Kistler 9295B1 Owner's manual

Instruction

Manual

9295B_002-635e-12.16

RoaDyn® P530

Measuring Hub for

Tire Test Stands

Type 9295B

Instruction

Manual

9295B_002-635e-12.16

RoaDyn® P530

Measuring Hub for

Tire Test Stands

Type 9295B

Page 19295B_002-635e-12.16

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 obliga-

tion to notify any person or organization of such changes

or improvements.

expressly provided herein, no part of this manual may be

reproduced for any purpose without the express prior writ-

ten consent of Kistler Group.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

Fax +41 52 224 14 14

info@kistler.com

Kistler Instrumente GmbH

Division Automotive Research & Test

Umberto-Nobile-Str. 14

71063 Sindelngen

Germany

Tel. +49 7031 3090 0

Fax +49 7031 3090 980

info.de@kistler.com

www.kistler.com

Foreword

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 2

Content

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

2. Important Notes...........................................................................................................................5

2.1 For Your Safety ...................................................................................................................5

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

2.3 How to Use the Instrument .................................................................................................6

2.4 What Happens After Modications? ...................................................................................7

2.5 Disposal Instructions for Electrical and Electronic Equipment ............................................7

2.6 Software Upgrades and Updates .......................................................................................7

3. Product Description ....................................................................................................................8

3.1 Overview .............................................................................................................................8

3.2 Features .............................................................................................................................9

3.4 Application ........................................................................................................................10

3.5 Measuring Chain ..............................................................................................................11

3.6 Technical Data ..................................................................................................................12

4. Mounting Instructions ..............................................................................................................13

4.1 Preparation and Tools .......................................................................................................13

4.1.1 General Notes .....................................................................................................13

4.1.2 Special Notes ......................................................................................................14

4.2 Test Stand Connection .....................................................................................................16

4.3 Mounting the Test Object ..................................................................................................17

4.4 Wheel Centering ...............................................................................................................18

4.5 Mounting a Brake .............................................................................................................19

4.6 Other Mechanical Interfaces .............................................................................................20

5. Oil Lubrication ...........................................................................................................................21

5.1 Oil Connection ..................................................................................................................21

5.2 Oil Circulating Lubrications ...............................................................................................21

5.3 Oil Lubrication System ......................................................................................................23

6. Operation ...................................................................................................................................24

6.1 Denition of Forces, Moments and Offset ........................................................................24

6.2 Friction Torque My ............................................................................................................................................................ 25

6.3 Warm-up Phase and Tk0 ..................................................................................................26

6.4 Service Life of Bearings ....................................................................................................27

6.5 Permissible Force Range .................................................................................................28

Page 39295B_002-635e-12.16

Total pages 38

7. Calibration .................................................................................................................................29

7.1 Calibration Congurations ................................................................................................29

7.2 Special Calibration ............................................................................................................30

7.3 Checking Calibration, Function Test and Recalibration ....................................................30

7.4 Maintenance Work ............................................................................................................30

7.5 Crosstalk in Function of Force Application Point and Length of the Lever Arm ................31

7.5.1 Setup 1 ................................................................................................................31

7.5.2 Setup 2 ................................................................................................................32

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

8.1 Fault Location and Rectication .......................................................................................33

8.2 Technical Support .............................................................................................................34

9. Accessories and Spare Parts ..................................................................................................35

9.1 Included Accessories ........................................................................................................35

9.2 Optional Accessories ........................................................................................................35

9.3 Wearing Parts for Oil Lubricated Version..........................................................................35

9.4 Wearing Parts for Grease Lubricated Version ..................................................................36

9.5 Additional Kistler Products for this Application .................................................................36

10. Appendix ....................................................................................................................................37

Content

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 4

1. Introduction

Thank you for choosing a Kistler quality product

characterized by technical innovation, precision, and long

life. 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 complied

with, nor for products used other than those listed under

Accessories.

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 specic measurement applications

Data transmission modules (telemetry)

Kistler also develops and produces measuring

solutions for the application elds of engines, vehicles,

manufacturing, plastics, and the 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 of our products.

If you need additional help beyond what can be found

either online or in this manual, please contact Kistler's

extensive support organization.

Important Notes

Page 59295B_002-635e-12.16

2. Important Notes

Please read these notes carefully before operating the

equipment. Kistler is not responsible for damage that may

occur when this system is used in any way other than that

for which it is intended.

2.1 For Your Safety

This product has been manufactured in compliance with

current valid safety regulations. It has left 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 or imprinted on the product itself.

The equipment should be installed and operated only by

qualied persons who are familiar with devices of this

type.

If there is evidence that safe operation is no longer possi-

ble, the instrument must be disconnected from the power

supply 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 unsuit-

able conditions

has been subjected to rough transit conditions

It is absolutely important to install the measuring hub

correctly at the test stand. For details please refer to

section 4.2 ff.

Secure all parts mounted to the shaft in accordance with

the expected forces!

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 6

2.2 Warnings

Kistler measuring hubs have been developed and manu-

factured to the state of the art and according to the best

technical knowledge. However, the high-performance

components are not designed for unlimited service life

as they are heavily utilized up to the permanent load and

therefore subject to wear.

The following safety measures must be strictly observed:

Strict compliance is required with the operating

instructions during mounting, in particular concerning

tightening torques for screws, the correct tting of parts,

adequate clearance for the xation arms and safe cable

installation

Loading for measuring hub Type 9289A… and its

accessories must not exceed the overload ranges and

operating temperature range specied in the data sheet

If there is a reason to assume that these overload

ranges have been exceeded, the parts must be tested

(e.g. visual inspection, crack analysis, etc.)

All parts must be subjected to an inspection on each

occasion before use.

A crack test must be carried out after the rst 100 hours

operating time

After 500 hours operating time, the instrument wheel

and the accessories must be subjected periodically to

a crack test

For wheel force measurements, it is important to install

the measuring hub to the test stand correctly!

2.3 How to Use the Instrument

The torque measuring wheel may only be used under

specied environmental and operating conditions.

Protect the signal output of the instrument against con-

tamination and do not touch it with your ngers. Fit the

cover supplied when the connection is not used.

Protect the torque measuring wheel while it is not in

use by keeping it in the transport and storage box sup-

plied.

Important Notes

Page 79295B_002-635e-12.16

2.4 What Happens After Modications?

As a rule, modications to instruments result in altera-

tions of the operating instructions. In such cases, inquire

at your Kistler distributor about the possibilities of updat-

ing your documentation. The current instruction manuals

are available for download from the Kistler website (www.

kistler.com, registration required) or at your local Kistler

representative.

2.5 Disposal Instructions for Electrical and Electronic Equipment

Do not dispose of old electronic instruments in municipal

trash. For disposal when the product has come to the end

of its service life, please return it to an authorized local

electronic waste disposal service or contact the nearest

Kistler Instrument sales ofce 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 that has not been upgraded or

updated with the latest available software.

For further information, please contact Kistler Instrumente

GmbH, by phone +49 7031 418 17 0 or

E-Mail info.de@kistler.com

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 8

3. Product Description

3.1 Overview

The RoaDyn P530 measuring hub is the ideal instrument

for measuring the wheel force and torque on tire test

stands in the laboratory as well as on mobile test vehicles.

The system measures the orthogonal forces

Fx (tangential force)

Fy (lateral force)

Fz (vertical force)

and torques

Mx (restoring torque)

My (driving and braking torque)

Mz (overturning torque)

The RoaDyn P530 measuring hub is a robust, high-

precision instrument equipped with quartz sensors. Four

3-component force sensors are mounted with a high

preload between two plates. Inside, a rotating shaft with

bearings holds the mounted wheel in place.

The path-independent measurement of the force compo-

nents naturally results in a minimum crosstalk between

the components and a resonant frequency of the complete

measuring system. The end of the shaft is led through the

rear side of the dynamometer and is prepared for con-

necting to a brake or driving device. It provides oil circula-

tion for lubrication and cooling of the bearings, resulting

in consistent heat conditions even when high loads are

applied.

The P530 measuring hub is also available with grease

lubrication.

The mechanical interfaces for mounting on the tire test

stand allow front or rear side mounting.

The dynamometer is protected against corrosion, splash

water and dust. The measured signals are transmitted to

the charge amplier (with summing amplier) via a robust

high-insulation cable.

Product Description

Page 99295B_002-635e-12.16

3.2 Features

Maximum measuring accuracy during high dynamic

testing

Fits to wheels with rim size 13 inches or larger; smaller

rims may be mounted with a compatible adapter

Fits to standard rims with interchangeable adapters;

custom rims not required

Bearings with oil lubrication and cooling for rotational

speeds up to 3 000 min-1 at full load

Alternative grease lubrication for rotational speeds up

to 2 000 min-1 for short running periods available upon

request

3.3 Nomenclature

RoaDyn P530 Measuring Hub Type 9295B

Oil lubrication 1

Grease lubrication 2

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 10

3.4 Application

Measurement of force and torque resulting from tire

non-uniformities, even at high speeds (non-uniformity

tests)

Quasi-static, dynamic and highly dynamic measure-

ments of tire characteristics

Tire vibration measurement

Universal measuring tool for laboratory tire test stands

in the elds of research, development and quality

control

Fig. 1: RoaDyn® P530 measuring hub

front and rear view

Product Description

Page 119295B_002-635e-12.16

3.5 Measuring Chain

Measuring Hub

RoaDyn P530

Type 9295B...

Connection Cable (straight plug)

Type 1677A5 ( l = 5 m)

Type 1677Asp ( l = 1 ... 20 m)

Extension Cable

Type 1678A5 ( l = 5 m)

Type 1678A10 ( l = 10 m)

Type 1677Asp ( l = 1 … 20 m)

Charge Amplifier

Type 5070A...1

Customer Data

Acquisition

not included

or

Connection Cable (90° plug)

Type 1679A5 ( l = 5 m)

Type 1679Asp ( l = 1 ... 20 m)

If you have any questions or problems concerning the

setup, please contact your local Kistler representative.

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 12

3.6 Technical Data

Measuring range Fx, FykN –20 ... 20

FzkN 0 ... 30

MxkN·m –7,86 ... 7,86

MykN·m –3,00 ... 3,00

MzkN·m –1,24 ... 1,24

Calibrated range Fx high

Fx low

Fy high

Fy low

Fz high

Fz low

kN

0 ... –20

0 ... –2

0 ... 20

0 ... 2

0 ... 30

0 ... 3

Linearity Fx, Fy, Fz%FSO ≤±0,5

Crosstalk 1) Fx –> Fy, Fz% ≤±2 (≤±1,0)

Fy –> Fx, Fz% ≤±2 (≤±1,0)

Fz –> Fx, Fy% ≤±2 (≤±1,0)

Natural frequency f0 (x, z) Hz ≈2 400

Rotational speed

grease lubrication min-1 ≤2 000

oil lubrication min-1 ≤3 000

Operating temp. range °C –20 ... 80

Degree of protection (cable

mounted)

IP65

1) typical values in brackets

Table 1: Important specications

For complete specications please refer to data sheet

000-991, available on www.kistler.com.

Mounting Instructions

Page 139295B_002-635e-12.16

4. Mounting Instructions

Measuring hubs of Type 9295B are precision instruments

and must be handled carefully. Please take note of the

following:

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 severe damage

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 nd information on

installing the measuring hub and basic details for setting

up the test rig.

4.1 Preparation and Tools

4.1.1 General Notes

Clean the contact surfaces thoroughly prior to assembly

Take care to ensure that the measuring hub is lying

absolutely at against the surface. Even the smallest

air gap causes unwanted elasticity and leads to a

reduction in the natural frequency of the measurement

alignment

Lay all of the connected cables and lines in such a way

that nothing can tear off or out during operation of the

measuring hub

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 14

4.1.2 Special Notes

Please comply with the following notes for correct

mounting of the measuring hub:

The measuring hub must be installed only by qualied

persons who are familiar with devices of this type

The connecting cable is connected rst of all to the

measuring hub. The two plug sides (measuring hub

and cable) are to be cleaned with Type 1003 cleaning

and insulation spray. The enclosed O-ring is used for

sealing. The contact surfaces for the O-ring must be

clean. The O-ring is inserted and the ange of the

cable is screwed to the measuring hub with the two

screws and tightened up to the surface

Check the atness of the installation surface on a roller

test bench or a testing apparatus before assembly

of the measurement hub. Uneven contact surfaces

cause interior tensions that subject the individual

power sensors to additional heavy lift loads and could

increase crosstalk

Observe the following instructions for the wiring of the

measurement system:

The connection cable from the measurement hub to the

charge amplier must have a high degree of insulation

and exhibit little static electricity. For that reason, use

only the specied connecting cable

Normal cables can be used for the connection between

the charge ampliers and the display or evaluation

devices

Observe careful and clean procedures while performing

any work involving electrical connections. Do not

remove the cover caps on the connections until just

before a cable is connected.

Mounting Instructions

Page 159295B_002-635e-12.16

4.1.3 Measuring Hub Mounting Location

The coordinate system of the measuring hub is designed

so that, with horizontal drum axle and with the test instru-

ment at the top, it conforms to the ISO system of coordi-

nates applicable to the wheel force (Fig. 2).

The measuring hub is provided with oil lubrication or

grease lubrication and must therefore only be used in the

position with its Fz axis upwards.

For a lateral arrangement (Fig. 2, location 2 or 3) at the

customers option the forces measured must be assigned

to the customers coordinate system.

In these cases, the load ranges of X and Z direction can

be exchanged (see Table 2).

Fig. 2: Horizontal drum axle with different positions of

the measuring hub

Location

1 2 3

Fx (kN) –20 ... 20 0 ... 30 0 ... –30

Fy (kN) –20 ... 20 –20 ... 20 –20 ... 20

Fz (kN) 0 ... 30 –20 ... 20 –20 ... 20

Table 2: Load ranges

P530 Measuring Hub for Tire Test Stands, Type 9295B

9295B_002-635e-12.16Page 16

4.2 Test Stand Connection

Measuring hubs of Type 9295B1 and Type 9295B2 can

be connected at the front side using 3xM16 or 4xM12

screws, or at the rear side using 8xM16 screws (scope

of delivery). Fig. 3 shows the corresponding geometry.

When using the 90° angle plug, an additional slot must be

cut (width 25 mm, depth 25 mm, length >80 mm).

Fig. 3: Test stand connection - dimensions

Deep

Mounting plate

(customer)

pcd 226,27/3xM16x32

(xation from front

side)

pcd 260/8x ø17,5

(xation from rear

side)

pcd 226,27/4xM12x28

(xation from front

side)

* only when used with 90° connector

Mounting Instructions

Page 179295B_002-635e-12.16

4.3 Mounting the Test Object

The test object is mounted on the front side of the shaft,

either directly or by using an appropriate adapter. The

designated hole patterns are at 100/135 and 160 mm on

the pitch circle diameters.

Fig. 4: Test object installation - dimensions

rotating parts are highlighted in blue

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