With profi t margins as low as 2%, many European haulage fi rms are keen to increase the load capacity of their trucks. To meet this demand, Volvo is investing heavily in weight-optimizing its trucks from the wheels up. This work calls for an exceptional test rig. “Volvo has the world’s largest test rig for axles and suspension systems. No other rig can deal with such massive forces as our rig can,” reveals Göran Johansson, head of Volvo Trucks’ department for durability testing of axles, suspension units, steering and brakes. Volvo’s new weight-optimized materials and designs had to be subjected to the stresses encountered during real-life operation (see Making Tracks box, left), with the data then entered into the test rig to create duplicate inputs.
The rig is operated from a control room with a signal amplifi er and control electronics where programming of the various driving environment profi les is dialled in. Once all the installations and control programs are ready, what remains is monitoring and adjustments during the course of the test. “It’s similar to working in mission control at a rocket site,” says test engineer Emil Skoog, who is responsible for the rig.
The time savings, compared with the testing of axles and suspensions out on the test track, are invaluable. The shorter test duration on the rig also makes it possible to release new features and products much sooner. Without test rigs and test tracks, it might take fi ve to 10 years to test a new, lighter axle design, according to Volvo. On the proving ground, the test process would take six to 12 months, whereas the test rig can complete the same test in two months. Moreover, the rig offers greater precision. “Our measurements are precise to within about 1%,” states Skoog.
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