Service

Test & Engineering

We support you regarding your test tasks round-the-clock with our flexible and dynamic team as well as with the application of more than 120 test systems.

We develop new test methods for you, which have been approached by the development centers of the automotive industry and by the latest findings of science and research.

Besides a big choice of universal resonance test machines and special test machines for axial, bending and torsional loads within the load range from 0.01 N up to 1,000 kN or rather 1 Nm up to 250,000 Nm as well as a pneumatic test laboratory for low load ranges, a big choice of flexible applicable hydraulic actuators for one or multiaxial service load tests is at your disposal. Moreover, we can excite force vectors up to 22 kN using shaker systems.

An operation-related load of your components is guaranteed using conditioning devices, hot-gas generators, corrosion devices, temperature chambers and internal pressure systems up to 4,000 bar.

The accomplished accreditation according to DIN EN ISO / IEC 17025 and regular re-audits ensure a constant quality at a high level.

If the question is to test your components for load and reliability, we will have the right solution for you.

Scope

Dynamic strength tests

At SincoTec dynamic strength tests are carried out within the field of the finite life fatigue strength and the endurance strength with a constant amplitude or block programs to determine the strain of the components and materials. These Wöhler fatigue tests are accomplished with tensile/compression, bending or torsional load. The mechanical strain can always be combined with different environmental conditions as e.g. temperature, corrosion, humidity, dirt, etc.

Service strength tests

We accomplish one and multiaxial lifetime tests with service loads using high dynamic test systems. With test systems up to 12 channels, both service strength tests and synthetic collectives or standard collectives can be accomplished. In this process both iterative and intelligent control systems are used. Depending on the application, servo hydraulic, servo pneumatic, electromechanic actuators or resonance test systems are applied. An experimental simulation of the environmental conditions is practicable without any problem.

Lifetime valuation

A calculative lifetime valuation is carried out with the help of the experimentally determined S/N-curve and the local extensions, which are measured during operation. From the determined data, test specifications or rather quality requirements can be fixed.

Environmental simulation

To meet the growing requirements of our customers or rather to perform the complexity of test requirements, the SincoTec test laboratory equips itself continuously with new, mobile test devices. Conditioning devices (-40 up to 150°C), hot-gas generators (up to 900°C), corrosion devices, internal pressure units, temperature chambers, etc. are at your disposal. Due to their flexibility, the devices can be positioned at any point within the test laboratory and can get controlled by our dynamic test systems.

Measurement and application technology

With the help of experienced experts within the field of the measurement and application technology, SincoTec has a comprehensive knowledge available regarding the assembly and accomplishment of static and dynamic measurements.

Including:

  • Tension gauge or rather strain measurement with "cold" or "hot" application technology regarding all materials
  • Measurement of forces, moments, strokes, angles, accelerations, revolution speeds, temperatures, pressures, etc.
  • Calibration of all physical values and manufacturing of calibration components
  • Preparation of measurement signals and generation of test programs

 

Crack detection and damage analysis

To evaluate the tested components and samples regarding cracks, we use different crack detection analysis methods. Depending on material, crack length, constructive design or surface structure, the methods red-white test, magnetic powder test, special crack detection medium and UV-test are applied. Using different analysis systems, we have got the opportunity to detect and to analyze micro-cracks as well as other damage processes already during the accomplishment of the test.

Providing test specifications and test standards

To secure the manufacturing processes, we develop quality or rather test specifications, which we validate experimentally and which we secure statistically. The test specification contains data regarding the applied test technology, test method, test evaluation as well as regarding the obtainable statistical data.

Case of damage analysis and surveys

As a result of a comprehensive knowledge regarding the fields of fatigue strength, material engineering and machine construction, we offer consulting and surveys in the case of damage.

Scope

Dynamic strength tests, service strength tests, lifetime valuations, environmental simulations, measurement and application technology, crack detection and damage analysis, preparation of test specifications and test standards, case of damage analysis and surveys

Equipment

Universal high frequency test systems

In our test center we keep a big number of high frequency test systems at your disposal to test your components. With these test systems, loads from 5 kN up to 1,000 kN, strokes up to 12 mm and frequencies up to 300 Hz can be generated.

Servo hydraulic

Our test laboratory has got several, flexibly usable spans and a big number of servo hydraulic cylinders with a load range from 10 kN up to 500 kN or rather moments up to 200,000 Nm available. With these, one and multiaxial service load tests as well as single step tests can be accomplished. Using a flexible add-on system, user-defined test set-ups are realizable. With special load application systems e.g. torsion moments, bending moments or combined loads as e.g. torsion/axial tests, etc. can be generated. The six-axial swinging table can excite different automotive components and systems also under temperature from -40°C up to 150°C in all six degrees of freedom.

Servo pneumatic

Our pneumatic test laboratory is equipped with several load frames and cylinder units. Forces from 1 N up to 20 kN, strokes up to 150 mm and frequencies up to 50 Hz can get achieved. Beside single step tests, even complex multiaxial tests can be accomplished.

Rotating bending test system

Using rotating bending test systems, components like e.g. motor or gear components, wheels, wheel flanges as well as material samples are loaded with a rotating bending moment from 5 Nm up to 200,000 Nm.

Including:

  • 4-point-rotating bending test systems up to 400 Nm
  • Mass loaded rotating bending test systems up to 4,000 Nm
  • Rotating bending resonance test systems up to 250,000 Nm
  • Biaxial wheel bearing / wheel flange test systems

The rotating bending loads can optionally be overlapped with axial or torsional loads.

With the wheel test systems, both automotive and commercial vehicle wheels can be stressed dynamically with rotating bending loads. The tests can be executed both under dry and under corrosive conditions (e.g. 5 % NaCl-dilution) in high-grade steel test chambers.

Torsion and bending resonance test systems

With component specific and universal bending and torsion resonance test systems, components like e.g. crankshafts or camshafts, driveshafts, converters and rotors as well as material samples can be loaded up to a moment of 35,000 Nm.

Rear axle test systems/ stabilizer test systems

Several rear axle and stabilizer test systems, designed as electromagnetic resonance test systems, are applied for bending and torsion loads as well as servohydraulic test systems.

Bearing / wheel bearing-friction torque test system

With a friction torque test system, you can verify different bearings / wheel bearing units with the influence of vertical and lateral forces regarding their efficiency.

Spring test systems

Being a competence center for spring tests, we operate a big number of different spring test systems. Because of the resonance drive, we generate strokes up to 300 mm and speeds up to 10 m/s within continuous operation. The test frequencies are between 7 Hz and 45 Hz depending on range and type of spring.

On servohydraulic systems we test springs with a service load test and with free selectable signals, even under corrosive conditions (e.g. 5 % NaCl-dilution) in high-grade steel chambers.

According to the state of technology, air springs only could be tested on servohydraulic systems. Now it is also possible to test air springs with uniaxial tests, block programs or RANTEC tests using resonance spring test systems.

Shaker

On several swing test systems automotive components as well as motor components are excited up to a force vector of 22 kN. Beside the swing test, it is also possible to load the components with sinus excitation, sweep, noise, shock or with a resonance lingering test.

Internal pressure test systems

As a drive system for internal pressure test systems, servohydraulic, servopneumatic as well as resonance driven systems are available. With resonance driven high-pressure test systems it is possible to generate pressures of more than 4,000 bar with frequencies up to 50 Hz.

Compared to usual, servohydraulic driven test systems, which operate with max. 10-12 Hz at an energy consumption of more than 100 kW, the resonance driven high-pressure test systems are characterized by a much higher test frequency and a much lower energy consumption of max. 4 kW.

On servohydraulic and servopneumatic test systems, service load tests and special signals can be generated. The test systems cover the following pressure ranges: 30 bar, 300 bar, 1,000 bar, 2,000 bar as well as 4,000 bar.

Railway wheel set test/ railway specific components

In the accredited and from the Federal Railway Authority approved test laboratory a multitude of test systems for tests on railway specific components is available. Using two rotating bending test systems, equipped as an electromotor driven resonance test system, rotating bending tests on wheelset axles and wheel discs up to a rotating bending moment of 250,000 Nm can be accomplished.

Via the integrated calibration device, the relation between the induced bending moment and the local distensions can be established. With our high frequency pulsators POWER SWING, components like e.g. side rails or wheel tire segments can be tested regarding their load.

Burst tests

With a burst test system, components can be loaded up to 20,000 1/min. Both burst tests and circular speed characteristics can be accomplished. Brake discs, two mass fly wheels, rotors, drive components, etc. are typical components.

Environmental simulations

In order to meet the growing requirements of our customers or rather the complexity of test requirements, the SincoTec test laboratory equips itself continuously with new test devices. The upgrade comprises several conditioning devices (-40 up to 150°C), hot wind generators (up to 1,200°C), corrosion devices, internal pressure units, temperature chambers, etc. You can operate the devices at all test systems because of their mobility. Parallel to the dynamic induction of loads, the components are tested correspondent to the environmental stresses, which prevail during operation. So a realistic investigation can be guaranteed.

Test systems

Universal high frequency test systems, servo hydraulic, servo pneumatic, rotating bending test systems, torsion and bending resonance test systems, rear axle test systems/ stabilizer test systems, bearing / wheel bearing friction torque test system, spring test systems, shaker, internal pressure test systems, railway wheel set tests / railway specific components, burst tests, etc.

Calibration laboratory

Exact calibration for an ideal function

High-tech test technology requires a high precision. This can be achieved, amongst others, by regular calibrations. We support you, that your quality meets your high requirements.

In our calibration laboratory hundreds of transmitters are checked and calibrated with traceability to DKD standards annually.

We are able to calibrate force transducers from 1,000 N up to 450 kN with our newly developed, modern calibration system. For small and middle-sized axial and torque transducers, there are mobile calibration systems at your disposal, with which we can calibrate your transducers on site.

We calibrate torque transducers up to 30,000 Nm as well as bending moment transducers from 1,000 Nm up to 50,000 Nm. We calibrate path sensors within in the measuring range from 0.5 mm (e.g. for crack progress measurements, etc.) up to a measuring length of 300 mm.

For the calibration of angle sensors an extreme exact incremental angle standard is at your disposal. With this, every incremental or potentiometric angle sensor can be checked very precisely.

Pressure sensors can be calibrated up to a maximal pressure of 5,000 bar.

Calibration capacity:

  • DKD force transducer (250 N up to 450 kN)
  • Torque moment transducer (2 Nm up to 30,000 Nm)
  • Bending moment transducer (1,000 Nm up to 50,000 Nm)
  • Displacement transducer (0.5 mm up to 300 mm)
  • Angle sensors (5 degrees up to 1,000 degrees)
  • Pressure sensors (10 bar up to 5,000 bar)
  • Measuring amplifier

Calibration systems

DKD force transducer, torque moment transducer, bending moment transducer, displacement transducer, angle sensor, pressure sensor, measurement amplifier

Maintenance

Our specially trained, competent service team from the fields engineering, electronics and software are at your disposal regarding consulting, repairing and maintenance.

Our maintenance agreements offer you the opportunity to monitor your test systems continuously, to optimize the reliability and to minimize non-operating periods.

Mr. Hellmann, the contact person for service, maintenance and customer complaints, is at your disposal.

Thomas Hellmann

Head of Service Department

Tel.: +49 (5323) 9692-529

Fax: +49 (5323)9692-629

E-Mail: thomas.hellmann@sincotec.de

Calibration

To ensure, that the measurement results between the calibrations are absolutely right, a regular calibration of the sensors has to be accomplished.

Wrongly adjusted or because of overload or rather wrong assembling damaged or "drifting" transmitters can result in wrong test results and as a consequence in expensive product recalls.

We offer our customers a customized service including the following services:

  • Regular calibrations of the transmitters, traceable back to DKD standards
  • Regular calibrations of the transmitters, traceable back to DKD standards as well as calibrations of the complete measuring chain on site with mobile calibration equipment
  • Check of all software settings on site