The 2-column drop tower, a compact and mobile version of the 4-column drop tower from CFM's product ranges, is designed for battery testing by means of crash tests.
This drop tower consists of two vertical columns and a crossbeam on which a freely movable trolley is mounted. This makes it easy to reach any test position.

TESTING ACCORDING TO

» IEC 62281:2016 RLV
» UN38-3

The special feature of the drop tower is the guided fall, particularly in the impact area. The possible energy of the impulse load results from the drop height and mass of the so-called impactor and from the test setup. The drop tower consists of a steel structure up to approx. 3700 mm high with two high-precision guides. The steel structure with its high-precision guide columns enables the impactor to fall in a guided manner via its roller units with minimal resistance. A locking mechanism catches the impactor after the fi rst impact. This ensures that no second impact falsifies the result.

The CFM crush test rig for testing the mechanical integrity of batteries / high-voltage storage systems is used to examine cells, modules and
complete high-voltage storage systems. Compression and crush tests can be carried out by load or displacement control.

The CFM crush test rig consists of a base frame in a highly rigid design, a longitudinally adjustable reaction bracket with threaded hole pattern and the electro-mechanical crush unit. The electro-mechanical crush unit consists of a very rigid mounting bracket for the electro-mechanical actuator, a compression frame mounted in precision guides, the load cells and the pressure plate. Various crush plates can be mounted on the pressure plate.

The crush plates according to UNECE R 100 and GB/T31467.3-2015 are available as accessories.

The CFM controller XiControl with the software package XiMotion is used to control the CFM crush test rig. The XiControl is a universal digital controller for test applications, enabling functions including displacement and load control. The XiControl controller can be used with linear actuators (electric or hydraulic) as well as with rotary actuators or electric machines.

CRUSH TEST OF HIGH-VOLTAGE BATTERIES ACCORDING TO

» UNECE R 100
» SAEJ 2464:2009
» GB/T31467.3-2015

The XiControl has a clock frequency of 2.5 kHz, analog measuring inputs, strain gauge measuring inputs and analog outputs. Various signal functions are available on its function generator. ± 10 V analog outputs are used to control the actuators. Using the XiControl controller and XiMotion software, the crush test rig can be operated in both displacement and load control modes. Test sequences can also be pre-programmed. The compression, holding and retraction procedures can be freely configured. Forces and displacements are recorded synchronously during the test sequence. It is also possible to record additional measured values and also record a synchronized video.

The base frame of the movable fire screen is also made of steel and is equipped with welded T-profiles at a distance of 242 mm and a support width of 10 mm, in accordance with the standard, so that firebricks of type FFP-ECE R34 (240x120x70mm) can be inserted and replaced if necessary. In order toextinguish the fire in the fire bowl after the test if necessary, a telescopic extinguishing cover made of steel is installed, which is pulled over the fire bowl after the test and thus smothers the fire. All steel components are painted with temperature-resistant thermal paint. The test bench is controlled by a PLC, which allows the fully automatic movement of all driven axes to stored positions. Since the electric drive motors are operated with a frequency converter, the travel speeds of the individual movable elements can be adjusted. The test bench is operated using a hand-held control panel with an integrated Siemens KTP 700 display.

Length: 12200 mm
Width: 2950 mm
Height: 1725 mm
Weight: 4,5 t

Fuel pan dimensions (L x W x H): 3560 x 2450 x 60 mm
Fire screen dimensions (L x W x H): 3490 x 2650 x 75 mm
Dimensions of extinguishing cover (L x W): 3600 x 2500 mm
Dimensions of test specimen holder (L x W): 3400 x 2500 mm
Max mass of test specimen: 1200 kg

» Remote controlled, electric fuel ignition
» Hand control panel (Rose Limanda ) with Siemens KTP 700 touch panel (wired)

The CFM combined fire test bench includes a burner surface with a propane gas burner system (LPG).

This allows not only to control the fl ame exposure also the UNECE R100 and the KMVSS (Annex 1 -Part 48) can be fulfi lled. The burner system consists of 9 atmospheric burner segments, which are divided over an area of 3,400 x 2,400 mm. The burner segments are each divided into 5
burner strips and are each ignited by an individual igniter and monitored at the end by an ionization electrode. The ignition is electrically realised. The burner system complies with DIN 746 Part 2 for thermal processing systems. Each burner segment includes a manually lockable ball valve, two electric gas shut-off valves and an electrically controlled gas flow regulator (DN 32). The test bench has a separate control cabinet for valve, regulator and ignition control as well as monitoring of the burner segments. The burner control also reports burner segment errors. The flame characteristics can be influenced by the electrically controllable pressure regulator. The burner bars are mounted on a steel base frame that is painted with temperature resistant coating. The gas consumption is approx. 750 kg/h.

High-voltage batteries for motor vehicles play an important role in the emission-free mobility of the future. Multi-axial servo-hydraulic vibration tables with a climate chamber are used to test these HV storage systems. These simulate vehicle movements in all six degrees of freedom under extreme temperatures and electrical loads.

In the event of an accident, rapid evacuation is required to prevent damage to the climate chamber and the test stand. Automatic evacuation is required to minimize the risk of personal injury.

For this reason, CFM supplies evacuation systems for removing the damaged test specimen from the test chamber, in addition to the vibration foundation on CFM air springs.

The evacuation system consists of a raised fl oor, a clamping system with test specimen pallet and a winch system. The raised floor is placed on the floor of the climate chamber and forms a level at the height of the table surface in the minimum position. It is equipped with electrically extendable segments around the simulation table. These are retracted during test operation to provide the necessary clearance for the oscillating table movements. In the event of an accident or to ensure convenient access to the test specimen, the elements are moved back towards the table so that the surface is closed. The automatic cover is designed to be weight-optimized and corrosion-protected. The electric cylinders for opening and closing the cover are also suitable for use in the climate chamber.

The clamping system clamps the pallet, which serves as a support for the test specimen, to the oscillating table so that the mechanical test loads can be applied. In the event of an evacuation or for normal set-up work, the hydraulic clamping is automatically released and the pallet and battery can be pulled out of the chamber using the winch.

The pallet is then pulled into a basin or a safe area so that the battery can burn off in a controlled manner.

» The oscillating table moves to the minimum position (not via CFM control)
» The cover is closed (via CFM Control system)
» The hydraulic clamping elements release the pallet (via CFM control)
» All cables and hoses to the battery are disconnected (not via CFM control unit)
» The air conditioning chamber door is opened (not via CFM control)
» The pallet is pulled out of the chamber with the winch chamber (via CFM control)

If an add-on or component test stand is used to test high-voltage batteries or other flammable components for trucks or passenger cars, evacuation with a cable winch is generally not possible, as the actuators must be firmly connected to the test specimen.

Nevertheless, in the event of an accident, rapid evacuation is necessary to prevent damage to the test bench and the test chamber. To minimize the risk of personal injury, automatic evacuation is also required here.

CFM therefore also delivers evacuation systems for add-on or component test benches with any number of channels or actuators to remove the damaged test specimen from the test chamber.

The evacuation system consists of our patented locking and unlocking units on the ball joints on the cylinder rod, an adapter plate as a counterpart on the test specimen, automatically movable chain hoists including electrically driven trolleys as well as various pneumatic and electric actuators and a customized steel construction of the split crane runway. This is located above the test area and extends into the secured area.

During normal operation of the test bench, the evacuation system is in a standby state and all moving parts are parked in non-critical positions to provide the necessary space for the movements of the test bench. Only the locking units are in direct contact with the test bench and ensure the connection to the test specimen - due to the high preload force, the entire force is transferred directly from the actuators to the test specimen without any losses. The units are designed as a mechanically clamping system that is unlocked hydraulically.

In order to be able to move the test specimen, four partly mechanically coupled trolleys including hoists and drives are used. These are mounted on a split evacuation track that closes automatically in the event of an evacuation. This allows the test specimen to be moved into the secured area outside the test chamber after unlocking.

To prevent vertically installed actuators from tilting, a pneumatically operated locking mechanism can be provided. Electric actuators can be used to support the horizontal cylinders.

All actuators are equipped with limit switches and sensors, which enables safe and automatic operation - both in the event of an emergency and for setting up the test bench.