Advanced Mayr solutions for use in test benches
In a rapidly evolving market, where test accuracy is becoming increasingly critical, innovation also involves high-performance mechanical components. Advanced materials, optimized design, and tailor-made solutions are now enabling factors for more efficient, responsive, and sustainable test benches. In this context, the choice of transmission elements—such as couplings—has a direct impact on the final performance of the system. That is why designers and integrators are looking with interest at technically advanced solutions such as Mayr aluminum couplings, which combine light weight and torsional rigidity to meet the dynamic and energy efficiency requirements of modern test systems.
Test benches: designs and market between turnkey solutions and custom systems
Test benches are systems designed to simulate real operating conditions and test the performance, reliability, and safety of mechanical, electrical, or electronic components. In the automotive sector, for example, they are used to validate engines, transmissions, batteries, and braking systems by subjecting them to controlled stresses (torque, speed, temperature).
There are two main approaches to their construction:
- · Integrated (or “turnkey”) test benches, developed by specialized companies: these solutions offer standardization, pre-integrated certifications, and reduced commissioning times, making them ideal for industrial contexts where test repeatability is a priority.
- · Custom systems, designed and built in-house by original equipment manufacturers (OEMs) or research centers. This option is preferred when unique configurations are required, for example for advanced prototypes or applications with special requirements.
Mayr couplings are used in both scenarios thanks to their versatility. In turnkey test benches, they guarantee compatibility with the dynamic, robustness, and lightweight requirements of manufacturers; in customized benches, they offer designers the freedom to optimize transmissions without space or weight constraints.
The evolution of test benches in the era of electric mobility
In the test bench sector, innovation is driven by growing demand for precision, energy efficiency, and reliability. The electrification of vehicles, the introduction of advanced materials, and the focus on reducing consumption are placing increasingly stringent requirements on testing equipment.
According to data from the German association VDMA, in 2023 the global test bench market grew by 7%, thanks in particular to demand for high-performance test systems in the electric automotive, aerospace, and renewable energy sectors. This growth is set to continue in 2024, driven by the global race towards the electrification of mobility. According to ACEA, over 21% of new registrations in Europe in 2023 will be for electric or plug-in hybrid vehicles. As a result, there is growing demand for test benches capable of testing increasingly sophisticated engines, inverters, and traction systems.
Italian manufacturers, with their consolidated know-how and recognized engineering tradition, are responding to this dynamic scenario with technologically advanced solutions able to meet the expectations of domestic and international customers.
Lightweight = efficiency: a strategic advantage
In this context, the choice of components used in test benches plays a crucial role in determining the performance of the entire system. Lightweight aluminum couplings are an ideal solution for meeting high-dynamic testing requirements: they enable precise torque transmission, helping to keep rotating mass down in transmission sections where every gram can make a difference.
Although the weight of the coupling has a limited effect on the total mass when testing large components, the reduction in local inertia still has positive effects: it reduces vibrations and unbalanced forces and allows for more accurate control of test cycles thanks to high torsional rigidity. In addition, the light weight also simplifies the transport and handling of the coupling itself and the machinery in which it is installed, reducing energy consumption throughout the entire product life cycle: from logistics to commissioning and maintenance.
Aluminum: technical performance and environmental benefits
With a specific weight of approximately 2.7 g/cm³ compared to over 7.8 g/cm³ for steel, aluminum offers weight savings of over 65% for the same volume. In test bench couplings, this difference translates into a significant reduction in rotational inertia, with a cascade of benefits: lower energy consumption during test cycles (thanks to the reduced power required to accelerate/decelerate the masses), less stress on motors and drives, and longer life for components such as bearings.
Modern aluminum alloys, enriched with elements such as silicon, magnesium, or zinc, offer an optimal combination of lightness, mechanical strength, and dimensional stability. Thanks to heat treatments and advanced processing technologies, aluminum can also be used in high-dynamic applications, ensuring durability and compatibility with harsh environments.
A further advantage is the sustainability of the life cycle: aluminum is 100% recyclable without loss of mechanical properties, reducing the environmental impact both during production (up to 95% less energy compared to production from raw materials) and in the disposal of machinery at the end of its life. For test bench manufacturers, this feature represents added value in terms of the circular economy, aligning with environmental, social, and governance (ESG) standards, which are increasingly considered central to the market.
Greater design freedom, better overall performance
In addition to direct functional benefits, the use of lightweight aluminum couplings offers test bench designers greater freedom in the design phase. The reduction in weight allows for the optimization of load-bearing structures, the resizing of actuators, and even the improvement of component layout in confined spaces. All this translates into more compact, responsive, and flexible machines capable of adapting more easily to the testing requirements of ever-changing components. In R&D, where test benches must be modular and reconfigurable, lightweight construction is a real design enabler.
Lightweight couplings for high-performance testing
Among the Mayr solutions best suited for use in test benches, the ROBA-DS series couplings stand out for their reliability and precision; they are also available in aluminum versions, specifically designed to meet the requirements of light weight, torsional rigidity, and dynamic precision. ROBA-DS is a high torsional rigidity disc coupling, particularly suitable for applications requiring precise, backlash-free transmission even under high loads. The aluminum versions reduce rotational inertia without compromising robustness, minimizing rotating masses even in medium-long transmission systems, making these couplings ideal for high-frequency dynamic testing or for cycles requiring rapid torque changes. Compact and highly modular, Mayr aluminum couplings are suitable for test configurations with limited space or complex architectures. Thanks to the lightness and strength of aluminum, they offer low mass without sacrificing precision, making them effective in tests where high acceleration and deceleration values are required.
These models are specifically designed to meet the requirements of modern test systems: high responsiveness, fine motion control, and compatibility with increasing demands for precision and energy efficiency. The use of optimized components such as these allows test bench manufacturers to achieve high performance and design systems in line with the latest international standards.
