Component testing on safety friction clutches for the automotive industry

Friction clutches in electric tailgates of vehicles are safety-relevant components that prevent uncontrolled closing. To ensure that these clutches function reliably, they are tested using a special testing system from Hegewald & Peschke that simulates both pressure and torque loads under realistic conditions.

Testing system and setup

The testing system is based on a universal testing machine inspekt table with a maximum test force of 5 kN. Above the moving crosshead, a torsion module is integrated that applies a torque load to the test piece while simultaneously applying a compressive force via the crosshead. This combination enables a realistic simulation of the mechanical stress on friction clutches.

An important component of the friction clutch are friction discs with, for example, carbon fiber friction linings. For testing, at least one friction disc and the corresponding counter friction surfaces are placed on top of each other in a special clamping.

• The friction disc is rotatably mounted
• The counter friction surfaces are fixed

Under axial load, the friction disc rotates between the support surfaces – the resulting torque is precisely recorded by the LabMaster test software. With a data acquisition rate of 1 kHz, even very fast torsional movements up to 1600 rpm can be evaluated accurately.

Testing under temperature conditions

For practical tests, the system is equipped with a temperature control chamber. This enables tests to be carried out at temperatures ranging from –40 °C to +120 °C in order to investigate the friction behavior and stability of the couplings even under thermal stress.

Flexible parameterization and versatile testing options

The LabMaster test software allows numerous parameters to be individually set and controlled, including:

• Torque
• Speed
• Axial force
• Temperature
• Direction of rotation
• Rotation angle

This allows various types of tests to be carried out, such as:

• Step or continuous running tests
• Determination of the breakaway torque
• Stability tests of the friction connection

The compact friction test bench can accommodate friction discs of different diameters and friction packages of different thicknesses.

Quick conversion for different geometries is possible in just a few simple steps.

Operation and data evaluation

The test bench is operated and programmed using LabMaster. The software offers a wide range of options:

• Convenient definition of the test sequence via the integrated block program
• Definition of detailed termination criteria for reliable monitoring of the test
• Direct evaluation of measurement results and export in a variety of formats (e.g., CSV format)

Thanks to its high degree of flexibility and automation, the LabMaster software is ideal for complex friction tests – without additional modules or external programs.

Conclusion

The test system is compact, flexibly configurable, and allows quick changes between different friction discs and component geometries – ideal for testing safety-relevant clutch components in automotive development and quality assurance.

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