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Dynamometer
Auxiliaries

Road Surface Shell

Development and installation on the roller surface of Chassis Dynamometer
Development Background: TeSys' Road Surface Shell

In the past, the harshness test of the target vehicle was conducted with the actual vehicle being driven by a driver to gather data, which has been very inefficient for end-users.

The design and production of the TeSys road surface shell, along with the background of owning a patent, are as follows. A dedicated road surface for harshness testing is perfectly replicated, and the road surface shell is attached to the roller surface of the chassis dynamometer installed indoors, which is currently used by the customer (Hyundai Motor Company & NEXEN Tyre). This allows convenient simulation of test data without the need for direct driver involvement in the harshness test scenario.

TESYS -Dynamometer - Auxilaries - Road Surface Shell

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Overview

The typical Road Surface Shell is manually crafted or produced through 3D machining. This involves high unit costs and considerable time, leading to functional issues as outlined below

  • Portions that do not match the actual road surface as required by the customer. When produced through manual and machine processes, the road surface is measured using 3D scanning, but the roller fails to connect seamlessly as a whole. Even when creating multiple pieces with one pattern or producing the entire 3D model, errors occur due to data bending during the transformation from road surface (flat data) to circular surface (round data)

Road Surface Shells produced manually or through machining result in noise issues due to problems with run-out, surface flatness tolerances, and connection points between shells

  • The displacement difference and run-out values of the surface shell are not consistent, leading to juddering caused by weight imbalance. This phenomenon occurs due to an irregular, non-circular shape, causing an imbalance in the object, akin to a 'bouncing' effect
  • Interference and noise occur between shells due to interference and spacing issues (Pop/Crack Noise)

Tapping noise occurs due to pattern discontinuity on each shell, as well as problems with vibration between the steel roller and the shell, and assembly issues

  • The steel roller and road surface shell that are mounted do not fully adhere, resulting in noise due to separation
  • Noise occurs in the seam area due to the lack of pattern continuity between shells
"As a result of continuous research to address these issues, TeSys has applied aluminum casting methods and subsequently developed a new processing process. After resolving the aforementioned problems, the company has completed full domestication, supplying to major OEM customers such as Hyundai Motor Company and Nexen Tyre and obtaining patents."
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Features

The road surface shells that were previously dependent on overseas imports were made of resin, resulting in a very high unit cost. Additionally, based on a 72-inch roller standard, 8 to 12 pieces were all produced as identical pieces, leading to inaccurate data.

Our road surface shells, based on a 72-inch roller, are produced in continuity, with 12 pieces providing more accurate Harshness test data.

The road surface shells previously dependent on overseas imports did not have perfect adhesion between the roller and the road surface shell, causing damping noise at regular intervals during rotation and resulting in inaccurate Harshness test data.

Due to the use of aluminum casting, our products are more durable than those made of resin. The surface where the roller is attached is coated with NBR rubber to prevent damping noise while ensuring excellent adhesion between the roller and the road surface shell.

To simulate the roughness of actual roads, the road surface shell is coated with urethane to enhance surface roughness and durability.

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Specifications

Downloads

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