35

10.Appendix ..................................................................................................................................... 36

10.1Rear plate for oil hose mounting ........................................................................................ 36

10.2Screw for oil hose fixation .................................................................................................. 37

10.3EC Declaration of conformity ............................................................................................. 38

Total pages 39

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

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

moment

 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.

Installation

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 instrument has been thoroughly tested and has

left the factory in perfectly safe condition. In order to

maintain this condition and to ensure hazard-free

operation, the user must comply with the information

and warning notes contained in these operating

instructions.

 The measuring hub must only be installed, operated

and serviced by personnel who are familiar with the

instrument and are adequately qualified.

 If it is determined that safe operation is no longer

possible, the instrument must be shut down and made

safe against accidental start-up.

Safe operation is no longer possible

 when the unit shows visible signs of damage,

 when the unit is no longer operating,

 after lengthy storage under unsuitable conditions,

 after very rough transport conditions

For wheel measurements, secure the measuring hub

to the test bench according to the directions! For

details, read chapter 4.3 Mounting the Measuring

Hub.

Secure all parts mounted on the shaft according to

the anticipated forces!

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 6

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, fati

g

ue stress.

For this reason, the following safety measures must be

strictly observed:

 The loading for the measuring hub and accessories

must 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, all parts must be 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

For wheel force measurements, secure the

measuring hub to the test bench correctly!

Installation

Page 7

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.

Place supplied cover over connection when not in use

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

keeping it in the supplied transport and storage box

2.4 Hints for using the operating instructions

We recommend reading the entire operating instructions

as a matter of principle. If you’re in a hurry, however, and

you’ve already gathered experience with Kistler

measuring hubs, you can confine your reading to the

information that applies to your application needs.

We have arranged these instructions so that you can find

the information you need without difficulty.

Please keep these Operating Instructions in a safe place

where they can be consulted at any time.

If the instructions get lost, just contact your Kistler

distributor and they will be replaced without delay.

All information and directives in these instructions may be

modified at any time without prior notification.

2.5 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.

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 8

3. General description of the instrument

3.1 Field of application for multi-component measuring hub S260

The measuring hub is used for rolling resistance

measurements according the commonly used global

regulations (ISO 28580, SAE J1269, ECE R117) for truck

tires above 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 the 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 to be used for test

stand controlling.

The measuring hub 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.

Fig. 1: Measuring hub Type 9289A113

Installation

Page 9

3.2 RoaDyn S260 measuring chain digital and analog

Fig. 2: Digital measuring chain RoaDyn S260

Fig. 3: Analog measuring chain RoaDyn S260

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 10

4. Installation

4.1 Important Notes

The measuring hub Type 9289A113 is a precision

instrument whose inherent accuracy will only be

maintained when the instrument is carefully handled.

Please take note of the following requirements:

 Do not drop the measuring hub or expose it to any

hard knocks! The maximum force of such shocks

could exceed the measuring range of the instrument

and cause permanent deformations

 Do not use a hammer for positioning the rim adapter,

since hammer blows can cause deformation of the

bearings or rim

In the following chapters, you will find information on

installing the measuring hub and basic details for setting

up the test rig.

4.2 Dimensions

Fig. 4: Dimensions of RoaDyn S260

Installation

Page 11

4.3 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

personnel who are familiar with the instrument and are

adequately qualified

 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. 5). Plug in the cable until a proper

contact is made

 Before mounting the measuring hub on a test bench

or another test device, connect the oil hoses as

explained in chapter 5.1 and mount all additional

equipment on the shaft rear side such as resolver or

slip ring

 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 which could reduce the accuracy

Fig. 5: Connecting

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 12

4.3.1 Measuring hub mounting location

The measuring hub could be mounted either on the left or

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

Fig. 6: 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 the picture below (Fig.

7).

Installation

Page 13

4.3.2 Mounting on tire test bench

Standard mounting of the measuring hub is done using

the twelve M16x60 mm screws, supplied at delivery.

These screws are on a 410 mm pitch circle diameter and

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 410 mm.

The positioning pins allow accurate mounting and

remounting of the measuring hub.

Therefore, adjustment of position according the

regulations must be done on a second layer.

Fig. 7: Measuring hub with wheel mounted on tire test

bench

 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 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 S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 14

4.3.3 Mounting oil hoses

In order to not create any force interaction between

measuring hub and test machine, the piping has to be

done as follows:

Fig. 8: Piping

Oil hoses should be taken to the rear side without

bending. They should be guided by using a

corresponding plate (not within the scope of delivery, see

appendix 10.1).

Check the distance between oil connector (supplied

within the scope of delivery) and rear plate according the

picture below and adjust length of oil hoses if necessary.

Fig. 9: Distance between rear plate and oil connector

Distance between rea

r

Plate and oil connector

2 … 4 mm

Installation

Page 15

Fig. 10: Plug in the oil hoses into the 90° oil connector

(red highlighted)

Mount screws (see appendix 10.2) and nuts in the

corresponding holes and adjust the level in order to avoid

any force interaction to the measuring hub.

Fig. 11: Mount screws and nuts

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 16

Fig. 12: Hose fixation by using cable straps

To avoid any force interaction on the dynamometer,

ensure that the oil hoses are not contacted hard by other

parts. This should also be checked during moving of the

sledge.

4.4 Connection and cables for the measuring system

 After proper mounting of the measuring hub connect

the two cables with the electronics (see 3.2 and

instruction manual of the used electronics)

 Ensure accuracy and cleanliness in all work involving

electrical connections. Only remove the cover caps

from the connections immediately before connecting a

cable

Installation

Page 17

4.4.1 Connection of RoaDyn S260 with digital electronics KiRoad Tire Testing

Type 9820A…

Fig. 13: Digital measuring chain

4.4.2 Connection of RoaDyn S260 with analog electronics Type 5633A1

Fig. 14: Analog measuring chain

RoaDyn S260 Measuring Hub for Tire Test Machines Type 9289A113

Page 18

5. Oil lubrication

The oil circulating helps to keep the bearing friction low

and is essential for a long lifetime of the bearings. In

addition, the oil also helps to cool the measuring hub.

For tests under hard conditions (high speed/high loads)

the lubrication system could be upgraded by using an

additional cooling system (e.g. secondary water-cooling

system).

5.1 Oil connection

To ensure proper oil lubrication, the connections on the

top side must be used as oil inlet and the connections on

the bottom side are for oil outlet.

If the oil inflow and outflow of the measuring hub are

not in the correct position, the bearings or the seals

will be damaged within a short period because of

improper oil lubrication or overpressure in the

measurin

g

hub!

Fig. 15 Oil connections (Top  oil in/bottom  oil out)

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