Testing Machines and Systems for the Automotive Industry

Product catalog summary

Zwick Roell Group Overview
Zwick Roell AG, founded in 1992, specializes in testing machines and systems for the automotive industry, offering products from manual hardness testers to complex systems. The company is ISO 9001 certified, ensuring high quality.

Current Conditions in the Automotive Industry
The automotive sector faces global competition, requiring both computer-based and actual testing to ensure materials meet necessary standards for stiffness, rigidity, and fatigue.

Testing Machines and Systems
Zwick provides a variety of testing machines for the automotive industry, including hardness testers, materials testing machines, and systems for simulating road conditions, supported by software and data analysis tools.

Research and Basic Development
Zwick's machines test mechanical properties of automotive materials, accommodating temperature variations from -80°C to 1,600°C.

Fatigue Strength in Automobile Construction
Fatigue strength testing involves understanding stress interactions, with S-N tests for material properties and complex tests for components with variable amplitudes.

Joining Technology in Automobile Construction
Testing focuses on life expectancy, crash safety, and stiffness, requiring mechanical characterization under various loading conditions.

Overview of Testing Methods in Automobile Construction
The document outlines testing methods for quality assurance, life expectancy, and crash calculations, emphasizing specimen geometry and load ratios.

Testing Requirements in Series Development and Production
Emphasizes readiness for series production, examining material properties and developing systems for efficiency and reduced emissions.

Fatigue Testing of Engine Components
Describes fatigue testing for engine components using Vibrophore and servo-hydraulic machines, highlighting efficiency and cost benefits.

Clutch Testing
Focuses on axial and axial/torsion tests, emphasizing torque characteristic curves and test equipment features.

Chassis Testing
Essential for vehicle dynamics and safety, involving static and dynamic loadings on steering components.

Brake and Exhaust System Testing
Discusses testing methods for brake pads and exhaust components, focusing on lining thickness and fatigue under multi-axial loads.

Elastomer Bearings and Pneumatic Springs Testing
Covers testing for visco-elastic characteristics and fatigue at various temperatures.

Temperature Chamber and Testing Systems
Describes a temperature chamber operating between 80 to +250 °C and the Amsler HB100 servo-hydraulic system.

Precision-Spring Compression Testing Fixture
Details Zwick’s precision-spring testing kit with features for accurate vertical movement and overload protection.

Multi-Channel Spring-Testing System
Assesses spring penetration points and load components using multi-channel platforms.

Wheels and Tires Testing
Discusses systems for testing static and dynamic characteristics of wheels and tires, including deformation and hardness tests.

Automobile Tire Stiffness Testing
Outlines stiffness testing requirements using Zwick Z050 machines and testXpert® software.

Tests on Tire Components
Includes tensile, tear growth, hardness, and abrasion tests on elastomers and cords.

Body and Bumper Testing
Describes systems for testing vehicle bodies, including bumper stiffness and friction coefficient tests.

Vehicle Door Testing
Includes buckling and seal testing to ensure safety features function correctly.

Electronics and Mechatronics Testing
Covers testing of electronic components, wire insulation, and solder points.

Interior and Safety Testing
Focuses on testing car seats, headrests, seat belts, and airbag materials for durability and safety compliance.

Quasi-Static Materials Testing
Concludes with hardness testing using Zwick/ZHR Rockwell testers.

Hardness Testing Machines

Rockwell and Super Rockwell Method: Utilizes Zwick/ZHR 8150 with various pre-loads and test loads, offering models with different operational conveniences.
Micro Vickers Hardness Testers: ZHV1 and ZHV2 models cater to different load ranges, offering manual to automatic operation.
Universal Hardness Testing Machines: Equipped with digital systems for various hardness tests.
Zwick/ZHU topLine Hardness Tester: Features optical zoom and image analysis for multiple testing methods.

Materials Testing Machines

Applications: Determine strength and deformation under various loads, featuring long travel and wide test-speed ranges.
Basic Concept: Offers zwicki-Line, ProLine, and Allround-Line series for different testing needs.
Load Frames: Rated up to 2,000 kN, with special versions available.
Drives: Includes electromechanical, hydraulic, and hybrid drives for precision and force application.

Measurement and Control Systems

testControl Electronics: Offers synchronized data recording and real-time processing.

Overview of Testing System and Software
Describes a PC-operated testing system using testXpert® software, offering flexibility and reliability.

testXpert® II Software Features
Standardized software for materials testing, supporting online language swapping and industry-specific terminology.

Load Cells and Measurement Platforms
Available for accurate force measurement, featuring automatic identification and temperature compensation.

Specimen Grips
Range of grips for different materials and conditions, including hydraulic and pneumatic options.

Extensometers
Measure extension against test load, with various types for different materials and conditions.

Overview of Extensometers
Details various extensometers for measuring material deformation, including optical and laser options.

Temperature Conditioning Devices
Highlights the importance of temperature in testing, with chambers offering precise control.

High Temperature Furnace
Provides furnaces for high-temperature testing, crucial for thermal-elastic behavior assessment.

Additional Drive Options
Offers electro-mechanical and pneumatic actuators for expanded testing capabilities.

Fatigue and Dynamic Strength Testing
Describes servo-hydraulic machines for testing under various load conditions.

Components for Servo-Hydraulic Test Bench Solutions
Provides components for flexible testing systems, including electronics and software.

Overview of Testing Systems, Software, and Services
Focuses on servo-hydraulic testing, modernization packages, and support services.

Specifications and Features

HydroWin 96xx Controller: Detects transducer connections automatically.
Control Cube: Supports up to 32 channels for testing.
testXpert® QX Software: Modular software for fatigue testing.
Hydraulic Power Packs: Available in various pressure stages and delivery rates.
Servo-Hydraulic Testing Actuators: Range from 10 kN to 1,000 kN.
Vibrophore: Known for minimal energy consumption and high frequencies.

Testing Machines and Applications

Impact Strength Testing Machines: Used for high-speed penetration and tensile tests.
Pendulum Impact Testers: Meet international standards with ergonomic design.

Modernization Packages