RAV RT003

Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
RAV RT003
Instruction operation
and maintenance manual
Code M0029 - rev. 1.1
Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
IMPORTANT!
This guide is integral part of the product and is intended to give the user instructions for use of
RAV RT003 brake test stand. Read it carefully before using the machine. Keep it in a known and
easily reachable place for the whole operation life of the product. Read it in case of any doubts. All
machine operators must be allowed to read this guide. The Manufacturer disclaims all responsibility
and holds Ravaglioli S.p.A. harmless for damages due to non-compliance with the indications given
in this guide and improper use.
Instructions for the installation and set-up of the product, reserved to the installer (specialized
technician), are given in a separate manual (part no. R0025)
Proper drawings, available at Ravaglioli dealer, indicate required building works and details on
system features.
RAVAGLIOLI S.p.A. reserves the right to make any changes to the models described in this
manual at any time for technical or market reasons
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
TABLE OF CONTENTS
1. INTENDED USE...........................................................................................................................1
2. TECHNICAL FEATURES ...........................................................................................................1
2.1. Control units............................................................................................................................1
2.2. Roller block.............................................................................................................................1
2.3. Weighing frame.......................................................................................................................1
3. SYSTEM DESCRIPTION.............................................................................................................2
3.1. Control unit .............................................................................................................................2
3.1.1. Remote control (optional) ................................................................................................3
3.2. Roller block.............................................................................................................................3
3.3. Weighing frame (optional)......................................................................................................4
4. INSTRUCTIONS FOR USE .........................................................................................................5
4.1. Staff training ...........................................................................................................................5
4.2. Emergency cases .....................................................................................................................5
4.3. Precautions ..............................................................................................................................5
4.4. Loading test program ..............................................................................................................6
4.5. Measuring axle weight ............................................................................................................6
4.6. Brake testing ...........................................................................................................................7
4.6.1. Rolling resistance force and brake heating.......................................................................7
4.6.2. Disc oval or eccentricity...................................................................................................8
4.6.3. Braking graduality, unbalance calculation and braking efficiency ..................................9
4.7. Automatic cycle ....................................................................................................................10
5. TROUBLE-SHOOTING .............................................................................................................11
5.1. Error signals ..........................................................................................................................11
6. MAINTENANCE ........................................................................................................................12
7. SYSTEM STOPPAGE AND DISPOSAL...................................................................................12
COMPOSITION OF MANUAL
16 pages (including cover pages)
02 numbered pages with Roman numerals
12 numbered pages
01 white page
10 Figures
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
I
Instruction Manual
RAVAGLIOLI S.p.A.
II
RAV RT003
Code M0029 - rev. 1.1
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
1.
RAV RT003
Code M0029 - rev. 1.1
INTENDED USE
This machine is intended for testing brakes in front and rear axles of cars not exceeding 35 q, under
full load conditions.
Max. load allowed for each roller block axle is 3.000 daN.
Warning! If above weight limits are not complied with, some system parts might irremediably
damage.
2.
TECHNICAL FEATURES
2.1. Control units
Power supply
Rated power (motors at working speed)
Max. absorbed power (motors at max. absorption)
Max. displayed braking effort
Accuracy
Weight
380V 3ph + neutral
6 kW
9 kW
500 daN
±0,5%
22
Table 1
2.2. Roller block
Roller size
Roller inner edge distance
Roller outer edge distance
Max. load allowed for each axle
Motors
Roller peripheral speed (loadless)
Grip coefficient
Weight
700 - φ 204
800 mm
2200 mm
3000 daN
M100 3kW
5,2 km/h
>0,75
390kg
Table 2
2.3. Weighing frame
Max. load allowed for each axle
Weight full scale for each axle
Accuracy
Weight
3000 daN
2000 daN
±2 %
30kg
3000 daN
2500 daN
±0,5%
30kg
Table 3
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Page 1/12
Instruction Manual
RAVAGLIOLI S.p.A.
3.
RAV RT003
Code M0029 - rev. 1.1
SYSTEM DESCRIPTION
3.1. Control unit
1
2
3
4
5
6
7
8
9
Figure 1
The control unit (or console) consists of an analog pointer display and a control cabinet.
Analog pointer display consist of the following, as shown in Figure 1.
1. Red signaling lamps
2. Black pointer
3. Red pointer
4. Red led bar
5. Yellow led bar
6. Green led bar
7. I.R. receiver for remote control
8. Green signaling lamps
Figure 1 also shows the control cabinet, including the main switch (ref. 9). The electric panel for
system power supply and motor start is housed inside the control cabinet.
CAUTION!:
Page 2/12
The control panel can be opened by authorized personnel only: high voltage into
the above panel might be dangerous to unskilled operators.
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
3.1.1.
RAV RT003
Code M0029 - rev. 1.1
Remote control (optional)
12-key infra-red remote control is the main control interface with the console.
The whole test can be fully performed on the remote control. The meaning of the keys can be easily
understood thanks to symbols on them. Function keys (F1, F2, F3 and F4) are used for special
procedures (e.g. setting) by authorized personnel.
Abandon or stop test
Start test
Save test
Select parking brake
F1 function key
F2 function key
F3 function key
F4 function key
Select oval procedure
Figure 2
3.2. Roller block
Roller blocks of RAV RT003 brake meter consist of a metal frame (bent sheet) with reinforcements
and channels for housing testing devices and equipment.
Roller motor drive consists of a gearbox (one for each roller pair) equipped with a load cell secured
to the frame.
During braking rollers are subject to a tangential force producing a torque resisting to gearbox
action, so that gearbox would tend to rotate around roller rotation axis if not secured to the load cell.
In practice, the load cell absorbs torque produced during braking.
Then the load cell sends a signal to the console. This signal is used for managing calculation and
displaying results.
Each roller pair has a proximity sensor (called CAR-ON sensor) for car presence detection. If
sensor support is lowered down, the microswitch will stop detecting support presence, contact will
close and an electric signal will be sent to the console. This signal enables motor start.
If either proximity switch does not close the contact, the console will receive no enabling signals
and test will be stopped. Therefore, test can be properly performed if both “CAR-ON” sensors are
lowered down by tested vehicle axle.
Each roller pair has also a proximity sensor, called TACHO sensor, for roller rotations speed
detection and car wheel rotation speed detection. This value is continuously measured and
compared with wheel initial speed; it determines sliding conditions causing test stop.
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Page 3/12
Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
Therefore, rollers will stop when set sliding threshold is reached; this threshold value usually
coincides with detection of max. braking power of tested axis.
Test can also be stopped by the operator in case of emergency or need by means of the remote
control or keyboard.
3.3. Weighing frame (optional)
Weighing frame consists of two sheet cross bars for securing the cells against which roller stand
frame rests.
Either two cut load cells or four cut load cells send a signal to tester, which is proportional to the
force exerted by the axis of the tested car, to the console, thus allowing weight measuring.
Weighing frame has two devices or four devices for adjusting roller stand level.
Page 4/12
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
4.
RAV RT003
Code M0029 - rev. 1.1
INSTRUCTIONS FOR USE
4.1. Staff training
The system can be used by duly trained and authorized personnel. For optimal machine control and
efficient testing, operators must be properly trained to work in compliance with the indications
given by the Manufacturer. Read the instructions for use in case of doubts; if still in doubt after
reading, do not try and interpret given information but call authorized service centers or technical
assistance department of RAVAGLIOLI S.p.A..
4.2. Emergency cases
CAUTION!:
In case of emergency, there is an emergency device (see Figure 1 – ref. 9) on
the console back. Always install the console so to have easy access to this
device. Roller start is usually inhibited if the vehicle axle is not on the roller
block. Press STOP on the remote control, if available, the rollers will stop
anyway within a set time, in case vehicle brakes do not work efficiently and
therefore do not cause roller automatic stop.
CAUTION!:
Non-authorized persons are not allowed within the testing area. Just one
operator must work within this area and should not come out of the vehicle
when close to the roller stand. If, for any reasons, the operator cannot come out
of the vehicle, he/she must call a second operator, who can enter the testing
area only after enabling the emergency device.
4.3. Precautions
CAUTION!:
Sometimes the vehicle may slide out of the rollers during brake testing. Pull up
parking brake if it does not affect tested axle to limit this possibility.
CAUTION!:
Vehicle is to be tested with engine on so to fill servo brake chamber. It is
important that engine is on above all if tested vehicle has hydro-pneumatic
suspensions. In any case, tested vehicle should not have antitheft steering lock
locked.
CAUTION!:
Ensure that brakes are dry and tires are inflated to correct pressure value before
starting brake test.
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Page 5/12
Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
4.4. Loading test program
Position the main switch to I to start the system (see Figure 1 – ref. 9). Allow operative program to
load and pointers of analog display to reset until all bar display flash in turns (see Figure 3).
NOTE: do not operate testing device during operative program loading (e.g. do not drive on
weighing frame) as system is checking for their proper operation.
Inner Led and outer Led
Flashing alternatively
Figure 3
4.5. Measuring axle weight
If a weighing system is available, weigh vehicle axle before the test so that the system can calculate
braking efficiency value. Drive the car onto the weighing device. As soon as vehicle is on rollers,
green lights will turn on. Then axle weight is indicated by the red pointer. The example shown in
Figure 4 this value is ~ 8,80kN (weight is indicated on outer scale).
If the system detects a stabile weight for several seconds, axle weight is automatically saved.
Weight pointer
Green lights on
Weight outer scale
Figure 4
Page 6/12
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
4.6. Brake testing
Brake tester can take the following values:
-
Rolling resistance force;
Disc oval or eccentricity;
Max. wheel braking powers;
Braking unbalance between wheels belonging to same axle;
Braking efficiency for service and parking brake;
Testing of parking brake conditions is automatically requested by the system after rear axle service
brake test. The operator can manually select front axle parking brake test before roller start by
pressing the key with parking brake symbol (see Figure 2 on page 3).
During testing phase of : front axle – rear axle and parking brake proper led at bar display bottom
will flash (see Figure 5).
Parking brake test in progress
- red led at the bottom is flashing
Rear axle test in progress
- yellow led at the bottom is flashing
Front axle test in progress
- green led at the bottom is flashing
Figure 5
After driving the vehicle onto roller block, the system is enabled to start the rollers as well as
braking procedure. Press START to start the rollers.
When rollers are not working, green lights are on. When rollers start, green light will turn off and
red light will turn on, first on left hand side and then on right hand side. Red lights will flash for
several seconds. Barking procedure can be started only when lights stop flashing and stay on.
4.6.1. Rolling resistance force and brake heating
After starting the rollers, allow red lights to stop flashing and become fixed and braking power
values to be shown by red and black pointers. DO NOT BRAKE at this stage. Values displayed on
analog indicator show the force required to drive non-braked wheels (rolling resistance force only).
Note: Red pointer indicates left force, whereas black pointer indicates right force.
Slowly press brake pedal until a force value of at least 0.6-0.8 kN is displayed on indicators; keep
this values for some time to allow brake friction elements to warm up. Release brake pedal and
observe power values on indicators; see whether values go immediately back to min. values
corresponding to rolling force.
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Page 7/12
Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
Red lights on
Force values on
inner scales
Figure 6
4.6.2.
Disc oval or eccentricity
Press the brake pedal until a force value of 0.8-1 kN is displayed on the indicators. Then press the
key with oval symbol on remote control (see Figure 2 on page 5). During oval procedure all lights
will be flashing. Keep exerting this force steadily onto the brake pedal for the whole period of time.
Red and green
lights flashing
Oval values on
inner scale
Figure 7
At this stage the absolute value for braking power variation due to disc oval or drum eccentricity
(called “oval”) is displayed.
Note: oval value indicated by (red and black) pointers on inner scale is meant divided by 10. (Figure
7 shows oval values of approx. 0.12 and 0.16 kN)
Press again the oval key and release the brake pedal to return to min. values for rolling resistance
force before starting braking graduality analysis described in paragraph 4.6.3.
Page 8/12
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
4.6.3.
RAV RT003
Code M0029 - rev. 1.1
Braking graduality, unbalance calculation and braking efficiency
Slowly and gradually press the brake pedal. Then observe braking power values on analog
indicators and examine their graduality.
braking power on
inner scale
Figure 8
Continue pressing slowly and gradually the brake pedal until wheels stop (*). Red and black analog
indicators will indicate max. braking power values for several seconds.
NOTE (*) : If wheels cannot be stopped (it may often happen with rear axle), press STOP on
remote control to manually stop the rollers.
Also % UNBALANCE (dynamic braking unbalance) value will be indicated by red pointer, which
moves to calculated value, for several seconds. (see Figure 9);
Now see whether it falls within allowed tolerances according to the following:
if within tolerances
but close to limit values
if outside tolerances
Æ green lights are on as well as green bar top
if within tolerances
Æ green lights are flashing and yellow green bar top is on.
Æ red lights are flashing and red bar top is on
Out of tolerance:
red lights flashing
% unbalance value
within tolerances:
green lights on
% unbalance within
tolerance – green bar
top on
within tolerances but
close to limit values:
green lights flashing
% unbalance within
tolerances but close to limit
values – yellow bar top on
% unbalance out of
tolerances – red bar top on
Figure 9
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Instruction Manual
RAVAGLIOLI S.p.A.
RAV RT003
Code M0029 - rev. 1.1
If brake test stand is equipped with a weighing system, it can evaluate % braking efficiency of
service brakes and parking brake at the end of braking procedure for rear axle and emergency brake
(if it works on rear axle).
Press F2 on remote control (see Figure 2 on page 3), red pointer of analog indicator will indicate %
braking efficiency on outer scale. While displaying braking efficiency, colored bars are all on.
Note: press F2 on remote control to display % unbalance (Figure 9) and braking efficiency (Figure
10) alternatively.
all colored bars on
% braking efficiency
value on outer scale
Figure 10
After examining braking results, the operator can press ENTER to save data or START to restart
rollers and repeat the test.
WARNING! To switch to next stage after examining axle under testing, vehicle axle must be driven
out of the roller seat. If driving axle is on rollers and brake tester motors are not of the self-braking
type, press START to start the rollers and drive vehicle axle out more easily.
4.7. Automatic cycle
RAV RT003 –TEST LINE can be set for “AUTOMATIC CYCLE” only.
Automatic cycle consists of fully automatic braking procedure carried out by system managing
program.
To start testing, power on the brake tester (see paragraph 4:4) and then drive the vehicle onto the
test brake stand. Once the program has detected vehicle stabile weight, rollers will automatically
start for brake test.
After roller stop (*), max. braking powers –black pointer for r.h. side and red pointer for l.h. sideand, after a few seconds, unbalance value (see Figure 9 on page 9) are displayed. Now drive out of
rollers. To test another vehicle, drive on brake test stand; rollers will start automatically.
If vehicle stays on roller after brake test has been completed, rollers will start automatically after a
few seconds for a new braking cycle.
(*) : If wheels cannot be stopped (it may often happen with rear axle), rollers will automatically
stop after a braking limit time of about 10-15 seconds.
Page 10/12
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]
Instruction Manual
RAVAGLIOLI S.p.A.
5.
RAV RT003
Code M0029 - rev. 1.1
TROUBLE-SHOOTING
Possible RAV RT003 troubles are listed below. RAVAGLIOLI S.p.A. disclaims all responsibility
for any damages to people, animals or objects caused by non-authorized personnel or use of nonoriginal spare parts. Before starting any trouble removing procedure, switch off the main control
panel. In case of doubts, make no attempts but call RAVAGLIOLI technical service department for
safe instructions.
Items marked with this symbol require Technical Service Operators.
Do not try yourself!
TROUBLE
CAUSE
SYSTEM DOES NOT OPERATE
- No mains voltage
- Protection fuses blown
REMOTE CONTROL
- Obstacles between transmitter
and receiver
- Flat battery (red led does not
turn on)
- No signal
BRAKE TESTER MOTORS DO - Starting relays faulty
NOT START
BRAKE TESTER MOTORS STOP - Speed sensors faulty
AFTER A FEW SECONDS
NO ENABLING SIGNAL FOR
- CAR-ON sensor faulty
BRAKE TESTER MOTOR
START
REMEDY
- Check mains voltage
- Check protection fuses
- Check for possible obstacles between
transmitter and receiver
- Replace battery
- Check connection of receiver cable to
motherboard
- Check starting relays
- Check speed sensors
- Replace CAR-ON sensor
5.1. Error signals
During RAV RT003 TEST LINE STAND operation, in case of mistakes made by the operator or in
case of defective devices, errors will be signaled on the analog display. In case of error, all four
lamps will alternatively flash: r.h. green and red lamps and l.h. green and red lamps.
If the system has a remote control, press STOP during error signaling to return to previous program
phase. As for automatic cycle (with no remote control), program will automatically stop error
signaling and restart braking test.
If the error persists even after following given instructions, call RAVAGLIOLI technical service
department.
NOTE: in case of errors during the automatic cycle, braking test will be automatically restarted for
three times; the fourth time the system must be power off and on.
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
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Page 11/12
Instruction Manual
RAVAGLIOLI S.p.A.
6.
RAV RT003
Code M0029 - rev. 1.1
MAINTENANCE
CAUTION!
Before starting any maintenance procedure, unplug the machine.
If brake test stand covers need to be removed, limit the working area with proper
enclosures so to allow entry to authorized personnel only.
Perform the following checks every 6 months. Perform them every 2-3 months in case of system
frequent use:
- grease brake tester roller driving chain;
- check for proper tensioning of brake tester chains. Adjust, if needed. Be sure rollers are properly
aligned;
- deeply clean brake tester and suspension tester channels with a vacuum cleaner. All parts must
move freely. Air scoops and water drain tubes must not be clogged.
CAUTION!:
7.
Any other maintenance procedures not described above, such as setting checks, are
described in the installation manual. These procedures must be performed by
specialized personnel duly authorized by RAVAGLIOLI S.p.A.
SYSTEM STOPPAGE AND DISPOSAL
Stoppage: in case of long stops, unplug the machine and disconnect all power sources. Also protect
parts, which might damage due to dust.
Grease all parts that might damage because of drying process.
Disposal: if not used any longer, the system must be disabled first.
- disable all potentially dangerous parts
- evaluate machine class according to its disposal degree
- dispose of the machine as iron scraps in authorized disposal centers
- if considered special waste, disassemble and divide into homogeneous classes. Then, dispose of
in compliance with current laws.
Page 12/12
RAVAGLIOLI S.p.A. – 40044 Pontecchio Marconi (BO) Via I Maggio, 3
Tel. 051/ 67.81.511 – Fax 051/ 84.64.67
e-mail: [email protected]