Global military deployments often require repair of heavy combat vehicles close to deployment locations, far away from fixed infrastructure and peacetime-equipped workshops. Mobile test systems can provide support in assessing damage and confirming the success of repairs carried out in the field.
Modern combat vehicle engines are characterised by high power density, and use electronic control units to ensure optimum operation under all environmental conditions. This makes it possible to analyse faults and thus control maintenance in a targeted manner, even in the field. However, due to their complexity, analysing faults and targeted control of repairs can be both time-consuming and difficult.
Mobile test systems offer a solution here, as they can be transported where required and operated in the field at manageable cost. Based on 60 years of testing experience in the production of transmissions for heavy combat vehicles, Renk Group has developed a mobile variant of its stationary test systems.
Renk Group subsidiary Renk Test System GmbH (RTS) has been working on mobile test benches since 2022 following a customer enquiry, resulting in two development directions. The first is a roller test bench for complete vehicles. The second is a mobile load test system for engines. These are due to be presented at the International Armoured Vehicle (IAV) 2024 conference in London. The next development steps planned are test solutions for suspension elements, drivetrains, and turret drives.
Mobile test systems
A mobile test system consists of dynamometers in containers, a container with cooling and supply equipment, and a container with the control station. The system is transported on two trucks: an all-terrain tractor with a low-bed semitrailer for the dynamometers and the control station, and an off-road truck for the supply container. The components are handled using standard logistics equipment when setting up the test equipment.
Credit: Renk Group
Dynamometers are at the heart of the system, used to simulate the driving resistance. The test bench uses the complete vehicle power pack for the test and drive power is provided by the engine, allowing the engines to be tested under realistic load conditions. The brakes used are eddy current brakes. The mobile system does not require any infrastructure or access to an external electrical grid, it is designed to be self-sufficient.
Testing
The power pack, consisting of the engine, gearbox, and cooling unit, is installed on the mobile test bench for fault analysis. This field testing capability can allow significant time savings for frontline units – without a mobile test system, the entire power pack would need to be replaced and transported to a regional depot or control centre workshops for minor repairs. For major repairs, the power pack is transported to the manufacturer for repair – typically either directly to the manufacturer or a contracted local repair centre with the appropriate equipment.
After the test bench run, a decision is made as to whether the entire power pack or just individual components need to be repaired. The test bench enables identification of defective components, which can then be replaced, and the engine re-tested to ensure it is functioning correctly. This means that only the defective component(s) need to be sent to the manufacturer, instead of the complete power pack.
Once the defective components have been repaired, power pack repair can be completed in the operator’s country. The final functional and acceptance test can again be carried out on the mobile test stand. This ensures that only a fully functional power pack is reinstalled in the combat vehicle.
Operational benefits
With a mobile test stand permitting monitoring and testing of components in the field, logisticians have a tool capable of increasing the operational availability of combat vehicles. By regularly running test procedures according to manufacturer specifications, repairs and maintenance can be performed more rapidly, thereby increasing operational availability.
Precise fault analysis and repairing or replacing only the defective components allows the user to quickly restore vehicles to operational readiness. Additionally, this reduces the amount of equipment required to be transported to the manufacturer, which saves on logistics costs and frees up transport capacity.
Further steps
Renk RTS is due to present the mobile test stand at the IAV 2024 conference, and discuss the solution with potential users in a workshop session. The concept will then be developed to completion and offered as a modular solution on the market.
Gerhard Heiming