Test stand technology for automotive drives is undergoing a fundamental change. The rise of emobility is reshaping test routines, speed profiles and requirement landscapes. However, precision, reliability and process safety remain indispensable in measurement technology. Mayr power transmission is presenting its coordinated portfolio for test stand technology, ranging from the lightweight ROBA DS Type 9120 coupling and proven safety brakes to intelligent monitoring solutions.

Shaft misalignment compensation couplings are essential components in test stands. Based on the proven ROBA DS steel disk pack coupling, Mayr power transmission offers a weight-optimised aluminium variant with the ROBA® DS Type 9120. Compared with the steel version, the outside diameter is reduced by up to 10 mm, while mass and mass moment of inertia are 40 per cent to 60 per cent of the steel version, depending on the design and size, with unchanged performance density.

The development incorporates extensive knowledge gained over many years in test stand technology, where high speed ranges have long been standard. The ROBA® DS 9120 is also suitable for speeds of up to 32,000 rpm. Its lightweight construction, low mass inertia and high performance density offer measurable advantages. The balance between rigidity and elasticity ensures the lowest possible restoring forces on the system. A balance quality of G 2.5 at 5,000 rpm ensures smooth running and low-vibration operation, providing a decisive basis for high measurement accuracy across all speed ranges.

As standard, the coupling features manufacturing tolerance IT6. A nickel-plated surface, stainless-steel disk packs and galvanised connecting screws provide comprehensive corrosion protection. Backlash-free shaft connections through shrink disk hubs or external shrink disk hubs ensure reproducible measurement results. The coupling is compatible with all common torque transducers as standard.

Thanks to its modular construction system, the ROBA® DS 9120 can be flexibly configured from a variety of connection variants and modules, supporting applications from high-performance test stands in research and development to end-of-line testing.

Safety brakes for test stands

Alongside coupling technology, Mayr power transmission is also presenting its extensive portfolio of safety brakes for test stand applications at Automotive Testing Expo. Test stands for automotive drives frequently include vertical axes and linear movements that must be reliably secured during test operation, maintenance work or in the event of a fault.

The ROBA guidestop profiled rail brake acts directly on the moving masses of vertical axes and clamps them into position in a backlash-free manner with high rigidity. It is available in hydraulic, pneumatic and electromagnetic designs and is compatible with all common linear guides.

The ROBA linearstop piston rod brake secures linear movements on round rods. It is a fail-safe safety brake, meaning it is closed in the de-energised state, and is designed for dynamic emergency braking. The series comprises six sizes, with forces ranging from 70 N to 17,000 N.

The ROBA-stop M series provides a robust motor brake for compact protection directly at the drive motor. As a holding brake, it clamps reliably and holds the system in position. As a dynamic brake, it brings the load to a standstill in the shortest possible time.

Smart modules for intelligent monitoring

Constant, meaningful data streams are now indispensable in modern test environments. The ROBA  brake-checker module monitors safety brakes without sensors and simultaneously supplies them with power. Through advanced analysis of current and voltage, it detects the switching condition of the brake and issues a warning before the brake can no longer release under current operating conditions.

This supports planned maintenance and enables users to investigate critical boundary conditions, including low supply voltage, incorrectly dimensioned supply lines, elevated coil temperature and an enlarged air gap.

In combination with the ROBA gateway module, the solution becomes network-compatible. Brake data can be continuously read through an Ethernet connection and displayed visually on a dashboard. Anomalies in the test process can be detected at an early stage, maintenance becomes plannable, and downtime can be specifically minimised. Integration into remote maintenance systems is also possible.