Wheel endurance test stand

Test wheels safely before they hit the road

High-performance wheels (rim, spokes, hub) face huge loads, for example in a full stop from 250 km/h or hard off-road use. Vehicle manufacturers and authorities therefore require proof of fatigue strength, for example for German type approval (ABE).

The TMX wheel endurance test stand runs defined load scenarios realistically and fully automatically. Sinusoidal torques and optional adjustable radial forces load the part until it fails or for a set number of load cycles.

Typical test requirements

• Proof of fatigue strength for wheels and rims (motorcycle and car)
• Loading the rim with sinusoidal torques
• Testing over a defined number of cycles
• Testing with or without radial force
• Assessment of weak points around the brake disc mount
• Compact solution for test stands with changing wheel types

The TMX wheel test stand in detail

The TMX wheel endurance test stand is based on a well-designed mechanical concept that combines rugged construction with intelligent control algorithms. The result is a compact, low-maintenance and highly flexible test stand that covers all common rim types, from lightweight sports rims to rugged everyday wheels.

Test stand mechanics

The rugged mechanical design loads the rim cyclically and realistically, in a compact, easy-to-maintain package.

• Rugged mechanics apply forces to the rim efficiently, as in real driving dynamics
• Exact torque control through variable deflection
• Radial force can be set separately or to 0 N
• Compact design with mobile protective enclosure

Drive and control

Two servo drives load the wheel dynamically. A control concept with two independent loops keeps the load profiles consistent, even over long test cycles.

• Two frequency inverters control the servo motors
• Control loop 1 secures a sinusoidal torque curve
• Control loop 2 also controls the radial force (optional)
• Load applied at the brake disc mount (motorcycle rim) for a realistic force flow

Measurement and control technology

All acting forces are monitored continuously for accurate evaluation. Sensors and control work together to keep test conditions repeatable and to shut down safely in case of a fault.

• Force transducers measure tensile and compressive forces with high accuracy
• Control via the lever arm: exact derivation of the applied torque
• Ring buffer allows an unlimited number of cycles in endurance runs
• Automatic failure detection shuts down the test stand
• Works with a wide range of rim sizes and materials

Operating software

The test software guides the user safely through every step, from configuration to automatic documentation of results. Efficient operation needs no deep test stand know-how.

• TMX test sequence editor for quick configuration of test parameters
• Step-by-step test preparation with visual status display
• All test parameters and results saved as a report
• Operation via a separate control panel on the cabinet with clear user guidance

Summary

The TMX wheel and rim endurance test stand combines simple operation with high flexibility and technical accuracy. Modular design, rugged mechanics and a flexible fixture make it a good fit for development departments, test service providers and rim manufacturers, from small series to approval testing.