Product Info End of Line Testing - durr-assembly.com Info End of Line Testing Dürr Assembly Products GmbH, Püttlingen. Product Information Welcome to our product info End of Line

�

�

�

�

�

�

�

x-wheel

x-3Dprofile

x-light

x-DASalign The test stand for driver assistance systems

x-tronic The

The innovative chassis geometry test stand

Dürr reinvents wheel geometry measurement

The flexible and modular headlamp and distancesensor setting systems

x-road The multi-function roll / brake test stand

x-cruise, x-brake The test stand duo for short cycle times

technology for advanced electronic testing

Product Info End of Line Testing

Dürr Assembly Products GmbH, Püttlingen

Product Information

Welcome to our product infoEnd of Line Testing

Page 2

Dürr AssemblyProducts GmbHKöllner Strasse 122-12866346 Püttlingen/GermanyPhone: +49 (0) 68 98-692-0Fax: +49 (0) 68 98-692-5400www.durr-ap.com

We

lco

me

The customers in the Professional segment attach great importance to economicefficiency, durability and quality. With the “c” (compact) products we have configured acomplete, cost-saving standard system for our customers with a performance better thancomparable special designs at the same price.

The products of our “s” (smart) line meet the basic requirements for plants in the“emerging markets” or for rework with low degree of automation. For these products purefunctionality is most important.

Dürr Assembly Products always offers flexible solutions to meet your productionrequirements.

As an international partner of the automobile industry Dürr Assembly Products offerstesting and setting stands as well as assembly systems for different vehicle types andproductions.

Vehicles of low-cost segment as well as premium luxury limousines or sports cars aremanufactured and tested on our systems. The spectrum of quality requirements andtechnical contents is very large, too large to meet them with a standard product only.

For this reason Dürr Assembly Products has divided the testing and setting systems ofthe end-of-line sector and the assembly technology in different system types. Thus, thespecific, technological and economic requirements can be covered in an optimal way.

This brochure presents you a selection of our products which are applied in the segmentsProfessional, Compact and Smart.

C o n t a c t:

Your contactperson inPüttlingen

Dr. Thomas TentrupPhone +49 (0) 68 98-6 92-58 85Fax +49 (0) 68 98-6 92-54 00E-Mail [email protected]

We hope that this product information has met your interest. If you have any suggestions orwishes we are looking forward to hearing from you. Thank you very much for your attention.

Product Information

Page 3

x-w

he

el


x-wheel - the innovative chassis geometry teststand

Tasks:

In order to guarantee the increasing level ofcomfort required when driving a modernautomobile, the wheel geometry must bemeasured and adjusted exactly, in the range ofangular minutes, with regard to a perfectlyhorizontal steering wheel position when drivingstraight-ahead. The most important wheelgeometry parameters are the individual toeangles, the total toe angles, the camber anglesand the castor angles. The individual toeangles of the rear axle determine the drivingdirection of the vehicle.

Innovations:

The Dürr wheel alignment stand x-wheel issubject to a permanent, further innovativedevelopment to optimize the process of chassisgeometry setting as well as to adapt it to therequirements of modern vehicles. The mainfurther developments are:

1994: Market introduction of the first non-contact measuring system x-contour for toeand camber angle measurement (lasertriangulation).

1996: Extension of the measuring system x-contour to include ride height measurement.

2001: Development of the patent-registeredwheel support positioning system.

2002: Hysteresis measurement to determinethe centre of the steering wheel play.

2006: Market introduction of the non-contactmeasuring system x-3Dprofile for toe andcamber measurement and the introduction ofthe ride height measurement at each wheelvia sensor.

2007: Automatic steering wheel levelling via awheel support of the front axle resulting in afundamental improvement of the settingprocess with regard to a straight steeringwheel when driving straight ahead.

�

�

�

�

�

�

For this, Dürr has

received the Henry

Ford Technology

Award 2008 together

with Volvo.

The correct setting of the individual toe anglesat the front axle in relation to the drivingdirection and to the steering wheel angle leadsto an exactly horizontal steering wheel positionwhen driving straight ahead. The adjustment ofthe total toe angles at the front axle and therear axle to the nominal values defined by themanufacturer, reduces the tyre wear, and thecorrect camber and castor angles prevent thevehicle from pulling to the left or to the rightside.

As premium vehicles are equipped with activesuspension systems the toe and camber angleare strongly depending on the ride height.Therefore, the ride height measurement in asubmillimeter range has become more andmore important over the last years. The rideheight is determined by the difference betweenthe height of the wheel centre point and theheight of the wheel house edge. Today, theexact measurement of the ride height and thevehicle's driving direction is of currentimportance for the aiming of headlamps withregard to the vehicle inclination and the exactsetting of modern distance sensors to thedriving direction.

x-wheel with chassis geometry measuring systemx-3Dprofile

Layout: x-wheel with chassis geometry measuringsystem x-3Dprofile

� Today: More than 465 wheel alignmentstands x-wheel have already been delivered.

Product Information

Page 4

x-w

he

el

Dürr AssemblyProducts GmbHKöllner Strasse 122-12866346Püttlingen/GermanyPhone: +49 (0) 68 98-692-0Fax: +49 (0) 68 98-692-5400www.durr-ap.com

Experience and Flexibility:

Picture: vehicle positioning system via wheel support

Quality:

The wheel alignment stand x-wheel as well aseach sensor of the chassis geometrymeasuring system are subject to a defined,internal test in order to meet the high customerrequirements. Each wheel alignment stand isequipped with a calibration gauge which isused to transmit the sensor coordinates of themeasuring systems to a coordinate system.The calibration gauge can also be used tocheck the sensors of the measuring systems.The gauge itself is traceable to nationalstandards when measured by a coordinatemeasuring machine.

As an option a reference chassis frame can bedelivered, which is able to present four differentbut set toe and camber angles with differenttyres on each wheel support.

Picture: Calibration gauge

To perform these tasks in cycle times between1.5 and 3 minutes depending on the settingprocedures and with an availability of > 98%Dürr has developed the wheel alignment standx-wheel.

Its main modules are:

The wheel supports which guarantee arotation of the wheels without any lateralforces and toe and camber setting at the non-rotating wheel without any resistance.

The patent-registered wheel supportpositioning system which positions thevehicle without any contact, with an accuracyof +/- 1 mm (no lateral contact rollers at thetyres).

The wheelbase adjustment, which adjusts thewheel alignment stand x-wheel safely todifferent wheel bases (standard version: from2300 mm to 3200 mm).

The steering wheel balance “x-tronicbalancer” which detects the steering wheelangle with an accuracy of 0.1° and transmitsit to the test stand control system (wireless).

The well-proven measuring system x-contourbased on laser triangulation and theinnovative measuring system x-3Dprofilebased on stereo-photogrammetry, whichmeets the highest flexibility requirements withregard to vehicle mix.

The setting system which guarantees exact,manual, semi-automatic or fully automatictoe, respectively camber setting, dependingon the vehicle design.

The automation system x-line to control,visualize and store the measurement, settingand nominal values in a data base and toconnect with plant networks.

�

�

�

�

�

�

�

Technical data x-wheel:

Pit dimension: WxLxD: 5000x7500x2600mm

Accuracy toe: <1' <1'

Accuracy camber: <2' <2’

Accuracy height: <1mm <1mm

Reproducibilitycastor: +/-0,2° +/-0,2°

Measuringfrequency: 30Hz 20Hz with

difference imagealgorithm

Measuringprocedure: Triangulation Photogrammetrie

with a laser line up to 40 laser lines

Measuring volumes: 3 sensors 1 sensorper wheel per wheel(x,y) 168* 252 (x,y,z) 1000*400*690

Measuring system: x-contour x-3Dprofile

Product Information

Page 5

x-w

he

eld


x-wheel - the Chassis Geometry MeasurementNEWLY defined

d

Innovations:

Tasks:

Test stand layout x-wheel d

With the x-wheel Dürr Assembly Productshas newly defined the chassis geometrymeasurement with innovative x-3Dprofilemeasuring system. The test stand is designedfor vehicle production with large complexity andsmall quantity.Due to the optimum cost-performance-ratio ofthe x-wheel the test stand is ideally suited forthe chassis geometry measurement in AUDITand rework areas, special car production, CKDplants and other car production with highquality requirements.

The test stand fulfils the manufacturer-specificrequirements related to measuring accuracy,reproducibility and setting regulations.

d

d

In order to guarantee the increasing level ofcomfort required when driving a modernvehicle, the wheel geometry must be measuredand adjusted exactly, in the range of angularminutes, with regard to a perfectly horizontalsteering wheel position when driving straightahead. The most important wheel geometryparameters are the individual toe angles, thetotal toe angles, the camber angles and thecastor angles. The individual toe angles of therear axle determine the driving direction of thevehicle.

The correct setting of the individual toe anglesat the front axle in relation to the drivingdirection and to the steering wheel angle leadsto an exact horizontal steering wheel positionwhen driving straight ahead. The adjustment ofthe total toe angles at the front axle and therear axle to the nominal values defined by themanufacturer, reduces the tyre wear. Thecorrect camber and castor angles prevent thevehicle from pulling to the left or to the rightside.

To perform these tasks in cycle times >= 6minutes depending on the setting proceduresand with an availability of > 98 % DürrAssembly Products has developed the x-wheel

.d

The main modules are:�

�

�

2 automatically moved x-3Dprofilemeasuring sensors to measure the totalchassis geometry. Ambient light: max. 2500Lux

2 lanes, mounted on the floor

2 wheel supports at the front axle, designedfor steering angle test +/- 45

�

�

�

�

2 wheel supports at the rear axle, designedfor a wheelbase range from 2300 to 3200mm (required for the rear axle setting).

=> The wheel supports guarantee a toe andcamber setting at the non-rotating wheelwithout any influence by lateral forces.

Calibration gauge for the calibration as wellas for the checking of the measuringsensors.

PC based automation system x-line forcontrol, visualization and storage ofmeasuring values, setting values andnominal values (approx. 100,000 vehicles)as well as connection to high-level plantnetworks.

1 radio controlled steering wheel balance “x-tronic balancer”. The steering wheel balancedetects the steering wheel angle with anaccuracy of 0.1° and transmits the angle tothe test stand control system (wireless). Forthat purpose the test sequence can directlybe started at the steering wheel balance.

Measurement tasks

Possible setting:

�

�

�

�

�

�

�

individual and total toe angle at the front axleand at the rear axlecamber angle at the front axle and at therear axlecastor angle at the front axlemax. steering angle at the front axlesteering wheel angle

toe setting at the front axle and at the rearaxlecamber setting at the front axle and at therear axle

Steering wheel

balancer

Screen

Control cabinet

Front wheel support

Laser measuring sensor

Lane

Rear wheel support

Steering wheel

balancer

Screen

Control cabinet

Front wheel support

Laser measuring sensor

Lane

Rear wheel support

Product Information

Page 6

x-w

he

eld


Measurement and setting process:

Example:1.

The wheel geometry is measured in 2 different vehicle positions. By this procedure the axial run-out ofthe wheel is measured and compensated accordingly.

Reach measuring position 1 (marking by ramp on the driving surface).Exit, input of vehicle type via keyboard at the control panel (as an option: via barcode scanner).Enter vehicle and adjust steering wheel via steering wheel balance.

Drive on�

�

�

2.

3.

4.

Measure chassis in measuring position 1

Measure chassis in measuring position 2

Set chassis geometry

�

�

�

The operator starts the test cycle at thesteering wheel balance.(As an alternative at the control cabinet)The vehicle's front axle geometry ismeasured in measuring position 1.The laser measuring sensors automaticallymove to the rear axle and measure thevehicle's rear axle geometry in measuringposition 1.

The vehicle is manually driven to measuringposition 2 with the steering wheel balance inplace.The laser measuring sensors automaticallymove to measuring position 2 (rear axle) andthe vehicle rear axle is measured.The axial run-out is calculated andcompensated.The laser measuring sensors automaticallymove to the front axle and measure thevehicle's front axle geometry.The axial run-out is calculated andcompensated.

By means of a screen in the pit, the frontaxle is adjusted according to the pre-setvalues. (In case of vehicles with rear axlesetting the rear axle is adjusted first.)Setting is confirmed by the operator.

�

�

�

�

�

�

�

5. End�

�

�

�

�

The steering wheel balance is removed andreturned to the holder at the control panel.Data storage (as an option: printout via printer)The vehicle is manually driven off the test stand.The laser measuring sensors automatically moveto measuring position 1, home position.The test stand is ready for a new vehicle.

Measuring position 1(front axle)

Measuring position 1(rear axle)

As an alternative the test stand can alsobe delivered as floor-mounted variant tobe connected with an existing operatorpit.

Technical data x-wheel :dThe test stand can be built up on an existing, even hallfloor or be installed beside an existing pit. In the drivingarea of the installation an evenness of +/- 5 mm isrequired.

Lane distance: 1550 mmLane width: 400 mmWheelbase range: 2,300 mm to 3,200 mmRim size: 14” to 20”Accuracy toe: < 2' (master gauge)Accuracy camber: < 4’ (master gauge)Colour: according to Dürr standard (VDI/VDE)Mechanical and electrical design (components):according to Dürr standard (VDI/VDE)All indicated accuracies are based on the measurements at thecalibration gauge.

Measuring position 2(rear axle)

Measuring position 2(front axle)

Product Information

Page 7

x-w

he

elc


x-wheel c - complete, short-term, cost-effective

Customer requirements:

Improved quality and additional scope ofsupply with shorter delivery period and lowcosts - the wish of all customers.

With the chassis geometry test standx-wheel c (compact) Dürr Assembly Productshas configured a compact test stand usingwell-proven components – a test stand whichmeets more than 95% of the systemrequirements defined by the automotiveproducers. Functions and design of this teststand are based on our experience with morethan 460 sold test stands of the x-wheelseries.

Our innovations such as x-3Dprofile, radiolinked steering wheel balance and non-contact positioning have been integrated inthis product, as well as other well-provencomponents such as the low-friction floatingplates, the automation system x-line etc.

On this basis, the measurement tasks andthe individual design features have beencompared. The resulting intersection isreflected in the following detailed scope ofsupply and services (see back side).

The x-wheel c offers the same featuresconcerning measuring accuracy, systemavailability and quality of design that can befound in the well-known Dürr AssemblyProducts test stands which are manufacturedaccording to the customer specifications.

With the defined system configuration DürrAssembly Products, however, is able topresent an attractive cost/performance ratio.Moreover, this compact design even allowsus to offer a reduced delivery period of only 3months (ex works Püttlingen facilities).

Innovations

3D Layout: x-wheel

x-wheel c with chassis geometry measurementx-3Dprofile

x-wheel c in the line

To adapt this test stand to further customerspecific requirements (e.g. heightmeasurement at the wheel house edge) thereis a range of corresponding options which canbe selected.

attractive price

short delivery period

x-wheel “technology”(measurement and setting accuracies,functions, ...)

complete scope of supply

Your benefits:

�

�

�

�

Technical data measuring system x-3Dprofile:

Accuracy toe: <1'

Accuracy camber: <2’

Accuracy height: <1mm

Reproducibilitycastor: +/-0.2°

Measuring frequency: 20Hz withdifferential imagealgorithm

Measuring process: photogrammetryup to 40 laser lines

Measuring volume: 1 sensor per wheel(x,y,z) 1000*400*690

Product Information

Page 8

x-w

he

elc


Technical data:

� Measuring system x-3Dprofile (32 lines)

Measuring task toe/camber at FA and RA

Master gauge master gauge for x-3Dprofile with possible linearity measurement

Setting toe and camber at FA and RAmonitor in pit at FA and RAconfirmation via 1 control panel in the middle of the working platform

Floating plates 2 off 45° floating plates at FA (steering angle)2 off 10° floating plates at RA

Positioning floating plates positioning with SEW servomotors

Base frame designed for a pit depth of 2600 mm

Peripherals mechanics - complete pit cover- lane with guide rollers- roller sets in the entry area- cover for measuring units

Working platform FA and RA, static, access stairs, on the face side, front

Steering wheel balance - x-tronic balancer, “RADIO LINK” left, radio frequency 2.4 Ghz- 1 off calibration device

Control panel - control panel Start left

Peripherals electrics - 1 off barcode: Datalogic, Firescan D 131- 1 off printer: Star, SP - 712

Type identification vehicle type is read out with barcode. The corresponding vehicletype must be decodable directly via an assessment chart. Typerequirements to external computer system, decoding from files, etc.can be quoted as an option.

Sequence control test sequence, without pre-set control values via “externalsystem”; test sequence control via “external system” can be quotedas an option

Control cabinet control cabinet integrated in the base frame,temperature range: 0°C to 45°C

PC Industrial PC with Slot PLC

Illumination Working place illumination in the area of working platform

Wheelbase adjustment 2300 - 3200 mm, adjustment speed 60 mm/s

Track width 1550 mm

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

Scope of supply and services

� Prompting: basic language package, possible languages:(Production process dialogues German/English/French/Italian/Spanishcontrol buttons + safety advice) Russian/Chinese/Portuguese/Czech

Parameter set-up dialogues,setting, diagnosis: German/English

Operating manual and maintenanceinstructions: according to basic language package

Documentation: parts lists,layouts, etc. German/English

EPLAN according to Dürr standard (DIN 40719), German/Englishmarking systematic according to Dürr Standard

Layout standard layout, standard pit drawing

�

�

�

�

�

Language/Documentation

� control cabinet RAL 7035 (light grey)

static parts RAL 7035 (light grey)

movable parts RAL 1023 (traffic yellow)

�

�

� design according to the valid DIN,VDI/VDE regulations.

Painting

Production means regulations

� height measurement

castor measurement via laser

operation + peripherals right

automatic steering wheel levelling

interface to external systems

individual type identification

�

�

�

�

�

Options:

Product Information

Page 9

x-3

Dp

rofile


x-3Dprofile – dynamic Pattern Projection

Quality:

Safety:

The market requirement for larger measuringranges for wheel geometry measuring systemscaused Dürr to initiate a new development on thebasis of the more than 460 wheel alignment teststands x-wheel already sold and the positiveexperiences made with its proven laser measuringsystem.

The intention was to respond to the increasingvehicle mix with a reliable and simple-to-para-meterize solution which can comply with moremeasuring tasks in an optimized cycle time.The solution now available from Dürr AssemblyProducts GmbH is also very tough, requires littlemaintenance, has a long lifecycle and consumesless energy and - in contrast to beamer solutions -works more independently of surrounding lighting.Such a solution was not available on the market atacceptable prices until now.

Dürr combines the quality of the proven lasermeasuring technology with the measuring rangeof a camera projection system without thedisadvantages of a beamer solution. This isachieved with the help of the x-3Dprofile compactsensor that was designed during a joint programof research with supplier VisiCon.

x-3Dprofile uses stereo photogrammetry and laserarrays. This means that laser lines of high lightintensity are used as illumination for the wheel tobe measured. These laser lines are point laserswhich have been ex-panded to a line by cylindricallenses and they form a two-dimensional linematrix and can be switched individually.

In addition to its independence of surroundinglighting, it is the fail-safe reliability of x-3Dprofilethat stands out. If one beamer lamp overheats oris defective the associated system comes to acomplete standstill. If one laser line fails, however,– or even if several do – this is of little significanceas far as measuring performance is concerned.

That sensorsupplies point coordinates of the laser linesprojected. An algorithm developed by Dürrcalculates the toe and camber angles of the wheelas well as the ride height with high accuracy anddynamics.

The measurement of the wheel arch edges isilluminated by an additional LED strip. Thereflection edge caused by this will also be eva-luated by stereo photogrammetry which suppliesthree-dimensional coordinates (x, y, z) for thewheel arch edge, the ride height. These valuescan be considered in the wheel aligner, but also inthe succeeding test and setting stations for driverassistance systems.

x-3Dprofile - Dürr reinvents wheel geometrymeasurement

With the Dürr process, measurements result fromstatistical evaluation of a multitude of measuredlines thus attaining a high level of measurementaccuracy without unnecessary data collection.

The sensor is very robust, small and can be placedfreely in any position. It can be calibratedredundantly and it is integrated into the proved Dürrx-line software.In the introduction phase the sensor can be usedwith the same calibration gauge in parallel to thesystem which is to be removed.

x-3Dprofile - greater reliability as a result ofmeasurement based on a multitude of laser lines of highlight intensity

Schematic diagram of the sensor with laser matrix (lateralview)

Laser matrix

with max. 2x4x8 laser lines;

Each laser can individually be switched

in time with the image processing

„Black Box“:

image processing evaluation

& control unit

camera 2

with red filter

camera 1

with red filter

z-axis

y-axis

Ethernet

z-axis

y-axis

Product Information

Page 10


The system represents further innovative Dürrsolution - one that not only assures quality but alsocontributes to lowering costs.

Comparison x-contour, x-3Dprofile and beamer measuring system

x-3

Dp

rofile

x-wheel with x-3Dprofile

Flexibility:The large measuring range is excellently suitablefor extreme vehicle mix with reference to trackwidth difference, ride height difference anddifferent tyre sizes. In comparison with the beamerthe sensor is of a smaller size, has a longerdurability and consumes lower energy. Itdistinguishes itself by a faster availability formeasurement and due to the application-orienteddata volume by a measuring frequency

Abenchmark shows that the x-3Dprofile measuringsystem is clearly superior to the triangulationmeasuring system existing on the marketconcerning these points as well as theinsensitiveness to external light.

x-3Dprofile system VisiCon is a trailblazing wheelgeometry measuring system that in terms of suc-cessful measuring sensors such as PerceptronDTC and VisiCon LCS will enrich the DürrAssembly Products specialists portfolio.

that istwice as high in case of differential imagealgorithm.

In comparison with a beamer measuring systemwith evaluation of triangulation the stereophotogrammetry offers the advantage that themeasuring method works independent of thecorrect position of the measuring lines.

x-contour

x-3Dprofile

Measuring surface

x-contour

Ride height

measurement

Measuring

volume

x-3Dprofile

Floating plates

positioning

x-contour

x-3Dprofile

Measuring surface

x-contour

Ride height

measurement

Measuring

volume

x-3Dprofile

Floating plates

positioning

z-axis

x-axis

Plate with

4x8

laser line arrays

camera 1

camera 2

Tyre

Wheel arch edge

lighting wheel

arch edge

z-axis

x-axis

camera 1

camera 2

t:300*h:700*b:550t:122*h:720*b:300t:70*h:300*b:70Sensor size

Stand off: 800mmStand off: 800mmStand off: 400mmWidth of wheel alignment stand

Life duration beamer lamp(2000 h)

Life duration laser(> 7000 h)


Constancy

<10 Hz20 Hz by differential imagealgorithm(40 Hz image evaluation)

30 Hz per laser lineMeasuring frequency

Colour beamer lightSensitivity: highIntensity of external light<1000 Lux)

Laser light (Lclass 2m)Sensitivity: very lowIntensity of external light <2500Lux)

Laser light (Lclass 2m)Sensitivity: lowIntensity of external light<2500 Lux)

Sensitiveness to external light

Sensor consisting of colourcamera, beamer and PC

Sensor with 2 cameras, laserarray & evaluation unit

Sensor with camera, laser& evaluation unit

Hardware configuration

1 sensor per wheeldelta_x:1000 mmdelta_y:400 mmdelta_z:600 mm


Measuring range persensor,min. 3 sensors per wheeldelta_x:168 mm(VisiCon LCS: 300mm)delta_y:252 mm

Measuring rangei.e. flexibility relating to differenttyre sizes

toe < 1mincamber < 2minheight < 1mmaverage determination viafeatures, contourmeasurement with colourlines out of beamer mapping

toe < 1mincamber < 2minheight < 1mmaverage determination viafeatures, contour measurementwith many laser lines

toe < 1mincamber < 2minheight < 1mmcontour measurement withone laser line

Accuracy

Beamer measuring systemx-3Dprofile systemx-contour

t:300*h:700*b:550t:122*h:720*b:300t:70*h:300*b:70Sensor size

Stand off: 800mmStand off: 800mmStand off: 400mmWidth of wheel alignment stand

Life duration beamer lamp(2000 h)



Constancy

<10 Hz20 Hz by differential imagealgorithm(40 Hz image evaluation)

30 Hz per laser lineMeasuring frequency

Colour beamer lightSensitivity: highIntensity of external light<1000 Lux)

Laser light (Lclass 2m)Sensitivity: very lowIntensity of external light <2500Lux)

Laser light (Lclass 2m)Sensitivity: lowIntensity of external light<2500 Lux)

Sensitiveness to external light

Sensor consisting of colourcamera, beamer and PC

Sensor with 2 cameras, laserarray & evaluation unit

Sensor with camera, laser& evaluation unit

Hardware configuration



Measuring range persensor,min. 3 sensors per wheeldelta_x:168 mm(VisiCon LCS: 300mm)delta_y:252 mm

Measuring rangei.e. flexibility relating to differenttyre sizes

toe < 1mincamber < 2minheight < 1mmaverage determination viafeatures, contourmeasurement with colourlines out of beamer mapping

toe < 1mincamber < 2minheight < 1mmaverage determination viafeatures, contour measurementwith many laser lines

toe < 1mincamber < 2minheight < 1mmcontour measurement withone laser line

Accuracy

Beamer measuring systemx-3Dprofile systemx-contour

Product Information

Page 11

x-lig

ht


x-light - the flexbile and modular headlamp anddistance sensor setting systems

Experience

inproduction, CKD plants as well as audit andrework sectors

:

New headlamp models and technologies aswell as different legal guidelines worldwiderequire the use of sophisticated setting andtesting technology in the area of headlampaiming.

Operator independent headlamp aimingsystems with image processing provide highlyprecise and reproducible test and settingresults. These setting systems are part oftoday's standard testing and setting technologyin vehicle production. Dürr develops and sellsheadlamp aiming systems with the name“x-light” which are tailored to the highrequirements of the end-of-line area in vehiclemanufacturing plants. Within the last 20 yearsmore than 293 manual, semi-automatic as wellas fully automatic headlamp aiming systemshave been successfully installed worldwide inalmost all OEMs.

The flexible and modularly extendable, manualx-light in gantry design serves as basis for theDürr headlamp aiming system.

Due to the increasing use of driver assistancesystems in vehicles, the image processing withheadlamp aiming systems becomes more andmore important. The setting of driverassistance systems based on infrared distancesensors and the setting of radar systems withauxiliary laser systems can also be performedwith x-light.

x-light's optimal flexibility is given by variouspossible applications such as manual, semi-automatic or fully automatic version. It isparticularly suitable for increasing the settingquality of headlamps and distance sensors

in the automotive industry,while complying with the documentationrequirements.

Photo: x-light in gantry version, version shown in thepicture can be equipped with extras.

Quality:

Dürr has constantly improved and extended thequalities of the camera-based measurementtechnology, the image processing performance aswell as the technical versions of the mechanicalcomponents. This is reflected in the well-knownDürr automation software x-line used in the end-of-line area as well as in the flexible use of thissystem.

The automation software x-line analyses theimage data recorded by the CCD camera. Varioustested measurement algorithms are availablewhich execute an online measurement of mainheadlamps, foglamps and high beam headlampsaccording to legal regulations. As an option,algorithms to measure the motorway light and tocheck the light intensity of headlamps areavailable.

Furthermore, some proven algorithms can beused to set the distance sensors based oninfrared, and to detect the light intensity of thesignal. Moreover, some new measurement andevaluation algorithms are continuously developedand improved to measure new types ofheadlamps and sensors.

Operator visualization with headlamp aiming values

Product Information

Page 12

x-lig

ht


x-light light collecting box with operator terminal; theindicated system can be equipped with specialextras.

All measuring values are available in the x-linesoftware and will be processed in variousvisualization dialogues and displayed to theoperator. x-line stores all values with MSAccess, simplifying the evaluation via the pre-setting quality of headlamps and sensors.

Due to the modular design and the highflexibility the setting systems make sure thatfuture requirements can be met without anyproblems.

The powerful automation reduces theproduction costs and provides highly preciseand reproducible test and setting results at anergonomic workplace.

The operation of the x-light's light collecting boxis, in case of a manual version, ensured bymeans of a comfortable height adjustment. Thetoothed rack and cable stroke drives of theautomatic positioning unit, available as anoption, is manufactured in a sturdy andmaintenance-free design and ensures a long-term application.

Flexibility:

The light collecting box is positioned directly infront of the headlamps with an accuracy of two-tenths of a millimetre, depending on the vehicletype.

When the system is used in combination with aDürr wheel alignment stand the high Dürrstandard is also applied.

Adjustmentscrewdrivers forheadlamp aimingsystem x-light

In this case, vehicle information and settingrelease are sent to the headlamp aiming systemvia a defined interface. After calibration on themaster gauge of the wheel alignment stand bymeans of a laser pointer, the rear axle correctionangle which has been detected by the wheelaligner is taken into account for the measuringvalues of the x-light. According to the type ofoptions included on the wheel alignment standsome correction values of the vehicle height canbe taken into account for calculating themeasuring values.

As an option, x-light can also be combined via adefined interface with wheel alignment standswhich have not been produced by Dürr.

The semi-automatic adjustment screwdrivers,which are available as an option, offer theoperator a perfect ergonomic workplace incombination with the operating terminal easilyvisible on the Z-column.

After the screwdrivers have been attached, theheadlamps are automatically bolted to nominalvalue.

If x-light is applied as a stand-alone headlampaiming system for audit, quality assurance orrework areas, a vehicle adjustment unit or ameasuring unit which detects the vehicleinclination and transmits it to the x-light, can beordered as an option.

Furthermore, an optional programming ofheadlamp ECUs, e.g. for headlamp rangeadjustment and cornering light, can be executedby Dürr x-tronic components at any time.

Product Information

Page 13

x-lig

ht

s


x-light - the smart aiming systems forheadlamps and distance sensors

s

The optimum cost/performance ratio of x-lightis particularly suitable for increasing the settingquality of headlamps and distance sensors in

and it is suited to fulfil the responsibility fordocumentation.

s

� CKD plants

the production of trucks, busses andtractors

the audit and rework sectors of vehicleproduction

�

�

Quality:

Dürr has assigned the qualities of the camera-based measurement technology to x-light , atechnology well-proven over many years. This isreflected in the well-known Dürr automationsoftware x-line used in the end-of-line area aswell as in the flexible use of this system.

The Dürr automation software x-line analyses theimage data recorded by the CCD camera.Various, tested measurement algorithms areavailable which execute an online measurementof main headlamps, foglamps and high beamheadlamps according to legal regulations.

s

Headlamp aiming systems based on imageprocessing gain more and more in importancebecause of the significantly increasing number ofvehicles which are equipped with driverassistance systems. These systems - often alsoequipped with infra-red distance sensors - canalso be adjusted with the x-light .

The low-cost Dürr headlamp aiming systemx-light has been developed to satisfy thedemand of a cost-saving and standard systemwhich on one hand has the same imageprocessing performance with Dürr experience asusual in the vehicle plant's end-of-line area andwhich on the other hand is independent of theusual degree of automation.

s

s

Experience:

Operator independent headlamp aiming byimage processing is part of today's standardtesting and setting technology in vehicleproduction. Dürr develops and sells manual,semi-automatic and fully automatic headlampaiming systems with the name “x-light” which aretailored to the high requirements of the end-of-line area in the vehicle manufacturing plants.Within the last 20 years, more than 293headlamp aiming systems have beensuccessfully installed in almost all OEMsworldwide.

The shown model may be equipped with special extras.


As an option, algorithms to measure the motorwaylight and to check the light intensity of headlampsare available.

Furthermore, some tried algorithms can be usedto set the distance sensors based on infra-red.

Headlamp aiming system “x-light s” with floor rails,cabinet and light collecting box

Operator's monitor with keyboard for nominal valuesediting and maintenance purposes

Product Information

Page 14


x-lig

ht

s

Operator's visualization with headlamp aiming settingvalues

Light collecting box with guide column

All setting values are visualized via x-line on amonitor of computer system and are stored inMS Access by the computer. Thus, even thequality of the headlamp pre-setting, for example,can easily be evaluated statistically.

The non-wearing precision guide column, arugged and maintenance-free construction,guarantees long-time application, even for theproduction of large numbers of vehicles.


FlexibilityThe high flexibility starts with the set-up and theinstallation of x-light . The installation site mustonly be equipped with a 230 V socket. Thus, alater relocation of the system is only a matter of afew hours.

A comfortable and non-clamping heightadjustment and a balancing weight integrated inthe Z column ensure the ergonomic operation ofthe light collecting box of the x-light .

s

s

A long vertical transfer distance (250mm -950mm) allows the measurement and the settingof foglamps and main headlamps as well as ofdistance sensors with a large type mix ofvehicles.

When the system is used in combination with aDürr wheel alignment stand the high Dürrstandard is also applied. In this case, vehicleinformation and setting release are sent to theheadlamp aiming system via a defined interface.After calibration on the master gauge of thewheel alignment stand by means of a laserpointer, the rear axle correction angle which hasbeen detected by the wheel aligner can be takeninto account for the measuring values of the x-light .s

Technical data x-light :s

Light collecting box:

Measuring accuracy:

Lens:

Guide column and light collecting box:

Dimensions of computer station:

Camera:

L x H x W: 550 x 420 x 400 mm3

Standard transfer distance (middle of lens):250 mm to 950 mm

Recommended distance headlamp to lightcolleting box: 300 mm to 700 mm

Optimized nano coated projection plate

< 0.1 % (3.43’)

lens type: Fresnel lensfocus: f = 500 mmW x H x D: 367 mm x 247 mm x 1.9 mmoptimized for headlamp light

H x L x W: 2200 x 850 x 790 mm

L x W x H: 640 x 610 x 1700 mm

GigE camera system with automated exposurecontrolCamera with progressive-scan process

boundary condition:light emerging point atthe headlamp ispositioned in front of thecentre of the lens

Option for infrared distance sensors:Monochrome camera with high sensitivity invisible and near-infra-red area.

Via a defined interface x-light can also becombined with wheel alignment stands whichhave not be produced by Dürr.

A second available variant of x-light , a stand-alone version, is equipped with a swivelling Zcolumn. Combined with a line laser which recordsthe vehicle's symmetry axis, the light collectingbox can be adjusted in a range of +/- 10° to thedirection of this symmetry axis.

s

s

Product Information

Page 15

x-D

AS

alig

n


x-DASalign - Test stand for driver assistancesystems

Driver assistance sensor technology in the vehicleprovides more safety in road traffic. The numberand the complexity of the systems in the vehicleincrease and require efficient calibration andsetting processes which have to be carried outunder consideration of dynamic chassisparameters.

The multitude of sensors built into first-classvehicles requires separate setting stations for theoptimized and quick testing and calibratingprocess. The manufacturers of components andvehicles develop and use a multitude of sensorsand calibration concepts which differ in functionand use and which can be integrated flexibly inthis type of test stand.

By means of laser triangulation or stereometrymeasuring heads, chassis height, symmetry ofchassis as well as chassis parameters like runningdirection of rear axle are measured and taken intoconsideration during the calibrating process of thesensors.

Automated flexibly by x-line and calibrated by x-tronic products, all components for the testing taskcan be provided by one supplier.

Driver assistance test stand “x-DASalign”

Tasks:

Innovations:

In the beginning, distance radar sensor testingwas integrated into the Dürr headlamp aimingand wheel geometry test systems. Apart fromradar based sensor technology, infrared distancesensor tests were to be integrated shortly after.With new sensor concepts, essential furtherdevelopments followed up to a separate teststand for the testing and calibration of the driverassistance sensors in the vehicle.

1997: Radar based distance sensorsintegrated into headlamp aimingsystems and wheel geometry testsystems.

2001: Infrared distance sensor test inheadlamp aiming systems.

2004: Development of an independent teststand concept for parallel testing (withoptimized cycle time) of different driverassistant system components.

�

�

�

�

�

Testing and setting of radar baseddistance sensors(Adaptive Cruise control)Testing and setting of infrared baseddistance sensors (Lidar)Testing and calibration of rear viewcamera (Rear view)Testing and calibration of lanedeparture camera system(Lane departure warning)Testing and calibration of lane changeassistant (Blind spot detection)

To this day, approximately 200individual systems have been integratedinto existing or new test stands.Altogether, 24 independent test standshave been delivered to customers.

�

�

�

Infrared night view camera (Nightview)Distance warning in close-up range,parking sensor technologyEnvironment camera systems:Sideview, Topview

2005: Integration of a test system for thesmart beam assistant

2006: Further development of the stand-alone test stand concept withadditional test functionalities.

2010: HUD:Head Up Display - Calibration

Product Information

Page 16

x-D

AS

alig

n


Experience and flexibility

2 1

5

6

4

3

7 5

5

52 1

5

6

4

3

7 5

5

5

Layout: Driver assistance test stand

Sensor test:

The essential sensor tests and settings alreadyrealized comprise of the following:

Radar systems with active evaluation of thesensor signals

- Evaluation via fixed mirror systems- Evaluation via rotating mirror systems(rotation by Z- and Y-axis)

- Evaluation via radar antenna: Triple mirror(Corner reflector)

Radar systems with passive evaluation of thesensor signals: Laser adapter

Infrared systems- Black/white cameras- NIR LED’s- Heating wires

Trapezium correction for camera systems- Printed reference plates- Nano particles coated, traversable

reference plates

�

�

�

�

1. Lane departure warning

2. Adaptive cruise control

3. Lane change assistant,Doppler units

4. Rear view

5. Laser units for body heightand drive direction

6. Guided drive lane

7. Cabinet

Test stand calibration:

Chassis geometry options:

The different aiming and calibrating devices of thedriver assistance test stand can be checked fastand efficiently by means of setting gaugesespecially produced for the test stand.

In completely automated test stands, thecalibration procedure can be carried outautomatically, independently from the operator,fast and efficiently by the test stand itself.

After putting in the setting gauge, point lasers areturned on. The individual targets which areequipped with light-sensitive sensors areautomatically directed past the reference lasers.By means of the light-sensitive sensors, thenominal position is controlled.

These chassis geometry options are required forthe chassis geometry, body symmetry and heightsensors. The test stand can be retrofitted byadditional sensor technology for these tasks:

Triangulation line laser sensors “x-contour”Stereometry multi-line laser sensors“x-3Dprofile”

�

�

Product Information

Page 17

x-r

oa

d


x-road - Multi-function Roll / Brake Test Stand

Experience:

The rapid development of control units in orderto optimize the driving and braking behaviour ofa vehicle leads to increasing test requirementsto ensure function and quality of thesesystems. Such systems are e.g. ABS, ESP,ASR and driver assistance systems.

The objective of the test system developmentshould be to create a system for this increasingcomplexity of test requirements which issuitable to comply with today's and tomorrow'srequirements of vehicle testing. Reliability, easyoperation and easy maintenance should alsobe granted.

The solution offered by Dürr AssemblyProducts is x-road. The x-road combines theincreased requirements to the test environmentdue to modern vehicle technology with areduced complexity of the test stand and high-precision measuring technology.

It consists of roll systems, each of them cansupport one wheel. Standard passenger cartest stands comprise 4 off roll systems, for thespecial vehicle sector the test stand can beequipped with up to 8 roller systems. Each ofthese roll systems is equipped with adynamically frequency-controlled electronicdrive. Thus, some driving situations can besimulated for each wheel while provoking andmeasuring the reactions of the vehicle'sintelligence equipment.

Due its modular structure and sophisticatedself diagnosis the x-road represents a reliableand flexible partner in order to test modernvehicles.

Tasks

�

�

�

�

�

General function test of the vehicle duringdynamic test mode

Gearbox function tests (automatic and manual)

Tests of the vehicle's braking system

Acceleration and deceleration tests under roadconditions

Tests of sensors in the vehicle(ABS, ESP, ASR)

Quality

Safety

The x-road combines highly reliable systemtechnology with precise measuring technique. Thequality of the measured values is thoroughlychecked before delivery.

Therefore the measuring system x-cal, which hasbeen developed especially for this purpose, isused.

With x-cal the inertiaof the completelyassembled roll systemsis precisely recorded.This is the basic conditionfor accurately determiningthe brake forces duringdynamic measurement.

x-cal is also used to check the speed and forcemeasurement of each x-road.

In case of high speed the different safety devicessuch as:

Lateral contact rollersRestraint rollersand a wheel base which can be adjusted withmillimetre precision

can be used to ensure a stable mode.

�

�

�

double roller set

exhaust gas flap

Drive

Product Information

Page 18

x-r

oa

d


Environment: Due to the functionality of the energy recovery system which is integrated in each x-road, any surplus energy will be returned to the grid. This saves energy costs and has a positive effecton the CO2 balance, too.

Layout Standard x-road

Various display and warning devices as well asan exhaust gas extraction system serve assafety devices for the driver.

First of all, the high flexibility of the x-road isdetermined by the intelligent drive control on allrollers and the versatility of the automationsystem x-line. With the basic modes ofoperation

roll mode

static brake mode (v=const) and

dynamic brake mode (dv/dt)some different test situations and loads can begenerated, according to the requirements. Inthis case, it is not important whether the testsequence is configured and documented viainterface by an external system, or whether thetest sequence systems integrated in x-line areused.

�

�

�

Conception of the roll system:

Mechanicalstructure:

Energy anddata flow:

MM MM MM MM

x - line

Intermediatecurrentcircuit

D: rotational speed sensorL: rollerM: AC motor

Actual data Nominal data

Control

Power supply andEnergy recovery

DM

L

L

DM

L

L

DM

L

L

DM

L

L

DM

L

L

DM

L

L

DM

L

L

DM

L

L

DMM

L

L

control

(software model)

DM

L

L

DMM

L

L

DM

L

L

DMM

L

L

DM

L

L

DMM

L

L

Max. test speed 200 km/h

Typical motor traction force for each roller set

(37kW motor / 37kW frequency converter)(in relation to the roller circumference, v = constant)

Fnenn = 1500 NFmax = 3000 N

Accuracy of the speed detection(in relation to the roller circumference)

typical < ± 0.05 % of finalvalue

Accuracy of the brake force detection(dynamic test: dv / dt)

< ± 1.00 % of final value

Accuracy of the brake force detection(static test: v = constant)

< ± 1,00 % of final value

Max. difference speed, FA roller to RA roller (with v = constant) typical < ± 0.05 % of finalvalue

Max. difference speed, roller of driven axle to roller of non-driven axle (with a = constantand y 6m/s²)

<=0.5 km/h

Wheel base max. adjustment speed 60 mm/s

Positioning accuracy ± 1 mm

Technical data x-road:

Product Information

Page 19

x-r

oa

dc


x-road - the complete roll/brake/ABS teststand

c

Innovations:

x-road c in the line

To adapt this test stand to further customerspecific requirements (e.g. calibration set,weight measurement on the lifting bar, cabin,ventilation etc.) there is a range ofcorresponding options which can be selected.

attractive price

short delivery period

x-road “technology”(measurement accuracies, functions, ...)

complete scope of supply

Your benefits:

�

�

�

�

calibration unit x-cal

With the roll/brake/ABS test standx-road (compact) Dürr Assembly Productshas configured a compact test stand usingwell-proven components – a test stand whichmeets more than 95% of the systemrequirements defined by the automotiveproducers.

Functions and design of this test stand arebased on our experience with more than 360sold test stands of the x-road series.

On the basis of the large number of deliveredsystems, the individual design features havebeen compared. The resulting intersection isreflected in the following detailed scope ofsupply and services (see back side).

With the x-road , Dürr Assembly Productsoffers the possibility to carry out vehiclefunction tests including: dynamic drivingtests, parameter set-up tests, and tests ofelectrical control devices for front wheel drive,rear wheel drive or 4 wheel drive vehicles inthe end of line area.

Different dynamic driving conditions aresimulated under circumstances similar toroad conditions. The automation of the teststand ensures reproducible test results.Freely definable test sequences complete theflexibility of the concept. The x-road offersthe same features concerning measuringaccuracy, system availability and quality ofdesign that can be found in the well-knownDürr Assembly Products test stands whichare manufactured according to the customerspecifications. With the defined systemconfiguration Dürr Assembly Products is ableto present an attractive cost/performanceratio. Moreover, this compact design evenallows us to offer a reduced delivery period ofonly 3 months (ex works Püttlingen facilities).

c

c

c

Application:

drive double roller set

retaining

rollers

exhaust gas

flap

3D Layout: standard x-road

Technical data x-road :c

�

�

�

�

�

�

�

maximum test speed: 170 km/h

typical motor traction force F = 1700 N

for each roller set: F = 3500 N

accuracy of speed detection: < 0.05% offinal value

accuracy of brake forcedetection: final value

accuary of brake forcecalculation: final value

maximum difference speed,FA roller to RA roller(with v = constant) final value

maximum difference speedroller of driven axle to roller ofnon-driven axle(with a = constant and y 6m/s ): <= 0.5 km/h

nenn

max

+

< 1.00% of

< 1.00% of

< 0.05% of

+

+

+

2

Quality:

The x-road combines highly reliable systemtechnology with precise measuring technique.The quality of the measured values isthoroughly checked before delivery.

For this, the measuringsystem x-cal, which hasbeen developed especiallyfor this purpose, is used.

c

Product Information

Page 20

x-r

oa

dc


�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

drive system: 37 kW motor with corresponding frequency converter technology

rollers: double roller, 502 mm diameter, coated, m 350 kg

fixed roller distance

restraint rollers: with retaining rollers at the rear axle

exhaust gas flap: over the total test stand width, 2300 mm x 500 mm (l x w)

steel subframe/cover: pit dimension: 8100x5000x2200 mminner/outer covermoving cover

control cabinet: installed in driving direction, right sidetemperature range 0° to 45°C

monitors: 1 x control cabinet 15” TFT1 x system 32” TFT, in driving direction front, right, on rack

type identification: type ID via manual input resp. via external system

sequence control: basic test sequence without ABS for one vehicle type includedtest sequence via “EditNominals” (database)

PC: industrial PC with Slot PLC

wheelbase adjustment: 2300 - 3200 mmadjustment speed 60 mm/s with +/- 1 mm accuracy

wheel diameter: 550 - 700 mm

overhang: max. 1200 mm

red

width of test stand: roller outer diameter: 2300 mmroller width: 800 mm

lifting bars: 4 off, max. lifting force: 1000 kg wheel load

vehicle recognition: 1 x analogue “front left”1 x digital “rear right”

track width: 1300 - 1700 mm

� Prompting: basic language package, possible languages:(Production process dialogues German/English/French/Italian/Spanishcontrol buttons + safety advice) Russian/Chinese/Portuguese/Czech

Parameter set-up dialogues,setting, diagnosis: German/English

Operating manual and maintenanceinstructions: according to basic language package

Documentation: parts lists,layouts, etc. German/English

EPLAN according to Dürr standard (DIN 40719), German/Englishmarking systematic according to Dürr Standard

�

�

�

�

� Layout: standard layout, standard pit drawing

� control cabinet RAL 7035 (light grey)

static parts RAL 7035 (light grey)

movable parts RAL 1023 (traffic yellow)

�

�

� design according to the valid DIN,VDI/VDE regulations.

Scope of supply and services

Language/Documentation

Painting Options:

Productionmeans regulations

Technical data:

�

�

�

�

�

�

�

calibration set

weight measurement on lifting bar

Carlink B

test sequence control by Dürr orexternal system

control panel incl. peripherals left orright

manual force transmitter, pedal forcetransmitter

cabin and ventilation

Product Information

Page 21

x-c

ruis

e,x-b

rake


x-cruise, x-brake - the Test Stand Duo for ShortCycle Times

x-brake in the line

Innovation:

Modules:

Layout: x-brakeLayout: x-cruise

To meet the requirements of the tests for“driving dynamics” and “brake testing”,particularly within cycle times less than 100seconds, Dürr Assembly Products hasdeveloped the test stand combinationx-cruise and x-brake.

On the roll test stand x-cruise some “drivingdynamic” tests can mainly be executed under“road” conditions. Measurement and evaluationof the maximum vehicle brake force at lowspeed are done on the brake test stand x-brake.

Both test stands are suitable to test front, rearand 4-wheel driven vehicles.

The main modules of are:x-cruise

�

�

�

�

�

�

�

double roller set with lifting bar at front andrear axle to support the vehicle wheels

flat belt connection between front axle andrear axle

option: speed detection at each wheel set todetect the speed of each individual wheel

option: toothed belt connection within theroller set, to exactly simulate the inertia

option:3 off switchable clutches for separateevaluation of each individual vehicle wheel

motor-driven wheelbase adjustment for awheelbase range of 2,300 to 3,200 mm

automation system x-line to control, visualizeand store measurement, setting and nominalvalues in a database as well as to connectwith high-level plant networks

The main modules of are:x-brake

�

�

�

�

�

�

�

�

double roller set with lifting bar at front andrear axle to support the vehicle wheels

4 off AC motors to drive the double rollersets, speed 2.5 km/h. Option: frequency-controlled in the speed range of 0-10 km/h

load cells at each roller set for brake forcemeasurement

contact rollers for vehicle detection andspeed measurement, e.g. slip rate detection

motor-driven wheelbase adjustment for awheelbase range of 2,300 to 3,200 mm

option: weight measurement integrated inthe lifting bar to determine the exact axleweight (required for maximum brake forceevaluation)

option: hard-wired transducer for hand brakeforce resp. foot brake force

automation system x-line to control, visualizeand store measurement, setting and nominalvalaues in a database as well as to connectwith high-level plant networks

Product Information

Page 22


x-c

ruis

e,x-b

rake

Technical data x-cruise:

�

�

�

�

�

Maximum test speed: 150 km/h

Measuring accuracy of speed detection: +/- 3%

Wheelbase range: 2,300 mm to 3,200 mm

Colour: according to Dürr Standard

Mechanical and electrical version (components): according to Dürr Standard

x-cruise:

�

�

�

general function tests of the vehicle indynamic test mode--> roll mode to test the gearshift and the

power train--> roll mode to check the cruise control

and/or the speedometeracceleration and speed tests under roadconditionswarming up (only in combination with“increased roller mass” available as anoption)

x-brake:

�

�

�

�

brake test (max. brake force)

brake force balance lh/rh

ABS test at low speed

function test of parking brake

The test stand combination of x-cruise and x-brake is able to fulfill these tasks, depending on therequired test processes, in cycle times lower than 100 seconds with an availability of >98%.

Vehicle tests:The following test can be performed with the test stands respectively with the test standcombination:

*under the condition that the used control unit resp. vehicle test system supports the tests andenables the ECU communication. o = option

XSlip rate detection and control

XoABS sensor – commutation test (with ECU communication) *

XoABS valve – commutation test (with ECU communication) *

XCruise control test, definable load levels

X„static“ brake test v-constant, driven by test stand

XABS sensor – quality test (with ECU communication) *

XDetermination of braking distance (with ECU communication)

X4wheel test, acceleration of fixed rotating masses

XCruise control test, set, hold speed, release

X

X

X

X

x-cruise

Warming up

Engine and gearbox test (without ECU communication)

General function tests

� test of gearshift and power train

� test of cruise control and/or speedometer

Speed test (speedometer test)

x-brake

XSlip rate detection and control

XoABS sensor – commutation test (with ECU communication) *

XoABS valve – commutation test (with ECU communication) *

XCruise control test, definable load levels

X„static“ brake test v-constant, driven by test stand

XABS sensor – quality test (with ECU communication) *

XDetermination of braking distance (with ECU communication)

X4wheel test, acceleration of fixed rotating masses

XCruise control test, set, hold speed, release

X

X

X

X

x-cruise

Warming up

Engine and gearbox test (without ECU communication)

General function tests

� test of gearshift and power train

� test of cruise control and/or speedometer

Speed test (speedometer test)

x-brake

Technical data x-brake:

�

�

�

�

�

�

�

Test speed: 2.5 km/h

Maximum test force: 5000 N

Measuring accuracy of speed detection: +/- 3%

Wheelbase range: 2,300 mm to 3,200 mm

Colour: according to Dürr Standard

Mechanical and electrical version (components): according to Dürr Standard

Maximum force tolerance, static: +/- 2% of final value

Tasks:

Product Information

Page 23


x-t

ron

ic

Market success :

x-tronic - Dürr technology for advancedelectronic testing

The following features - that also illustrate theirhigh performance - proved decisive in promptingcustomers to opt for Dürr products:

x-tronic offers the unique combination of astandard operating system with a specializedautomation system and the most advancedhardware available.

�

With the addition of our most recent projects inRussia and India the number of installations sincethe x-tronic instrument generation was introducedhas risen to more than 65 worldwide. Not onlyGAZ, SeverStal and TATA but also 35 other automanufacturers and Tier 1 suppliers use electronictest systems supplied by Dürr.

�

�

�

The system's multi-session capable ECUcommunication instruments carlink andvport can be used in conjunction with multi-tasking automation system x-line to createthe best possible means of carrying outparallel test processes.

With its graphically presented test processeditor x-flow and the open developmentenvironment provided by x-line x-tronicoffers customers full access and simpleparameterization and thus the ability tomaintain and update their own systems.

In addition to this, Dürr has available 100%internal know-how and experience in thecomplete process world of the automobilefinal assembly (assembly, filling, settingand mechanic testing).

At TATA Motors Ltd. the commissioning of twox-tronic stations together with a server station forcentral administration of test instruments recentlyconcluded with the successful completion of finalacceptance procedures. TATA has thus taken afirst step in the direction of a modern,comprehensive and integrated electronic testsystem. The next steps will take the form of rolltest stands with integrated electronic testing, adata management station handling all end of lineprocesses and the equipping of other lines withmobile test instruments.

This enables Dürr to offer the best possiblesolutions for integration and synchronization ofelectronic testing and end of line processes.

SeverStal Auto chose Dürr electronic testingtechnology for the Fiat Ducato that it producesunder license at its Elabuga facility. Mobilesystems for testing control units and consumersat the end of line and test stations for the pre-assembly of door and cockpit modules will beintroduced mid 2008.

As from mid 2008 the electrics and electronics onboard of the new GAZ Siber will also be tested inthe end of line with x-tronic systems.Special highlight in this application: Flashprogramming of the engine control by thecheckboard will take place in the line.

control PC

standardlaptop

remote control

PDAcarlink B

clamp

balancer

vehicle communicationinterface

ammeter

clamp

WLAN Router

checkboard evo

control PC withvehicle communication interface

Product Information

Page 24

x-t

ron

icVariant for the production

Variant for developpment, trail and quality assurance

�

�

�

�

�

�

�

�

measurement of power consumption („ECOS“)

ECU communication

steering wheel balance “balancer” for test line

wireless ECU communication on test line

measurement of power consumption (”ECOS”)

ECU communication

interface units: robust and mobilecontrol PC: standarddesktop version

use of rework,parameter set-up station,development and trial,quality assurance orsmall series production.


x-tronic , Starter Package:s

x-tronic, mobile diagnostic systems

carlink D

carlink B

vport

checkboard

Mobile test instruments x-tronic:

checkboard - universal mobile test system

carlink - mobile ECU communication device

vport - mobile ECU communication device in OBD plugformat

�

�

�

�

�

�

PC test system, usable regardless of location, withstandard Windows operating systemCheck Out System (”ECOS”) in the line and at the end oflineAll ECU tasks: diagnosis, parameter set-up, flashprogramming

Wireless ECU communication in test stands and processstations (CAN, K-Line, ...)Testing tasks with operator interaction (carlink D)

Wireless ECU communication in test stands and processstations (CAN, K-Line, ...)

Documents

Product Info End of Line Testing - durr-assembly.com Info End of Line Testing Dürr Assembly Products GmbH, Püttlingen. Product Information Welcome to our product info End of Line