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2VS-30VS User Manual 2012

1. Caution Ensure that there is no shock in the machine and that the crossbar is raised so that the actuator shaft cannot come in contact with the load cell before measuring the stroke a2 6 Operating the Dyno 6 1 Becoming Familiar with the dyno 1 Columns 2 Crossbar 3 Clamps 4 Load Cell 5 Clevis 6 Shock 7 IR Temp 8 Handle 9 Clevis 10 Actuator 11 E Stop Figure 6 1 2 3 5VS Left 10 20VS Right 43 Figure 6 2 Dyno Top View Typical 1 Data Acquisition Box 2 Electronics Board 3 Main Power 4 Motot Conttol Cable 5 Motor Controller Figure 6 3 5 5VS Damper Dyno 1 Column Clamps 2 Velocity Sensor 3 Actuator Shaft 4 Scotch Yoke 5 Square Beating 6 Displacement Sensor 44 4 5 1 Figure 6 4 10 20VS Damper Dynamometer 1 Column Clamps 2 Velocity Sensor 3 Actuator Shaft 4 Scotch Yoke 5 Square Beating 6 Displacement Sensor 6 2 Getting Started Once the dyno has been commissioned as described in Section 5 it is now ready for use First power up both the dyno and the computer system Make sure all connections to the computer ate made Once the computer has booted start the Roehrig Shock program Load the shock to be tested following the procedure laid out in Section 4 2 The operator can now create and run a test The following Section will describe the functionality of the Roehrig softwar
2. 19 3 6 Machine Danger Zones There are three danger zones on the damper dynamometer the drive belt zone in the back of the machine which is guarded by the rear cover the scotch yoke mechanism in the front which is guarded by the front cover and the testing are between the crossbar and the actuator shaft which is guarded only on CE machines equipped with a cage 3 7 Other Risks The operator should be aware that dampers convert mechanical energy into heat and therefore the damper being tested may get very hot Always use caution when handling a damper which has been tested Also there is the possibility of a damper failure which can cause hot oil to be sprayed from the damper itself Warning Dampers may be Extremely Hot after testing Always handle tested dampers with caution 3 8 In Case Of Emergency In case of emergency press the emergency stop button and immediately call for help 20 4 Dynamometer Functionality 4 1 Overview of Dyno Functions The 2 3 5 and 10 20 30VS dynamometers are capable of carrying out standard PVP Peak Velocity Plot or CVP Continuous Velocity Plot tests on almost any type of linear damper The dyno is also capable of running a warm up cycle on the damper and can measure both gas force and friction force The technical paper below describes in more detail the fundamentals of damper dynamometers and their function 4 2 WHAT IS A SHOCK DYNAMOMETER Dampers produ
3. 8 El SN TA AAN LF aa e TT S B s 3 l i aj um a d 358 1mm 4140mm 2VS Crank Dyno P 3 Isometric View t ko 23 6 800mm m 19 5 4 5 3mm E FN a 2V5 Crank Dyno 2V5 Crank Dyno Side View Front View m A ROEHRIG ENGINEERING INC RORMEIS Notes 2V5 Crank Dyno 1 2VS Crank Dyno shown with standard length columns custom lengths available E brad crass Ewa 8 7 6 5 4 3 2 1 Figure 1 2VS Dimensioned Drawing N l 2 554 1407 Omm gt D a a e n d n S 14 163 l la aH 583mm 4140mm amp 23 6 600 0mmm NEN 19 5 495 3mm 3VS and 5VS Crank Dyno 3VS and 5VS Crank Dyno Side View Front View LM 75399 UNLESS CTHERWEE SPECRED oles aean vare Crank dyno shown with standard length columns custom lengths available Ed 3VSand 5VS crank dynos have same outside dimensions NEITASSY USED OM M APRICATON DO NOT SCALE DRAWN 5 4 3 Log 3VS and 5VS Crank Dyno Isometric View ROEHRIG ENGINEERING NC A BV and SVS Crank Dyno 3hp and Shp Motor xp see y sehr EAE meg oT Figure 2 3VS and 5VS Dimensioned Drawing 10VS Weight 650lbs 295kg 20VS Weight 710lbs 322kg s T
4. Roehrig Hardware Not Under Warranty E mail is the preferred method to address non warranty service problems out of watranty e mail we be answered at no charge or the customer may use the Customer Service Request Form for troubleshooting problems via fax at no charge REI may charge for phone non warranty problems If the initial trouble shooting does not resolve the problem then all factory assessments and repairs will follow the following procedure Factory Repairs 1 Thecustomer sends the part to Roehrig Engineering 2 The estimated repair cost will be given to the customer prior to the repair The total cost must be paid prior to beginning of service 3 System testing evaluation and repairs can take up to two weeks However the part will be scheduled for a service as soon as it arrives at the factory 4 Roehrig Engineering will return the repaired part via UPS ground service in the USA only If the customer is outside the continental USA the customer is responsible for shipping charges Expedited service can be arranged at the customer s expense Repairs at Customers Facility 1 Customer will pay all travel expenses of Roehrig Engineering service personnel Travel rate is 0 485 per mile plus 35 00 per hour maximum 200 00 per day If it is necessary to fly to the customers location customer will pay full cost of the airline ticket plus 35 00 per hour maximum 200 00 per day travel not including airline ticket 2
5. The 3 5 and 10VS are available in two configurations 220V or 380 440VAC The 20VS is only available in 380 440 VAC Supply power is a choice that is determined when machine is ordered main voltage changes require a different inverter internal to the unit Step down up transformers can be used in conjunction with unit 2VS 220VAC single phase 3VS 5VS 220VAC US single or three phase Europe single phase or 380 440VAC three phase 10VS 220VAC US single or three phase Europe single phase or 380 440VAC three phase 20 30VS 220VAC not available 380 440VAC three phase Caution Please review the Yellow Tag attached to the dyno for specific power requirements If you have any doubts about wiring the dyno STOP and call a Roehrig representative before continuing Dynos made for customers in countries other than the U S could have different power requirements and should not be wired without consulting an REI representative REI recommends using a power box with a fuse protected breaker installed For your own convenience you may want to use the power box in conjunction with an On Off switch if your power box is not equipped with one To wire the power in single phase the White and Black wires are for power and the Green wire is for ground The Red wire is not used for a single phase hookup and should be capped off with a wire nut For three phase power the White Red and Black wires are for power and the Green wire is fo
6. and currently selected active template 6 3 9 Help Ki Search for i Contents EMail Support Interactive Troubleshooting Authorize About Figure 6 40 Help Menu Help Menu Provides searchable electronic version of this manual which can also be listed by its table of contents E mail support link and interactive trouble shooting manual also provided The About option provides information about the software vetsion motor and datacard 83 6 4 Creating and Running Tests First power up both the dyno and the computer system Make sure all connections to the computer are made Once the computer has booted start the Roehrig Shock program Load the shock to be tested following the procedure laid out in Section 4 2 If the user wishes to create a new test click on the Create icon either from the Test menu or from the toolbar The create test wizard will appear Pick the desired test type and click next The wizard will guide the user through the rest of the test creation procedure Once finished the user will be asked to name the test Enter a unique name and click OK Once the test has been created or if the user wishes to run a previously created test click on the Test icon either from the Test menu or from the toolbar The test screen will appear Click on the desired test in the test profile column left side of the test screen The desired test will now be h
7. 0 0178 misec Post Test Move To Speed 0 0178 m sec r Ok la Cancel Figure 6 31 Advanced Properties Window 75 Test Opens the test control panel The user can select create edit and run tests from this screen The test names appear in the upper left corner of the test screen To select a test simply click on it To edit a test double click on it and the edit window will appear Right clicking on the test allows the user to delete or rename a test Tests may also be organized into folders Simply right click on the folder in which you wish to create another folder and select new folder The tests can be dragged and dropped into the desired folder To create a test right click on an existing folder and choose new test Note When editing a test the user has the option of saving it as a new test with a new name by clicking the save as button Test Profile Column Upper half of column displays available test hierarchy Lower half of column displays the name and major parameters for the test which is currently selected Commands Column Contains command buttons Start Test Starts the currently selected test Skip Step Skips the current step in the test Zero Load Cell Zeros the load cell reading The program will retain this zero value until the program is exited or the zero load cell button is pressed again Cycle Motor Moves dyno one complete cycle at slow speed Go to BDC
8. 77 Create Batch Allows user to create a batch test multiple tests run together The user can string together any available tests in any order and have the software automatically run each test and save the data The available test hierarchy is displayed on the left side of the window To add a test to the batch click on the test and then click on the right arrow button The test will be added to the batch Tests can be deleted from the batch using the black X button The order of the tests can also be changed using the up arrow and down arrow buttons Each test is assigned a default data file name This name can be changed by the user If the user does not want to collect and save data for a given test in the batch simply uncheck the data box The batch test is given is given a default name in the lower left corner of the window This name can be changed by the user Click the OK button when finished Batch Test Editor Tests Batch Test Order Ei CJ Tests Data File wp 10ips ji BatchData 1 evp 20ips BatchData 2 O Tests 2 BatchData 3 PYP Std PYP BatchData 4 Batch Test Name Figure 6 33 Create Batch Test Window 78 Run Batch Allows user to tun a previously created batch test Select a batch test from the list The individual tests for that batch will be listed at the bottom of the window At this point the batch test can be edited if requir
9. File menu or from the toolbar Graph Report pvp Mfg Report Scaling Histogram CADesktop Folders Test Data Shack Data 1 PVP 6 45 58 AM 3 June 2008 127 00 mm sec 25 48 mm 2 228 60 mm sec 25 48 mm 500 00 mm sec 25 48 mm 750 00 mm sec 25 48 mm 800 00 mmjsec 25 48 mm Graph Fields Constants Run Information Run Constants Field I Mehide an Location Compression Valving Rebound Valving Piston Valving Diher Valving Compression Setting Rebound Setting Preload Setting Notes p Test Results Stroke Peak Velocity Test Speed Gas Force Shaft Diameter Gas Pressure Seal Drag NA 786 11 mmjsec Nia 229 94N 16 00mm 2 2xp 11 44 Bar 38 44 N Velocity Increment Actual bd Export Clipboard File Figure 6 43 Template with open PVP Data File Report Display Tab Selected 87 The PVP Mfg Report tab displays two user definable graphs along with the field data and the tabbed force vs velocity data for the selected PVP data file The report data can also be printed by clicking on the Print icon either under the File menu or from the toolbat Graph Report PVP Mfg Report scaling Histogram un 127 00 mmjsec 25 48 mm 1 769 11 500 228 60 mmjsec 25 48 mm 1 000 500 00 mm sec 25 48 mm 500 750 00 mm sec 25 48
10. Import File Export Exit Figure 6 4 File Menu New Template Creates a new template Templates allow the user to open analyze and save single or multiple data files in one place The Legend and Tabbed Analysis Window make up a template Multiple templates can be opened at the same time Open Template Opens a previously saved template Save Template Saves the current template Save Template As Saves the current template as a new template with a unique file name Open Data Opens a previously saved data file and places it in the current template A data file is created and saved after running a test A data file contains all the data for a single test only Open XML Datafile Opens a previously saved xml data file 47 Print Allows the user to print graphs and reports from the current template Print Options Graph Layout Report Options Report Fonts Printer B AP ei FEE sae r Title Lago fw Show Logo Divder at IV Logo Stretch Shrink Fit 8 C Program FilesRoehrighS hock printiogo bmp m Legend Divder at 2 A 90 Left Right Top Bottom Divder at Left Right Top Bottom 30e Figure 6 5 Print Options Graph Layout Graph Layout Allows user to size graph legend and notes on the printout The show logo box adds a user defined logo to the Title block The logo stretch shrink fit box adjusts the s
11. Moves dyno to bottom dead center The box to the right of this button indicates if the dyno is at bottom dead center If the box is green the dyno is at BDC If the box is black the dyno is not at BDC Done Exits test control panel Status Column Lower half of this column displays live sensor readings and current test step which is being executed 76 Abort This button aborts the current test Please note This button is NOT an emergency stop button Close after test When this box is checked the test control panel will close after the test is complete Pause after gas test When this box is checked the dyno will pause after the gas test allowing the user to make adjustments to the shock The dyno will only resume after the user hits the continue button Results This box lists data from the last test run Roehrig Shock Test Control Panel Ei D Tests Commands Bm 2 Close after test PYP pvp Tests 2 H Start Test evp 20ips LI Pause after gas test a Zero Load Cell Results Stroke 50 94 mm Peak Velocity 0 000 m sec Gas Test N i ips 3 Cycle Motor krek T Midpoint offset 0 00 mm Velocily 0 000 m sec Max Travel 50 96 mm ge Temperature 27 31C Wave Form Sine Amplitude 25 48 mm Frequency 1 59 Hz Speed 0 254 m sec Configuration lt Default gt Test Profile Column Commands Column Figure 6 32 Test Control Panel
12. exists Sound pressure levels ate worst case using a 5VS Damper Dynamometer performing a standard PVP test cycle with 7 speeds up to the maximum frequency of the machine a warm up and a gas test Cycle time is 90sec Equivalent Continuous A weighted Sound Pressure Level 72dB Peak C weighted instantaneous Sound Pressure Value 86dB 2 4 Other Emissions The 2 3 and 5VS damper dynamometers produce no vibrations which are harmful to the operator since the operator is not in contact with the machine while it is running There are no other harmful emissions produced by the machine 2 5 Machine Features The 2 3 5 10 and 20VS damper dynamometers are fully computer controlled variable motor speed models They are capable of testing at different strokes up to 2 inches 50mm for the 2 3 and 5VS models and up to 7 inches 175mm for the 10 20VS The SHOCK Test Control and Damper Analysis software enables you to perform static and dynamic gas tests temperature or time based warm up of a dampet as well as stop at bottom dead center of the damper stroke The software also allows the user to run CVP PVP or Multi CVP tests Specifications and features of each model are given on the next page 11 2VS Features e 2 Hp Motor 220V e Zero Lash Belt Drive Precision scotch yoke weat plate system e 2 Standard English Strokes 1 00 and 2 00 e Standard 48 Steel Columns 28 700mm eye to eye test area e 2000 l
13. 0 deg Top Dead Center IDC 180 deg and 90 270 degrees When the crank pin is at BDC the damper is fully extended As the crank rotates clockwise it s compressing the shock in the bump direction so that the damper piston accelerates from a stop to maximum speed at 90 degrees and then slows to a stop again at TDC Rotation continues and the piston accelerates in rebound direction to maximum speed at 270 degrees and slows to a stop again at BDC Figure 3 shows force data taken continuously during one revolution of the crank Shaft speed in the down direction is positive and compression force is positive The bottom patt of the curve shows shaft speed and negative force increasing as the crank goes from TDC 180 deg to 270 degrees and then decreasing as the curve goes back toward zero speed and force at BDC 0 deg As rotation continues speed goes negative compression and force increases to a maximum at 90 degrees and back to 0 at TDC 180 deg The speed and force data taken to produce a graph like this comes from a velocity sensor and a strain gauge load cell A data acquisition system in a personal computer reads these sensors 1 000 times a cycle or more Software processes the data and displays it in this form This can be confusing and you might have to look at this sketch and the graph a while before it becomes clear The important point is the force increases with piston speed On the lower section of the curve the piston is accelera
14. 99 in and speed 10 00 Spead 10 00 in sec in sec 0 00 sec remaining Configuration Default 15 Depending on the test you have selected the dyno may run one speed or several speeds It may perform additional warm ups and gas tests This is all dependant on your settings for the test If you have selected to pause between runs the following window will appear Once you are ready to proceed with the testing click Continue Shock Test Paused The tastis paused selecting Continue will restart the motor and continue with the next phase of the tast 31 16 After the test is complete the Save As window will appear name the file and click Save to save to the hard drive Save MCR Files Save in YO My Documents cf fr Pe My Music SAMY Pictures My Recent Documents Desktop b My Documents man My Computer an T My Network Places Save as type MCF files vi Cancel File name Lower 4 Warning Never try to install or swap a shock while the dynamometer is running The program will display the graph of the last collected data file automatically after a test has been run and a name given to the file File names are displayed on the left side of the main screen 4 4 Swapping Shocks Shocks may be swapped on the dyno only when a test cycle is not being run First remove the shock which is currently installed by raising the crossbar to remove any
15. Customer will pay for all replacement parts plus 100 00 per hour labor 3 Payment required at time of repair 4 It may take up to 4 weeks to schedule a service call to the customer s location 104 Roehrig Engineering Software Under Warranty A one year warranty comes with the purchase of all new Roehrig Engineering developed software The warranty includes 1 Free telephone e mail and fax support for all trained users 2 Free updates and new releases of Roehrig Engineering developed software Roehrig Engineering Software Not Under Warranty Once the warranty has lapsed on Roehrig Engineering software the following applies 1 REI may charge for telephone support at standard service rates 2 Questions may be faxes or e mailed to Roehrig Engineering s customer service department at no charge Please use the attached form for fax request Hardware and Software Training Roehrig Engineering s training program is designed to instruct trainees in the operation of the equipment that the customer has purchase The training sessions are set up for each trainee to obtain valuable hands on application exposure This will help the trainees in their everyday use of the equipment Training for additional personnel and advanced training is available at additional expense 105 ROEHRIG ENGINEERING INC 100 Lexington Parkway Lexington NC 27295 336 956 3800 Transfer of Warranty Service Plan Agreement ROEHRIG ENGINEE
16. Detailed Assembly Drawings e Exploded Assembly Drawings Hlectrical Schematics 101 10 Warranty and Service 10 1 Warranty For one year from the date of delivery date equipment leaves RET Roehrig Engineering Inc will provide free of charge parts and service labor to repair or replace any part of the dynamometer that fails because of a manufacturing defect This warranty is extended to the original purchaser and any succeeding owner of the product within the one year time period 10 2 Technical Support Roehrig Engineering Inc is committed to providing the best technical support to out customers If you have any problems using one of our products please follow these steps before contacting out Technical Support Representative e Be sure to read the equipment manuals Many times the answer is right there Document the problem you are experiencing Be as specific as you can The more information you have the easier the problem will be to solve e If you still cannot resolve your problem have your equipments serial number available before calling 102 Technical Support hours are 8 00AM to 5 00PM Eastern Time Monday through Friday E mail support roehrigengineering com You may also fax in your problems or questions 24 hours a day Faxes sent outside regular working hours will usually be answered before 10 00AM ET the next working day Please be sure to use the Customer Service Request Form found later in
17. Filter Data to Single Complete Cycle Check this box to display only one cycle from the data collected The dyno by default runs three cycles at each given speed Save Only PVP Peak Vel Points Check this box to save only the peak velocity data points Do not check this box to save the entire CVP data for each PVP test speed Stop at BDC Check this box to have the dyno automatically stop at bottom dead center after each test Enable autofill from last run Check this option to automatically fill the Fields with the data from the last test Gas Test Settle Time This sets the length of time the dyno pauses when measuring the gas force Zero Velocity Settle Time This sets the length of time the dyno pauses when taking the zero velocity recording for a PVP test Enter Test Description Allows the user to choose when the Fields are displayed for test description entry Data Options Check these boxes to automatically save a csv or xml file when you run and save a test Shock Preferences Colors Data Display Field Defaults Folders and Files Legend Math Signals Smoothing Snapshot Test Preferences _ Enter Test Description Filter Data to Single Complete Cycle After Test O Save Only PVP Peak Vel Points __ Before Test Stop at BDC Never O Enable autofill from last run Gas Test Settle Time 2 00 sec Data Options Zero Velocity Settle Time Auto export as CSV 1 00 sec Auto expo
18. Shock Preferences colors ata i Field Defaults Folders and Files Math signals smoothing snapshot re wes Graph snapshat options The graph snapshot function can be modified to create different size bitmaps when used To change the size of the snapshot generated alter the snapshot width and height The width of the legend within the snapshot can also be modfied Snapshot Width 152 40 mm Snapshot Height 101 60 mm Snapshot Legend Width 38 10 mm a Apply v Ok la Cancel Figure 6 16 Preferences Window Snapshot Folder and Files This page allows the user to set the default file names and default directories where the files ate saved Shock Preferences legend Methsgnas smoothing J snapshot test data bs Field Defaults Folders and Files Folder Options Default name for new files Enter a default name for new data files Shock Data Enter a default name for new template files Shock Template O Use last entered file name when saving new files Q Always retum to the last directory used by the program Use a predefined folder for each kind of shock file Templates C Program Files Roehrig Shock T emplates Data C Documents and Settings Marcus Desktop Test Data Settings C Program Files Roehrig Shock Settings a aro 2 A ca Figure 6 17 Preferences Window Folders and Files 60 Test This page allows user to edit default test settings
19. Torque crank bolt to 70 ft Ibs Re set the Emergency Stop button unplug the machine and wait 30 seconds plug the machine back into power This will re set the Emergency Stop error In the software program go to Hardware Motor Yes at the warning Click Measure Stroke and allow the software to calculate the new stroke If the number matches your desired stroke begin testing Roehrig Hardware Motor Configuration Roehrig Engineering Demo Motor Configure ka a Measure Stroke For some 10 20VS models the E stop will not provide the necessary braking In this case use a physical stop between the yoke and the center actuator shaft block The physical stop can be an aluminum bar that will stop the movement of the yoke 34 5 Commissioning the Dyno 5 1 Anchoring the Dyno The 2 3 5 and 10 20 30VS units require no special anchoring when used at a stationary facility Anchoting the dyno is recommended when the dyno is being used in a tide trailer or other mobile facility Any type of bracket may be used as long as it is attached directly to the dyno s aluminum frame and is capable of supporting the loads Do not attach brackets to either the front or rear cover or to any moving part on the dyno Ensure that the brackets do not interfere with any moving parts on the dyno The 2 3 and 5VS dynos may be placed on a workbench cart or any other type of stand that can support its weight plus
20. Valving The internal parts of the shock piston shims bleeders which can be changed to modify the shock curve 8 3 Shock 6 0 Math Syntax Functions The following functions are supported by the Roehrig Math system All functions unless specifically noted operate on all types of signals 94 Expression Description ABS Returns the absolute value of the expression SGN Returns the sign of the expression If expression is greater then 0 SGN returns 1 If expression is equal then 0 SGN returns 0 If expression is less then 0 SGN returns 1 SIN SIN returns the sine value of expression expression is assumed to be in radians cos COS return the cosine value of expression expression is assumed to be in radians TAN TAN returns the tangent of expression expression is assumed to be in radians ASIN ASIN returns the sin of expression Acos ACOS returns the cos of expression ATAN ATAN returns the tan of expression EXP EXP returns the values of e to the expression power or expression LOG LOG returns the natural log of expression 95 SQRT SQRT returns the square root of expression DIFF DIFF differentiates expression with respect to time The sample rate of expression is assumed to be that same of the data being used to evaluate expr
21. delete keys to add and remove rows Speed Lhe LI Re execute gas test prior to each speed O Include zero velocity sample o Use peak velocity for each speed to generate PVP trace Average values in a O window centered around zero 3 18 mm displacement Window Size o Lise peak force for each speed to J generate PVP trace Insert Series x 1 Advanced Back Cancel Figure 6 29 PVP Test Window 73 Multi CVP Allows user to run multiple CVP cycles in one test CVP cycles may be run at the same speed or at different speeds The user will be prompted to enter a table of speeds at which to run the CVP cycles The values in the table may be entered manually using the insert button or a table can be automatically generated using the series button An instruction may be entered after each speed This instruction will be displayed between cycles if the Pause after runs box is checked and will also be displayed as part of the cycle name when appearing in the legend Pause after runs When this option is checked the dyno will pause between each CVP cycle allowing the user to make adjustments to the shock The test will not resume until the user hits the continue button Re execute warmup When this box is checked the warmup cycle will run again after each CVP cycle Re execute gas test When this box is checked a gas test will be performed after ea
22. f 79 9 9 2030mm Gn ren f l 4 i k M 7 i a d 33 9 360 4 e imm 214mm 28 l e Isolation feet x 140mm WC N ur n 10V5 and 20N5 Crank Dyno 1 la Isometric View M i gt f Y b P 1 1 1 M 23 6 Bi es 19 5 comm 495mm 10VS and 20VS Crank Dyno 10VS and 20VS Crank Dyno EAD Side View Front View ROEHRIG ENGINEERING NC les Crank dyno shown with standard length columns custom lengths available 10VS and 20VS crank dynos have same outside dimensions Vibration isolation feet removable for permanent installation JOVS end 20S Crank Dyno 10hp and 20hp Motor No l 2 3 8 7 6 5 4 3 2 1 Figure 3 10VS and 20VS Dimensioned Drawing 2 2 Power Requirements and Hookup The 2 3 and 5VS require two power hookups one powers the electronics and the other powets the motot Make sure that both connections are properly made before using the dyno Electronics Hookup The electronics power supply is available in three configurations 2 3 5 10 20 30VS Internal Wiring with no wall plug 110V Wall Plug 220V Wall Plug An appropriate surge protected power strip is recommended Main Motor Hookup Motor horse power is rated based on three phase supply single phase results in reduction The 2VS is available in a 220VAC version only
23. grease fitting on each See the above instructions for how to gain access to the inner bearing 91 8 Appendix 8 1 USB to Senal Adapters In the case where your computer does not come with a Serial port the use of a USB to Serial Adapter will be required Roehrig Engineering recommends USB to Serial Adapters from Keyspan for reliability Model USA 19HS Cam Figure 8 1 Keyspan USB to Serial Adapter Model USA 19 HS When installing the drivers for the device follow the manufacturer s directions 92 8 2 Glossary Automatic Gas Test The dynamometer automatically measures and removes the gas force Collection The act of stroking the shock absorber and measuring the forces produced Collection Speed The speed at which the crank rotates See the Frequency Versus Peak Velocity chart to convert this to shaft speed in inches per second Continuous Velocity Pick off CVP When data is collected over a complete cycle of compression and rebound The graph produced is a smooth curve Cycle One revolution of the crank It is equivalent to the shock being compressed and extended one time Damper Shock Absorber Export Taking data from the shock program and turning it into coma separated ASCII files that can be used in other programs Gas Force The internal forces in the shock caused be the pressure of the nitrogen gas This is why the shock automatically extends itself Gas Test The measurin
24. mm o 800 00 mm sec 25 48 mm J 500 1 000 1 000 1 500 a J 1 500 2 000 J 2 000 2 500 J 2 500 3 000 4 3 000 3 500 J 3 500 4 103 0 tA A 24 103 900 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 og a Velocity mm sec INA Displacement mm Ti oo0o00g HAAN Test Results CilDesktop Folders Test DatalShock Data 1 PVP 6 45 58 AM 3 June 2008 Stroke Peak Velocity Test Speed Gas Force Shaft Diameter Gas Presswe SealDiag Temp NIA 786 11 mmjsec Na 229 94N 16 00 mm 2 2xpl 1144 Bar 3844N 40 54C Field Data Shock Name Shock ID Vehicle Location Compression Valving 4 z Rebound Valving 750 00 739 86 1432 Piston Valving eJ 60000 7861l 150737 Other Valving Compression Setting Rebound Setting Preload Setting Nose Figure 6 44 Template with open PVP Data File PVP Mfg Report Display Tab Selected 88 The Histogram display tab allows the user to create a histogram using data from the selected trace The user must define which data channel to display the bin size and the start and end points G File Graph Report PVP Mfg Report Scaling Histogram 7 Shock Data 1 PWI e y SE ptt els 4 000 00 N 4 000 00 N u OU 2 u Iv M JI 5 800 00 mmjsec 25 gt 1000 00 500 00 1 000 00 0 00 500 0
25. that data The tabbed analysis window allows the user to view the data in several different ways Show Hide Display i File Graph Report PVP Mfg Report Scaling Histogram AY 8 T ddododd sisi sisi sisan 1 3 4 5 6 7 8 9 1 Shock Data 3 PWP 75 00 mm sec 25 00 mm 0 475 00 mm sec 25 00 mm 25 00 mm sec 25 00 mm 125 00 mm sec 25 00 mm 175 00 mm sec 25 00 mm 225 00 mm sec 25 00 mm 275 00 mmjsec 25 00 mm 325 00 mmisec 25 00 mm 375 00 mm sec 25 00 mm 425 00 mm sec 25 00 mm 200 250 velocity mm sec Graph Tabs Figure 6 41 Template with open PVP Data File Graph Display Tab Selected 85 When the Graph display tab is selected the user defined graph will be displayed in the analysis window The user can choose the desired graph either from the Graph menu ot from the toolbar The show hide check boxes allow the user to turn on and off selected traces When the check box under the S column is checked the selected trace will show up on the graph and vice versa When the check box under the G column is checked the gas force if measured will be subtracted from the trace and vice vetsa A template can have multiple graphs Right click on one of the graph tabs lower left to create delete or rename a graph Once the desired graph is chosen the user can use the zoom line and averaging tools on the se
26. the actual delivery date Roehrig Engineering reserves the right to implement such changes without the Purchaser s consent however nothing contained herein shall be construed as obligating Roehrig Engineering to include such changes in the Dynamometer Software or System provided to the Purchaser 6 0 Non Disclosure 6 1 All Software including without limitation any Roehrig Engineering special user programs provided to the Purchaser as part of the system either at the time of or subsequent to the delivery of the Dynamometer is the intellectual property of Roehrig Engineering The Purchaser shall not reproduce or duplicate disassemble decompile reverse engineer sell transfer or assign in any manner the Software or permit access to or use thereof by any third party The Purchaser shall forthwith execute any further assurances in the form of non disclosure or licensing agreements which may reasonably be required by Roehrig Engineering in connection with the software 7 0 Entire Agreement Governing Law Misc Guarantee 7 1 7 2 7 3 7 4 7 5 These Purchase conditions constitute the entire agreement between Roehrig Engineering and the Purchaser in respect to the Product There are no representations or warranties by Roehrig Engineering express or implied except for those herein contained and these conditions supersede and replace any prior agreements between Roehrig Engineering and the Purchaser No representative of Roehr
27. this document Include your FAX and phone numbers and the name of the user Fax support number 336 956 3870 Phone support number 336 956 3800 103 10 3 SERVICE POLICY Roehrig Hardware Under Warranty A one year warranty comes with the purchase of new Roehrig Engineering manufactured hardware products Supplemental service plans ate also available at additional cost The following is a summary of what service can be obtained under the Standard warranty Factory repairs on hardware product defects Factory repairs are usually completed within 3 working days of Roehrig Engineering s receipt of the defective item The customer is responsible for returning the hardware to Roehrig Engineering Roehrig Engineering will return the hardware via UPS 2 day air service USA only If the customer is outside the continental USA the customer is responsible for all shipping expenses Expedited service can be arranged at the customer s expense Free technical support for technical problems and applications for all trained users Warranties can be renewed annually on Roehrig Engineering products A warranty cannot be purchased if the original or renewed warranty has expired FWON OR ue cm Warranties ate transferable to subsequent owners under certain conditions The equipment is currently under warranty The new owner undergoes training on the equipment a warranty transfer form is completed and submitted to Customer Service
28. using a small flat head sctewdtivet Figure 5 5 Screw Connector on Load Cell Step 4 Connect the motor control cable serial cable to the computer If the computer does not have a serial port a serial to USB adapter must be used Figure 5 6 Motor Control Cable 39 Step 5 Connect the USB cable provided to the data acquisition box at the left rear of the dyno Connect the other end to the computer Figure 5 7 All Connections Made Step 6 Plug the cable from the data acquisition box into the Data Cable port on the electronics board Tighten the screws using a small flat head screwdriver NOTE Setup instructions for 30VS models will be included in the Equipment Installation Guide 40 5 4 Initial Operation Once assembly is complete and the software is installed the dyno can be operated Ensure that the software key is installed Start the Roehrig Shock program by double clicking on the icon Once the software is up and running the user must verify that both the motor and data card are recognized by the software There are two boxes in the lower right hand corner of the software with the words motor and datacard If the word is shown in a black font then it is recognized by the software If the word is shown in a grey font then it is not recognized by the software Velocity ome Vs Absolute Velocity Motor Datacard 10 55 AM 5 26 2008 Figure 5 8 Shock6 Lower Right Corner Scree
29. with the Safety Considerations Technical Descriptions and Operating Instructions contained within this manual before operating the test system 16 Always ensure that the test equipment is operated within its design limitations The test equipment should only be operated when regular maintenance schedules have been carried out and when it is known that the test equipment is in good wotking otder If the test equipment is producing unusual or excessive noise and or vibration stop the operation of the test equipment until such a time as the systems have been checked for possible faults Maintenance procedures must only be carried out AFTER ensuring that all pneumatic and electrical power has been dissipated and that the electrical power has been disconnected from the main supply 17 3 2 Emergency Stop Operation All Roehrig damper dynamometers described in this manual are outfitted with an emergency stop button The emergency stop button is a large red button located in plain sight on the front of the machine and labeled as such To shut the machine down using the emergency stop button simply push the button To release the emergency stop button twist it in the direction indicated on the button The machine will not automatically restart when the emergency button is released The power to the machine must be shut off for one minute in order to reset the machine NOTICE In case of any emergency push the emergency stop but
30. 0 500 00 0 00 1 000 00 500 00 1 500 00 1 000 00 Force N BE C Desktop FoldersiTest Data Shock Data 1 PVP 2 000 00 1 500 00 2 500 00 2 000 00 3 000 00 2 500 00 3 500 00 3 000 00 lt 3 500 00 Percent Figure 6 45 Template with open PVP Data File Histogram Display Tab Selected 89 7 Maintenance Procedure To ensure proper performance of your Roebrig Dynamometer follow these maintenance procedures As Needed Columns Keep cleaned and lightly oiled to prevent rust Un treated Steel Only Check the wear plates for grease The dimples in the wear plates should be filled with grease at all times for proper lubrication Wear Plates Wear plates should be greased with Mobil 1 Red Grease or any non molybdenum or non Lithium grease Remove the crossbar handles and nuts if equipped and apply anti Crossbat seize to the crossbar studs Keep dust and oils away from the electronics boatd clean as needed General DO NOT apply cleaners or solvents to the IR Temperature sensor chemicals may damage the lens Every TWO Months Your dyno is equipped with dry linear bearings at the actuator shaft and at the two shafts for the scotch yoke These bearings DO NOT require lubrication Bearings Visually inspect the three bearings on the front of the machine The bearings should look clean and free of debris Note When the machine is i
31. ALITY eeeeeeeeeeenee 21 4 1 Overview of Dyno FUnCctiODS 0 v0eeereseoooeosooososoooooooonooooonoooooonooooonoooooooenoooooonooooonosooe 21 4 2 WHAT IS A SHOCK DYNAMOMETER 000eereeeooeooeooosoooooooooooeooooooooosoooooeoooneon 21 How It Works rene re n re eren rede Te PERS 23 Data from an Entire Cycle ssssssssesseseeeeeeenr ener 26 4 2 Overview of Dyno Operation creer esee reete eese testen ense ta tuse ta sensn sensn statuae 28 4 3 Running a Tet P seesi 28 4 4 Swapping SHOCKS eseseseseerosaosaooaoooooosoooooorosoeooooonoonnooonoonnoonnosaoonaooasouooonooonooneooeoooonnne 32 4 5 Changing Stroke M 34 To change stroke ated te wk oe d ete eei det aime an 34 5 COMMISSIONING THE DYNO eeeeeeeeee eene nennen nnn 35 5 1 Anchoring the DYDnO 000ev0eeeeeresoeosooovosooooooooooooooooooooouoooooooooooooonoooooonosooonooooeooooooooeonon 35 5 2 Software Installation crece esee ee ee esee ee ette ense netna sense ta seta seta seta sete stesse to ase 36 5 3 Dyno Assembly A 37 5 4 Initial Operation P 41 6 1 Becoming Familiar with the dyno 0 e0reereeeeseeoseoooosoooooooonoooooooooooonosooosoooooooooooooeonen 43 6 2 Getting Started E 45 6 3 The So ftware SHOCKO itissesees
32. Dynamometer the Software the Computer and optional parts associated with the Dynamometer Purchase Order means the original document issued from the Purchaser to Roehrig Engineering listing all parts and or services to be purchased and the agreed purchase price Warranty Transfer Form means a document to be completed for the transfer of the Roehrig Engineering Warranty This document is available from Roehrig Engineering upon request 9 0 Software License Agreement The Software License Agreement is part of the Operating Manual for the product and software System that you have purchase from Roehrig Engineering Inc collectively the Licenser By your use of the software you are agreeing to the terms and conditions of this Software License Agreement Throughout this Software License Agreement the term Licensee means the owner of the System 94 9 2 9 3 9 4 9 5 The Licenser hereby grants the Licensee the non exclusive right to use the computer software described in this Operating Manual the Software The Licensee may sell the software key but may not assign sub license rent or lease the Software to any third party without the Licenser s prior written consent The Licenser further grants the Licensee the right to make a backup copies of the Software media and use the software in demo mode The Licensee agrees that it will not decompile disassemble reverse engineer copy transfer or otherwise use the Soft
33. NAMOMETER DANGER Always be sure the power is disconnected to the box before wiring the machine Use proper lockouts in accordance with local electrical codes WIRING DIAGRAM FOR 200 240 VAC THREE PHASE POWER HOOK UP IHPUT POWER 200 240 Three Phase 50 60Hz 3VS 6 amps 5VS 10 amps 10VS 20 amps GEHERAL DUTY FUSIBLE SAFETY SWITCH BOX GROUND GREEH or GREEH YELLOW L1 Brown or L1 L2 Black or L2 L3 Grey or L3 Heutral Blue TO THE DYHAMOMETER NOTE In non US countries where three phase power includes a ground and a neutral the neutral is not used DANGER Always be sure the power is disconnected to the box before wiring the machine Use proper lockouts in accordance with local electrical codes WIRING DIAGRAM FOR 380 440 VAC THREE PHASE POWER HOOK UP IHPUT POWER 380 440 VAC Three phase 50 60Hz 3VS 5 amps 5VS 6 amps 10VS 11 amps 20VS 23 amps GEHERAL DUTY FUSIBLE SAFETY SWITCH BOX GROUND GREEH or GREEH YELLOW L1 Brown or L1 L2 Black or L2 L3 Grey or L3 Heutral Blue TO THE DYHAMOMETER DANGER Always be sure the power is disconnected to the box before wiring the machine Use proper lockouts in accordance with local electrical codes 10 2 3 Airborne Noise Emission Sound pressure levels measured at a distance of 1 meter from surface of machine and at a height of 1 6 meters from floor per CE standard where no specific workstation
34. P Crank Dynamometer 20VS 20HP Crank Dynamometer 30VS 30HP Crank Dynamometer 1 2 Manufacturer Identification Roehrig Engineering Inc 100 Lexington Parkway Lexington NC 27295 Phone 1 336 956 3800 Fax 1 336 956 3870 1 3 Normal Operation and Usage The 2 3 5VS and the 10 20 30VS damper dynamometers are intended for the sinusoidal testing of linear dampers Any linear damper which is properly installed with the correct fixture may be tested by a trained operator These units are designed for continuous usage 1 4 Incorrect Operation and Usage The 2 3 5VS and the 10 20 30VS damper dynamometers should never be used to test anything other than a linear damper The damper must be properly installed using the correct fixtures Only trained operators can correctly and safely use these machines The dynamometer should only be used if correctly set up and installed by a professional The machine may not be run if any safeguards have removed damaged or tampered with 1 5 Operator Workstation There is no specified or defined operator workstation however it is recommended that an operator be present at all times while the machine 1s running and in reach of the emergency shut off switch 2 technical Data 2 1 Machine Weights and Measurements 2VS Weight 245Ibs 111kg 3VS Weight 285Ibs 129kg 5VS Weight 308lbs 140kg or A ai p 7C
35. P Test The user will be prompted to enter a table of speeds at which to run the PVP test The user may enter the values in the table manually using the insert button or a table can be automatically generated using the series button The PVP graph can be generated using one of three methods peak velocity pickoff average values about 0 displacement or peak force pickoff Re execute gas test prior to each speed When this option is checked a gas force test is performed before each speed Include zero velocity sample When this option is checked a zero velocity data point is measured This is done at mid stroke The settle time can be set in preferences Use peak velocity for each speed to generate PVP trace When this option is checked the data points generated correspond to the peak velocities seen for each test speed Average values in a window centered around zero displacement When this option is checked the data points for each test speed are generated by taking the average values inside the given window centered around zero displacement mid stroke Use peak force for each speed to generate PVP trace When this option is checked the data points generated cotrespond to the peak force values seen for each test speed Specify PVP Test PVP type test has been chosen to run Enter the speeds at which to test the damper Enter the speed in the order you want them to run Use the insert and
36. RING INC Seller s Name hereby waives all rights under wattanty service policy for Dynamometer Serial Number Purchased originally on date Buyer s Name hereby assumes all rights and obligations of the Hardware and or Software Warranty Service Policy from Date of Transfer This transfer is valid only under the following conditions 1 The Dynamometer is currently under warranty 2 New owner undergoes training from Roehrig Engineering 3 This watranty transfer form is completed and submitted to Customer Service AGREED Print Seller s Corporate Name Print Buyer s Corporate Name By X By X Print Name of Signatory Print Name of Signatory Roehrig Engineering Inc Approved by X 106 Purchase Conditions All Purchase Orders hereafter the Order for Roehrig Engineering provided products and services hereafter the Product are subject to the following terms and conditions which are agreed to by the Purchaser 1 0 Payment of Purchase Price 1 1 1 2 Purchaser hereby promises to pay to the order of Roehrig Engineering all deferred portions of the Purchase Price together with the interest on late purchase price payments payable at 1 5 per month 18 per annum the Purchaser grants to Roehrig Engineering a security interest in the products sold pursuant to the Order which may be perfected by UCC 1 Financing Statements to be recorded in the applicab
37. Standard Quick Release In 2 5 16 and 14 Universal Clevis C clamp Clevis In Any Size Motorcycle Fork Fixtures Bicycle Tube Fixture O OO OO 0 Custom Clevis Lista Brand Single or Double Drawer Roller Cabinets Movement Assisted Crossbar Ball Screw Actuated Crossbar Self Clamping Crossbar Protective Cage Enclosure CE Cage with power shut off 14 15 3 Safety 3 1 Safety Notice THE TEST EQUIPMENT DESCRIBED AND WRITTEN ABOUT WITHIN THIS MANUAL MUST BE OPERATED USING PROCEDURES THAT PROVIDE THE MAXIMUM LEVELS OF SAFETY TO PERSONNEL AND TO THE EQUIPMENT ITSELF All local and National Safety Standards together with company specific safety procedures MUST be observed at all times It is essential that a detailed study of the information contained within this manual is made before operating the test equipment The following guidelines are laid down as MINIMUM recommendations Ensure that safety interlocks are fully functional at all times Only operate the test equipment after ensuring that no personnel are present in any areas that may be regarded as potentially hazardous This includes the area around the test equipment and its component parts All potential work area hazards must be properly guarded and all guards correctly closed BEFORE the test equipment is operated Only trained personnel should operate the test equipment or be allowed to conduct tests using this equipment The operators MUST be fully conversant
38. Volume ROEHRIG ENGINEERING INC ROEHRIG ENGINEERING INC Damper Testing Equipment 2VS 3VS 5VS 10VS 20VS 30VS ROEHRIG ENGINEERING INC Shock Absorber Testing Equipment User Manual O Roehrig Engineering INC 100 Lexington Parkway Lexington NC 27292 Phone 336 956 3800 Fax 336 956 3870 Table of Contents 1 IDENTIFICATION AND MACHINE DESCRIPTION eeee 1 1 1 Dynamometer Identification eee eee esee essen ense en ene te tne ta sensn sets tn seta so notan 1 1 2 Manufacturer Identification 1 eere eee eee eee entes eene nete sins ta stata senses tn ses tn aen 1 1 3 Normal Operation and Usage eee eee e eee esee ente eene aeta tuse ta sse ta sens enses tuae 1 1 4 Incorrect Operation and Usage 00reeeeonooonoooooooooooooooooooooooooooooonoonooonooooooosooosooooosooen 2 1 5 Operator Workstation 4 eeeee esee eene eene enne tn neta etta seta stesse tones etas e tas ense ease ease 2 2 TECHNICAL DATA 24 uiuit ocu c cur toa E act n E uxt o nua FRE n ki e n PNAS an ka ak po 3 2 1 Machine Weights and Measurements 000evreseeooeoooosooooonoooooooonoooooooooovosoooooooooooooonnoooe 3 2 2 Power Requirements and Hookup eere eese seen eene tesis tn sensns tenen sets su sen senae 5 El ctromcs Hookup isi remet roe De B RR 5 Mam MotorHookup o oO HERO E AMO D REUS 6 2 3 Airborne Noise Emiss
39. a fluctuating vertical load of 50lbs 23kg The surface on which the dyno is placed must be solid and continuous covering the entire bottom of the machine as there is no lower guard The dyno may not be run on its side unless fitted with special feet and a special lower guard The 10 20 30VS units ate designed to sit on a solid floor with the factory installed isolation feet Make sure that the floor can support the full weight of the machine 1 000Ibs 46kg The dyno must be placed on a solid continuous surface which covers the entire base of the machine The dyno may not be run on its side unless fitted with special feet and lower guard 35 5 2 Software Installation The 2 3 5 and 10 20 30VS dynos require a PC running Microsoft Windows XP or win 7 The PC must have a minimum of two USB ports and one serial pott In the case that the computer has no serial port a third USB port is required along with a USB to serial adapter 1 2 3 To install the Roehrig Shock6 software first ensure that the USB software key is NOT inserted Insert the Roehrig CD provided with the dyno The software installation wizatd will automatically load If it does not automatically load double click on your CD ot DVD drive icon which contains the Roehrig CD under My Computer Follow the on screen setup instructions Do NOT insert the software key until prompted Once setup is complete your system will need to reboo
40. age allows the operator to select what cycles will be used to generate the PVP compos Roehrig Engineering historic method If this option is selected the program will average all collected cycles and use that average as the peak points for the PVP trace When you check this box you will also be given the option to clip to a single cycle in this mode the program will use the second to last cycle This is how previous versions of Shock 6 displayed PVP traces PVP cycle selection This option lest the operator select what cycle ot group of cycles they would like to use for PVP generation Any number of cycles can be selected Cycles to sample Defines the number of cycles that dyno will run and the user will have to select from increase this number to see more cycles under cycle selection Peak force and peak velocity method This method should not be used without contacting REI beforehand to make sure the operator has a complete understanding of the effects on the data Shock Preferences Graph Legend Math Signals Smoothing Snapshot Colors Data l Display Field Defaults Folders and Files Test Y Units PvPoptions PVP Options a Use Roehrig Engineering historic PVP methodology generating PVP summary trace averaging over all collected cydes Cydes To Sample 5 00 PVP Cyde Selection Selects the cycles to use for generation of a PVP graph C 2nd cyde from end If multiple cycles are selected the res
41. age the eleven data points to generate the value at that data point It uses eleven because it takes 5 points from left 5 points from the right and the data point itself CYCLE CYCLE evaluates expression and then clips the data to contains only the opendirection and closedirection portions of the dyno cycle opendirection and closedirection can be qith Rebound Compression or Ignore 97 Syntax expression binaryop simpleexpression expression simpleexpression number symbol function unaryoperation conditional smooth cycle number NUMBER NAN symbol SIGNAL CONSTANT Function ABS expression SGN expression SIN expression COS expression TAN expression ASIN expression ACOS expression ATAN expression EXP expression LOG expression SORT DIFF expression INTG expression POSITIVE expression NEGATIVE expression RAD expression DEG expression IN argumentlist AX argumentlist AVE argumentlist UNITS symbol measurement TOUNITS expression measurement argumentlist expression argumentlist expression unaryoperation expression l NOT expression binaryop expression expression l expression expression l expression expression l expression expression 98 expression measurement conditional smooth direction l cy
42. ak Velocity Pickoff and Multi CVP Multiple Continuous Velocity Pickoffs Choose test type to create Welcome to the Shock Test Wizard This wizard will guide you through the creation of a test profile Please select a test type to create PVP Multi CvP CYP Test A CYP is short for Continuous Velocity Pickoff It runs the dyno at a single maximum speed to provide a continuous stream of data for a full cycle Figure 6 25 Choose Test Type Screen 69 Select Warm Up Type Allows user to choose what type of watm up cycle to run on the shock There are four types of warm up cycles which the dyno can perform Do not perform a warmup When this option is selected a watm up cycle is not performed Run the shock at a set speed for a period of time The user will be prompted to enter a speed and period of time for the warm up cycle Run the shock at a set speed until a particular temperature is reached The user will be prompted to enter a speed and a target temperature for the watm up cycle Specify a set of temperatures to which to warm the shock Run the specified test once at each specific warm up temperature This watm up cycle can only be used with CVP tests The user is prompted to enter a speed and a table of temperatures The CVP test will run once at each specified temperature Select Warmup Type Please select the type of warmup that should be performed Warming each shock to matching temperatu
43. attached to the damper shaft through a linear bearing As the motor spins the crank the damper piston moves up and down just like the piston in a engine Bolt holes in the crank allow several different stroke lengths Different pulley diameters or a variable speed motor give different crank rotation speeds The load cell measures the damper force 22 We all know that the speed of a piston connected to a crank varies continuously as the crank rotates You might remember from high school math or physics that this type of motion is called sinusoidal because it vaties with the sine of the crank angle The piston comes to a stop at bottom dead center BDC accelerates to a maximum speed halfway up the cylinder and slows down to a stop again at the top TDC If you have a damper attached to a crank its piston does the same and the force generated also varies continuously We know howevet that the maximum speed of the piston happens only once per stroke when the piston is halfway between top and bottom and that s also when the damper generates maximum force With our simple shock dyno we could change the crank stroke to vaty the maximum shaft speed and or we could use drive pulleys of different sizes However both of these methods are cumbersome and time consuming during testing Variable speed AC motors allow easy manipulation of the crank RPM How It Works You put a damper in the dyno choose a stroke and RPM and turn on the motor The
44. bs S Beam Load Cell 16 bit resolution USB Data Acquisition standard e Full Computer Control with SHOCK Software 3VS Features e 3 Hp Motor 220V or 380 440V e Zero Lash Belt Drive e Precision scotch yoke wear plate system e 4 Standard English Strokes 0 50 1 00 1 50 2 00 or e 4 Standard Metric Strokes 15mm 25mm 40mm 50mm e Non contact Infra Red style Temperature Transducer e 48 Bright Nickel columns 28 700 mm eye to eye test area e 5000 lbs Pancake Load Cell 8 Channel Instrumentation and Signal Conditioning System 16 bit resolution USB Data Acquisition standard e Full Computer Control with SHOCK Software 5VS Features e 5 Hp Motor 220V or 380 440V e Zero Lash Belt Drive e Precision scotch yoke wear plate system e 4 Standard English Strokes 0 50 1 00 1 50 2 00 or e 4 Standard Metric Strokes 15mm 25mm 40mm 50mm e Non contact Infra Red style Temperature Transducer 48 Bright Nickel columns 28 700 mm eye to eye test atea e 5000 lbs Pancake Load Cell 8 Channel Instrumentation and Signal Conditioning System 16 bit resolution USB Data Acquisition standard e Full Computer Control with SHOCK Software 12 10VS Features e 10 Hp Motor 220V or 380 440V e Zero Lash Belt Drive e Precision scotch yoke wear plate system 6 Standard English Strokes 0 75 1 0 1 5 2 0 3 0 and 3 90 or 6 Standard Metric Strokes 15mm 25
45. ce would be set to Negative with Negative is on set to Top Right Display compression displacement as Display compression velocity as Display compression force as B ai Vo o a nu Figure 6 11 Preferences Window Data 55 Math Signals This page allows the user to create additional data channels which are created using constants math functions and collected data channels Math channels ate treated the same as collected channels and may be graphed ot used in other math channels The math syntax used in creating these channels is located in the Appendix Shock Preferences Display Field Defaults Folders and Files Math Signals Smoothing Snapshot Hide syst m channels Formula l Constants a Insert Channel gt Edit Channel Channel Units Formula Use the the insert and delete keys to add and remove formulae and constants Figure 6 12 Preferences Window Math Signals 56 Display This page contains the default graphing display options Display Preferences Check box options for PVP and CVP data display defaults Default Graph Allows user to determine the default graph which is initially displayed in the analysis window Manufacturer s Report Allows user to determine which two graphs are displayed in the manufacturer s report The manufacturer s report is only available for PVP test data Shock Preferences Legend Math Signals Smoothing Snapshot Test Colors Da
46. ce a force proportional to the speed of shaft movement If you compress a damper slowly it generates less resistant force than if you move it faster As mentioned before a damper on a race car does several very important things including providing a tunable feel for the driver during cornering controlling wheel travel over road irregularities and most important for a ground effects car stabilizing the under wing of the car at optimum ride height and rake Since dampers ate a critical component of a race car they should be tested petiodically to make sure they are working correctly Also when a race engineer finds a damper set up that makes the car faster under certain conditions at a certain racetrack that engineer will want to have dampers set up the same way the next time the car runs on that or a similar track As 21 with any ctitical component the race engineer would like to know more about how it works The shock dyno is a tool used to test dampers and learn about their behavior The force vs shaft speed graphs you see in this article come from data generated by testing a damper in what is generally known as a damper dynamometer or shock dyno This is a machine that compresses and extends a damper at known speeds and measure the forces produced by the damper We ll start out by describing the simplest form of a shock dyno Figure 1 shows a frame holding an electric motor with a drive belt and pulleys that spins a crank
47. ch CVP cycle Specify Multi CVP Test A Multi CVP type test has been selected Enter the speeds for damper testing List speeds in the intended execution order Use the insert and Pause after runs delete kevs to add remove rows A Multi CvP test can pause between each test re execute the warmup at gas test prior to each individual test speed DI Re execute gas test Instruction j insert ai DI Re execute warmup Advanced Back Cancel Figure 6 30 Multi CVP Window 74 Advanced This button appears in all three types of test profiles It allows the user to specify the move to speeds used during the test Changing the gas test move to speed may change the gas test results The gas test move to speed and the gas test settle time must be adjusted depending on the shock being tested The advanced button also allows the user to monitor the shock temperature and automatically shut down the test if a given temperature is teached Advanced Properties Move to speeds Temperature Monitoring The test move to speed is the default move to speed For all The temperature of the damper can be moves The gas test move to speed is used during the gas monitored during the test The test will abort kest The post test move to speed is used returning to the if the maximum allowed temperature is home position at end of test reached Test Move To Speed m sec Monitor test temperature She Mete Seki Maximum Temperature
48. ches or defaults by the Purchaser In the event more than one Product is being purchased pursuant to the Order unless otherwise set forth herein each payment received by Roehrig Engineering from Purchaser shall be applied pro rata against the cost of each product rather than being applied to the purchase price of any product 2 0 Delivery and Transportation 24 2 2 Delivery dates are estimates and not guarantees and are based upon conditions at the time such estimate is given Roehrig Engineering shall not be liable for any loss of damage whether direct indirect or consequential resulting from late delivery of the product The Purchaser s sole remedy if the Product is not delivered within 90 days of the estimated delivery date shall be to cancel the Order and recover from Roehrig Engineering without interest or penalty the amount of the down payment or deposit and any other patt of the purchase price which has been paid by the Purchaser Notwithstanding the foregoing such right of cancellation shall not extend to situations where late delivery is occasioned by causes beyond Roehrig Engineering s control including without limitation compliance with any rules regulations orders or instructions of any federal state county municipal or other government or any department or agency thereof force majuere acts or omissions of the Purchaser acts of civil or military authorities embargoes war ot insurrection labor interruption through strik
49. cle measurement expressio expressio expressio expressio expressio expressio expressio expressio expressio expressio expressio PPD O2 20005005 expression expression IF IF IF IF SMOOTH expression expression expression expressio expression expression gt expressio expression l expressio expressio expression AND expression OR expression XOR expression n expression expression expression expression expression expression HEN expression HEN expression ELSE expression NUMBE R COMPRESSION REBOUND IGNORE CYCLE M M PS NC S BS ZARPREQARHHRAQAZRWHY Cc KGF expression direction direction NKNOWNUNIT NCH H SE C EC M SEC M SEC EWTONS 99 G FT SEC2 P SEC 2 IN LBS FT LBS N M PSI BAR P V LBS IN N MM N CM N M KGF MM KGF CM KGF M OZ LBS GM KG FLOZ GAL EG AD H DOU N MM DEG N CM DEG N M DEG NEWTON CM NEWTON MM KGF MM KGF CM KGF M J KGF M DEG 5 N LBS DEG FT LBS DEG KGF MM DEG KGF CM DEG 100 9 Additional Documentation The following pages will contain information specifically related to your product Included are some all of the following
50. comma separated value file Export selected traces will export only the channels displayed on the current graph Both options will also export all field data Raw data may also be exported by using copy and paste from the signal vs time graph Exit Used to exit the Roehrig Shock6 program 51 6 3 2 Edit Ctri Delete Tet Snapshot v Show Line Style File Preferences Figure 6 8 Edit Menu Cut Used to cut the selected item and place it on the clipboard Copy Used to copy the selected item and place it on the clipboard Paste Used to paste the item on the clipboard to the selected location Delete Used to delete the selected item Snapshot Takes a snapshot similar to print screen of the current graph and legend and places it on the clipboard The snapshot can then be paste into any windows program such as Paint Word etc The size of the snapshot can be changed in Preferences F12 Show Click to display conceal the highlighted data file This command is also available as a check box on the legend Remove Gas Force Click to include exclude the gas force from the highlighted data file This command is also available as a check box on the legend Line Style Changes the line style for the highlighted data file File Allows the user to open and edit the data file properties description page also known as Fields 52 Prefere
51. crank turns and the damper shaft moves up and down until you turn off the motor If you know the crank RPM and the stroke you can calculate the maximum damper shaft speed For example let s say the crank turns 100 RPM and the stroke is 1 inch 100 rpm is 1 67 revolutions per second and the length of 1 revolution is the circumference of the circle traveled by the crank bolt or Pi times the stroke 1 67 x 3 14 x 1 inches is about 5 inches per second This is the maximum speed of the damper piston and it happens twice each revolution of the crank once with the piston going up in compression and once again with the piston going down in rebound If we keep this example really simple and connect the damper directly to a weighing scale with a circular dial we can stand there and read the scale pointer directly What we ll see is the pointer cycling from 0 to some maximum bump force as the shock compresses returns to 0 and then peaks out again at the max rebound force as the piston comes back down The needle on our scale goes from plus some number to minus some number as the damper cycles from comptession to rebound and back We can just write down the numbers at which the 23 needle peaks as it goes back and forth A commercially available shock dyno uses a computer to read the load cell and store the data Some dampers are set up to give more force in rebound than compression so as our simple machine cranks away we might see the scale
52. cus Font LES J iie la Figure 6 10 Preferences Window Legend 54 Data This page contains the default data display options Initially Remove Gas Force Check this box to initially remove gas force from data when displayed Assume Shock 96 Data has Gas Force removed Check this box if importing Shock 96 data which already has the gas force removed Filter Shock 96 Data to Single Complete Cycle Check to display only one complete cycle when importing Shock 96 data Sign Convention Allows user to change the default axis and sign convention used when displaying data Avg Force vs Velocity Graph Controls the cursor step size on the average force graph only Gas Force Gas Pressure Display Default shock shaft diameter used for calculating the gas pressure Shock Preferences Legend Math Signals Smoothing Snapshot Test Colors Data Display Field Defaults Folders and Files ptions Avg Force vs Velocity Graph Initially remove Gas Force Velocity Increment I Assume Shock 96 Data has Gas Force removed Filter Shock 96 Data to Single Complete Cycle 0 0064 m sec Sign Convention Gas Force Gas Pressure Display Use the sign convention parameters to display data with the desired Default Shaft Diameter sign convention and axis orientation For example if compression Force should be displayed as a negative number with compression on the top 16 00 mm half of the graph Display compression For
53. e Software media and all written materials together with any copy of such media or materials and the Licensee shall keep no copies of such items The interpretation of this Agreement shall be governed by the following provisions 9 8 A This agreement shall be construed pursuant to and governed by the substantive laws of the State of North Carolina and any provision of North Carolina laws shall not apply if the law of a state or jurisdiction other than North Carolina would otherwise apply B Ifany provision of this Agreement is determined by a court of competent jurisdiction to be void and non enforceable such determination shall not affect any other provision of this Agreement and the remaining provisions of this Agreement shall remain in full force and effect If any provision or term of this Agreement is susceptible to two or more constructions ot interpretations one or more of which would render the provision or term void or non enforceable the parties agree that a construction or interpretation which renders the term of provision valid shall be favored C This Agreement constitutes the entire Agreement and supersedes all prior agreements and understandings oral and written among the parties to this Agreement with respect to the subject matter hereof If a party engages the service of an attorney or any other third party or in any way initiates legal action to enforce its rights under this Agreement the prevailing party shall be enti
54. e in greater detail All operators should read this manual in its entirety before using the dyno 45 6 3 The Software Shock6 The following section will describe the various functions and tasks available within the Shock6 program All the functions and tasks can be reached through the drop down menus at the top of the screen Some of the more commonly used functions and tasks can also be found on the toolbar or can be accessed through hot keys The toolbar can be modified using standard windows procedures The following figure shows the main program screen Roehrig Shock 6 2 Template EI De EM Geh Tes Hortus View oua Meow tiep E r ea rape Sir Repo SES Scaling store Tabbed Analysis Window Velocity Fome Vs Absolute Velocity Motor Datacard 10 55 AM 5 26 2008 Figure 6 3 Shock6 Main Screen NOTE Data files saved in Shock96 or Shock5 can be opened and viewed with Shock6 46 6 3 1 File Open template Ctri Shift O Savetemplate Ctri Shift S Save template as Ctri Shift A Open Data Ctrl O Open XML datafile b Print C Desktop FoldersiCustomers MotoniMoton 5Y5 Roehrig reg Files 16 05 08 Master Clicker 4 16 05 08 C VP C Desktop Folders Customers Tenneco BelgiumYScreech FilesiRear No 5 PVP C Desktop Folders Customers Tenneco BelgiumiScreech FilesiRear No 4 PWP C Desktop FoldersiTest Data Shock Data 3 PWP
55. e or walkout transportation delays and other inability resulting from causes beyond Roehrig Engineering s control to obtain necessary labor manufacturing facilities or materials from its usual sources Any delays resulting from such causes shall extend estimated delivery dates by the length of such delay Responsibility for all costs and risks in any way connected with the storage transportation and installation of the Product shall be borne entirely by the Purchaser If any disagreement arises as to whether or not damage to the Product was in fact caused in storage transit or installation the opinion of Roehrig Engineering s technical advisers acting reasonably shall be conclusive 3 0 Installation and Operator Training 3 1 The Purchaser shall be responsible for installation of the Product including without limitation the preparation of its premises the uncrating of the product and setting up of the Product for operation Purchaser may elect to order contract services ftom Roehrig Engineering to perform this service should they elect to do so 107 4 0 Warranties and Limitation of Liability 4 1 Roehrig Engineering warrants that subject to Section 4 6 the Product shall be free from defects in workmanship or material affecting the fitness of the product for its usual purpose under normal conditions of use service and maintenance 4 2 Roehrig Engineering warrants that the software shall operate according to specifications and the sys
56. ed Before running the batch test the user is required to select an output folder for the data files which will be saved Once this is done click the OK button to begin the test Select batch test to run Select the directory to output the batch s data Then select the batch of tests to execute Finally select Ok to begin execution of the batch test Output Folder po Auto fill test individual test 5 A Edibatch IV felde hom st tet B By cance Max Test Travel 50 80 mm Data Data File BatchData 1 BatchData 2 BatchData 3 BatchData 4 BatchData 5 Unavailable tests are highlighted in red Figure 6 34 Run Batch Test Window Delete Batch Allows user to delete a previously created batch test or tests 79 6 3 5 Hardware m Datacard 5 Motor i Monitor Figure 6 35 Hardware Menu Datacard Contains information regarding the datacard including sampling rate and calibration data for each sensor Warning Altering these numbers will change the calibration of the dyno Please contact a Roehrig representative before making changes to the datacard values Motor Contains information regarding the motor including motor type and motor parameters All settings are preset at the factory and should not be changed by the user with the exceptation of Measure Stroke The Measure Stroke option should be run whenever the stroke on the dyno has been mechanically cha
57. ession INTG INTG integrates expression with respect to time The sample rate of expression is assumed to be that same of the data being used to evaluate expression POSITIVE POSITIVE returns the value of expression if it is greater then zero otherwise POSITIVE returns zero NEGATIVE NEGATIVE returns the value of expression if it is less then zero otherwise NEGATIVE returns zero RAD RAD converts expression from degrees into radians DEG DEG converts expression from radians to degrees MIN MIN evaluates each individual expression and then returns the minimum of all of the expressions MAX MAX evaluates each individual expression and then returns the maximum of all of the expressions AVE AVE evaluates each individual expression and then returns the average of all of the expressions UNITS UNITS ensures that symbol is returned in measurement units For example if Displacement may be in inches or millimeters UNITS Displacement Mm would ensure the Displacement is in millimeters 96 TOUNITS TOUNTIS assumes expression is in measurement units and forces it to convert to targetmeasurement units SMOOTH SMOOTH evaluates expression and averages the values of expression for each of the NUMBER data points before and after the each data point For example SMOOTH Displacement 5 would for each point of displacement it would aver
58. ettings listed under the settings menu on a regular basis in case of a computer crash System Settings Exports datacard settings motor settings or both These settings can be used to restore the motor properties and datacard properties sensor calibration in case of a computer crash To import these settings simply double click on the desired system settings file in any Windows Explorer window Export all Settings Exports all user and system settings and saves them as one file Math Settings Exports or Imports only the math channels created in preferences Can be used to transfer math channels to other computers running SHOCK6 When importing math channels the user can choose to replace existing channels with the new channels or merge the existing channels with the new channels Test Settings Exports or Imports only the user s tests Can be used to transfer tests to other dynos running Shock6 When importing tests the user can choose to replace existing tests with the new tests or merge the existing tests with the new tests Test settings cannot be transferred between crank dynos and EMAs Electro Magnetic Actuators 82 6 3 8 Window Tile Horizontally Tile vertically E Cascade Arrange Icons 1 Template 2 Template Figure 6 39 Window Menu Window Menu Allows user to arrange templates within the program using standard Microsoft Windows functions Also lists currently open templates
59. g of the shocks gas force Keypad This is not part of the computer but the square pad attached to the dynamometer itself It is used to manually control the machine s motor Live When a live reading of a sensor is referred to you are not collecting data but viewing real time results on the computer monitor Load Cell This is attached to the bottom of the cross bar It is either a blue or stainless cylinder or a steel S shaped piece The top of your shock attaches to it and it measures the forces generated by the shock during a collection Motor Units The type of numbers entered in the Test Options screen This is Hz RPM or Linear Velocity The Velocity is calculated by multiplying the Stroke times the Frequency Ratio times Pi times the desired crank Hz Peak Velocity Pick off PVP The dynamometer is run at different speeds and the data is collected and graphed only at the peak velocity of each cycle The resulting graph is a point to point line graph Seal Drag The internal friction of the shock caused by seals o rings and binding This number is generated during an Automatic Gas Test 93 Shock Absorber Damper Software Key The small white plastic square connected to the printer port of your computer Without this your computer will not talk to your dynamometet Temperature Sensor The black piece of plastic that clips around the damper It measures the temperature of whatever it touches
60. he Product to Roehrig Engineering in the original packing containers Roehrig Engineering will return the repaired or replaced Product Roehrig Engineering will incur the expense of the needed part and all return shipping charges to the Purchaser Roehrig Engineering may authorize of a component of the Product to perform the service B IFSYSTEM IS NOT UNDER WARRANTY The Purchaser is responsible for the cost of the replacement part or software and all shipping charges 4 8 Nothing herein contained shall be construed as obligating Roehrig Engineering to make service parts or repairs for any product available after the expiration of the Warranty Period 49 Limitation of Liability Roehrig Engineering shall not be responsible under any circumstances for special incidental or consequential damages including but not limited to injury or death of any operator or other person damage or loss resulting from inability to use the System increased operating costs loss of production loss of anticipated profits damage to property or other special incidental or consequential damages of any nature arising from any cause whatsoever whether based in contract tort including negligence or any other theory of law Roehrig Engineering s only liability hereunder arising from any cause whatsoever whether based in contract tort including negligence or any other theory of law consists of the obligation to repair or replace defective components in the System o
61. he font dialog box Import Creates a Roehrig data file from imported user data The imported data must be in a specific Excel format using the correct short unit names The data header and signal definition must be in the exact location The user can import as many signals as desired Each signal gets its own column Imported data cannot be 49 used for average graphs or data Always turn off all smoothing when viewing imported data Description Import Test Notes All smoothing must be off Displacement Force Velocity In Ibs In sec 0 500 12 0 500 5 0 300 3 100 1 0 0 0 0 29 1 0 42 3 69 5 108 12 Figure 6 7 Correct Format for Data Import Short unit names for SHOCK6 import In inches m meters cm centimeters mm millimeters In Sec inches per second m Sec meters per second cm Sec centimeters per second mm Sec millimeters per second Lbs pounds N newtons KGF kilograms force F Fahrenheit C Celsius RPM revolutions per minute Hz hertz Ft feet Mi mile Km kilometer Sec second Min minutes Hr hours Ft Sec feet per second MPH miles per hour KPH kilometers per hour G grams Ft sec 2 feet per second squared m sec 2 meters per second squared In Lbs inch pounds Ft Lbs foot pounds N m newton meters PSI pounds per square inch 50 Export Export is used to export the highlighted data file displayed in the current template Data files can be exported as an XML or CSV
62. ifference in readings is OK but the closer together the better If you ve got the tools and expetience you can overhaul your shocks and test them again Maybe 24 you ll find contaminated oil bad seals or worn parts Shocks wear out like any other mechanism and need to be rebuilt periodically o c 3 o o lt o A o LL Velocity ips Figure 2 A shock dyno also allows you to see the effects of external adjustments If the data above represents settings in the middle of the range of adjustments varying them in increments from full hard to full soft will give you curves that show the effect of those changes That will happen if your dampers produce changes big enough to be seen by your machine If you really are just reading a scale by eye you might miss some fine points That s why people buy dynos instead of building them Figure 2 above came from data generated by looking at maximum or peak velocities This is called Peak Velocity Pickoff and that s the way a simple dyno works We vatied crank speed and the damper stroke to give us peak velocities in out range of interest 25 Data from an Entire Cycle You can get more data from a damper by taking data over a complete cycle of compression and rebound and graphing that This is called a Continuous Velocity Plot and there are commercially available damper dynamometers that do this Figure 1 has notations around the crank for Bottom Dead Center BDC
63. ig Engineering has any authority to modify alter delete or add to any of the terms or conditions hereof Any such modifications shall be absolutely void unless made by instrument in writing properly executed by an actual authorized employee or agent of Roehrig Engineering The terms and conditions hereof shall be binding upon Roehrig Engineering and the Purchaser and shall not be construed in accordance with the laws of the State of North Carolina United States of America Roehrig Engineering shall be entitled to recover all of its reasonable fees and costs including but not limited to its reasonable attorney s fees incurred by Roehrig Engineering in connection with any dispute or litigation arising thereunder or in connection herewith including appeals and bankruptcy or creditor reorganization proceeds These conditions shall not be construed mote strictly against one party that another as a result of one party having drafted said instrument 109 8 0 Definitions 8 1 8 2 8 3 8 4 8 5 8 6 8 7 Roehrig Engineering means Roehrig Engineering Inc Purchaser means the party buying the Product who is legally obligated hereunder Software means all computer programs including diskettes containing such computer programs sold pursuant to the Order Product means the Dynamometer the Software operating manuals and any other product or merchandise sold pursuant to the Order System means a combination of the
64. ighlighted Click on the Start Test button Depending on the settings in preferences the user will be prompted to enter information regarding the test run at this point after the test is run or not at all The next screen displayed will be the Dyno Starting window When the user is ready to start the test click OK Once the test is completed the user will be prompted to save the data The data is saved as an individual file using standard Microsoft Windows functions Once the data is saved it will automatically open in the currently active template 84 6 5 J Viewing and Analyzing the Data Once a test run is completed the data is automatically opened in the currently active template The data file name is listed in the legend Multiple data files can be opened and displayed in the same template To open a data file click on the Open Data icon either from the File menu or from the toolbar The data will open in the currently active template To remove a data file from the template click on the data file in the legend and click on the Delete icon in the toolbar PVP data can be expanded to show the data from each individual speed Click on the to the left of the file name to expand the data tree Multiple templates can be open at the same time The user can save a template which also saves all associated data files with it Once the data of interest is opened in the template the user can now analyze
65. ion ee eee eese eese eee eene etna seta setas eta sten stes tenete sees s sto ase 11 2 4 Other EMISSIONS NER asouossonssw ssoasassassn ooo ako es soiasos ass suasan on 11 2 5 Machine LU RR 11 2N S Features eot ea en e RE DR D OE RSS 12 RN TED rE E 12 SVS FOAtUres sx EE 12 TONS Features iui histo tee ecient REO RE AREE E SERO UE cee 13 20V S BeatUres vetet e e ei e VI te toi A QV ES ence eee 13 2 6 ACCESSOTICS teks pin ese sssuas s as odosoabisnssin asie kose vivw u po ass sa sese pasa es SE nosas god ass ousi swasso son 14 MESI FE EE IY wc ik a pe a CR 16 3L Safety NOUCE 16 3 2 Emergency Stop OperatiON 0ee0eeerooooooosooooonooooooooooosoonoooooonooooonoooooooonoooooonooooonosooe 18 3 3 CE Cage Door Interlock Operation 0reoeeeoooooooonaooosooosooooosonosonoooooooooonononoonooonoone 18 3 4 Personal Protective Equipment 0000e0reoreooeoooosooooouooooosoonoooooooooooososooosoooooooonooooeonen 19 3 5 Product Specific Warnings eee ee eee eese seen ense en tene ta sensns tosta stessa enses ense 19 3 6 Machine Danger Zones crees eese eee ette etes esto neto ase ta seta sete sete stesse tte see sss to ase 20 CN E dem 20 3 8 In Case Of Emergency eese eese eese eee seen etes en neta setas etas ta seta seta seta sete stesse to ase 20 4 DYNAMOMETER FUNCTION
66. ition The front cover may then be re installed Note Only the bolt on the slit side of the column clamp needs to be loosened using a 1 4 Allen key Figure 5 3 Slits on Column Clamps 37 Step 1b On the 10 20VS the upper columns will be shipped apart from the machine Remove the front cover using a 1 8 inch Allen Key loosen the side clamping bolts on the upper column blocks with a 3 16 inch Allen Key See Number 1 in Figure 6 4 Set the column in the upper block and tighten until it meets the lower column Tighten the column clamping bolts Re install the front cover Step 1c On the 10 20VS slide the crossbar assembly on the columns with the handles facing the operator Step 2 Install the IR temperature sensor if equipped Using a 3 16 Allen clamp the IR temperature sensor to one of the columns such that the red handle can be used to loosen and tighten the assembly This allows the temperature sensor to be easily repositioned for different shocks Plug the sensor into the IR Temperature port on the electronics board located at the left rear corner of the dyno Tighten the screws on the connector using a small flat head screwdriver Figure 5 4 IR Temp Sensor Installed on Column 38 Step 3 Connect the load cell cable Connect the round screw type connector to the load cell Plug the other end of the load cell cable into the Load Cell port on the electronics board Tighten the screws on the connector
67. ize of the logo to fit within the Title block The Legend and Notes blocks can be moved to different positions using the corresponding sliders Their sizes can be adjusted using the Divider at boxes The number entered in this box is the percent of the page from the top or left from which each block will start 48 Print Options Graph Layout Report Options Report Fonts Graph Size iv Include graph Partial page graph Include time stamp I Include speeds in legend Graph Page 100 Data Report IV Shock notes Iv Test summary results IV Test data PVP summary data only PVP Options IV Report each speed Ignore blank fields and undefined PYP ine 0 00 constants v New page for each test GE ine 1 00 Jee eel Cancel Appi Figure 6 6 Print Options Window Report Options This page allows the user to define all parameters for the numeric report page which is printed after the graph page To print only the graph page with no report remove all the checks from the Data Report section To print only the reports uncheck the Include Graph box To print the actual PVP speeds enter 0 in the PVP inc box The graph page and report page can be printed on the same page by checking the Partial page graph box and adjusting the graph page size Report Fonts This page defines the font used for each area of the graph and report pages Double click on each area to open t
68. le County of the Purchaser s business location and filed with the Secretary of State s Office which security interests will remain in effect until payment in full of the purchase price together with the interest on late purchase price payments payable thereon had been received by Roehrig Engineering If the Purchaser fails to make full payment of the purchase price within the period set out in the Order Roehrig Engineering shall have the following remedies which shall be cumulative and not alternative A the right to cancel the Order and enter the Purchaser s premises to re take possession of the Product in which event the Purchaser agrees that any down payment or deposit shall be forfeited to Roehrig Engineering as liquidated damages and not as a penalty and all costs incurred shall be payable by the Purchaser upon written demand B the right to enter the Purchaser s premises and remove any Software components of the Product or other items necessary in order to render the Product inoperative C the right to withhold all services which would otherwise be required to be provided by Roehrig Engineering pursuant to the Warranties set out in Section 5 hereof D terminate any existing software license agreement E pursue any other available remedy including suing to collect any remaining balance of the purchase price No waiver by Roehrig Engineering of its rights under these conditions shall be deemed to constitute a waiver of subsequent brea
69. lected trace in the graph The selected trace is the trace which is highlighted in the legend A cursor crosshair will also be displayed on the selected trace on the graph This cursor can be moved using the arrow keys on the keyboard or by clicking on the desired point with the left mouse button The data values for this point where the cursor is located are displayed in the status bar The displayed graph can also be printed by clicking on the Print icon either under the File menu ot from the toolbar Figure 6 42 Graph Analyzing Tools Located in the Main Toolbar The graph scaling can be changed by clicking on the Scaling display tab When the scaling display tab is selected the scaling preferences are shown for both the x and y axis The user has the option of auto scaling by checking the box under auto or manual scaling If auto scaling is not checked the values under min and max will be used to manually scale the graph The Repott display tab allows the user to view the data from the selected trace in a tabbed format The repott tabs allow the user to display different information associated with the selected trace The measured force vs velocity data is also shown in the bottom table The velocity increment for this table can be changed by clicking on the velocity increment pull down box The report data can also be printed by clicking on the Print icon either under the
70. lti point mid point at the test mid point Minimum and maximum must be positive and negative numbers on each side of the offset It is recommended to luse the same offset test mid point as the offset you will specify in the test The minimum and maximum displacement inputs should be the largest amplitudes used in the test Scotch yoke dynos may have to make a number of cycles to stop at every point For PVP and multi CVP reexecuting the multi gas test before each stroke will run the gas test at the same offset as the test Af test point must be within the minimum and maximum displacement points for the Settle Time test ac oka eed cee oa al eia 0 500 sac points from both directions Rotary dynos are limited to the current dyno stroke Points Y Generate table Back Next gt Cancel Figure 6 27b Multi Point Gas Test CVP Test The user will be prompted to enter the test speed for the CVP test cycle The minimum and maximum speeds possible for the dyno at the current stroke are displayed Durability In this mode the CVP test will run for the given number of cycles The test will collect data on the first cycle only Specify CVP Test Speed A CVP type test has been chosen to run Enter the speed at which to test the damper Test Speed 0 2540 m sec Min 0 0024 m sec Max 0 8627 m sec Durability Advanced Back Next Cancel Figure 6 28 CVP Test Screen 72 PV
71. lumns with available signals channels 65 Show Live Allows user to manually operate dyno while showing the live data on the current graph Enter a speed in the motor speed panel and hit enter to start the dyno BDC Moves dyno to bottom dead center Cycle Moves dyno one complete cycle at slow speed 0 Load Zeros the load cell Gas Test Performs a gas test Result is displayed in Gas Force panel Pause Stops the data collection Continue Starts the data collection Color Changes the line color Clear Clears the data collection Stop Stops the motor Done Exits Show Live Min 0 000 m sec Max 1 170 m sec Motor Speed 0 000 m sec c BDC sy Cycle Gas Force 0 00 N la Color x Clear IF i ae Figure 6 22 Show Live Screen 66 Toggle Validation Turns current validation parameters on and off Validation Parameters Allows user to enter a validation table based on a master shock or manually inputted data This table is visually displayed on the graph and a green or red box in the legend indicates if the given data file passes or fails the validation Gas force and seal drag can also be included in the validation Click Import PVP to create a validation table based off of a master shock file The user can choose the deviation tolerance as a percentage absolute or both The user can also create a table manually b
72. mm 40mm 50mm 75mm 100mm Non contact Infra Red style Temperature Transducer e 48 Bright Nickel columns 28 700 mm eye to eye test area e 5000 lbs Pancake Load Cell 8 Channel Instrumentation and Signal Conditioning System 16 bit resolution USB Data Acquisition standard e Full Computer Control with SHOCK Software 20VS Features e 20 Hp Motor 380 440V e Zero Lash Belt Drive e Precision scotch yoke wear plate system e 7 Standard English Strokes 0 75 1 0 1 5 2 0 3 0 and 3 90 and 6 0 or e 7 Standard Metric Strokes 15mm 25mm 40mm 50mm 75mm 100mm and 150mm e Non contact Infra Red style Temperature Transducer e 48 Bright Nickel columns 28 700 mm eye to eye test area e 5000 lbs Pancake Load Cell 8 Channel Instrumentation and Signal Conditioning System 16 bit resolution USB Data Acquisition standard e Full Computer Control with SHOCK Software 13 2 6 Accessories Roehrig Engineering provides a full line of accessories for your 2 3 5 and 10 20VS Dyno Please see the list below IR Temperature Sensor Standard on 3 5 10 20VS Various Load Cell Configurations Including o 500lb o 1000lb o 2000lb o 5000lb Nickel Plated Columns Standard on 3VS 20VS Longer Length Columns Pressute Sensor Harness w Sensors USB to serial Adapter Add on Spring Rater 16 Channel Instrumentation Capability Quick Open Front Cover Various Clevis Sets Including
73. mpression close graph Depicts other half of the cycle 64 Force vs Displacement Changes current graph to force vs displacement Commonly known as football or potato plot Average Force vs Absolute Velocity Changes current graph to average force vs absolute velocity Depicts the average of the compression forces and the average of the rebound forces vs the absolute velocity Roehrig Engineering does not recommend the use of this graph as it is a poor representation of the shock data Absolute Compression Open Rebound Close Changes current graph to absolute compression open rebound close graph Same as compression open rebound close graph except all force values are shown as positive values Absolute Rebound Open Compression Close Changes current graph to absolute rebound open compression close graph Same as rebound open comptession close graph except all force values are shown as positive values Signal vs Time Allows user to plot any signal or math channel vs time A menu will appear with a list of all available signals channels Select the channel to be graphed Hold the Ctrl key to select multiple channels Signal vs Signal Allows user to plot any signal or math channel vs any other signal or math channel The user must first select the units for the x axis Once units are selected hit insert plot Pull down menus will appear under the x axis trace and y axis trace co
74. n Shot Motor and Datacard recognized If motor is in grey click on hardware in the pull down menu and select motor A warning will appear Click yes to continue Click configure and ensure that the correct COM port is selected If a serial to USB adapter is being used ensure that it is assigned to a COM port number less than 8 and that it is always plugged into the same USB port Note that not all serial to USB adapters are compatible Contact Roehrig for a current list of compatible adapters If selecting the correct COM port does not correct the issue contact Roehrig for technical assistance See Appendix for more details on using a serial to USB adapter 41 If datacard is in grey click on hardware in the pull down menu and select datacard A warning will appear Click yes to continue Click configure Board 0 in the upper left should be selected as the default Change to Board 1 If this does not correct the issue contact Roehrig for technical assistance If both motor and datacard are shown in a black font click on hardware in the pull down menu and select motor A warning will appear Click yes to continue Ensure that there is no shock in the machine and that the crossbar is raised so that the actuator shaft cannot come in contact with it when the machine is run Select Measute Stroke Once complete the dyno is ready to run
75. n motion these bearings may move up and down slightly this is a normal operating condition 90 Yearly Maintenance Belts Check the inner and outer belts of your dyno for excessive wear and or damage Also check for lose belts or ovetly tight belts The belts should be able to twist 45 90 degrees on the longest side To gain access to the belts FIRST TURN THE POWER OFF Remove the rear cover by removing the two cap screws from the back side and loosening the 3 cap screws on each side with a 1 8 inch Allen tool The rear belt will be visible Remove the front cover and unplug the connector from the Emergency Stop by pushing the tab to the unlock position Remove the 3 flat head cap screws from the top plate and the smaller button head cap screw from the front of the electronics board At this point gently lift the top plate from the front and rear and move it upward on the columns so that it is out of the way Check the condition of the belts and grease the green drive bearings see below When the maintenance is complete replace the top plate while catefully aligning the electronics board to be mated with the connectors Attach the Emergency Stop switch and lock the tab in place Replace the cap screws in the top plate and electronics board and install the front reat covets Drive Bearings There are three drive bearings inside the machine mounted on the rear plate Grease the bearings through the
76. nces Opens the preferences window The majority of the default settings for the program are found here Keep in mind many of these settings can be changed in other areas of the program without affecting the default settings Colors This page controls the default colors and order used when displaying data traces Left click on the color bring up the color selection window Shock Preferences Legend Math Signals Smoothing Snapshot Test Colors Data Display Field Defaults Folders and Files Trace Colors O PVP individual speeds same as PVP result graph O Reset to start of color list for every change Additional signal vs time plots same color as original Additional signal vs signal plots same color as original I Multiple CYP run color same as first speed En Em em gt m NN ENS NN NND ONE SD ES 76 Show Live Color inem A i ok A emen Figure 5 Preferences Window Colors 53 Legend This page controls the default colors and fonts for the legend Click on the color to bring up the color selection window Click on the font box to bring up the font dialog box Hide Gas Fotce Pressute Column Check to conceal the Remove Gas Force check box in the legend Shock Preferences Data Display Field Defaults Folders and Files Math Signals Smoothing Snapshot Test Legend 1 Altemate iahliah Background Beskou Highight ABC Font 0 Hide Gas Force Pressure Column Asc Fo
77. nged To measure the stroke ensure that there is no test specimen in the machine then click the Measure Stroke button Monitor Displays the live senor readings for the dyno 80 6 3 6 View Template List Standard Toolbar Status Bar Toolbars Figure 6 36 View Menu Template List Displays a list of the currently open templates in a toolbar Standard Toolbar Displays the standard Roehrig toolbar which contains the most commonly used functions Status Bar Displays the lower status bar Toolbars Lists and displays all other available toolbars Toolbars may be moved by clicking on the crosshatching located on the left side of the toolbar and dragging it to the top bottom left or right side of the program window or to the center to display it in a new window The more options icon located on the right side of the toolbar can be used to modify the contents of the toolbar Figure 6 37 Standard Toolbar Crosshatching More Options Icon X Offset Y Offset Offsets selected trace on currently displayed graph 81 6 3 7 Settings User settings System settings Export all settings Math Settings Test Settings Figure 6 38 Settings Menu User Settings Exports or Imports user settings User settings include all settings contained in the preferences including all user tests and math channels It is recommended that the user export and backup all s
78. not binding by Roehrig Engineering 4 11 4 13 4 14 The Warranties extend only to the Purchaser and are transferable only under the following conditions A The Dynamometer is currently under warranty B New owner undergoes training C A Roehtig Engineering warranty transfer is completed and submitted to customer service All claims under the Warranties must originate with the Purchaser or any subsequent owner and the Purchaser will indemnify and save Roehrig Engineering harmless from any claims for breach of warranty asserted against Roehrig Engineering by any third party Oral representations of Roehrig Engineering or its sales representatives officers employees or agents cannot be relied upon as correctly stating the representations of Roehrig Engineering in connection with the system Refer to this purchase order any exhibits hereto and any written materials supplied by Roehrig Engineering for correct representations PURCHASER ACKNOWLEDGES THAT IT HAS PURCHASED THE SYSTEM BASED UPON ITS OWN KNOWLEDGE OF THE USES TO WHICH THE SYSTEM WILL BE PUT ROEHRIG ENGINEERING SPECIFICALLY DISCLAIMS ANY WARRANTY OR LIABILITY RELATED TO THE FITNESS OF THE SYSTEM FOR ANY PARTICULAR PURPOSE OR ARISING FROM THE INABILITY OF THE PURCHASER TO USE THE SYSTEM FOR ANY PARTICULAR PURPOSE 5 0 Design Changes 5 1 The Dynamometer the Software and the System are subject to changes in design manufacture and programming between the date of order and
79. nssessoninissons oasssesosonoyossonsssondedossokosasosovosanssnasoonikossasstenns 46 OS FM EE A RE RAN L nens PE NE ot ET as waren A e acess 47 6 3 2 Edlt 5s puse ac tee aD RH D ERR eed ee e Eier HERR 52 6 3 3 Graphics tto ono Damen RD UH ORO CBE ERAT EE 63 6 341 Testi iot pen ac ORO HERPES A toes ea 69 6 3 5 Hard Wate ree de mee S RD D ka Sado n cane cas ORB EET ava ba ese rELUGE 80 6 3 6 VIEW ee pun ac RD ERU RR ORIGO T D e esye ny 81 6 JI T Settings ics dto noD umenpo ei name REED ATE Deis 82 6 3 8 WindOW s i lounGn aco prf tae eel apts TT 83 6 3 9 HelpzitisceosenhoouRpa ER ERIS HERD T rU PRU EUR UH ORDRE IRRURE 83 6 4 Creating and Running Tests Leere eee eerte eese enenatis enata tastes suse ta sone ta an 84 6 5 Viewing and Analyzing the Data 4 ccce eee eee eese eese eese en sete setate stans tu nse 85 CHAP rad e tS ce ert Tr tue 89 7 MAINTENANCE PROCEDURE cc ceeeeeeeeeeeeeennenn nnne 90 As Needed 20 Ev ry TWO Months 4 kk 0e s isk vise ns ooo sessosssoossakvon sissosooaoosonnos sasens ou as sov s vsoavosnvkas QM 90 Yearly Maintenance M 91 8 APPENDIX qm 92 8 1 USB to Serial Adapters 0000020oeooeoooeooooooooooooooosovoooooonooonoooooonsooosooooooooooooooooooonooooeononone 92 LIA DET M 93 8 3 Shock 6 0 Math SYDtAX L0ee02eeeseeetesovesovooooeooooovoooooonooooooooooooooosooosoeooosoooo
80. o continue The Dyno Starting warning prompt will appear Dyno Starting The dyno is about to start sere The dyno is about to start When ready select the Gas Test Travel N A CR of select the Cancel button to abort Max Test Travel 0 00 in Prelad m Ensure the damper is loaded with enough preload so 0 00 that it will not bottom out Damper Travel in Use Last Entered Dk la Cancel 14 Click OK The dyno will now start to run If you have selected to perform a warm up it will do that first It will then run any gas test or seal drag tests that ate required It will then begin running the test s Use the Skip Step button to cancel out of the warm up or the gas test and proceed to the next step Use the Abort button to cancel the test completely 30 Roehrig Shock Test Control Panel BO Tests Commands Status ep 10 5 Cvp Cw psp ab MCYP Stan Test JA Abort r k 135 19 BO Pr Options C CVF z Skip step kI Close aftertest oO Pause aitergesiest Zaro Lond Cell Results Stroke 0 00 m Gas T si Peak Velocity 0 00 in sec 13610 ANA ZAN Displacement 0 89 in PEN cm ad AR Ta Force 3 53 ibs Midpoint ofese 0 00 In Velocity 439 in sec Max Travel 1 98 in Goto BOC Temperature 7134F Wave Form Sine Amplitude 0 99 in F 161H Running Sine Wave test at offset 0 99 Kay in amplitude 0
81. om dead center the actuator shaft is at its lowest position Lower the cross bar and fix the shock ends to the upper and lower clevis Lower the crossbar in order to compress the shock to the desired position Pre load Tighten the crossbar Ensure that the shock has sufficient travel for the given stroke setting on the dyno Select the desired test from the test screen and start the test Once the test is complete save the data and remove the shock Caution Always be sure that the dynamometer is at bottom dead center before installing the damper Also be sure that the damper has sufficient travel for the stroke which the dynamometer is set at 4 3 Running a Test Once the shock is correctly installed a test may be selected and run Select a test from the list given in the test screen or you may create your own Step by step running a test 28 1 When you are ready to collect data click on Test in the pull down menu and then click Perform test This will bring up the Perform Test window 2 Select your test profile and click edit if you wish to make any changes 3 At this time be sure the dyno is at bottom dead center 4 Hang the shock damper from the upper clevis so that it is not touching lower clevis 5 Click the Zero Load Cell button to zero the load cell and take the weight of the shock out of the data You can verify the results by looking at the live force reading 6 Lower the cross bar and connect
82. ooooonooooeonoone 94 junii e EET 94 lDqU C d P 95 Description eC 95 9 ADDITIONAL DOCUMENTATION cere 101 10 WARRANTY AND SERVIGE iiir nicucicirk akin md niae nonl cnl a drea 102 10 1 Warranty eee tette tene tete reir ie ee ES REDE e eere 102 10 2 Technical SUppott e t ertet fee eon nri eet 102 10 3 SERVIGCE POLICY 2 moog io ROGER URINE DOR D ERE 104 Purchase Conditions epe iro te ERE CRUCE REPERI EE tags sothas seal aenseedagis 107 1 0 Payment of Purchase Price sees 107 2 0 Delivery and Transportation eese 107 3 0 Installation and Operator Training eee 107 4 0 Warranties and Limitation of Liability eee 108 5 0 Design Changes iiss secant oer PERU DRE em 109 6 0 Non DISCloSUre 4 nir enter petet ERREUR AREE ak URNA 109 7 0 Entire Agreement Governing Law Misc Guarantee 109 8 0 Definitions 4 oe ett UTER EROR IRE ERR T ER Lider RAY 110 9 0 Software License Agreement essssssssseeeeeeeeneneneeneeeneene 110 ROEHRIG ENGINEERING INC Ci i 1 Identification and Machine Description 1 1 Dynamometer Identification This manual will cover the following Roehrig Crank Dynamometers 2VS 2HP Crank Dynamometer 3VS 3HP Crank Dynamometer 5VS 5HP Crank Dynamometer 10VS 10H
83. peak at 190 pounds in compression and 250 pounds in rebound So we know that at a shaft speed of 5 inches per second the damper produces 190 pounds in compression or bump and 250 pounds in rebound We d like several data points so we can draw a cutve If we reduce the crank speed to 50 RPM and 25 RPM and also speed it up to 150 and 200 RPM this gives us five data points After we make these runs and read the scale we can make a table like this CRANK MAX SPEED BUMP FORCE REBOUND FORCE RPM IN SEC LBS LBS 25 1 3 75 50 50 2 6 170 150 100 52 190 250 150 7 8 220 350 200 10 4 250 470 Chart 1 Presented as a force vs shaft speed graph it looks like Figure 2 We generated this data by running the crank at a 1 0 stroke and changing the crank RPM to give us 5 maximum piston speeds and we read the bump and rebound forces at those maximum speeds Then we made a graph by connecting the dots If we want data at higher shaft speeds we need to speed up the crank or lengthen the stroke Figure 2 shows us that the shock we tested has a pretty steep rebound curve while the compression curve starts low rises quickly and then levels off The real benefit of a machine like this comes when you test all four dampers off your race car and find out that they all give different readings even though they are supposed to have the same valving and you ve hopefully set them all to the same external adjustments before you started the test Some small d
84. point being smoothed Command Der Acceleration Drive Profile Force Bas Force Figure 6 14 Preferences Window Smoothing 58 Field Defaults Allows user to edit the fields which are stored with each test and displayed in the report tab The fields can be edited separately for each type of test When editing the fields for a specific test use the insert key to add a row and the delete key to delete a row The names for each row can be edited by clicking on that particular cell The number of lines displayed for each row can also be edited by clicking on the lines cell Constants are number which can be used with math channels Shock Preferences Legend Math Signals Smoothing Snapshot Test Colors Data Display Field Defaults Folders and Files Each file type has a set of fields and constants that used to initialize the contents of a data file when a test is performed The defaults can be edited to initialize each new test Any changes here will effect all new test executed after the editing is completed Changes cannot be undone once accepted gr Edit CVP Defaults a Edit Multi CVP Defaults A Edit PVP Defaults A Edit Custom Test Defaults a Apply i ye Figure 6 15 Preferences Window Field Defaults 59 Snapshot This page allows the user to alter the size of the snapshot taken of the graph and legend when using the snapshot function
85. pre load in the shock Tighten the crossbar Next remove the shock from the clevises Install the correct set of clevises for the new shock which is going to be tested Hang 32 the shock from the top clevis making sure that the crossbar is high enough so that the shock hangs freely above the bottom clevis Open the test screen in the software and zero the load cell Once the load cell is zeroed the shock can be fully installed Before installing the shock ensure that the dyno is at bottom dead center the actuator shaft is at its lowest position Lower the cross bar and fix the shock ends to the upper and lowet clevis Lower the crossbar in order to compress the shock to the desired position Pre load Tighten the crossbar Ensure that the shock has sufficient travel for the given stroke setting on the dyno 33 4 5 Changing Stroke To change stroke 1 2 3 4 5 6 7 8 9 Depress the Red Emergency Stop button on the top of the dyno Once depressed you will have 4 seconds to loosen the crank bolt During the 4 second braking period use a 1 inch socket to remove the crank bolt Re set the Emergency Stop button and turn the power off Remove the square bearing from the crank and replace the bearing in hole with the desired stroke Tighten the square bearing until it comes in contact with the crank Turn the power on Press the Emergency Stop button and tighten the crank bolt during the 4 second braking period
86. r Dynamometer subject to the limitations set out above in this section This disclaimer of liability for consequential damage extends to any such special incidental or consequential damages which may be suffered by third parties either caused directly or indirectly resulting from test results or data produced by the system or any component thereof and the Purchaser agrees to indemnify and save Roehrig Engineering harmless from any such claims made by third parties 4 10 The foregoing shall be Roehrig Engineering s sole and exclusive liability and the Purchaser s sole and exclusive remedy with respect to the system THE SOLE RESPONSIBILITY OF ROEHRIG ENGINEERING UNDER THE WARRANTIES IS STATED HEREIN AND ROEHRIG ENGINEERING SHALL NOT BE LIABLE FOR CONSEQUENTIAL INDIRECT OR INCIDENTAL DAMAGES WHETHER THE CLAIM IS FOR BREACH OF WARRANTY NEGLIGENCE OR OTHERWISE OTHER THAN THE EXPRESS WARRANTIES HEREIN STATED ROEHRIG ENGINEERING DISCLAIMS ALL WARRANTIES INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS Roehrig Engineering does not authorize any person whether natural or corporate to assume for Roehrig Engineering any liability in connection with or with respect to the Products No agent or employee of Roehrig Engineering has any authority to make any representation 108 or promise on behalf of Roehrig Engineering except as expressly set forth herein or to modify the terms or limitations of the Warranties Verbal statements are
87. r ground Most European models and other non US models come equipped with an appropriate plug In this case simply plug the dynamometer into the matching receptacle WIRING DIAGRAM FOR SINGLE PHASE POWER HOOK UP FOR COUNTRIES WHERE 220V IS MADE USING TWO HOT LEGS IHPUT POWER METTE 220VAC Single Phase 220 240 From ground to leg should 60Hz 50Hz have 120VAC 2VS 7 amps service 3VS 10 amps 5VS 17 amps 10VS 34 amps Leg to leg should be 220VAC Will run on 200 240VAC GEHERAL DUTY FUSIBLE SAFETY SWITCH BOX GROUND L GREEN or GREENYELLOW L1 Power Leg L1 or Brown Power Leg L3 or Grey TO THE DYHAMOMETER DANGER Always be sure the power is disconnected to the box before wiring the machine Use proper lockouts in accordance with local electrical codes WIRING DIAGRAM FOR SINGLE PHASE POWER HOOK UP FOR COUNTRIES WHERE 220V IS MADE USING ONE HOT LEG AND A NEUTRAL INPUT POWER SINGLE PHASE 200 240 VOLTS 50 60 Hz 2VS 10 Amp Service Needed 3VS 10 Amp Service Needed 5VS 20 Amp Service Needed METALLIC SHIELDED CONDUIT GROUND GENERAL DUTY FUSIBLE SAFETY SWITCH O D TANT GREEN WIRE GROUND NEUTRAL WIRE WHITE RED WIRE CAP WITH WIRE NUT 2 LIQUID TIGHT CONDUIT CONNECTOR O LIQUID TIGHT FLEXIBLE SHIELDED CONDUIT FROM DY
88. res will produce more repeatable and comparable test Do not perform a warmup Run the shock at a set speed for a period of time o Run the shock at a set speed until a particular temperature is reached Specify a set of temperatures to which to warm shock Run the specified test once at each specific warm up temperature Next Cancel Figure 6 26 Select Warmup Window 70 Select Gas Test Type Allows users to perform a gas test and or seal drag test after the watm up cycle is complete The gas test takes a static force measurement to determine the rod reaction force due to the gas pressure inside the shock The seal drag test is used to determine the friction force due to the seals in the shock Do not perform a gas test When this option is selected gas force and seal drag measurements are not taken Perform a gas test The user will be prompted if they would like to override the zero displacement test position If this box is not checked the rod reaction force will be measured at zero displacement mid stroke If the box is checked the user will be prompted to enter a new test position A value of 0 corresponds to mid stroke Positive or negative values may be entered relative to the mid stroke position Values entered which are beyond the maximum amplitude of the machine will cause the machine to run endlessly during the gas test cycle Perform a seal drag test only The user will be promp
89. rt as XML E Apply v Ok la Cancel Figure 6 18 Preferences Window Test 61 Units This tab allows the user to select the unit type to be displayed Custom units are a user defined set of Standard and Metric units change the converted units by clicking on the unit and selecting a new conversion from the drop down list Umit Precision controls the level of precision for each unit type valid precisions are between zero and five Shock Preferences Data Display Field Defaults Folders and Files Math Signals Smoothing Snapshot Test d Unit Precision Colors Legend r Conversions Units Standard Metric Conversion f e l o a tava Figure 6 19 Preferences Window Units Graph This page allows the user to change the default cursor grid options fonts data trace style and data trace width Shock Preferences Cursor Color Imi Large Circle Circle Large Plus Plus Large X x Standard None Trace Width J Screen 9 e 29 4 5 Data Display Field Defaults Folders and Files Grid Background E n Grid Legend Background DashDot Dot Dash Solid Graph Fonts _ E ms xard Plus ase vou 53 Connected ABc Axis Lael Asc Y xis Lael Data Point Display Circle f w a A c Figure 6 20 Preferences Window Graph 62 PVP Options The PVP option p
90. t Once the system is tebooted locate the reg file s on the Roehrig CD Right click the CD or DVD drive icon which contains the Roehrig CD under My Computer and select Explore The reg file s will be located under the main directory on the CD Double click on the reg file s to install You will be prompted would you like to add these files to the registry Click Yes The Roehrig software and the calibration for your dyno are now installed Note The reg files only need to be installed if the Roehrig software is being installed for the first time on a particular computer The reg files do not need to be reinstalled if the software is being updated within Shock6 If upgrading from Shock5 or older to Shock6 new reg files will be provided by Roehrig Engineering Note The Roehrig software may be installed on as many computers as desired allowing users to view and analyze data however the software key is required in order to run the dyno Figure 5 1 Shock 6 USB Software Key 36 5 3 Dyno Assembly Step 1a On the 2 3 and 5VS ensure that the columns are fully extended and tightly clamped To do this first remove the front cover on the dyno using a 1 8 allen key Ensure that the columns are fully extended upward i e the stop at the bottom of the column is up against the lower column clamp If the columns are not fully extended unclamp the columns and re clamp them in the fully extended pos
91. ta Display Field Defaults Folders and Files Display Preferences Default Graph Auto show hide PYP individual speed graphs Average Force vs Absolute Velocity 35 5 e Hide 0 0 point on PVP graphs Mese d zoa Auto expand multiple CVP test tree Force vs Displacement 5 Rebound Close Compression Open WAN ANY MAN CST RE Compression Close Rebound Open Force vs Absolute Velocity ES Force vs Velocity Manufacturer s Report Summary Plot Detail Plot Force vs Displacement Force vs Displacement Rebound Close Compression Open Rebound Close Compression Open Compression Close Rebound Open Compression Close Rebound Open Force vs Absolute Velocity Force vs Absolute Velocity Force vs Velocity Force vs Velocity Z apab e x la Figure 6 13 Preferences Window Display 57 Smoothing This page is used to place a moving average filter on a selected channel s All collected channels and all math channels are listed here Use caution when using smoothing values above 5 Smoothing can cause phase shifts and attenuation in the data If using smoothing it is best to use the same amount of smoothing on all channels Shock Preferences Trace Smoothing display Field Defaults Folders and Files mem rm e Specify the properties to use for the individual traces Smoothing is applied prior to plotting andis a moving averaging using X points on either side of the
92. ted to enter a test window and speed for the seal drag test The test window is the amount of displacement on either side of 0 displacement mid stroke for which the friction force is measured Perform a seal drag test then a gas test When this option is selected both a gas force test and a seal drag test are performed Select Gas Test Type A gas test determines how much gas force is generated by the gas charge in the shock absorber A seal drag test determines how much drag the seals generate This is best done on a shock with no valving installed on the piston The gas test takes two readings at zero displacement to determine the gas pressure The combination seal drag and gas force test moves through zero displacement at low speed to calculate both quantities 9 Do not perform a gas test Perform a gas test Q Perform a seal drag test only Perform a seal drag test then a gas test Te SS Figure 6 27a Gas Test Window 71 Multi Point Gas Test Executes a gas test using multiple positions in the compression and rebound direction Build a table surrounding zero displacement mid stroke using positive and negative displacement values Specify Multipoint Spring Test Enter the displacements to stop and take force readings These force readings will be used to create a linear look up table of the spring and or gas force The look up table will be subtracted from the test force trace with the mu
93. tem shall operate and perform in the manner contemplated in connection with the usual purpose for which it was designed 4 3 The warranties set out in paragraphs 4 1 and 4 2 above together called the Warranties shall expire at the end of the twelve 12 month period commencing on the first day of the first month after the date of shipment from the Roehrig Engineering factory the Warranty Period 4 4 Subject to the limitations contained in Section 4 6 the Warranties shall apply to any defects found by the Purchaser in the operation of the Dynamometer or the software and is reported to Roehrig Engineering within the Warranty Period If the Dynamometer or the software is found by Roehrig Engineering acting reasonably to be defective and if the defect is acknowledged by Roehrig Engineering to be the result of Roehrig Engineering s faulty material or workmanship the Dynamometer or Software will be repaired or adjusted to the extent found by Roehrig Engineering to be necessary or at the option of Roehrig Engineering replaced with a new Dynamometer Software ot parts thereof at no cost to the purchaser Claims under the Warranties shall be made by delivering written notice to Roehrig Engineering of the defect in the System Dynamometer or the Software Within a reasonable time of receipt of such service personnel and warranty service will be provided at no cost to the Purchaser If in the reasonable opinion of Roehrig Engineering the d
94. the damper to lower clevis 7 Pull cross bar down a minimum of 1 4 inch to pre load damper and tighten clamps this is done to prevent the damper from bottoming out in extension 8 Tighten the clevis handles by turning clockwise until brass button in clevis seats against shock eye This is done to remove any free play in the damper ends 9 The program by default is set to do an automatic gas test to measure and record the gas force in the shock If you have changed this setting to do a manual gas test click Gas Test record the gas force 10 Connect the temperature sensor to the damper body Skip this step if you have a non contact IR temperature sensor 11 Click Start Test to begin the test 12 The File Properties window will now appear Enter data and valving information that you want to save with your data The constants tab allows you to enter constants related to this damper This is useful if you are using any math signals This properties page may appear at the end of the test or not at all This is set in the Test tab of the Preferences window 29 File Properties Description Constants a es on Shock Name a Shock ID Vehicle Location Compression Valving Rebound Valvina Piston Yalvina Other Valving Compression Setting Rebound Setting Preload Setting Notes ind Fill from file Fill from last test Clear fields 13 Click OK on the File Properties window t
95. ting where the curve is headed down and slowing down as the cutve swings back up It s the same on the top part The piston speed and damping force increase to a maximum and then slow again This is a lot more data than we had when we just changed crank RPM and looked at the damper force at maximum piston speed So why doesn t the damper develop the same force when it s slowing down as it did when it speeded up I m not certain myself but remember you ve got a bunch of oil moving through the washer stacks and bypass paths and it has some mass and momentum Those washer valves do not necessarily close the same way they open Also the fact that the damper 26 piston is always accelerating slowing down or speeding up may have something to do with the shape of this curve 27 4 2 Overview of Dyno Operation Operation of the damper dynamometer is very straight forward The first step is to powet up the dyno and computer system From the computer start the Roehrig Shock software ensure that the software key is installed on the computer Install the correct set of clevises for the shock which is being tested 1 Hang the shock from the top clevis making sure that the crossbar is high enough so that the shock hangs freely above the bottom clevis Open the test screen in the software and zero the load cell Once the load cell is zeroed the shock can be fully installed Before installing the shock ensure that the dyno is at bott
96. tled to recover all reasonable costs and expenses including reasonable attorney s fees before trial and in appellate proceedin 110
97. ton 3 3 CE Cage Door Interlock Operation CE compliant dynamometers are outfitted with a protective cage and door interlock system The type of cage door interlock and relay system used can vaty depending on customer requirements Supplemental literature is provided for CE dynamometers describing in detail the functionality of that machines specific cage and interlock system 18 3 4 Personal Protective Equipment Operators should always wear required safety gear for the environment in which they are in When operating or working near the dynamometer personnel must always be wearing safety glasses No loose fitting clothing should be worn and long hair should be tied back 3 5 Product Specific Warnings Safety glasses must be worn at all times when operating or working near the damper dynamometer Always ensure that all guards and shields are properly installed before operating the machine Always disconnect power before removing front cover when changing the stroke on the crank Only trained operators are permitted to use the damper dynamometer Caution Always be sure that the dynamometer is at bottom dead center before installing the damper Also be sure that the damper has sufficient travel for the stroke which the dynamometer is set at Caution Always be sure that the damper is installed securely using proper fixtures and that the crossbar is properly tightened before running a test
98. ults from 3rd cycle from end the individual cydes are averaged 4th cyde from end When running exact cyde counts on an EMA dyno exact cycle count must be equal to the cydes to samples for PVP generation to function properly Use of this switch is NOT RECOMMENDED Ifusiing peak velocity method coerce peak force to be reported at peak velocity ZEN gr avv wa x la Conca 63 6 3 3 Graph Force vs Velocity Force vs Absolute Velocity Compression Open Rebound Close Rebound Open Compression Close Force vs Displacement Average Force vs Absolute Velocity Absolute Compression Open Rebound Close Shift F4 Absolute Rebound Open Compression Close Shift F5 Signals vs Time F7 Signals vs Signal F8 Validation Parameters An Shift v Validation Attributes Insert Figure 6 21 Graph Menu Force vs Velocity Changes current graph to force vs velocity graph Depicts a full 360 degree stroke showing positive and negative velocity values Force vs Absolute Velocity Changes current graph to force vs absolute velocity graph Depicts a full 360 degree stroke however all velocities are shown as positive in value Compression Open Rebound Close Changes current graph to compression open rebound close graph Depicts half of the cycle Rebound Open Compression Close Changes current graph to rebound open co
99. ware except as permitted by this section The Licensee is licensed to use the Software only in the manner described in the Operating Manual Use of the Software in a manner other than that described in the Operating Manual or use of the Software in conjunction with any non Licenser product which decompiles or recompiles the Software or in any other way modifies the structure sequence or function of the Software code is not an authorized use and further such use voids the Licenser s Warranty as set forth below The only watranty with respect to the Software and the accompanying written materials is the warranty if any set forth in the Quotation Purchase Order and Service Policy pursuant to which the Software was purchased from the Licenser THIS WARRANTY IS IN LIEU OF OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICLUAR PURPOSE WITH RESPECT TO THE SOFTWARE AND WRITTEN MATERIALS IN NO EVENT WILL THE LICENSER BE LIABLE FOR DAMAGES INCLUDING ANY LOST PROFITS RO OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE SOFTWARE NOTWITHSTANDING THAT THE LICNESER MAY HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE LICENSER WILL NOT BE LIABLE FOR ANY SUCH CLAIM BY ANY OTHER PARTY In the event of any breach by the Licensee of this Agreement the license granted hereby shall immediately terminate and the Licensee shall return th
100. y using the Insert Row button and manually entering the appropriate values Validation tables can be saved using the Save Validation button or previously saved validations can be opened using the Load Validation button Build Validation Table Velocity Units Meters per second Force Units Newtons lt New Table gt Gas Force Validation q r Seal Validate Gas Force N Gas Force Minimum N Seal Drag Minimum Gas Force Maximum N Seal Drag Maximum Zero Speed Validation Zero Speed Minimum Zero Speed Maximum 0 00 N 0 00 N Clear Table Velocity C Min AMn Ama x E Import PVP gr Load Validation B Save Validation le Insert Row Figure 6 23 Validation Parameters 67 Validation Color Allows user to change the color of the displayed validation parameters Validation Attributes Allows user to change the line style of the displayed validation parameters Insert Creates another graph inside the current template User can toggle between graphs using the tabs displayed on the bottom of the legend Delete Graph Deletes the selected graph from the current template 6 3 4 Test Create Batch Run Batch Delete Batch Figure 6 24 Test Menu Create Allows the user to create and save a test There are three test profiles which the dyno can perform CVP Continuous Velocity Pickoff PVP Pe
101. ynamometer and Software are not defective the Purchaser shall pay the cost of setvice which shall be the amount that Roehrig Engineering would otherwise charge for that service and shall include without limitation shipping handling and an hourly service charge 4 5 The Warranties do no apply to A any defects in any component of a System where if in the reasonable opinion of Rochrig Engineering the Dynamometer Software or System has been improperly stored installed operated or maintained or if Purchaser has permitted unauthorized modifications additions adjustments and or repair to any part of the System or which might affect the System or defects caused or repairs required as a result of causes external to Roehrig Engineering workmanship or the materials used by Roehrig Engineering As used herein unauthorized means that which has not been approved and permitted by Roehrig Engineering B The Warranties shall not cover replacement of expendable items including but not limited to fuses diskettes printer paper printer ink printing heads disk cleaning materials wear plates or similar items C The Warranties shall not cover minor preventative and corrective maintenance Any equipment or its components which was sold or transferred to any party other than the original Purchaser without the expressed written consent of Roehrig Engineering 4 7 Factory Repairs A IF SYSTEM IS UNDER WARRANTY The Purchaser agrees to ship t

2VS-30VS User Manual 2012

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