Modern Advancements in Power Train Testing featuring ATW test technology and technology from some of my key vendors.

1. morrell ‘We Keep Things Moving’ Modern Advancements in Power-Train Test Stands Welcome! Measurements in Motion morrell

2. morrell ‘We Keep Things Moving’ Improving Verification and Data collection Drives & Control Technology for High Performance Introduction; Advancements in Test Stand Machinery Dynamic Response and Real World Duplication Sound and Particle Verification Sensor Technology for Verification Improving Performance and Product Life Sessions

3. morrell ‘We Keep Things Moving’ Introduction Introduction To Advancements; Power Train Test Stands Basic Methodology of ATW Designs Modern Use of End-of-Line Test Data Overview of ATW’s Patented Quiet Drive

4. Introduction: Bob Ussery & Jeff Trumble morrell ‘We Keep Things Moving’ Bob Ussery Technical Leader in ATW’s Livonia R & D area. Inventor of NVH Lab & Production Systems & Test Processes Jeff Trumble President; JDT-ProcessWorks Six Sigma Black Belt Former NVH Manager; FORD

6. Over 40 Years of Experience in Test Stands

7. 70+ Full Time Employees

8. Design & Engineering Expertise

9. Full 3-D (Solid Works)

10. Dynamic Modeling Capabilities

11. Strong Network of Resources;

12. Wayne State University

13. Michigan State University

14. PCB

15. Anger Associates

16. Morrell/Rexroth

17. ATI

18. JDT-ProcessWorks

19. SenSound

22. Timing

23. Budget

25. Timing

26. Budget

27. Proper FlexibilityATW Core Strength; We Understand Functional Testing/NVH & How to build Robust Tester that hits statistical Targets

30. Timing

31. Budget

32. Proper FlexibilityCustomer’s Needs

33. Introduction to ATW’s Advanced Power Train Design Philosophy System Signature = S¹ Machine/Process Contribution = M¹ Parts (Masters) = P¹ ATW’s Quiet Drive Technologies S¹ = P¹ + M¹ Goal = M¹ AS SMALL AS POSSIBLE

34. Introduction to ATW’s Advanced Power Train Design Philosophy Example; Functional Tester with NVH / Balance Check

35. Introduction to ATW’s Advanced Power Train Design Philosophy Advanced Power Train FED / Experimental Data Resources Experimental FRF’s FEA Modeling

36. Introduction to ATW’s Advanced Power Train Design Philosophy Example; Functional Tester with NVH / Balance Check

39. Introduction to ATW’s Advanced Power Train Design Philosophy Example; Up Stream In Process NVH with Dynamic PLRO Analysis

40. Introduction to ATW’s Advanced Power Train Design Philosophy From This…… To This……

41. Introduction to ATW’s Advanced Power Train Design Philosophy Customer’s Needs

42. Introduction to ATW’s Advanced Power Train Design Philosophy …and High Correlation ATW Tester’s Goal; High GRR

43. Introduction to ATW’s Advanced Power Train Design Philosophy

44. Introduction to ATW’s Advanced Power Train Design Philosophy

45. Advanced Signature Analysis in NVH Testers Coordinator – Put name here… “From recent advancements in Test Stand Technology to Drive & Control systems for the industry, we will present methods to dramatically improve your verification efficiencies. Discussions will center on such aspects as XXXXXX, yyyyyy, zzzzz, etc and improving you overall machine technology.” morrell ‘We Keep Things Moving’

46. morrell ‘We Keep Things Moving’ Agenda: Modern Advancements in Powertrain Test Stands Put in Topic Put in Topic Put in Topic Put in Topic

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68. Accelerometers pushed against pinion nose.

69. Acquiring torsional acceleration measurements from the rotating shaft eliminates inertial dampening due to the axle housing and how it is secured.

71. Can be ranged as low as .01G full scale, or as high as needed.

72. Gravitational effects are cancelled.

75. Collar is powered inductively with loop antenna.

76. Signal processing performed inside transmitter unit. Includes 5-pole low pass filter.

77. Transfer rate of 50K samples/second.

78. Infinite resolution.

79. Low noise floor.

81. Rotating collar has LED showing power status.

82. Loop antenna connects to Induction Power Supply.

83. Long cable runs to Receiver permitted.

84. Systems can be used to collect data in-vehicle, for real world correlation.Torsional Vibration Collar and Stationary Loop Antenna

85. Measurements in Motion Torsional Vibration Measurements - Phil Merrill Advanced Telemetrics International New Power Indication LED Torsional Vibration Monitoring System

86. Measurements in Motion Torsional Vibration Measurements - Phil Merrill Advanced Telemetrics International Torsional Vibration Monitoring System Installation

87. Measurements in Motion Torsional Vibration Measurements - Phil Merrill Advanced Telemetrics International Torsional Vibration Monitoring System Installation

89. Used extensively for in-vehicle torque monitoring.

90. Dual Range Dynamic Torque monitoring telemetry system provides second channel, which can be ranged as low as 1% of primary range.

91. 5X safe overload of primary range.

92. Dynamic channel is AC coupled, to ignore static torque level.

94. Measurements in Motion Torsional Vibration Measurements - Phil Merrill Advanced Telemetrics International Advanced Telemetrics facility in Spring Valley, Ohio, USA

95. NVH Test Stand System The “trace” or “plot” or “signal” from any system can be expressed as S¹. S¹ is the actually the sum of signal from part being tested (P¹) and the signal produced by driver (test stand) itself (M¹). Thus, the equation S¹ = P¹ + M¹ Precision NVH test machine builders designs then must try to reduce M¹ content in formula so that the system signal (S¹) is as close to the part signal P¹, which is the part under test.

97. NVH Test Stand System-Acoustic Sensor For a system based on acoustic sensors, the system equation is further compounded by the environmental noise around the test stand S¹ = P¹ + M¹ + d¹ Where, d¹ represents the error induced into the system signal by environmental/background noise.

99. This results in poor separation between good and bad products noise measurements, which causes bad products to pass or good products to be rejected

101. Better throughput and reliability Greater reliability SenSound Enclosures Human ear Higher throughput

102. SenQC ROI

104. A cost effective alternative to an enclosure

105. A cost effective way to pass/fail noisy products

108. Test was conducted inside regular engineering test facilities without any acoustic treatment.

109. Conventional sound and vibration tests were used as benchmark.

110. Demonstrate the statistical robustness of SenQC’s ability to see defects with a high level of confidence.

112. M2 SPL (dB) P M1 Frequency (Hz) SenQC Implementation To guarantee bad products are unambiguously separated from the good ones, we modified Shainin’s formulation to consider the worst case scenario in QC testing as shown below: where M1 represents measurement errors of a product, M2 the variations of a benchmark good product, and P the smallest separation between bad and good products.

113. D < D Since , M M MSenQC Raw SenQC D D P P SPL (dB) > MRaw D D M M Raw SenQC increased! is separation So Frequency (Hz) Individual Presentations - Put in header for each speaker SenQC enables one to strip out background noise, thus reducing the measurement errors M and variations in benchmark data. Consequently, the separation ratio is significantly increased.

114. Measured Raw Data MRaw SenQC data MSenQC SenQC Comparison of ratios Traditional Direct measured data vs. SenQC data

116. Comparison of Confidence

118. In addition, SenQC was able to detect several additional defects with high level of confidence that the traditional cold test could not detect.

119. SenQC is able to significantly enhance signal to noise ratios that traditional methods cannot.