Product: Transfer Cases, GM project series 600 and 800

A transfer case test stand comprising of an Input drive from a 200 hp variable speed AC motor with a torque transducer and torque limiter. Front and rear output drives both incorporate 200 hp variable speed AC motors with torque limiters. The input and output drives are mounted on linear slides operated by hydraulic cylinders. The LH output drive is on an inclined slide to enable the LH load motor to couple with different positions of the LH output on various models of transfer box.
A lifting cradle is provided to load the transfer box from the input conveyor into the machine. A hydraulic unit provides power to the clamps, cradle lifter, clamping and electrical connections.
The machine is monitored and controlled by Rockwell SoftLogix with an industrial PC that interfaces with a vibration analysis system.

Weight: 14 metric tons

Dimensions (millimeters): 6700W x 2860D x 2300H

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Product: Test Stand for Transfer Cases: Single and dual speed commercial transfer cases with PTO options

An end of line, commercial transfer case test stand comprising of a 200HP (150KW) variable speed AC drive motor with a speed range of 0-3500 rpm and providing an input torque of 339NM (250 LB/FT). The input drive assembly incorporates a torque transducer rated at 500Nm and a torque limiter set to disengage at 500Nm. The machine incorporates two output load assemblies. The front output on the left and the rear output on the right of the machine. The outputs loads are simulated by the use of electric retarders. The input and output assemblies are mounted on servo driven slideways to facilitate loading/unloading. A cross slide on the rear output provides two output positions and there are also two input and two output spindles to suit different models. The transfer case is fitted in a special fixture, which is then clamped in the machine. A high speed, Hy-Vo chain drive is incorporated into the input drive and front output to provide the two spindle positions on each input and output.

The machine is monitored and controlled by Rockwell Soft-Logix software running in an industrial PC.

An Anthony Best Dynamics NVH system uses five microphones and a single accelerometer to monitor and report noise inconsistencies.

Weight: 13.4 metric tons

Dimensions (millimeters): 7150W x 4800D x 2600H

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Product: An End of Line Test Stand for testing transfer case assemblies

The transfer case (located on a pallet) is automatically loaded from a conveyor system. The input and output drive spindles are mounted on linear slides to facilitate engagement with the transfer case. The 100HP (75KW) input variable speed AC electric motor and twin 50HP (37KW) output variable speed motors subject the transfer case to a series of pre-programmed tests in the speed range 0 to 4000 rpm with maximum torque of 100 ft. lbs. (136 Nm). After testing, transfer cases that have passed are automatically part marked and are automatically unloaded and dispatched on to the conveyor system.

A hot oil unit comprising of four 200-liter tanks, supplies hot oil at 100°C for automatic filling and emptying of the transfer cases.

A 160 litre capacity hydraulic unit powers all the machine clamping, locating and pallet transfers.
Noise analysis is carried in conjunction with an 'Ometron' single-point laser vibrometer.

The machine is monitored and controlled by an Allen Bradley series 5 PLC.

Product: BMW Transfer Cases

Weight: 14 metric tons

Dimensions (millimeters): 6470W x 8570D x 3800H

Transfer boxes are manually placed on the pallets and then automatically transferred to one of the two test rigs where they are located, clamped and input/output shafts engaged to the drive and load motors. The transfer boxes are then tested by accelerating and decelerating the transmission between 0 to 3500 RPM whilst applying a 90 Nm load to the input shafts in both high and low range. The gear change being carried out automatically during the test cycle.

An 'ABD' noise measurement system is used to measure radiated noise emitted from the transfer box and results compared against known targets. Each test machine is contained within an acoustic booth for the noise analysis.

An oil fill and drain system supported by a 100 gallon reservoir is piped to both test rigs. The cell is monitored and controlled by three Allen Bradley SLC 5/04 PLCs.

Component: Land Rover Transfer Case LT230

Weight: 8 metric tons

Dimensions (millimeters): 15,150W x 7,540D x 2,400H

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