Measuring of rolling resistance of passenger car tires

12/2007 start of the project
05/2009 end of the project

A major automobile manufacturer from Southern Germany approached us with the task of equipping an external drum tire test bench with new drive and measuring technology in order to meet the increased requirements for exactness of roll resistance measurements according to DIN ISO 8767.

• External drum diameter: 2.0 m
• Mass moment of inertia: 400 kgm2

The specified maximum circumferential speed was 300 km/h, which for this drum is equivalent to a rotational speed of 796 rpm. Special attention was to be paid to measuring the drum drive motor, which, as the most important measuring value, reflects the rolling resistance of the tire. In addition, it was important to capture the rotational speed of drum and wheel exactly in order to use these measuring values to be able to determine the effective wheel circumference exactly during the test.

Antriebssysteme FAURNDAU GmbH solved this task as prime contractor, using modern components from in-house production and renowned manufacturers.

Low-inertia synchronous motor for the paper industry

10/2006 start of the project
08/2007 end of the project

Quality combined with high productivity – this was the requirement when engineering of an entirely new concept for the overlap area of cross cutters started in 2006. Modern cross-cutters reach track speeds of more than 400m/min. Due to the high track speed there is a risk that the sheet edges are damaged, because at this speed they cannot be directly moved into the stacking. The result: Lower track speeds so as to prevent damage to the paper, which results in lower productivity.

We developed a highly dynamic electro motor that reduces the speed of the roller from 400m/min to a final speed of 80 m/min within 8cm. The braking procedure repeats in a cycle of up to 8 times per second.

Motor test bench for technology centre in Karlsruhe

03/2010 start of the project
10/2011 end of the project

In co-operation with the in-house technology centre, the Technical University Karlsruhe realized for the project “Powertrain in the Loop” a test bench with the following features:

• Freely parameterizable and scalable combustion motor simulation
• Real-time driver-vehicle simulation and tire-slip simulation
• Execution of load change and abuse-load manoeuvres
• Flexible set-up of various power train configurations

The final realization of this concept included highly dynamic FAURNDAU generators (wheel machines) including the corresponding re-feeding capable 4Q converter system and was officially presented on 7 October 2011 officially in the scope of an inauguration celebration where renowned automobile manufacturers were present.

Special application DC current motors for pump dredgers for gravel extraction

The motors are specially dimensioned DC shunt motors with protection class IP 23 S, cooling type IC 06 or IC 26 and insulation class H/F with special impregnation and additional corrosion protection. Therefore, these motors can also be operated outside under a protective roof. Versions with standstill heating, current monitor and brush monitoring are also possible..

Water-jacketed cooled synchronous motors

Application case end-of-line gear unit test bench, location China

06/2012 start of project
02/2013 end of project

The following specifications were required for the motor:

• max. width of the motor 225 mm
• max. length of the motor < 700 mm
• Axle height ≤ 132
• Moment of inertia < 0,1 kgm²
• Noise level < 75dB(A)
• Lubrication and service free bearing up to 25,000 operating hours

Within a short time, a rotary current synchronous motor was developed that met all the customer’s requirements.

In cooperation with the customer, the current focus is on further development of the motor. In the future, the following features are to be delivered:

• Connection of a tool for power transfer to the gear unit to be tested
• Infeed and adaptation of the tool to the gear unit
• Safeguarding of the gear unit to be tested against mechanical overloads in case of failure
• Delivery as ready-to-install unit

F1 model

11/2005 start of the project
08/2006 end of the project prototype

The task was to remove expensive and short-lived formula 1 combustion motors from gear unit test benches and to replace them with a suitable electro motor (ICE simulation) that shows the same performance but a far higher lifetime than combustion motors. We were challenged to find an electro motor with a dynamic never reached before with the following data:

• P = 640 kW
• n = 17.000 rpm
• M = +/- 360 Nm max. 22,000 Upm
• J = 0,014 kgm².

These motors are still operated in the development test benches of renowned automobile manufacturers.

Gear unit test bench in container configuration

04/2010 start of the project
03/2011 end of the project

A renowned manufacturer of test benches was assigned to realise a 3-room concept (test room, operating room and separate technical room) in container configuration. In this project, energy efficiency was a main factor, in that drive energy and braking energy are maintained within the system. One of the main points in this concept was a the successful implementation and commissioning of a special FAURNDAU drive system (3 motor concept) including the corresponding re-feeding capable 4-Q converter system.

Special application DC current drives for fairground rides

The motors are specially dimensioned DC shunt motors with protection class IP 23 S, cooling type IC 06 or IC 01 and insulation class H/F with special impregnation and additional corrosion protection. Therefore, these motors can also be operated outside under a protective roof. The motors are vibration-resistant up to ca. 5g. Versions mounted with a specially designed brake and standstill heating, flow monitor and brush monitoring are also possible. The motors are designed for high overload capacities.

Pitch motors for optimally adjusted rotor blades in wind power plants

The motors are specially dimensioned DC compound motors with protection class IP 55, cooling type IC 410 and insulation class H with high overload capacity and attached special holding brake with emergency STOP function. The compact structure with stator and rotor in full housing and the housing design with specially aligned radial cooling ribs allow exposing the motor to ambient temperatures of 20°C to +60°C. Due to the special impregnation and additional coating of the housing, the motor can be used at high air humidity and therefore in offshore areas (sea atmosphere). The motors are directly mounted on the gear units and are used in normal operation in both rotational directions by means of an electronic DC chopper controller. In case of a malfunction of the servo regulator, the motors are compulsory excited and directly switched to energy storage. This way, safety travel used to move the rotor blades into vane position can be guaranteed, i.e. emergency travel is possible without electronic components.

Test bench for mechanical locking of tire pressure sensors

09/2011 start of the project
06/2013 end of the project

The task was to engineer a test bench that can be used for mounting all rim sizes (15” to 21” in from aluminium/steel) including tires. In addition, it must be possible to expose the wheel to an environment of -40°C to +160°C; this required that the shaft train including the wheel hub for mounting the wheel had to be connected to an environmental chamber. Speeds of up to 350 km/h had to be realized, operation with snow chains up to 80 km/h was an additional requirement for the vibration quality of the overall concept.

Here, FAURNDAU delivered the drive (motor and converter system capable for re-feeding) including the overall mechanical system (motor sub-structure and shaft train).

Motor test bench in orthogonal configuration

04/2012 start of the project
01/2013 end of the project

Small-volume motors, e.g. lawn mowers are often equipped with vertically installed crank shafts. In this project, a motor test bench for testing motors with horizontally configured and vertical crank shaft was to be engineered. Due to the orthogonal configuration, test sample and dynamo are always at right angles. By simply rotating the power train by 90°, the test bench can be easily re-fitted from motors with vertical crank shaft to horizontal crank shafts. The FAURNDAU dynamo and the re-feeding capable 4Q converter system provide the perfect drive for the system.

Special versions for use in the paper industry

The motors are specially dimensioned DC shunt motors with protection class IP 54, cooling type IC 37 in heat class H/F with additional impregnation, corrosion protection, standstill heating and brush monitoring. The demands of rough operation with aggressive vapours are met with a special air direction and special carbon brush design. This can easily ensure a long service life of the brushes in the operating conditions at hand. Versions with air flow monitoring are also possible.

Special application for compressor drive for air conditioning in military application

The motors are specially dimensioned DC compound motors with protection class IP 55, cooling type IC 411 with installed fan and air supply via a special aluminium air duct and insulation class H with additional corrosion protection. The design of the motor is very compact with low weight so as to meet the requirements of a low installation volume in the slide-in container. Use in ambient temperature of up to +55 °C and in rough sea atmosphere is made possible by the special aluminium die casting housing design. Due to a special electrical version with installed EMC components, the customer requirements with regard to strict EMC directives are fulfilled. The motor connection to the electronic system is realized via special, EMC-screened military cable for transferring capacity and status signals. The shock-resistant and vibration-resistant designs were proven by extensive shake tests, and the temperature behaviour of the drive was tested in a climatic chamber.