_2_Heavy-Characteristics_DRAFT.pdf

Roller Brake Test Stand # 2 Heavy Vehicle & Ramp without Load Simulation Brake Test Stand for …

Roller Break Tester (RBT) for TRK up to 18T axle load; 4WD; Axle play tester; Weighing device; Ramp system above floor.

1. Background:

Theater Logistics Support Center Europe (TLSC-E) is acquiring the replacement of the existing mobile roller brake tester along with initial equipment operator training. These do not comply with the guidelines for the application, quality and testing of brake testers (Brake Tester Guideline) from the Traffic journal (Verkehrsblatt) 09/2011 of 12.04.2011. The guideline for brake test stands, §29 StVZO Annex VIIId, states that all brake test stands must comply with the new requirements by December 2019. Use of non-compliant brake test stands will no longer allowed starting on 1 January 2020. The new requirements for brake test stands are mandatory from January 2020 for all brake test stands. This includes special requirements, e.g. the RBT must have a minimum roller diameter, and the rollers must have a certain friction coefficient, the test speed is compulsory and must be fitted with ASA live stream (the ASA live stream interface can be used to read out the measurements by the examiner).

The details, in particular regarding all functional requirements, specified in part 3 Requirements.

2. Service - Object delivery item

The subject of this service description is the delivery of brake test stands (roller) in mobile design, including accessories for the performance of effectiveness tests on brake systems of wheeled vehicles of the US Army, for testing and repair facilities of the Theater Logistics Support Center Europe (TLSC-E).

Brake tester in mobile design Commercial brake test stands in mobile design including accessories, which meet the requirements of Part 3 are to be supplied.

3. GENERAL overview

The Roller Brake Tester (RBT) shall:

- Consist of a pair of roller sets mounted inside frame.

- Have the capability of accepting an axle load of 18,000kg.

- Have the capacity to drive the rollers and record a minimum peak value of 4,000kgf.

- Have the capacity of recording Service Brake Performance and Parking Brake performance separately.

- Have the capacity of recording the static weight of each axle of the vehicle as presented.

- Have the capacity to operate and produce a printout of test reports independent.

- Be free of any disturbance from radio frequencies and electromagnetic fields.

- Operate reliably in all conditions likely to be encountered within the vehicle testing environment. The equipment recessed in the frame/floor shall meet a weather proof rating of IP42 or higher.

- Have the display and a user interface positioned on the driver’s side and ensure the vehicle tester, for all axles being tested, has an unobstructed line of sight and a clear view when in the driving position. The display must have adequate visibility of the readings during the test procedure, particularly in poor light conditions or bright sun light.

- Have the option of a wireless mobile display available.

- Ignore a test measurement value that is not part of the intended brake test e.g. when an axle is entering or exiting the RBT.

- Not commence a new vehicle test without clearing any existing measurements.

- Detect and ignore negative brake readings.

- Meet current health and safety regulations and standards.

The Brake Tester shall have fixed configuration is based upon the design of a mobile Roller Brake Tester that is design built for outside use.

On sight survey to ensure correct configuration of roller brake tester (RBT) is configured for the equipment that the Unit will brake test. This also includes axle joint play tester and scale for weighing vehicle. Complete installation of RBT that provides a full functional and operational RBT for the customer.

The brake tester must meet all the requirements of the guideline for the application, condition and testing of brake tester (brake tester guideline) in accordance with traffic journal 09/2011 of 12.04.2011.

Device must be build IAW and for the requirements of Brake Tester Directive valid from 1 January 2020 and shall have the capability to test vehicles IAW § 29 StvZO Annex VIIID inspection of motor vehicles and trailers.

Basic Requirements of §29 StVZO Annex VIIId:

- Standardized data interface (ASA livestream)

- Roll diameter min. 200 mm

- Friction coefficient between tire and roller dry: 0.7 and wet: 0.6

- Test speed min. 4 km / h

- Test stand shutdown at 27% slip (+/- 3%) between tire and brake roller

- Reference value method for determining the minimum braking force based on brake system pressure or optional foot brake on the brake pedal

- Also required is a weighing and weighting system that is integral with the brake test stand and an axle play detector.

TECHNICAL DESCRIPTION - DATA

Technical (Contractor shall provide)

• Roller Brake tester with Axle weighting system, Four wheel drive regulator set (4x4) (6x6) (8x8), Universal Impulse transmitter for tire profile, Two-speed operation, Axle play tester, over floor, Ramp unit, Industrial Laptop, touch screen, include digital display, computing technology and Printer system.

• The brake tester shall be used for performance of performance tests of brake systems on unarmored and armored wheeled vehicles with all-wheel drive (4x4, 6x6 and 8x8 driven vehicles) regulator set, Universal Impulse transmitter for tire profile, also with coarse-groove tread pattern tires and permanent through-drive without interfering with the brake system (without dismantling components in the drive train).

• Roller Brake Tester length & width depends of largest vehicle to be tested

• Capable of conducting brake tests on various vehicles

• Vehicles to be tested: Heavy Trucks and Trailer with up to twelve axles.

- PLS, HEMMT, HMMWV, LMTV, FMTV.

- Largest equipment tested is the PLS 11.0m

- M915 Truck + Trailer with approx. length of 18.5m

- M870A4 Vehicle Trailer: width of low bed 3,70m

• The drive of the brake tester must be designed for the loads emanating from wheeled vehicles, e.g.

STRYKER, MAXXPRO, COUGAR, HEMTT, Truck PLS (in particular the design of the transmission of the roller drive).

• Capable of compiling weight data for each axle to determine if there is a greater than 25% brake force difference between the left and right.

• Measure up to 40 kN of brake force, indicating the force percentages per axle as well as the total for the vehicle.

• Provided computer and printer for operation of the machine and printing of results.

• Contains digital gage panel with brake force, axle weight, brake force percentage read out, low brake force warning, speed and brake timing system for proper brake force calculation.

• Device shall have the capability for operation in open environment.

• Contains rain cover for all weather operation protection.

• The brake tester should be packed and transported inside of two 20’ ISO containers.

• The brake tester shall meet the requirements for outdoor operation in climate categories A1 - A3, B1 -

B3 and C0 and for year-round operation with at least 500 efficiency tests on brake systems.

Furthermore, the brake tester must be suitable for transport in climate categories M1 and M2.

• Includes minimum 2-year warranty that includes re-calibration as required during warranty time.

• Installation of machine required after purchase.

• Initial training of machine operators required that provides operator certification to operate machine and certify brake tests of vehicles.

Technical description - data:

• The brake tester must have a connection cable for the electrical supply.

• Length of connection cable: lConnection = 20.000 mm ± 5%.

• The brake tester shall be equipped with an automatic shut-off device and an anti-run-up device.

• Drive rollers and motors must be splash-proof.

• The brake tester must be zinc or powder-coated and resistant to salty sea air.

• All electrical systems shall be sealed (Protected) from wind driven rain (IP54 or IP65).

• The brake tester must have a switch cabinet with switch cabinet heating.

• Display brake force scale: 0 – 800 daN, 0 – 4000 daN.

• Roller brake tester with cable or radio pedal force meter.

• The brake tester must have a lockable main switch.

• The system shall be equipped with a minimum of one clearly labeled emergency stops.

• The brake tester shall be equipped with a sensor device to determine the wheel speed (also for wheels with a roughened lug profile).

• The brake tester must be equipped with connection options for other test devices during operation via the IT hardware and the wireless touch screen of the tester.

Technical data ramp and roller set:

• Special Version for Low-Bed Trailers.

• Both roller sets within one frame.

• Middle cover

• Roller cover plates, drive-over version

• Ramp width: wRamp = 1.700 mm ± 3%

• Ramp height: hRamp = 300 mm ± 10%

• Ramp length (incl. access and exit): lRincl ≤ 20.000 mm ± 3%

• Ramp length (excl. access and exit): lRexcl ≤ 14.200 mm ± 3%

• Test bench length (excl. entry and exit ramp): lBPS ≤ 21.000 mm ± 5%

• Test width: wTest = 3.700 mm

• Roll length: lroll = 1.600 mm ± 5%

• Roll diameter: dRoll = ≥ 250 mm

• Roller axis distance: daxis = 470 mm ± 5%

• Diameter of sensing roller: dRoll = 100 mm

• Rear roller elevated by min = 50 mm

• Surface of rollers: Steel welded surface

• Axle load (drive-over): mAxle load = 18.000 kg.

Technical data drive motor

• Power of drive motor: P Drive ≥ 2 x 11kW

• Power supply: 3/N/PE 400 V 50 Hz

• Fuse protection gG: 63 A

• Pedal force meter

• Friction coefficient of roller between tire and roller in the

- dry condition: at least 0.7µ

- wet condition: at least 0.6µ

- slip cut-off at an actual slip of I = 27 ± 3%.

• Roller test speed: vTs ≥ 2 km h; (Test speed 1: vTs1 = 3 km h, Test speed 2: vTs2 = 6 km h)

Weighing Capability:

Integrated static and dynamic weighing device with digital display.

The RBT shall measure individual wheel weight and provide individual wheel, axle and total weight reports Measuring range: 100kg mMeasuring range ≤ 18.000 kg.

The brake tester shall have a radio remote control, with control of the roller sets in manual mode and switching to single wheel operation.

The brake tester shall have a 4WD Visco and Rigid regulator set and two Different Test Speeds - manual switchover between standard and double test speed. (Test speed 1: vTs1 = 3 km h; Test speed 2: vTs2 = 6 km h)

The brake tester shall have five (5) pneumatic and two (2) hydraulic wireless design, pressure transducers (converters), including receiver and charging station.

• Adjust the settings on the pressure converters via Radio remote control

• Measuring range: pneumatic pressure transmitter: 0 bar ≤ pMeasuring range ≤ 20 bar

• Measuring range: hydraulic pressure transmitter: 0 bar ≤ pMeasuring range ≤ 160 bar

The brake tester must be equipped with connection options for other test devices during operation via the EDP hardware and the wireless touch screen of the tester (Connection for pedal force meter, Battery and recharging box etc.).

The brake tester must be equipped with a wireless trigger for data acquisition during operation via the IT hardware and the wireless touch screen.

The brake tester must be equipped with the following computing hardware:

• Industrial Laptop or PC including DVD burner.

• The brake test system runs automatically and provides pass/fail test results with the operator only having to drive the vehicle and apply the brakes. All functions of the tester shall be controlled with a wireless remote control while sitting in the normal driving position. Two (2) wireless transmitters shall be provided for each system, which eliminates the need to run cables to the bus.

• All controls and computer readouts must be visible in direct sunlight.

• Monitor with at least 24" display.

• Optional: RBT installation inside building

- Rotatable & Folding Wall Holder f. TFT-Industrial- Flat Screens Monitor (up to 42")

- Simultaneous Industrial- Flat Screens Monitor 32" incl. Pedestal, HDMI, (TFT-Standard)

- HDMI-Cable 30 m

• PC wheel mouse.

• Keyboard (protected industrial keyboard).

• Inkjet printer A4.

• Wireless touch screen for simultaneous screen display, test bench control and defect input.

Display units

• Infrared / Wireless remote control, with an operating distance of 15-25 meters.

• Large and easy-to-read display with analogue and digital readout of all relevant test data.

• Integrated guide.

• Large analogue dials showing readings of left and right brake forces.

• All controls and computer readouts must be visible in direct sunlight.

• Display brake force scale: 0 – 8kN, 0 – 40kN.

AXLE PLAY TESTER

The brake tester shall be equipped with an axle and joint play tester with multi-functional control, IAW Brake Tester Directive 2020/2023

Technical data:

Special Version for Flat-Bed Trailers Two test plates installed into frame/ramp unit Axle load (drive-over): mAxle load = 20.000 kg Wheel load: mWheel load = 10,000 kg

- Dimensions of test plate (L x W x H) 1100 x 750 x 10 mm ± 5%

- Test plate movement = 104 mm ± 5%

- Test plate speed = 30 mm/s

SOFTWARE

The brake tester must be equipped with the following software:

- Data management system according to the state of the art.

- Current operating system for industrial PC (Running Windows 10).

- Updateable (not online) test software according to the guideline for the application, condition and testing of brake test benches (brake test bench guideline) according to Road Traffic Bulletin 09/2011 of 12.04.2011.

IT security/architecture/standardization The Contractor shall provide updateable software for the brake tester. It should be noted that the brake tester is operated as a self-contained system (i.e. not connected to the Internet or Intranet US Army).

The brake tester must also be able to continue operating without an update or after expiry of a license in the last software configuration until the current update is available.

TRAINING

Vendor shall provide operator training and multiplier training, with a theoretical and practical part within the framework of the installation, handling and dismantling of the brake tester. After completion of the training, the Contractor shall submit to the Client the confirmation of participation with the surname and first name of the participants. The training course shall be held in German or English.

INSTALLATION

Installation requirements to be included in contractual performances:

• Removal of existing system

• All required project coordination to include upfront foundation planning and foundation preparation.

• Installation of machine required after purchase.

• Transport of the devices to the final destination point.

• Unloading of the equipment.

• Test stand will be mounted in open environment; or Optional:

- Installed inside the maintenance facility.

• Leveling and mounting to foundation.

• All required electrical and construction requirements.

• Disposal of packaging material, pallets and other trash.

• Test to include TÜV / DEKRA acceptance.

• Any other final activities required for proper operation, but not included in this document.

Upon delivery of the brake tester, the Vendor shall provide the Client with a maintenance/ servicing manual describing care and simple maintenance work and serving as the basis for the operator of the brake tester to carry out care and simple maintenance work. Vendor shall provide Operational and Maintenance manuals in English and German.

WARRANTY

• The manufacturer shall certify that the equipment shall meet or exceed the specified performance requirements and be free from defects in material or workmanship for a period of min two (2) year after installation.

• The warranty will include all parts, labor and travel to repair /calibrate machines if they become unserviceable.

• The Contractor agrees to carry out repairs on demand within 3 working days.

The Contractor shall provide an EC Declaration of Conformity as part of the operating instructions upon delivery.

By affixing a CE mark to the brake tester, the Contractor confirms that it conforms to the applicable European internal market law.

By affixing a GS mark to the brake tester, the Contractor confirms that it complies with the requirements of § 21 of the Product Safety Act.