Test benches
Precisely Tested to Enable Confident Decisions
Precise, Reliable and Safe – Couplings and Brakes for Test Benches and Testing Systems
Maximum Precision and Safety for Testing and Validation Procedures
Test benches must reliably evaluate technical components, drive systems and complete assemblies under defined conditions. This requires torque and force to be transmitted accurately, movements to be executed reproducibly and loads to be held securely. Any deviation can affect the result and, consequently, the validity of the entire test.
Depending on the application, test benches may operate with static loads, dynamic load profiles, rapid load changes or large numbers of repeated test cycles.
The couplings and brakes used must therefore engage with precision, hold reliably and protect the mechanical system in the event of overload or operator error.
Particularly important is the interaction between the drive system, the test specimen, sensors, controls and safety functions. Only when all components work together in a controlled manner can reproducible results and reliable conclusions about the tested technology be achieved.
When Measurement Results Must Be Reproducible
Mönninghoff components can be used in a wide range of test benches and testing systems, including
- Torque test benches
- Drive and gearbox test benches
- Test rigs for engines and electric motors
- Endurance and service-life test benches
- Dynamic load and functional testing systems
- Hydraulic test benches
- Test benches for couplings, brakes and shaft connections
- Aerospace testing systems
- Test and validation systems for mobile or marine drives
- Customised research and development test facilities
Requirements vary depending on the test specimen and testing procedure. A torque test rig requires highly accurate power transmission. An endurance test rig must operate reliably over many cycles. A dynamic testing system must control rapid load changes while protecting sensitive measurement and drive components.
The common objective is simple – the test bench must do exactly what the test requires, no more and no less.
Requirements for Couplings and Brakes
Test benches place specific demands on drive technology.
High measurement and transmission accuracy Torque, force and movement must be transmitted as accurately and reproducibly as possible.
Defined engagement and disengagement Drives and loads must be connected and disconnected in a controlled manner.
Reliable holding capability Test specimens and moving assemblies must remain securely held, even during standstill or power failure.
Overload protection The test rig, test specimen and sensors must be protected against excessive torque levels and load peaks.
Dynamic performance Rapid load changes and variable load profiles must be reproduced reliably.
Minimal backlash Unwanted movement or delay can affect measurement results and should be minimised.
High repeatability Tests carried out under identical conditions should produce comparable results.
Low-wear design During endurance and service-life testing, the components themselves must perform reliably over long periods.
Thermal stability Repeated engagement and braking operations generate heat and must be accommodated in the design.
Flexibility Test benches are often used for different test specimens, load profiles and test procedures.
Compact integration Installation space is frequently limited, even in complex testing systems.
Safety functions A defined safe state must be achieved in the event of faults, operator error or limit exceedance.
Comprehensive documentation The design, testing and performance of components should be fully traceable and documentable.
Drive technology must therefore achieve two objectives simultaneously: it should influence the test as little as possible while ensuring that it can be carried out safely. Precision and protection are not opposing goals; they belong together.
Transmit, Limit and Hold
Mönninghoff develops clutch and brake systems tailored to the torque, speed, load profile, cycle time, installation size and safety requirements of each individual test bench.
Overload Couplings
Overload couplings can interrupt power transmission when a predefined torque limit is exceeded. This helps protect the drive system, test rig, sensors and test specimen against blockages, operating errors and unexpected load peaks.
Potential applications include
- Protecting test rigs during blockages or seizure of the test specimen
- Limiting torque during dynamic test procedures
- Protecting drivetrains and shaft systems
- Safeguarding sensitive measurement and sensor components
- Disconnecting power transmission when limits are exceeded
- Preventing consequential damage following malfunctions
Appropriate specification depends on maximum torque, release characteristics, rotational speed and the desired behaviour following an overload event. The key objective is to ensure that the test rig does not continue applying uncontrolled loads during a fault condition.
Torsionally Rigid Shaft Couplings
Torsionally rigid shaft couplings provide highly accurate transmission of force and torque between the drive system, sensors and test specimen. They can compensate for minor misalignment while maintaining high torsional stiffness.
Typical applications include
- Connecting motors and test specimens
- Torque test rigs for shafts and gearboxes
- Testing of couplings and brakes
- Dynamic drive and load simulations
- Applications requiring minimal angular deflection
- Test systems with changing rotational directions and load profiles
A precision shaft connection helps minimise additional influences within the drivetrain. This allows the behaviour of the test specimen to be assessed as clearly as possible, without the coupling itself becoming an unwanted part of the measurement result.
Electromagnetic Tooth Holding Brakes
Electromagnetic tooth holding brakes can securely and precisely hold loads in a defined position through positive locking. This is particularly important when a test specimen must remain stationary during measurement, assembly procedures or safe operating conditions.
Potential applications include
- Holding test specimens and test-rig components at standstill
- Securing vertical or gravity-loaded axes
- Positioning assemblies for repeatable measurements
- Holding during power failures
- Securing assembly, maintenance and setup positions
- Supporting emergency-stop and safety functions
The positive-locking principle can provide a defined holding position with minimal backlash. Holding torque, switching time, positioning accuracy and system behaviour must all be considered together during the design process.
Magnetorheological Fluid Brakes
Magnetorheological fluid brakes offer continuously adjustable braking torque and damping characteristics. They may be especially suitable for dynamic testing procedures that require variable load profiles, controlled deceleration or finely tuned resistance characteristics.
Potential applications include
- Dynamic load and functional testing
- Variable braking and loading profiles
- Tests involving varying rotational speeds
- Controlled deceleration of moving masses
- Damping of movement and vibration
- Simulation of different operating conditions
The adjustable braking effect allows braking behaviour to be adapted to specific test requirements. This provides additional flexibility when a test rig must reproduce multiple real-world or simulated operating conditions rather than a single fixed load case.
Product Overview >
Customised Testing, Reliable Decisions
Whether for torque test rigs, hydraulic test facilities, endurance testing or dynamic test systems, Mönninghoff develops couplings, brakes, shaft connections and overload protection systems for applications requiring exceptional precision, safety and long service life.
Are you developing a new test benchg, expanding an existing test setup or looking for a precise solution for engagement, holding and overload protection? Talk to our experts about torque, speed, load profiles, test cycles, measurement accuracy and installation space. Together, we can ensure that your test rig delivers reliable results, test after test.
Protection for Test Systems and Test Specimens
Test benches are designed to generate and reveal loads. They should not themselves be damaged by unexpected load peaks. Protecting the overall system is therefore a fundamental part of the design process.
Depending on the application, the following functions may be relevant
- Limitation of maximum torque
- Rapid disconnection of power transmission during overload
- Controlled braking during faults
- Secure holding of the test specimen
- Protection of sensors and measuring devices
- Defined reset procedures following interrupted tests
- Monitoring of engagement, braking and holding states
- Integration into emergency-stop and safety circuits
- Safe recommissioning following a fault
The specific safety function must be evaluated together with the test-rig concept, control system and risk assessment. A test rig should explore limits, but not its own.
Prototypes for Early Validation
For customised testing systems, early validation provides significant benefits. Prototypes and functional samples can help assess the interaction between couplings, brakes and overload protection systems within the real test environment.
Potential evaluation criteria include:
- Transmission accuracy and repeatability
- Engagement time and engagement reliability
- Holding torque and holding accuracy
- Braking torque and deceleration performance
- Response to overload and blockage conditions
- Behaviour under varying load profiles
- Vibrations and resonance characteristics
- Temperature development during endurance testing
- Wear over long test durations
- Behaviour during power failure and emergency-stop events
- Integration with mechanics, controls and sensors
- Influence on measurement accuracy and test results
This enables optimisation opportunities to be incorporated early in the design process, reducing the risk of later modifications and creating a solid foundation for production approval and operational deployment of the test bench.
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