Froude Hofmann is a 130-year old global company that provides testing equipment for the aerospace, automotive, industrial, and marine industries. It has locations around the world and offers a wide range of dynamometers, control systems, and integrated test systems. Froude Hofmann prides itself on technical innovation, excellent customer service, and a commitment to developing world-class products to meet customers' needs wherever they are located.
2. 1 Froude Hofmann
“Froude Hofmann is committed to developing,
delivering and supporting world-class products
to our customers wherever they may be”
A carbon-friendly company – working to a cleaner future
Contents
Our vision 2
Who we are, what we do 4
Technology and innovation 6
Customer service 8
Products 10
Quality and the Environment 16
People 22
The future 23
Photograph: compliments of Applus Idiada Spain (NVH Chassis Dynamometer)
3. 3 Froude Hofmann
richard guest 2
managing director
our vision
we have a vision
we all believe in
f
roude Hofmann is over
130 years old and has a
long history of innovation,
achievement and industry
leadership. Today, at
Froude Hofmann we are investing
heavily to ensure our innovation
keeps us at the forefront of
technology and performance.
That is our Mission. A Mission
that is ingrained into our people,
because we only employ people
with the same core beliefs…
people who believe in our Vision:
“to provide our customers, wherever
they are located in the World, with
superior products that are delivered
on-time and supported with
world-class service”
Lets look at this in a little
more detail:
Technical Innovation
Throughout our history we have
always been known for innovation
and, with the backing of our owners
Harris Watson group, we have
significantly increased our product
development programme to
ensure our rate of innovation
exceeds that of our competition.
Our dedicated R&D team is
bringing a whole series of new
developments to the market that
give significant operational and
cost benefits to our customers.
From high-speed aerospace
dynamometer applications
to robot-drivers that are fully
integrated with emissions or
durability chassis-dynamometers,
our focus is in providing our
customers with superior technical
and operational solutions.
Operational Focus
When a client places an order
with us, he is assured of a
committed and thoroughly
competent team delivering
it. Our Project Management
team are qualified to the
internationally recognised
“Prince 2” standard, and use
gated project-management
systems in order to ensure
satisfactory project control.
Our manufacturing, supply-
chain and product-test teams
work within a lean-systems
environment to ensure a quality
product is delivered on-time.
Local – yet global – Service
To deliver world-class service
to our global customer base,
we have opened four new
international service centres
over the past two years to
supplement the three we already
have. This year we will open
two more to complete our
world-wide footprint.
“Wherever our customers need us to
be, we will be…”
Our spare-parts capability is
being enhanced too, with higher
stock-levels and a new spare-parts
website to allow our clients to see
what is in-stock on a real-time
basis. Add to this our 16/5 technical
helpline, and you have a compre-
hensive service support package
that surpasses most competition.
Delivering Excellence
Independent verification of
our commitment to delivering
Excellence is found in our
winning the coveted “Investor
in Excellence” award. This title
is only awarded to companies
who are found to comply with a
rigorous excellence framework
covering all aspects of business
performance. The IiE standard
is based on the European EFQM
and US Baldridge Excellence
models.
We have this coveted
standard, of course, in addition
to our quality accreditations of
ISO9001: 2000, ISO 14001
and TickIT.
People Matter
Our success can be only as good
as the people we have in our
business. Our philosophy is to
recruit the best, and to help
them develop within our team
environment by providing
the right training, continuous-
improvement and human-
resource culture.
Our Customers
Our customers of today are our
customers of tomorrow – we
never forget that for an instant.
From major new projects
through to spare-parts and
refurbishments, we ensure our
customers are fully satisfied
with our performance and
products. That is why we have
excellent references with major
customer groups such as
GE, Pratt & Whitney, Ford,
Volkswagen, General Motors,
Hyundai, Fiat and Renault.
Why Froude Hofmann?
We are dedicated to supplying
a comprehensive and specialist
range of top quality technologically
advanced solutions. Our team
is committed to providing
customer service that is second
to none, which is why the Froude
Hofmann name is the only one
that matters in the vehicle and
aerospace industries.
We stay by our customers
through any operational
challenges that may arise.
Your success is our success.
“Froude Hofmann over
the past 5 years, have
offered Mahle a very
fine product, at good
value, whilst providing
great support”
Ralph Kaczmarek,
MAHLE (NORTH AMERICA)
“From major new projects through
to spare-parts and refurbishments,
we ensure our customers are
fully satisfied with our performance
and products”
4. 5 Froude Hofmann
who we are, what we do 4
where we are
hull designs he established the
“Froude Number” – which is the
hydrodynamic equivalent of the
Mach number. This is still used
in ship design and many other
forms of flow characterisation
today. During this period he
invented the hydraulic
dynamometer (1877) for testing
ship engines and founded the
company Heenan & Froude
(1881). This company moved to
Worcester from Manchester and
extended its product range to
include equipment to test engines
for ships, cars and aircraft.
In parallel, Hofmann
Prueftechnik evolved from the
Kleinsorge Company which
who we are
F
roude Hofmann is a well
established international
high-technology company
dedicated to engineering
excellence in the supply of
testing equipment.
The company has been
trading for over 130 years and
takes its name from the
renowned English Engineer;
William Froude (1810 – 1879).
William Froude was educated
at Oriel College, Oxford (1828)
before working with Isambard
Kingdom Brunel (1837) on the
Great Western Railway and
subsequently turning his attention
to naval engineering. From his
extensive research with ship
W
ith this impressive
heritage, Froude
Hofmann today
provides a complete
product portfolio in R&D and
production environments in
these markets:
Aerospace>>
Automotive R&D>>
Automotive Production>>
Industrial Turbine>>
Motorsport>>
Marine>>
Over many years we have
developed an excellent range of
products within these markets.
From standard dynamometers
and control systems; through to
fully integrated automated test
systems, containerised test
facilities and turnkey solutions.
Aerospace & Industrial Turbine
Test Products
Froude Hofmann’s turbine test
systems use our unique hydraulic
dynamometers and Texcel VX100
control system to provide high
system response and load stability.
Performance covers speeds up to
30,000 RPM and power absorption
up to 30 MW. Scope of supply also
includes engine mounting test
stands, cradles/trolleys and inertia
flywheels to these segments:
R&D>>
Performance>>
Endurance>>
Quality validation>>
was formed in the late 1940’s
by Herr Kleinsorge, an
entrepreneurial engineer
previously engaged in design
and development at the Junkers
company, who acquired the
rights to manufacture the
“Junkers” smooth disc hydraulic
dynamometer. Additionally
Hofmann developed a range of
rolling road test rigs. In 1996
the two companies came together
to form Froude Hofmann –
maintaining the on-going
product portfolio expansion
strategy and bringing R&D
applications and production
test skills together in one
great organisation.
Our products are used on the
following customer systems:
Aerospace turboshaft/turboprop>>
Industrial turboshaft>>
Turbine development systems>>
Automotive Engine and
Transmission Test systems
Froude Hofmann offers a
comprehensive range of engine
dynamometers and associated
control systems which provides
accurate, reliable testing of
engines in all applications.
AC Dynamometers>> – road load
simulation capability with fast
response for full transient/high
dynamic engine testing
AG>> (Eddy Current) dynamometers
– high accuracy, robust power
absorption capability for
development, endurance and
production testing of engines.
Hydraulic>> (F-Type range) –
provides accurate high capacity
power absorption capability for
automotive petrol/diesel engines.
Texcel>> family of control systems
which offer control capabilities –
ranging from the simple Texcel V4
manual controller to the Texcel V12
providing full automation road- load
and inertia simulation control with
integrated data acquisition, to
complement the dynamometers.
A range of engine instrumentation>>
including fuel flow meters, fuel
conditioning systems and
combustion analysers
We also offer engine ancillary>>
equipment such as water and oil
coolers, made to order.
Our control systems include the
advanced Genysis software
platform, a system with superior
graphical user interface and high
dynamic test capability.
what we do
An additional application also
includes a “vDriver™”
simulation package, allowing
our clients to simulate real-world
driving conditions, driver
profiles and real-road routes in
their test cells.
Automotive Vehicle Test
In this market we offer Chassis
Dynamometers Systems, Robot
Drivers and special applications
including our “vDriver™”
simulation package. We provide
fully integrated, automated test
systems including; robot driver,
auto fuel filling, airspeed
simulation fans and data
acquisition. Our full portfolio of
standard and specialised chassis
dynamometer systems are
available for use in all vehicle
test applications including:
Emission and fuel economy testing>>
to international regulations
Power-train development>>
Performance reliability testing>>
Climatic (–40ºC to +60ºC)>>
Wind-tunnel and environmental>>
(inc. altitude) testing
Special “low-noise” designs for N.V.H.>>
testing in Semi-Anechoic Chambers
Light vehicle and Truck applications>>
Tractor and industrial vehicle>>
Automatic Robot driver systems
Our advanced robot driver
adds extensive flexibility and test
capability to the chassis dyna-
mometer test facility, providing
full control of all the vehicle’s
functions. The system will drive
the vehicle, under simulated road
conditions, to defined legislative
cycles, customer specific
schedules or utilise vDriver™
route recordings. The advanced
technology and control
techniques meet the high
reliability demands of endurance
testing with precision control for
exhaust emission, production
and performance testing.
production tests
Our End-of-Line test systems
offer solutions for cars, trucks,
agricultural vehicles and
motorcycles. We provide test
systems for quality, driveability,
function and also safety critical
systems for passenger cars
including parking sensors,
lane-control and collision
avoidance radar. Products
offered are:
Roll Test Stands (RTS) – testing>>
of all functions, performance,
brake testing and electronic driver
assistance systems (ABS, ESP,
EDS, MSR/ASR)
Wheel Alignment Measurement>>
(WAM) – utilising laser
measurement technology
Shake Roll Test Stands (SRTS) –>>
provides the ability to induce
vibrations and chassis twist into
the vehicle. Each roll is fitted with
variable pad heights to simulate
different amplitudes and effects
Test booth and integrated services.>>
Industrial and Marine Diesel
Engine Test
Since the Hydraulic dynamometer
was invented back in 1877, Froude
and more latterly Froude Hofmann
have been providing state of the
art machines suitable for testing
some of the largest Diesel engines
in the world. Many of today’s
High power, Low speed heavy
fuel engines used in Marine
propulsion systems have been
developed and refined against
Froude Hofmann equipment.
These LS machines along with the
smaller F type dynamometers
provide a complete range of
machines from 800kW to 60MW.
The dimensionless Froude
number is defined as:
Fr = V
c
where we are
UK – Worcester
Head Office,
8,000 sq m
Manufacturing,
sales, service
and support
USA – Detroit
1,000 sq m
Manufacturing,
sales, service
Brazil – Sao Paulo
600 sq m
Sales, service
and support
Spain
– Barcelona
Sales, service
and support
India
– Pune
Sales, service
and support
Australia –
Melbourne
Sales, service
and support
France – Paris
Sales, service
and support
Germany – Elze
5,000 sq m
Manufacturing,
sales, service
and support
China – Shanghai
Sales, service
and support
Czech Republic
– Brno
Sales, service
and support
Russia
– Moscow
Sales, service
and support
South Korea –
Seoul
Sales, service
and support
South Africa –
Durban
Sales, service
and support
ENGINE TEST PRODUCTS
VEHICLE TEST PRODUCTS
end-of-line TEST PRODUCTS
1877 1881 1903 1982 1995 1996 1997 2002 2005 2007 2009
William Froude Heenan Heenan Consine New facility Hofmann Brush ATS Go-Power Renamed Harris Watson Expansion
invents the & Froude & Froude Dynamics Blackpole, acquisition acquisition acquisition Froude acquires of global
hydraulic established relocate to join Froude Worcester Hofmann Froude Sales and
dynamometer Manchester Worcester Engineering Hofmann Service
5. technology and innovation 6
7 Froude Hofmann
evolution, revolution,
development, evolution
“our embedded policy of continual
improvement and development ensure
the products for the future test
requirements are produced effectively
and on time”
t
oday’s stringent testing
requirements for engines,
powertrain and full
vehicles produce ever-
increasing demands on
development, certification and for
quality engineers. We understand
the customer’s needs and utilise
this cross-functional knowledge
to provide innovative test
solutions. These solutions enable
testing to be performed
accurately and reliably, from the
early stage of an engine’s
development cycle, through to
full vehicle testing and finally
the production validation and
quality assessment. Focused
market research activities along
with a structured development
process ensure that the required
innovations are brought quickly
and effectively to our customers.
Gareth Deakin, (pictured)
Business Development Director
comments that these
developments are defined by
product focus reviews with
customers and key figures
within the automotive test
market, resulting in strategic
development objectives for our
products and ensuring we react
to the market demands. To bring
these ideas to the market quickly
and effectively, we have
dramatically increased our
development investment and
we are extending research
relationships with several
universities to utilise their
immense skills in simulation
and computational techniques.
Applications
With the industry constantly
changing, solutions are being
sourced for vital contemporary
market needs such as low
emissions and fuel economy on
a global level. An excellent
example of this foresight is the
evolution of the company’s fully
integrated chassis dynamometer
and ‘Robot Driver’ for automated
testing. The robot driver has
been a huge success in
powertrain and endurance
applications worldwide. Recent
developments provide lighter
components and materials,
easier, quicker installation with
reduced cabling and enhanced
automatic set-up in the vehicle.
These features ensure the robot
driver is an effective solution in
the emission calibration and
development environments
providing high repeatability and
accuracy of drive cycle control.
Complimentary to this is the
software application that
provides ‘Real-Driver Profiling’
and a route recording/playback
system that provides powerful
‘Real-World’ simulation
capability. With the combined
control system philosophy across
our products; this functionality
also benefits our Engine and
powertrain test systems.
Other products have seen
similar benefits with a new
distributed I/O control hardware
platform; providing full test
capability before despatch and
rapid installation and
commissioning. An advanced
graphical user interface is
provided on all our systems;
modularity is designed into our
chassis dynamometers and
engine test stands for greater
flexibility and new dynos have
been developed and added.
The future
We can be sure that the pressure
on automotive powertrains and
energy sources will continue to
increase with the related need to
develop more innovative
solutions in ever shorter
timescales. Emerging
technologies will become more
prevalent with the need to test
the systems accurately and
realistically to prove their
effectiveness and to decide on
the most efficient control
strategies such as the evolving
hybrid powertrain
configurations including HEV,
PHEV, Dual mode and full
electric vehicles.
New fuel sources such as
C.N.G., Bio diesel, E85 and flex
fuel are provided for, with
enhanced fuel delivery systems
that will re-fuel test vehicles
under automated control to
ensure uninterrupted testing.
Engine and vehicle testing
accuracies are continually
improving and will interface
more extensively with simulation
programmes for “hardware-in-
the-loop” developments.
The scope is only limited by
imagination in creating real
situations under controlled
laboratory test conditions.
To remain successful,
companies in the future must be
agile and proactive to market
demands, focused on the
customer’s real challenges and
thereby establishing future
solutions. They must be able to
provide effective local, and global
support, so that the customer
can achieve their need for
reliable and effective testing.
Whatever the challenges and
obstacles we all face, you can be
sure that we are equipped and
ready to support the demands
upon our industry in the future.
IT is the Future
According to Steve Sharpe, Group
Technical Director, the future lies
in software development, both
domestically and globally.
With a responsibility for the
company’s electronic and software
products range, Steve is in charge
of research and development,
and with an impressive back-
ground in engineering (including
a degree in engineering from
Balliol College, Oxford and
recipient of the Queen’s Award
for Innovation), he has a vision
for the future that involves
moving with market forces and
supplying solutions to ever-
evolving demands.
“Fuel economy and emissions
are the key issues in all
industries at the moment,” he
comments. “This is good news
for Froude Hofmann and the
“Fuel economy and emmisions are the key issues in all
industries at the moment, this is good news for Froude
Hofmann and the way forward is to capitalise upon the
software capabilities that we already have and that we
are constantly working upon”
way forward is to capitalize upon
the software capabilities that we
already have and that we are
constantly working upon. If we
look at our newly introduced
‘Robot Driver’, it comprises the
most up-to-date and
sophisticated software yet
developed and it is my job to
ensure that this consistency of
software evolution is up to the
increasing functional
requirements of our product
range.
“Our global expansion has
opened up a huge market –
effectively, we are developing the
same products for all marketplaces
and the Far East in particular is
demanding state-of-the-art
equipment. Our task is to
provide this and we are already
working to provide unique
design solutions.”
Gareth Deakin setting up the Robot Driver
IT IS THE FUTURE
6. 9 Froude Hofmann
customer service 8
Hybrid, Fuel Cell and Electric
propulsion
One of the key industry drivers
that is increasing exponentially is
the investment in “green” vehicle
technologies. This sees the next
stage of sophistication with regard
to hybrid powertrain solutions
requiring a more effective
integration of the powertrain
with all the vehicle’s subsystems:
ABS, traction and stability>>
control systems
Kinetic energy recovery>>
Stop/start strategies>>
Battery storage systems>>
Froude Hofmann are actively
supplying advanced 4x4 “all
independent” chassis dynamo-
meters for Hybrid and fuel cell
vehicle development. The unique
roll synchronisation control
capability of these chassis
dynamometers enables various
powertrain configurations to be
tested in accurately simulated
road and operational conditions.
Normally, with these powertrain
configurations, we have to test
“All-Wheel Drive” vehicles. The
demands placed on the chassis
dynamometer in this case are to
ensure that the synchronisation
of speed and the dynamic
adjustment of forces from front
to rear and left to right are
precise and highly responsive,
particularly important when
accelerating and braking. Under
these circumstances, the forces
have to be altered dynamically
between front and rear axles to
maintain the speed synchroni-
sation to simulate “through the
road” connection.
When this is achieved the
energy flow management system
of the vehicle will be able to
function correctly, and the test
will be representative. It is
important that the correct load
and the synchronisation is
maintained to ensure that the
correct powertrain regeneration is
observed especially as the testing
will predict key parameters such
as vehicle economy and distance
travelled etc. To obtain this level
of accuracy Froude Hofmann
have developed extremely
sophisticated control algorithms
and optimised the design of the
mechanical and electronic
sub-systems of the chassis
dynamometer to provide an
advanced system for this
demanding test application.
Hybrid Powertrain
Development of the various
configurations of Hybrid
powertrain continues to require
extensive testing to establish the
optimum configuration and
integration within the vehicle
systems. Froude Hofmann’s
individual/combined test bed
concept provides great flexibility
for testing and simulating
various configurations
Each prime mover in the
system (Electric motor and Diesel
internal combustion engine) can
be tested individually on their
respective AC dynamometer or
the two systems can be synchro-
nised together by the software
control system providing full
simulated road conditions. This
provides a unique test environ-
ment where the components can
be physically present or simulated
using software techniques
providing a full HIL system
These simulations include;
various hybrid strategy
evaluations, energy storage
simulation, battery cycler,
vehicle dynamics with various
driving styles applied.
Electric motor systems
for vehicles
The solutions for the full electric
motor vehicles require specific
test beds dedicated to high speed
synchronous AC or Permanent
Magnet motors and battery
storage devices. Our fully
integrated solutions provide the
dedicated invertor drive system,
angular rotor position
measurement, cooling systems,
instrumentation for current
sensing and battery simulation
to fully evaluate the device under
test. The battery simulator
incorporates seamlessly with our
control systems and invertor
drive systems and provides a
fully automated control and data
acquisition system.
Rocking the Real-World
Complimentary to all these test
technologies and the powertrain
solutions is the need to perform
“Real-World Simulation” testing
to ensure the product will
perform as expected and meet
all the objectives set. This is
particularly important where the
complex strategies of the latest
powertrain systems have to
accommodate varying and
interactive circumstances and
still perform and control
effectively.
Our solution is vDriver™
which can simulate the
variability associated with
particular driving styles and
routes. The system operates as a
distance based test sequencer
and enables users to reproduce
specific routes and driving styles
on their chassis, transient
engine and powertrain
dynamometers. Users can either
record routes, or select global
pre-recorded routes provided
with the vDriver™ package.
vDriver™ can then reproduces
realistic traffic and road-event
conditions in the test cell,
allowing the user to simulate
real operating conditions within
the development cycle quickly
and repeatedly. Each route
incorporates details of the road
type, speed limits, traffic lights,
stop signs and other road based
events that influence driving
styles.
These products are at the
cutting edge of testing demands
and relevant to the ongoing
developments within our
industry. Whatever these
challenges and obstacles we all
face, you can be sure that we are
equipped and ready to support
the demands upon our industry
in the future.
rocking –
the real world
“We believe that this product is one of the most
radical and cost-effective tools that manufacturers
can employ in their pursuit of product satisfaction.”
7. 11 Froude Hofmann
customer service 10
local yet global –
in customer services
t
erry Salter is Head of
Customer Services and his
team is unusual to say
the least. With many
years of service with Froude
Hofmann, the office-based team
employs energy, initiative,
reaction and on many occasions,
a certain amount of volatility.
Terry has been with the
company for over forty years,
working in every department
within the company except
finance – quite an amazing feat,
although the record for longevity
goes to another member of his
team, Alan Rowberry who has
managed to clock up an amazing
half century of service with the
company as man and boy.
Terry’s background as a marine
engineer has stood him in good
stead over the years, as it taught
him to work as a team, part of
a strategy that he employs as
key to his department’s success.
“Whilst working on the ships,
we had to make do with the
resources that we had available
and consequently, I learnt very
quickly that the key to success
was to how to fix things as a
team,” he comments. “And that
is precisely what we do here.
I have a fantastic team behind
me – proactive, off-the-wall
and enthusiastic and together,
we deliver real solutions.”
What Terry loves about his
job is the variety – one day
he can be dealing with small
high-speed Formula One
engines and the next, monster
marine engines. His team
deliberately comprises of people
who can contribute positively
to expanding the Froude
Hofmann network on a global
level by drawing on their own
experiences. “We set up service
infrastructures around the world
by finding a common approach,
and we strive for perfection,”
he says. And this team offers
a diverse approach. Del, sales
engineer, used to maintain
military aero engines in conflict
regions, ensuring that they
were kept in top condition for
frontline service. Dodging
enemy fire was just part of the
challenge, but it taught him
to go into tasks looking at every
eventuality. “We went into
situations that utilised all of the
resources that we had available
to us,” he comments. “And
I have learnt to apply this
philosophy to my job at Froude
Hofmann, where we are dealing
with a diverse and very
individual clientele.”
“We all have a unique
contribution to the team,”
continues Terry. “Our site
services manager, has a
background in transport: he had
the daily and unenviable job of
co-ordinating 100 British Rail
trains to run on time and on track.
His current job holds no fears or
surprises to him.”
E
x-naval engineer, Ian
is one of our technical
support engineers, he
previously worked on
UN projects installing
water pipelines and pumping
stations in the Sudan.
“We deliberately hire people
with a diverse background to
ensure we have a pool of
experienced talent,” continues
Terry. “And that’s what makes us
good. We don’t always look for
industry experience, we look for
skills and character traits that
may have applied in a completely
different way in other situations.
We don’t try to style our
operations on our industry, we
seek role models from other
industries whose methods and
performance excel.
As an example, to speed up
our machine repair turnaround,
we used the garage system as a
basis of our DYNOHAUL ‘fixed
price for fixed scope service.’”
The whole department is
greater than the sum of its parts,
and delivers consistently
excellent support to our customer
base whether global or local.
“In the time that we have
been working with Froude
Hofmann, the company
has consistently offered
the highest levels of
professionalism and
reliability. We are currently
jointly working on two
projects, and from the
beginning, Froude
Hofmann has met all of
the stringent technical and
commercial requirements
to which we work,
particularly within its
commercial area.”
antonio squillaro
(fiat group purchasing s.r.l. a s.u.)
europe region capital equipment &
indirect material
“We set up service infrastructures around the world by
finding a common approach, and we strive for perfection”
8. 13 Froude Hofmann
products 12
products:
turbine (aero)
With 60 years of experience in the Aerospace and Gas Turbine industry, Froude Hofmann
is the world’s leading supplier offering the most comprehensive range of dynamometers,
control systems and test stands for testing aerospace and industrial gas turbines.
Hydraulic dynamometers are
supplied for low and high speed
applications, they all use the
Froude design of vaned internal
power absorption elements which
together with the use of high
response servo controlled inlet
and outlet valves provide a stable
and high transient load change
capability.
Products
The ‘F’ range of dynamometer is
supplied for testing small to heavy
turboprop engines and indirect drive
turboshaft engines, up to 30 MW
in power. The ‘HS’ dynamometers
provide the solution for testing
T
his wealth of experience
enables us to provide
our customers with
dynamometers and
dynamometer control
systems tailor made for
the application of testing gas turbine
prime movers. The Texcel VX100
digital dynamometer control system
provides the user with the very latest
in controls technology, providing
the highest levels of accuracy in
measurement and control. They come
equipped with a comprehensive
health monitoring and safety systems
to ensure that the engine on test is
always protected.
direct drive turboshaft engines and
are capable of operating at speeds
of 30,000 RPM and up to 30 MW
in power.
To compliment the dynamometers
we also provide a range of high
and low speed flywheels when there
is a need to test the engine with
the same level of inertia as it would
experience when connected to the
airframe transmission.
To complete the in-cell equipment
offered we also provide complete
engine test stands and for smaller
engine applications mobile test
stands, integrating the dynamometer,
flywheel and engine mounting
system. Additional flexibility in test
cell use can be provide by using
pre-aligned interchangeable engine
cradles (adaptor frames) for same
engine or different engine types this
allowing out of test cell pre-rigging
reducing engine turn around time.
Customers
Our worldwide customer references
include: Avio SpA, GE, Mtu aero
engines GmbH, NPO Saturn,
Pratt & Whitney Canada, Rolls-Royce,
Turbomeca.
F84D dynamometer and flywheel
9. 15 Froude Hofmann
products 14
Froude Hofmann supply state-of-the-art, highly accurate and
extremely reliable Chassis Dynamometers to the automotive
and commercial vehicle markets. The range of vehicles that
can be tested included motor cycles passenger cars, light to
heavy duty trucks, buses and agricultural vehicles.
P
roducing Powertrain test
facilities requires the
combination of our
expertise and experience
in engine and chassis dynamometer
design and control, incorporating the
advanced techniques developed for
our own state-of-the-art robot driver
systems we are able to provide the
F
roude Hofmann’s “48”
Chassis Dynamometer
range has been designed
on a modular basis
configurable for 4x2,
4x4 and 4x4 independent
configurations. These are compliant
to worldwide Emission and fuel
economy standards and are fully
U.S.E.P.A. compliant. The configurable
design and distributed I/O control
hardware provides many benefits
including; full system testing before
despatch and greatly reduced
installation and commissioning
times. Many automated sub-systems
are provided to assist test set-up
and safe operation including
integrated centralising systems,
auto-roll guards and automated
floor covers.
Special, advanced design solutions
are available for a variety of
applications that demand attention
to detail and refinement of the
chassis dynamometer due to the
unique demands of the application:
Fully integrated, automated>>
endurance testing with our
robot driver
Powertrain testing including>>
Hybrid vehicles
Environmental and climatic>>
windtunnels – extreme temperature
testing and altitude simulation
Noise, Vibration and Harshness –>>
performed in a Semi Anechoic
chamber; the Froude Hofmann
chassis dynamometer has unique
design solutions for noise
attenuation and containment to
provide extremely low noise
operation.
Products
48” Roll diameter chassis>>
dynamometers
Endurance/Automated test>>
facilities (MACD)
Large roll chassis dynamometers>>
for special applications:
Climatic, NVH
Motorcycles to Passenger cars>>
to Trucks
Automation systems>>
very best solutions for your
Powertrain and transmission testing
requirements.
Experience drawn from our record
of providing first-class Chassis and
Engine Dynamometers allow us to
provide the hardware and software
that leads the way in Transmission
and Powertrain testing.
Control systems include full road
load simulation as well as advanced
features such as full journey replay
and simulation for rapid development
of Powertrain systems and
components.
Systems can be provided to
accommodate both 2 and 4 wheel
drive systems as well as additional
replacement of prime movers for
transmission only tests.
Whether the requirement is for
long term durability, emissions,
NVH or drivability testing the
Froude Hofmann systems provide
the right solution.
products:
vehicle
Automated Robot Driver
Froude Hofmann’s Automatic robot
Driver System provides the unique
ability to supply a fully integrated
automated test facility for any of the
test applications. The robot is designed
for rapid installation and with a fully
automated learn utility the robot driver
is quickly ready for testing in the
vehicle. Together with high accuracy
of drive cycle control and high
repeatability, the robot is ideally suited
for many test demands including;
emission calibration and development,
extended automated testing, climatic
and special chamber testing.
With the latest developments
providing “real driver” simulation and
route replay capability the system
brings many more advanced benefits
to our customers.
Customers
Our worldwide customer references
include all key OEM’s, Tier 1 suppliers,
research centres including: Renault,
Ford, GM, Hyundai, Honda, Jaguar,
Kia, VW, Idiada.
products:
powertrain
Main picture: 4x4 48˝ independent
chassis dynamometer
10. 17 Froude Hofmann
products 16
products:
end-of-line
As a worldwide expert in the design and supply of
End-of-Line test equipment for the automotive industry,
Froude Hofmann offers a wide range of Roll Test Stands
(RTS), Shake Roll Test Stands (S-RTS), Wheel Alignment
Machines (WAM) with Headlight Aiming Tester (HAT)
and if required also a Universal Test System (UTS).
until recently the Wheel
Alignment Machine was
designed specifically
for the adjustment of
toe and camber angles and the Roll
Test Stand was designed for vehicle
functionality and brake tests.
Now, these are combined into a
single test stand which also includes
a significant number of additional
functions for new features being
added to modern vehicles. Most
modern vehicles are equipped with
a large number of electric
components, in order to recognize
and correct potential errors at an
early stage, the vehicle and those
safety critical components are tested
following the final assembly.
Advances in the design and
performance of the Froude Hofmann
test machines have led to increased
flexibility, with the replacement of
many mechanical functions by
electric or electronic solutions.
Our Products are applied
to the following markets:
Roll Test Stand>>
Wheel Alignment Machine>>
Headlamp Aiming Tester>>
Universal Test System>>
Shake Roll Test Stand>>
Specialist Testing including:
ABS, EDS, ESP, FAS, ACC,>>
ASR or AWD etc.
EOBD>>
ECOS>>
Driveline Balance System>>
Brake Inertia Testing>>
ROLL TEST STAND
Froude Hofmann’s computer
controlled vehicle test systems can
be arranged to provide a total test
package at the end of the production
line or to meet the need for a
stand-alone test station for example;
development, quality audit or post
rectification tests.
Test stands are available for
passenger and commercial vehicles,
motorcycles (including quads) as
well as agricultural machinery and
can be configured for different
kinds of tests, typically: Shake,
Functional, Brake, ABS, EDS, ESP,
ASR or AWD. All of this is available
on a single machine.
WHEEL ALIGNMENT MACHINE
Froude Hofmann offer different
configurations of Wheel Alignment
Machines. These machines measure
toe, camber, and caster angles
of all four vehicle wheels and they
then provide data for the optimum
adjustment of the wheel angles.
Rear-view cameras and ACC Systems
fitted to the vehicle can also be
calibrated and certified as part of the
Wheel Alignment Machine.
Modular machines are available
with two different types of measuring
heads: either contacting rollers on
the tyre sidewall or non-contacting
lasers which view the tyre sidewall as
required. The laser systems are
available in 2 or 3 sets per wheel
configuration.
All Machines have wheel drive
rollers with a floating feature to ease
the wheel adjustment process.
UNIVERSAL TEST SYSTEM
As a unified automation and
measuring system the Universal Test
System (UTS) can control Roll Test
Stands, Wheel Alignment Machines
and Headlight Aiming Testers. This
covers the whole range of test
applications in the End-of-Line area
up to complex tasks like ABS or
motor management testing. Normally
the test device will be connected via
the central diagnosis interface in the
vehicle. The UTS provides programming
Froude Hofmann GmbH at Elze, Germany is the
design centre for our range of End-of-Line products.
The products are manufactured in Germany and
the UK, as required.
and diagnosis of vehicle control
units (EOBD) and test of electronic
components (ECOS) by measuring
and evaluating the voltage profile
and current profile of electrical
components.
EOL ACCESSORIES
As a supplier of turnkey solutions,
Froude Hofmann will supply the main
test stands, booths for noise protection,
ventilation systems for exhaust
extraction and fresh/conditioned
air supply In order to provide an
acceptable working environment.
Vehicles equipped with an
Adaptive Distance Radar (ADR) to
give the driver the maximum safety
in heavy traffic situations require
an exact orientation position of the
vehicle on the test stand to allow
adjustment. Froude Hofmann can
supply a high-precision centering
system as a single stand solution.
For simpler test requirements
and low production a single axle
Brake Tester can be provided. Simple
functionality and brake tests including
ABS tests with communication to
the vehicle’s ECU can be carried out.
For the quick examination of the
chassis alignment, a Side Slip Tester
can also be provided.
TRANSMISSION SOLUTIONS &
COMPONENT TESTS
DRIVELINE BALANCE
Based on an increase in demand
for drive comfort, Froude Hofmann
developed the Drive Line Balance
(DLB) System which will balance
the drive shaft of a completely
assembled vehicle on a Roll Test
Stand or on a dedicated test rig.
The imbalance is measured by a
non-contact measurement system
and the automatic balancing unit
removes or applies material as
required resulting in the ultimate
in balanced drive systems.
BRAKE INERTIA DYNAMOMETER
To fulfill the demand for more
comfort and efficiency, environmental
simulation, noise and vibration are
some of the most important factors
in the recent brake development.
To meet the requirements of our
customers, Froude Hofmann
supply a wide range of Brake Inertia
Dynamometers for testing the
components of passenger cars,
light and heavy commercial
vehicles, and railway and aircraft
applications.
Customers
We have extensive references
with many of the major OEMs
including Volkswagen, Skoda, Seat,
Daimler, Ford, Scania, CNH, Iveco,
Triumph, Avtotor, Avtovaz, Frendo
and Lucas.
11. 19 Froude Hofmann
products 18
products: marine
The LS-2 range has cast main
carcase sections, incorporating the
power absorption stator elements
directly into these casings provides
simplified construction and improved
reliability over the original stator
inserts.
The bedplate is a robust
fabrication designed to be clamped
at any position on its perimeter and
to protect all pipework and electrical
fittings/cabling from normal shipyard
rigours. Independently controlled
jacking systems provide a simple and
easy method of alignment.
Control of the power absorbed by
the dynamometer is by the unique
fast response characterised outlet
valve mounted directly on the casing.
This configuration provides a faster
response to load change demands
typically required for marine
propulsion system development. For
reversible dynamometers, logic
within the control system can
pre-charge the non-working
many of today’s
high-power,
low-speed heavy fuel
engines used in Marine propulsion
systems have been developed and
refined against our equipment. In
1979 with the market developing
more sophisticated drive systems
including Turbine and Nuclear fuelled
prime movers, Froude Hofmann
replaced the ever popular FA
machine and launched the innovative
LS range. These new machines
provided improved low speed control
and a number of additional features
specific for development of this new
breed of marine propulsion systems.
The Industrial and Marine Diesel
industry is well served by the FB and
LS ranges of dynamometers. The
smaller FB machines are available in
either unidirectional (AFB) or
bidirectional (BFB) versions whilst
the larger LS range comprises
machines available in unidirectional
(LS), direct reversible versions (RLS)
and double capacity (DLS) versions
covering a duty range in excess of
100,000kW
LS Dynamometers have continued
to be a key part of this ever
developing area of the marine market
and many of the original machines
are still providing reliable service to
Research and Development facilities
world wide. As part of the continuous
improvement program of this key
area of business, Froude Hofmann
continue to invest in the further
development of these machines and
control systems, this has resulted the
LS-2 range of Hydraulic
Dynamometers released this year.
All torque-transmitting
components are assembled using the
oil injection technique, eliminating
stress raising keys, keyways and
associated operating problems. This
technique also assures that
subsequent removal of components,
even after many years of service, is
simple, quick and non-destructive.
D
ynamometers, control
systems and ancillary
equipment are
available to test a
wide range of engines
from the latest automotive Hybrid
power units to large industrial and
marine diesel engines. Applications
range from Hot Test Production,
End-of-Line Quality Assurance
through to full Research &
Development.
DYNAMOMETERS
The dynamometer range includes:
AC transient machines rated up to>>
1.2 MW providing the most flexible
solution for advanced R&D or
power saving durability testing.
Eddy current dynamometers rated>>
up to 750kW for cost effective
testing of automotive or industrial
engines.
Hydraulic dynamometers rated up>>
to 50 MW for medium to large
industrial and marine diesel engines.
CONTROL SYSTEMS
Genysis software running on the latest
generation Texcel V12 CAN networked
control and data acquisition hardware
platform results in a highly flexible,
advanced test solution which meets
the most discerning customer
requirements. For systems not
requiring the sophistication of the V12
package there is the Texcel VX4 for
simple manual control of
products:
engine
With over hundred years of experience, Froude Hofmann is
providing innovative solutions for testing the next generation
of quieter, cleaner and more fuel-efficient engines.
dynamometer and throttle actuators.
ANCILLARIES
When combined with the Froude
Hofmann range of ancillary
equipment, such as engine oil and
water cooling modules, engine
stands, fuel meters etc; a total test
solution can be provided.
From the planning and specifying
of the engine test facility to the
installation, commissioning and
training, we provide the total solution.
THE TEAM
Our team of experienced multi-
disciplined engineers form the core
skill base on which our business is
built. From mechanical and electrical
design of dynamometers to the
development of sophisticated
software systems for control and
data acquisition, we can meet your
requirements.
THE AIM
Cost competitive>>
On-time delivery>>
Total customer support>>
High-quality reliable products>>
Customer satisfaction.>>
Customers
We have extensive references with
many of the major OEMs including:
Tier 1 suppliers, research institutes
and test centres, Bosal, Ford,
Bentley, ProCat Testing, Dongfeng,
Honeywell, Mahle.
Since the Hydraulic dynamometer was invented back in 1877, Froude Hofmann
have been providing state of the art machines suitable for testing some of the
largest Diesel engines in the world.
compartment to allow smooth
transition from ahead, through zero
load, to astern for direct reversing
tests. For absolute control through
zero the LS dynamometer may be
fitted with an optional friction brake,
controlled by the dynamometer
control system. This servo control
system makes the machine inherently
suitable for automation and permits
constant speed, constant torque as
well as the conventional ‘power law’
modes of control.
For major maintenance the rotors
can be supported by means of jacks
in the bottom half casing, enabling
the coupling, bearing and water seals
to be removed from the end of the
machine and re-fitted without
dismantling the casing. This can be
carried out rapidly due to the use of
oil injection techniques considerably
reducing downtime and maintenance
costs.
Comparison of the Froude LS
dynamometers with any other
conventional type of hydraulic
dynamometer of a similar duty will
clearly show why Froude are world
leaders in the production and design
of large dynamometers for testing
piston, turbine and electric prime
movers.
12. 21 Froude Hofmann
quality and 20
the environment
between teams and working
closer together, blurring the
boundaries between these, has
given us greater fluidity enabling
us as a company to react to
any diversity quicker and more
effectively. With the nature
of this business where much
of the products are tailored to
the customers requirement,
every time we build a machine
its almost like building it for
the first time and this always
presents challenges that need
to be dealt with, ensuring that
we deal with the problems as
quickly and effectively as
possible, whilst maintaining
the highest quality standards.
How We Work
“We develop our products and
operations in a systematic way.
Our product development feeds
from thorough research into our
customers’ future requirements.
Our product managers regularly
meet customers to discuss their
current needs, future needs and
any improvements they would
like in our products or services.
This allows us to move in the
direction that is required and
not waste time and resource on
projects that don’t give value to
our customers. Additionally we
aim to improve our operations
through continuous
improvement groups, and lean
events such as 5S and kaizen
activities. This allows individual
areas to own their processes and
change these rapidly if better
methods are identified or
become available”.
quality is not an act,
it’s a habit
right first time,
on time, every
time. This is the
ethos that Matt
is working to
as Continuous
Improvement
Manager at Froude Hofmann.
““My job is a dual role that
encompasses Continuous
Improvement and Quality which
are intrinsically linked, on the
Continuous Improvement side
it’s about improving every aspect
of the company. This is not
only the processes that make
up our day to day work but also
improving the products and
services. Our quality philosophy
goes all the way from the quality
of our ideas through to the
service provided to a customer
after they have had a machine
running for 15 years”.
After spending nearly 10
years in a blue chip automotive
manufacturer Matt understands
what is required to optimise
and maintain a World Class
manufacturing business and
says that the biggest changes to
be made are in the people and
the culture. “People are what
make your company work well,
and teamwork between these
people ultimately defines how
well you work as a company.
On the rugby field if I didn’t
know what my team mates
were doing and thinking then
I couldn’t move and change
my position to best support
them, and this is what we have
succeeded to bring in at Froude
Hofmann. Better communication
Accreditations
Along with ensuring that the
company complies with the
quality management systems
of ISO9001:2000, Tickit
(Software Quality Assurance)
and ISO14001, part of the role is
also ensuring that the company
complies with the Investors in
Excellence standard, “Based
around the EFQM framework
(European Foundation for
Quality Model). This ensures
that we are achieving
consistently good results for all
stakeholders with a customer
based approach. The EFQM
model ensures that we cover
all the bases of good business
practice and don’t lose sight
of the ultimate aim of excellent
customer satisfaction whilst
achieving sound financial
results”.
F
roude Hofmann is truly
proud of its established
environmental record
with no incidents
reported and a clean slate from
all relevant auditing bodies.
The job of consolidating health,
safety and environmental issues
is constantly changing, but also
constantly challenging. We
maintain a preventative outlook
whilst working to clearly defined
KPIs, ensuring that every
member of the team is kept
informed of the standards that
we have to work to. We are able
to boast a unique and exemplary
record of environmental
responsibility and continual
improvement, in all aspects of
daily operations.
“To support our customers we aim to improve our
operations through continuous improvement groups, and
lean events such as 5S and kaizen activities.”
“Our quality philosophy goes all the way from the quality of our ideas
through to the service provided to our customers”
ISO 14001
13. 23 Froude Hofmann
people 22
we’re connecting the
worldwide market
Production Manager, John has
been working for the company
for 23 years and exemplifies the
company’s ethos of embracing
all disciplines. From apprentice
to test engineer, test manager
through to his current position,
his extensive knowledge of the
engineering industry spills
over into his out-of-office
passion – auto grass. His
engineering background has
been invaluable in helping him
to build and maintain his
custom made Fiesta with two
specially adapted 900CC
motorbike engines which
he races whenever he can.
This dedication to perfection
is part of John’s determination
to keep the production
department producing the
same high quality components
that he demands for his car.
Asia Regional Sales Manager,
Paul spends his life working with
vehicles, enjoying racing off-road
cars in the National French
Championships. Paul is used to
travelling the length and breadth
of the globe developing the Froude
Hofmann presence in the Asian
market. Currently involved in
China, Paul has been instrumental
in developing the Asian market.
“This is a hugely influential area,”
he comments. “It is not just about
offering the highest quality product
at competitive prices, it’s also
about understanding and adapting
to different traditional cultural
diversities. China is one of the
largest developing markets and
with a physical presence in the
country now, we are in an excellent
position to capitalise upon its
significance.”
German born, Antje is a Project
Manager, a job she relishes.
“When a job lands on my desk,
it’s my complete responsibility
until it is signed off by the
customer,” she explains. Her
native German language has
been invaluable in liaising with
continental customers as well
as further afield, such as the
Russian market. Married to an
Englishman, Antje has made
her home in Worcestershire,
adapting to the English way
of life, which has been made
easier with the support of
her colleagues at the UK
headquarters.
Sales Engineer, Ian has every
reason to be pleased at Froude
Hofmann – supporting him through
his degree, and promoting him to
Germany where he met his future
wife. Ian has spent the past eight
years expanding our product range
in the German market. “As a
chartered engineer, I find it is
important to be able to explain the
technical details of our products,”
he says. “Through building up
relationships with the customer,
I can really understand their needs,
enabling us to offer the correct
products for their needs.” Ian
enjoys challenge and this is evident
in his spare time which is spent
running marathons, triathlons and
riding over the Alps.
f
rom boardroom to factory floor, Froude Hofmann’s value lies in the people it employs
to represent the company on every level in every country. Dedicated to supplying a
comprehensive and specialist range of top quality technologically advanced solutions,
the team is committed to providing customer service that is second to none,
which is why the Froude Hofmann name is the only one that matters in the automotive
and aerospace industries.
Sebastian is one of our newest
members of the team, appointed
Sales Manager for France.
Sebastian recently trained at
Worcester and has hit the
ground running in the French
and Benelux countries. Having
ten years experience in the
industry behind him already,
he is familiar with the Froude
Hofmann brand and is
enjoying working with the
team. “This is an excellent
opportunity for me and I look
forward to expanding the
Froude Hofmann name
throughout my new area,” he
says. “What I respect most
about the company is the
willingness and capacity to
invest in its people. I look
forward to constantly returning
to England and re-acquainting
with the terrific people I have
met here.”
Keeping Froude Hofmann
moving forward in the
America’s which includes the
United States, Canada, Mexico
and the newly created office in
Brazil, is the responsibility of
Andrew. As Sales Manager for
Froude Hofmann Inc, with 10
years experience with the
company focusing on engine,
vehicle and gas turbine testing.
“For me, I feel I have the best
position in the company,
offering a combination of
developing the North and
South America market along
with the opportunity to be
actively involved with new
technologies and applications
which are specific to a particular
region, the important aspects
for working at Froude Hofmann
are the talented team and our
commitment to complete our
obligation to the customer”.
For over two years, David has been
the company’s technical support
engineer which sees him completing
installations and commissioning on
site. In addition, the company
utilises his cultural background as
in the role of customer support for
the Chinese market. After graduating
from Tsinghua University in China,
he pursued a career in the R&D
centre of Dongfeng automotive
company for two years, experience
which he brought with him to
Froude Hofmann. David relaxes by
travelling and spending time with
other families, learning about their
traditions and cultures, as well as
participating in as many sports as
time allows.
Anthony enjoys drawing as a
hobby. His day job is commissioning
engineer which is a far throw from
his previous employment with
the Royal Navy and as a member
of the elite Parachute Regiment.
In fact, after achieving a degree
in engineering, Anthony has
moved around the country before
settling in Worcester and bringing
his mechanical and electrical
engineering experience to Froude
Hofmann. As well as the arts,
he also enjoys spending what
spare time he has with his
children, entertaining them with
his musical skills on the
saxophone.
Sports figure heavily in
Dave’s social life. Froude
Hofmann’s very own Marathon
Man took part in this year’s
London Marathon with a very
respectable finish time, and
has competed in numerous
half marathons. In addition,
he is often found hanging
from cliffs with his hobby of
rock climbing. This endurance
stands him in good stead in
his day job. Dave is often found
abroad in various locations
from India to the Far East
as well as all over Europe
in his role as Applications
Engineer. With a background
in mechanical engineering,
Dave deals with the chassis
business and having been with
the company for over ten years,
he is obviously still enjoying
the challenge.
Rachael is secretary to the
Manufacturing Operations
Director and the Technical
Director, and has been with
the company for 22 years.
A far throw from her first
job of working at a local horse
stud, she deals with the
administration within the
manufacturing department,
and within shop services as
well as purchasing and general
health and safety issues this
leaves her with little spare time
but she still finds time to travel
the country at weekends,
showing Bullmastiff dogs at
shows. Rachael’s success in her
hobby is reflected in the many
awards she has won and
includes qualification and
exhibiting at Crufts.
Mickey is the Company’s Sales
and Marketing Manager and with a
global working background, her
experience and motivational skills
are proving invaluable at Froude
Hofmann. Fluent in Italian, Mickey
previously held senior executive
roles in Italian and American
businesses in a sales and
marketing capacity, bringing her
into contact with many diversified
area’s where her outstanding
presentation and communication
skills have laid many foundations
for future and real prospects.
From living and working in
Singapore, Italy and USA with her
family, Mickey’s role in the company
is diverse and challenging but one
that she is facing head first with
innovation, determination and
experience.
Andy is the company’s Software
Manager, co-ordinating the
activities of a team of software
engineers that has grown
significantly during the last 12
months. In addition to working on
the development of new software he
also has responsibility for contract
related software and providing
assistance to the Technical Support
Desk. Andy has been with Froude
Hofmann for eight years and
previously worked in the fields of
accountancy and insurance but
fancied a software role in a
manufacturing company, for the
satisfaction of seeing his own
software controlling a physical
product. Previously Andy would have
been found out and about on two
wheels, either as a motorcyclist or
getting some exercise under pedal
power. He also counts dinghy sailing
as a hobby which he hopes to return
to when the boys are older.
14. the future 24
froude hofmann –
the future
Froude Hofmann is a business on the rise,
based on the firm foundation of customer service
excellence. Let us help you improve your R&D and
production performance by working with us to
develop new products, wherever and whoever you are.
Froude Hofmann maintains a policy of continuous research and
development and specifications are subject to alteration without notice.
Photograph: compliments of Applus Idiada Spain (NVH Chassis Dynamometer)