MSG equipment MS1000+ Test Bench for Testing Shock Absorbers Instruction Manual

MSG equipment MS1000+ Test Bench for Testing Shock Absorbers Instruction Manual

INTRODUCTION

This manual describes how to obtain data on the technical condition of the shock absorber on the MS1000+ test bench (hereinafter, “the bench”).

WARNING! The manufacturer is not responsible for any damage or harm to human health resulting from non-compliance with the requirements of this manual.

The bench is designed to record the operating diagram of the shock absorber (resistance force dependence on the position of the piston) and its working characteristics (shock absorber  resistance dependence on the speed of movement of the piston) by which it is possible  to determine:

• need to repair/replace the shock absorber;
• cause of the fault;
• quality of the repaired shock absorber;
• compliance with the performance characteristics of shock absorbers to technical requirements.

Also, the bench allows for long-term tests of the shock absorber.

WARNING! It is forbidden to check the shock absorbers with the spring, because this can lead to the breakdown of the bench.

The bench has the following possibilities:

• Diagnostics of all types of shock absorbers of vehicles with different types of fastenings and resistance force up to 1000 kg.
• Diagnostics of electronically controlled shock absorbers with MS203 adapter.
• The diagnostics of the shock absorbers on the bench can be carried out in automatic and manual modes:
• automatic mode is designed to remove the working diagram and the operating characteristics of the shock absorber;
• manual mode is designed for shock absorber pumping before diagnostics, shock absorber  analysis at a certain (desired) frequency and required time period, testing of  electronically controlled shock absorbers with MS203 adapter
• Keeping the results obtained in automatic diagnostic mode and printing them.
• Comparison of diagnostic results with reference data, for example, comparison of test results of new original shock absorber with diagnostic one.

TEST BENCH DESCRIPTION

The bench consists of the following main parts (fig. 1):

1.  mechanical compartment;

2. the test zone and contains a diagnostic shock absorber;
   English Test bench MS1000+ 6

3.  touch display provides diagnostic data output and control of bench functions;

4. block filling shock absorbers with nitrogen;

5.  control panel, provides power control of the bench and control of pneumatic clamps;

6.  electrical compartment;

7. pneumatic clamp control pedal unit, duplicates the buttons on the control panel.
   

Figure 1. Main elements of the bench

Work with the diagnosed shock absorber is carried out in the test area (Fig. 2) , which includes

1. pneumatic upper clamp;
2.  temperature sensor and zip tie for its attachment to the shock absorber;
3.  pneumatic lower clamp;
4.  stopper of the lower clamp;
5. wheels for adjusting of height lower clamp;
6. stopper for adjustment of lower clamp height.
   

Figure 2. Test area of the bench

The following elements are arranged on the control board ( Fig. 3):

1.  buttons for controlling pneumatic clamps;
2.  button «EMERGENCY STOP» – emergency power off of the bench;
3. button «OFF/ON» – power off/on of the bench. If the «EMERGENCY STOP» button is pressed, the «OFF/ON» button has no effect.

Figure 3. Control board

The shock absorber is fixed in the test area by pneumatic clamps, which have the following basic elements, see Figures 6 and 7.

Figure 4. Elements of the top pneumatic clamp: 1 – cam; 2 – slider guide; 3 – slider; 4 – locking nut; 5 – pusher

The lower pneumatic clamp (Fig. 7) has interchangeable fixtures (Fig. 2) which allow for the fixation of shock absorbers with different types of anchorages.

Figure 5. Elements of the lower pneumatic clamp:
1 – cam; 2 – slider guide; 3 – slider; 4 – locking nut; 5 – pusher; 6 – installation screw; 7 – device for fixing the shock absorber

TEST BENCH MENU

The initial menu of the bench (Fig. 6) is activated when the door of the test area of the bench is opened and contains:

Figure 6. The initial menu of the bench

1. Pneumatic clamp control buttons.
2. Information field that displays the current values of the stroke of the piston, the force on the rod.
3. Button to switch to the bench setup menu.
4. Button to switch to «Comparison of results» the menu.
5. Button «Turn off the bench». This button turns off the computer of the bench, complete bench disconnection is carried out by the button «ON/OFF» on the control panel (pos.3 fig.3).

The main menu of the bench (fig. 7) contains:

1. Information field in which the status of the bench readiness for diagnosis is displayed. The following values can be displayed: «OK» – stand is ready for diagnostics; «Failed» – sensor calibration error; «Low pressure» – low pressure in pneumatic system.

2. Buttons to prepare the bench for diagnosis:
   «Test turnover» – when pressed, the benchwill perform one operating cycle of the shock absorber and will calibrate the position sensor. After the test turnover is completed, diagnostics will be available. «Strain gauge calibration» – when pressed, the bench will calibrate the force sensor.

3. Select the diagnostic mode. The buttons become active after the test turn and successful calibration of the sensors.
   

The bench configuration menu (fig. 8) contains:

1.  Shock absorber temperature thresholds:
   «Tmax» – the maximum temperature value, after which the diagnostic process will be stopped;
   «Tmin» – the value of the temperature below which the diagnostics of the shock absorber after exceeding the temperature «Tmax» will be available.

2. On/off reading of temperature sensor.

3. Company logo selection field on the results report.

4. Field for specifying the name of the company and the employee who performed the diagnostics in the results report.

5. Interface language selection field.

6. Strain gauge settings. These settings can only be changed in consultation with MSG equipment Support.

7. Button of exit to the bench operating system.

8. Field for setting units of measurements: force, temperature and displacement.
   

APPROPRIATE USE

1. The bench is used only for its intended purpose (see sect. INTRODUCTION).
2. In the test area, it is prohibited to carry out any repair work on the shock absorber. This may lead to the breakdown of the bench.
3. The shock absorber mounts securely in the pneumatic clamp. Do not allow any backlash between the shock absorber and pneumatic clamps. This will result in unreliable diagnostic data and a breakdown of the bench.
4. It is prohibited to test a knowingly defective shock absorber and shock absorber with a spring.
5. The bench shutdown should be performed through the interface of the service program, by clicking on the «Turn off the bench». After the monitor goes out, you can turn the «ON/OFF» button into the «OFF» position.
6. Use the button «EMERGENCY STOP» only if necessary to stop the diagnostic process in an emergency.
7. The touch screen saving uses the stylus (supplied as a set).
8. The bench operating is prohibited in a defective condition and not connected to the ground.
9. To avoid damage or failure of the bench, it is not allowed to make changes to the bench at one’s discretion. The bench cannot change by anyone other than the official manufacturer.
10. Computer equipment and software use not designed to work with this bench voids warranty obligations (even if the software and equipment were subsequently deleted). Only the original MSG equipment software can be installed on this hardware.
11. In the case of a breakdown in the operation of the bench, it should be stopped further and contact the manufacturer or the sales representative.

Safety regulations

1. Specially trained persons who have been given the right to work at the bench of certain types and who have been instructed on safe techniques and working methods are allowed to work with the bench.
2.  Electrical supply of the bench is prohibited to turn on with the open doors of the mechanical and/or electrical compartments. It is also PROHIBITED to open the door of the  electrical compartment until 10 minutes after the power is cut.
3. Shock absorber on the bench mounting and then dismantling is extra careful to prevent the unit from falling.
4. The workplace shall always be clean, well-lit, and have enough free place.
5. The bench disconnects from the electrical network before starting any maintenance work.
6. To ensure electrical and fire safe PROHIBITED
   • connect the bench to the electrical network having faulty protection against current overloads or not having such protection;
   • to use a socket without a grounding contact to connect the bench; English Operation manual 13
   • use extension cords to connect the bench to the electrical network. If the socket is removed from the site of installation of the bench, it is necessary to make adjustments to the electrical network and install the socket;
   • operation of the bench in defective condition.
   • independently to repair and make changes to the design of the bench, because it can lead to serious damage to the bench and deprive the right to warranty repair.
7. It is forbidden to leave unattended units on the bench with the drive running.

SHOCK ABSORBER DIAGNOSIS

Preparing the test bench and shock absorber for mounting

Install one of the equipment sets (Fig. 9) corresponding to the type of mounting of the shock absorber in the lower pneumatic clamp, see Fig. 11. If the top mounting of the shock absorber has a threaded part, twist the prism on it (Fig. 10)

Figure 9. Interchangeable fasteners for lower pneumatic clamp for various types of shock absorber anchorages

Figure 10. Prisms for fixing shock absorbers

1. prisms for fixing shock absorbers with shaft threaded tip (identical);
2. prism with uncalibred holes (for non-standard shock absorber shafts). Prism is a workpiece for manufacturing a special shock absorber attachment by cutting the necessary thread.
   

Figure 11. Types of shock absorber mounts and a combination of devices for mounting them on the bench

To replace the shock absorber fixation device in the lower pneumatic clamp, it is necessary to unscrew the mounting screw pos.6 fig. 5 and pull out the device. Next, set the device to stop and spin the installation screw.

Figure 12. Replacement of the shock absorber fixation in the lower pneumatic clamp.

Mounting the shock absorber on the test bench

The shock absorber shall be mounted on the bench in the following sequence:

1. Turn on the bench.

2. Pull the shaft out of the shock absorber to the maximum value.

3.  Place and fix the shock absorber in the upper clamp with the shaft up, for this:

4. Position the top mounting of the shock absorber (prism) coaxially with the  pneumatic clamppushers (see fig. 15) and «Clamp» it.

5. Alternately rotating pushers (see pos.5 of Figure.4) position the shock absorber so that its shaft is located in the middle of the pneumatic clamp (Fig. 16). It is necessary to control the correct positioning of the cams (see pos. 1. fig. 4), they must be fully extended (see fig. 17).
   
   _ Figure 13. Correct position of pneumatic clamp pushers relative to shock absorber attachment before «clamping»
   _
   _ Figure 14. Shock absorber positioning in clamp
   _
   _ F_ igure 17. Position of the pneumatic clip cams in the «clamp» state a – not right; b – right.****

6. Additionally, tighten the pushers to the shock absorber mount (prism),and then tighten the lock nuts pos.4 fig.4 (see fig.18).
   
   Figure 18. Tightening of the locking nuts in the clamp

7. Install and fix the shock absorber in the lower clamp, for this:

8. 4.1. Loosen the stopper of the lower clamp by turning the lever pos.4 fig. 2 counterclockwise by 2 turns (see fig. 19).
   
   Figure 19. Loosening the bottom clamp stopper

9. Loosen the stopper for adjusting the height of the lower clamp pos.6 fig. 2 by turning the lever counterclockwise (see fig. 20).
   
   Figure 20. Loosening the lower clamp height adjustment stopper

10. While holding the pneumatic clamp from turning, use the lower pneumatic clamp height adjustment wheel to set the pneumatic clamp pushers coaxially with the lower shock absorber mount (prism) (see Fig. 21).
    
    Figure 21. Adjusting the height of the lower pneumatic clamp

11.  «Clamp» the pneumatic clamp and position the shock absorber along the middle of the pneumatic clamp in the same way as with the upper clamp, see pos. 3.2.

12. In addition, tighten the pushers to the shock absorber mount (prism), and then tighten the lock nuts.

13. By turning the height adjustment wheel of the lower pneumatic clamp counterclockwise, set the working height of the shock absorber. Usually it is 3 – 5 turns, but at least 2 turns.

14.  Fix the height adjustment stopper and the lower clamp stopper.

15. Place and clamp the temperature sensor on the shock absorber (Fig. 22).

16. Close the test chamber door.
    
    Figure 22. Installed temperature sensor

SHOCK ABSORBER DIAGNOSTICS IN AUTOMATIC MODE

To activate the diagnostic modes it is necessary to press the button «Test turnover», then «Calibration of the strain gauge» on the screen of the main menu see. pos. 2 fig. 8. After that, diagnostic modes become active.

WARNING! At the test speed, the operator’s hand should be on the emergency the bench disconnection button so that in the event of an emergency, the engine on the bench will stop instantly.

To switch to the automatic mode of operation of the stand it is necessary to press the button «Automatic mode».

The menu of the bench «Automatic mode» (fig. 23) contains:
Figure 23. Menu of the bench «Automatic mode»
Figure 23. Menu of the bench «Automatic mode»

1. Information field in which the results of measurements are displayed graphically. If necessary, you can extend the selected feature fragment. This field contains two buttons:

   •   returns the original scale of the chart display;
   • transition between charts.

2. Automatic mode menu: «Settings» – allows you to adjust the parameters and sequence of the diagnostic process; «Save» – go to the menu of saving diagnostic results. «Save» – go to the menu of saving diagnostic results.
   WARNING! Running the diagnostic process removes previous results if they have not been saved.
   saved.
   «Print» – switch in the menu of printing the results of diagnostics.
   «Clean» – Removes current diagnostic results.
   «Open» – Opens stored diagnostic results.

3.  «START» button starts the process of recording the measured data, the results are displayed  on the screen in real time. Pressing again stops the process.

4. Information field in which the numerical values of the measured parameters are displayed in.

5.  Button to go to the main menu.

6. Switch to manual mode.

Before starting to record the characteristics of the shock absorber, it is necessary to set the sequence in the “settings” menu (Fig. 24). In this menu you can specify the parameters: the frequency of oscillation and the time of execution of each stage, the parameter of the maximum speed of the piston is reference and calculated automatically. To change the value, press the field with the value and use the keyboard to remove the current value, and then set the new value. The established sequence of operations can be reused

Figure 24. Settings menu «Automatic mode»

Recording a working diagram

1. The shock absorber shall be pumped in at least four cycles in the range of 10 to  30 min-1before recording the flow chart. The operation is performed using the menu manual diagnostics.
2.  The working diagram shall be recorded during the piston from 50 to 100 mm. The temperature of the shock absorber shall be between 15 and 30 C before testing.
3. The working diagram shall be recorded at the maximum piston speed between 0.25 and 0.52 m/s, which corresponds to the oscillation frequencies:
   • from 95 to 180 min-1 at the stroke of the piston 50 mm;
   • from 47 to 98 min-1 at the stroke of the piston 100 mm.
4. The working diagram shall be recorded at the maximum piston speed of 0.08 to 0.20 m/s when operating the closed-valve shock absorbers, corresponding to the oscillation frequencies:
   • from 31 to 95 min-1 at the stroke of piston 50 mm;
   • from 20 to 47 min-1 at the stroke of piston 100 mm
5. 5. Leakage of the liquid through the sealing of the shaft (other than the inevitable  lubrication of the friction surfaces of the shaft) is not allowed. 6. While writing the working diagram listen to the shock absorber. Knocks, squeaks, and other noises are not allowed. It is allowed «hiss» caused by the flow of liquid through  the valves. “Hissing” is allowed caused by the outflow of fluid through the valves.

Recording shock absorber characteristics

The shock absorber characteristic, which is the resistance of the shock absorber dependent on the speed of movement of the piston, is constructed according to the working diagrams recorded on the piston wheels and frequencies providing maximum piston speeds  from 0.08 to 1.00 m/s which corresponds to the oscillation frequencies:

• * from 31 to 180 min-1 at the stroke of the piston 50 mm;

  • from 20 to 180 min-1 at the stroke of the piston 100 mm.

Assessment of test results

The process of comparison of results is carried out in the menu «comparison of results» (fig. 25). The buttons «1», «2», «3» make the selection of displayed graphs.

Figure 25. Diagnostic results comparison screen

Shock absorber manual test

«Manual mode» menu of the bench contains (fig. 26):

Figure 26. Diagnostic results comparison screen

1.  information field in which graphical parameters of the shock absorber operation;
2.  button to go to «Automatic mode» and «Clean» – removes current measurement results;
3.  returns the original scale of the chart display;
4. field in which the shock absorber frequency is specified:
   • 60/120/180 standard shock absorber diagnostic speeds;
   • buttons «+» and «-» you can specify random frequency of oscillations;
5.  button «STOP» – stops the drive of the bench;
6.  button to switch to manual mode.

CHANGING SHOCK ABSORBER WORKING STROKE

The working stroke of the shock absorber shall be adjusted as follows:

1. Turn on the bench.

2. Open the test area door and the mechanical compartment door.

3.  Loosen the 4th bolt pos.1 fig. 27.
   
   Figure 27. Diagnostic results comparison screen

4. The change in the working stroke is caused by the rotation of the adjustment screw pos.2 of fig. 27 : counterclockwise – increase, clockwise – decrease.

5. You need to control the value of the change of turn by the parameter «Position» on the initial menu of the bench. The value of the parameter «Position» should be changed to the value calculated by the formula:
   Value of change of parameter «Position» = (New working stroke – current working stroke)/2.
   WARNING! It is prohibited to set the shock absorber at more than 80% of its maximum stroke because this may cause the shock absorber and/or the bench to break down.

6. Tighten 4 bolts pos.1 fig. 27.

7. Close the mechanical compartment door

CUSTOMER SUPPORT

MSG equipment

HEADQUARTERS AND PRODUCTION
18 Biolohichna st.,
61030 Kharkiv
Ukraine

+38 057 728 49 64
+38 063 745 19 68

E-mail: sales@servicems.eu
Website: servicems.eu

REPRESENTATIVE OFFICE IN POLAND STS Sp. z o.o.
ul. Modlińska, 209,
Warszawa 03-120

+48 833 13 19 70
+48 886 89 30 56

E-mail: sales@servicems.eu
Website: msgequipment.pl

TECHNICAL SUPPORT
+38 067 434 42 94

E-mail: support@servicems.eu

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