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iii Froude Hofmann

Froude Hofmann – A World-Class Business.Froude Hofmann – A World-Class Team.

DETROIT

SAO PAOLO

WORCESTERMOSCOW

PARIS

ELZE

BRNO

BARCELONA

PUNESHANGHAI

SEOUL

MELBOURNEDURBAN

Froude Hofmann LimitedBlackpole RoadWorcester WR3 8YBEnglandTel +44 (0) 1905 856800Fax +44 (0) 1905 856811sales@froudehofmann.comwww.froudehofmann.com

©Froude Hofmann Limited 2009www.froudehofmann.comPart of the Harris Watson Group

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Froude Hofmann GmbHHeilswannenweg31008 ElzeDeutschlandTel +49 (0) 5068 462- 0Fax +49 (0) 5068 462- 129de@froudehofmann.com

Froude Hofmann Inc.45225 Polaris CourtPlymouth, MI 48170USATel +1 (734) 416 8000Fax +1 (734) 416 9113us@froudehofmann.com

Froude HofmannFroude Hofmann Indústria e Comércio de Equipamentos de Teste Ltda. Rua Frederico Grotte 120São Paulo, SPBrazilCEP 05818-270Tel: +55 (0) 11 5518 2699Fax: +55 (0) 11 8262 8733brsales@froudehofmann.com

Froude Hofmann (Shanghai) Co. LtdRoom 602, Building 6No.289 Bisheng RoadZhangjiang High Technology ParkPudong New DistrictShanghai, 201204Tel +86 (021) 339 32230Fax +86 (021) 339 32231chinasales@froudehofmann.com

LoCATIonS

1 Froude Hofmann

“Froude Hofmann is committed to developing, delivering and supporting world-class products to our customers wherever they may be”

A carbon-friendly company – working to a cleaner future

Contentsour vision 2Who we are, what we do 4Technology and innovation 6Customer service 8Products 10Quality and the Environment 16People 22The future 23

Photograph: compliments of Applus Idiada Spain (NVH Chassis Dynamometer)

3 Froude Hofmann

richard guest 2 managing director

our vision

we have a vision we all believe in

f roude Hofmann is over 130 years old and has a long history of innovation, achievement and industry leadership. Today, at

Froude Hofmann we are investing heavily to ensure our innovation keeps us at the forefront of technology and performance. That is our Mission. A Mission that is ingrained into our people, because we only employ people with the same core beliefs… people who believe in our Vision:

“to provide our customers, wherever they are located in the World, with superior products that are delivered on-time and supported with world-class service”

Lets look at this in a little more detail:TECHnICAL InnovATIonThroughout our history we have always been known for innovation and, with the backing of our owners Harris Watson group, we have significantly increased our product development programme to ensure our rate of innovation exceeds that of our competition. Our dedicated R&D team is bringing a whole series of new developments to the market that give significant operational and cost benefits to our customers.

From high-speed aerospace dynamometer applications to robot-drivers that are fully integrated with emissions or durability chassis-dynamometers, our focus is in providing our customers with superior technical and operational solutions. oPErATIonAL FoCuSWhen a client places an order with us, he is assured of a committed and thoroughly competent team delivering it. Our Project Management team are qualified to the internationally recognised

“Prince 2” standard, and use gated project-management systems in order to ensure satisfactory project control. Our manufacturing, supply- chain and product-test teams work within a lean-systems environment to ensure a quality product is delivered on-time.LoCAL – yET GLoBAL – SErvICETo deliver world-class service to our global customer base, we have opened four new international service centres over the past two years to supplement the three we already have. This year we will open two more to complete our world-wide footprint.

“Wherever our customers need us to be, we will be…”Our spare-parts capability is being enhanced too, with higher stock-levels and a new spare-parts website to allow our clients to see what is in-stock on a real-time basis. Add to this our 16/5 technical helpline, and you have a compre- hensive service support package that surpasses most competition. DELIvErInG ExCELLEnCEIndependent verification of our commitment to delivering Excellence is found in our winning the coveted “Investor in Excellence” award. This title is only awarded to companies who are found to comply with a rigorous excellence framework covering all aspects of business performance. The IiE standard is based on the European EFQM and US Baldridge Excellence models.

We have this coveted standard, of course, in addition to our quality accreditations of ISO9001: 2000, ISO 14001 and TickIT. PEoPLE MATTErOur success can be only as good as the people we have in our business. Our philosophy is to recruit the best, and to help

them develop within our team environment by providing the right training, continuous-improvement and human-resource culture.our CuSToMErS Our customers of today are our customers of tomorrow – we never forget that for an instant. From major new projects through to spare-parts and refurbishments, we ensure our customers are fully satisfied with our performance and products. That is why we have excellent references with major customer groups such as GE, Pratt & Whitney, Ford, Volkswagen, General Motors, Hyundai, Fiat and Renault.WHy FrouDE HoFMAnn?We are dedicated to supplying a comprehensive and specialist range of top quality technologically advanced solutions. Our team is committed to providing customer service that is second to none, which is why the Froude Hofmann name is the only one that matters in the vehicle and aerospace industries.

We stay by our customers through any operational challenges that may arise.

Your success is our success.

“Froude Hofmann over the past 5 years, have offered Mahle a very fine product, at good value, whilst providing great support” rALPH KACzMArEK,

MAHLE (NORTH AMERICA)

“From major new projects through to spare-parts and refurbishments, we ensure our customers are fully satisfied with our performance and products”

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5 Froude Hofmann

who we are, what we do 4where we are

hull designs he established the “Froude Number” – which is the hydrodynamic equivalent of the Mach number. This is still used in ship design and many other forms of flow characterisation today. During this period he invented the hydraulic dynamometer (1877) for testing ship engines and founded the company Heenan & Froude (1881). This company moved to Worcester from Manchester and extended its product range to include equipment to test engines for ships, cars and aircraft.

In parallel, Hofmann Prueftechnik evolved from the Kleinsorge Company which

who we areF roude Hofmann is a well

established international high-technology company dedicated to engineering

excellence in the supply of testing equipment.

The company has been trading for over 130 years and takes its name from the renowned English Engineer; William Froude (1810 – 1879). William Froude was educated at Oriel College, Oxford (1828) before working with Isambard Kingdom Brunel (1837) on the Great Western Railway and subsequently turning his attention to naval engineering. From his extensive research with ship

With this impressive heritage, Froude Hofmann today provides a complete

product portfolio in R&D and production environments in these markets:

Aerospace > Automotive r&D >Automotive Production >Industrial Turbine >Motorsport >Marine >

Over many years we have developed an excellent range of products within these markets. From standard dynamometers and control systems; through to fully integrated automated test

systems, containerised test facilities and turnkey solutions.AEroSPACE & InDuSTrIAL TurBInE TEST ProDuCTSFroude Hofmann’s turbine test systems use our unique hydraulic dynamometers and Texcel VX100 control system to provide high system response and load stability. Performance covers speeds up to 30,000 RPM and power absorption up to 30 MW. Scope of supply also includes engine mounting test stands, cradles/trolleys and inertia flywheels to these segments:

r&D >Performance >Endurance >Quality validation >

was formed in the late 1940’s by Herr Kleinsorge, an entrepreneurial engineer previously engaged in design and development at the Junkers company, who acquired the rights to manufacture the “Junkers” smooth disc hydraulic dynamometer. Additionally Hofmann developed a range of rolling road test rigs. In 1996 the two companies came together to form Froude Hofmann – maintaining the on-going product portfolio expansion strategy and bringing R&D applications and production test skills together in one great organisation.

Our products are used on the following customer systems:

Aerospace turboshaft/turboprop >Industrial turboshaft >Turbine development systems >

AuToMoTIvE EnGInE AnD TrAnSMISSIon TEST SySTEMSFroude Hofmann offers a comprehensive range of engine dynamometers and associated control systems which provides accurate, reliable testing of engines in all applications.

AC Dynamometers > – road load simulation capability with fast response for full transient/high dynamic engine testing AG > (Eddy Current) dynamometers – high accuracy, robust power absorption capability for development, endurance and production testing of engines.Hydraulic > (F-Type range) –

provides accurate high capacity power absorption capability for automotive petrol/diesel engines. Texcel > family of control systems which offer control capabilities – ranging from the simple Texcel V4 manual controller to the Texcel V12 providing full automation road- load and inertia simulation control with integrated data acquisition, to complement the dynamometers.A range of engine instrumentation >including fuel flow meters, fuel conditioning systems and combustion analysersWe also offer engine ancillary >equipment such as water and oil coolers, made to order.

Our control systems include the advanced Genysis software platform, a system with superior graphical user interface and high dynamic test capability.

what we do An additional application also includes a “vDriver™” simulation package, allowing our clients to simulate real-world driving conditions, driver profiles and real-road routes in their test cells.AuToMoTIvE vEHICLE TESTIn this market we offer Chassis Dynamometers Systems, Robot Drivers and special applications including our “vDriver™” simulation package. We provide fully integrated, automated test systems including; robot driver, auto fuel filling, airspeed simulation fans and data acquisition. Our full portfolio of standard and specialised chassis dynamometer systems are available for use in all vehicle test applications including:

Emission and fuel economy testing >to international regulations

Power-train development >Performance reliability testing >Climatic (–40ºC to +60ºC) >Wind-tunnel and environmental >(inc. altitude) testingSpecial “low-noise” designs for N.V.H. >testing in Semi-Anechoic ChambersLight vehicle and Truck applications >Tractor and industrial vehicle >

AuToMATIC roBoT DrIvEr SySTEMSOur advanced ROBOT DRIVER adds extensive flexibility and test capability to the chassis dyna-mometer test facility, providing full control of all the vehicle’s functions. The system will drive the vehicle, under simulated road conditions, to defined legislative cycles, customer specific schedules or utilise vDriver™ route recordings. The advanced technology and control techniques meet the high reliability demands of endurance

testing with precision control for exhaust emission, production and performance testing. ProDuCTIon TESTSOur End-of-Line test systems offer solutions for cars, trucks, agricultural vehicles and motorcycles. We provide test systems for quality, driveability, function and also safety critical systems for passenger cars including parking sensors, lane-control and collision avoidance radar. Products offered are:

Roll Test Stands (RTS) – testing >of all functions, performance, brake testing and electronic driver assistance systems (ABS, ESP, EDS, MSR/ASR)Wheel Alignment Measurement >(WAM) – utilising laser measurement technologyShake Roll Test Stands (SRTS) – >

provides the ability to induce vibrations and chassis twist into the vehicle. Each roll is fitted with variable pad heights to simulate different amplitudes and effectsTest booth and integrated services. >

InDuSTrIAL AnD MArInE DIESEL EnGInE TESTSince the Hydraulic dynamometer was invented back in 1877, Froude and more latterly Froude Hofmann have been providing state of the art machines suitable for testing some of the largest Diesel engines in the world. Many of today’s High power, Low speed heavy fuel engines used in Marine propulsion systems have been developed and refined against Froude Hofmann equipment. These LS machines along with the smaller F type dynamometers provide a complete range of machines from 800kW to 60MW.

The dimensionless Froude

number is defined as:

Fr = V c

where we are

UK – WorcesterHead Office, 8,000 sq m

Manufacturing, sales, service

and support

USA – Detroit1,000 sq mManufacturing, sales, service

Brazil – Sao Paulo600 sq mSales, service and support

Spain – BarcelonaSales, service

and support

India – Pune

Sales, service and support

Australia – MelbourneSales, service and support

France – ParisSales, service and support

Germany – Elze5,000 sq mManufacturing, sales, service and support

China – ShanghaiSales, service and support

Czech Republic – BrnoSales, service and support

Russia – Moscow

Sales, service and support

South Korea – SeoulSales, service and support

South Africa – DurbanSales, service and support

EnGInE TEST ProDuCTS vEHICLE TEST ProDuCTS EnD-oF-LInE TEST ProDuCTS

1877 1881 1903 1982 1995 1996 1997 2002 2005 2007 2009William Froude Heenan Heenan Consine New facility Hofmann Brush ATS Go-Power Renamed Harris Watson Expansioninvents the & Froude & Froude Dynamics Blackpole, acquisition acquisition acquisition Froude acquires of globalhydraulic established relocate to join Froude Worcester Hofmann Froude Sales and dynamometer Manchester Worcester Engineering Hofmann Service

technology and innovation 6

7 Froude Hofmann

evolution, revolution, development, evolution

“our embedded policy of continual improvement and development ensure the products for the future test requirements are produced effectively and on time”

today’s stringent testing requirements for engines, powertrain and full vehicles produce ever- increasing demands on

development, certification and for quality engineers. We understand the customer’s needs and utilise this cross-functional knowledge to provide innovative test solutions. These solutions enable testing to be performed accurately and reliably, from the early stage of an engine’s development cycle, through to full vehicle testing and finally the production validation and quality assessment. Focused market research activities along with a structured development process ensure that the required innovations are brought quickly and effectively to our customers.

Gareth Deakin, (pictured) Business Development Director comments that these developments are defined by product focus reviews with customers and key figures within the automotive test market, resulting in strategic development objectives for our products and ensuring we react to the market demands. To bring these ideas to the market quickly and effectively, we have dramatically increased our

development investment and we are extending research relationships with several universities to utilise their immense skills in simulation and computational techniques.

APPLICATIonSWith the industry constantly changing, solutions are being sourced for vital contemporary market needs such as low emissions and fuel economy on a global level. An excellent example of this foresight is the evolution of the company’s fully integrated chassis dynamometer and ‘Robot Driver’ for automated testing. The robot driver has been a huge success in powertrain and endurance applications worldwide. Recent developments provide lighter components and materials, easier, quicker installation with reduced cabling and enhanced automatic set-up in the vehicle. These features ensure the robot driver is an effective solution in the emission calibration and development environments providing high repeatability and accuracy of drive cycle control. Complimentary to this is the software application that provides ‘Real-Driver Profiling’ and a route recording/playback

system that provides powerful ‘Real-World’ simulation capability. With the combined control system philosophy across our products; this functionality also benefits our Engine and powertrain test systems.

Other products have seen similar benefits with a new distributed I/O control hardware platform; providing full test capability before despatch and rapid installation and commissioning. An advanced graphical user interface is provided on all our systems; modularity is designed into our chassis dynamometers and engine test stands for greater flexibility and new dynos have been developed and added.

THE FuTurEWe can be sure that the pressure on automotive powertrains and energy sources will continue to increase with the related need to develop more innovative solutions in ever shorter timescales. Emerging technologies will become more prevalent with the need to test the systems accurately and realistically to prove their effectiveness and to decide on the most efficient control strategies such as the evolving

hybrid powertrain configurations including HEV, PHEV, Dual mode and full electric vehicles.

New fuel sources such as C.N.G., Bio diesel, E85 and flex fuel are provided for, with enhanced fuel delivery systems that will re-fuel test vehicles under automated control to ensure uninterrupted testing. Engine and vehicle testing accuracies are continually improving and will interface more extensively with simulation programmes for “hardware-in-the-loop” developments.

The scope is only limited by imagination in creating real situations under controlled laboratory test conditions.

To remain successful, companies in the future must be agile and proactive to market demands, focused on the customer’s real challenges and thereby establishing future solutions. They must be able to provide effective local, and global support, so that the customer can achieve their need for reliable and effective testing.

Whatever the challenges and obstacles we all face, you can be sure that we are equipped and ready to support the demands upon our industry in the future.

IT IS THE FuTurEAccording to Steve Sharpe, Group Technical Director, the future lies in software development, both domestically and globally.

With a responsibility for the company’s electronic and software products range, Steve is in charge of research and development, and with an impressive back-ground in engineering (including a degree in engineering from

Balliol College, Oxford and recipient of the Queen’s Award for Innovation), he has a vision for the future that involves moving with market forces and supplying solutions to ever-evolving demands.

“Fuel economy and emissions are the key issues in all industries at the moment,” he comments. “This is good news for Froude Hofmann and the

“Fuel economy and emmisions are the key issues in all industries at the moment, this is good news for Froude Hofmann and the way forward is to capitalise upon the software capabilities that we already have and that we are constantly working upon”

way forward is to capitalize upon the software capabilities that we already have and that we are constantly working upon. If we look at our newly introduced ‘Robot Driver’, it comprises the most up-to-date and sophisticated software yet developed and it is my job to ensure that this consistency of software evolution is up to the increasing functional

requirements of our product range.

“Our global expansion has opened up a huge market – effectively, we are developing the same products for all marketplaces and the Far East in particular is demanding state-of-the-art equipment. Our task is to provide this and we are already working to provide unique design solutions.”

Gareth Deakin setting up the robot Driver

IT IS THE FuTurE

9 Froude Hofmann

customer service 8

HyBrID, FuEL CELL AnD ELECTrIC ProPuLSIonOne of the key industry drivers that is increasing exponentially is the investment in “green” vehicle technologies. This sees the next stage of sophistication with regard to hybrid powertrain solutions requiring a more effective integration of the powertrain with all the vehicle’s subsystems:

ABS, traction and stability >

control systemsKinetic energy recovery >

Stop/start strategies >

Battery storage systems >

Froude Hofmann are actively supplying advanced 4x4 “all independent” chassis dynamo-meters for Hybrid and fuel cell vehicle development. The unique roll synchronisation control capability of these chassis dynamometers enables various powertrain configurations to be tested in accurately simulated road and operational conditions. Normally, with these powertrain configurations, we have to test “All-Wheel Drive” vehicles. The demands placed on the chassis dynamometer in this case are to ensure that the synchronisation of speed and the dynamic adjustment of forces from front to rear and left to right are precise and highly responsive, particularly important when accelerating and braking. Under these circumstances, the forces have to be altered dynamically between front and rear axles to maintain the speed synchroni-

sation to simulate “through the road” connection.

When this is achieved the energy flow management system of the vehicle will be able to function correctly, and the test will be representative. It is important that the correct load and the synchronisation is maintained to ensure that the correct powertrain regeneration is observed especially as the testing will predict key parameters such as vehicle economy and distance travelled etc. To obtain this level of accuracy Froude Hofmann have developed extremely sophisticated control algorithms and optimised the design of the mechanical and electronic sub-systems of the chassis dynamometer to provide an advanced system for this demanding test application.

HyBrID PoWErTrAInDevelopment of the various configurations of Hybrid powertrain continues to require extensive testing to establish the optimum configuration and integration within the vehicle systems. Froude Hofmann’s individual/combined test bed concept provides great flexibility for testing and simulating various configurations

Each prime mover in the system (Electric motor and Diesel internal combustion engine) can be tested individually on their respective AC dynamometer or the two systems can be synchro-nised together by the software

control system providing full simulated road conditions. This provides a unique test environ-ment where the components can be physically present or simulated using software techniques providing a full HIL system These simulations include; various hybrid strategy evaluations, energy storage simulation, battery cycler, vehicle dynamics with various driving styles applied.

ELECTrIC MoTor SySTEMS For vEHICLESThe solutions for the full electric motor vehicles require specific test beds dedicated to high speed synchronous AC or Permanent Magnet motors and battery storage devices. Our fully integrated solutions provide the dedicated invertor drive system, angular rotor position measurement, cooling systems, instrumentation for current sensing and battery simulation to fully evaluate the device under test. The battery simulator incorporates seamlessly with our control systems and invertor drive systems and provides a fully automated control and data acquisition system.

roCKInG THE rEAL-WorLDComplimentary to all these test technologies and the powertrain solutions is the need to perform “Real-World Simulation” testing to ensure the product will perform as expected and meet all the objectives set. This is

particularly important where the complex strategies of the latest powertrain systems have to accommodate varying and interactive circumstances and still perform and control effectively.

Our solution is vDriver™ which can simulate the variability associated with particular driving styles and routes. The system operates as a distance based test sequencer and enables users to reproduce specific routes and driving styles on their chassis, transient engine and powertrain dynamometers. Users can either record routes, or select global pre-recorded routes provided with the vDriver™ package.

vDriver™ can then reproduces realistic traffic and road-event conditions in the test cell, allowing the user to simulate real operating conditions within the development cycle quickly

and repeatedly. Each route incorporates details of the road type, speed limits, traffic lights, stop signs and other road based events that influence driving styles.

These products are at the cutting edge of testing demands and relevant to the ongoing developments within our industry. Whatever these challenges and obstacles we all face, you can be sure that we are equipped and ready to support the demands upon our industry in the future.

rocking – the real world

“We believe that this product is one of the most radical and cost-effective tools that manufacturers can employ in their pursuit of product satisfaction.”

11 Froude Hofmann

customer service 10

local yet global – in customer services terry Salter is Head of

Customer Services and his team is unusual to say the least. With many

years of service with Froude Hofmann, the office-based team employs energy, initiative, reaction and on many occasions, a certain amount of volatility.

Terry has been with the company for over forty years, working in every department within the company except finance – quite an amazing feat, although the record for longevity goes to another member of his team, Alan Rowberry who has managed to clock up an amazing half century of service with the company as man and boy.

Terry’s background as a marine

engineer has stood him in good stead over the years, as it taught him to work as a team, part of a strategy that he employs as key to his department’s success.

“Whilst working on the ships, we had to make do with the resources that we had available and consequently, I learnt very quickly that the key to success was to how to fix things as a team,” he comments. “And that is precisely what we do here. I have a fantastic team behind me – proactive, off-the-wall and enthusiastic and together, we deliver real solutions.”

What Terry loves about his job is the variety – one day he can be dealing with small high-speed Formula One

engines and the next, monster marine engines. His team deliberately comprises of people who can contribute positively to expanding the Froude Hofmann network on a global level by drawing on their own experiences. “We set up service infrastructures around the world by finding a common approach, and we strive for perfection,” he says. And this team offers a diverse approach. Del, sales engineer, used to maintain military aero engines in conflict regions, ensuring that they were kept in top condition for frontline service. Dodging enemy fire was just part of the challenge, but it taught him to go into tasks looking at every

eventuality. “We went into situations that utilised all of the resources that we had available to us,” he comments. “And I have learnt to apply this philosophy to my job at Froude Hofmann, where we are dealing with a diverse and very individual clientele.”

“We all have a unique contribution to the team,” continues Terry. “Our site services manager, has a

background in transport: he had the daily and unenviable job of co-ordinating 100 British Rail trains to run on time and on track. His current job holds no fears or surprises to him.”

Ex-naval engineer, Ian is one of our technical support engineers, he previously worked on UN projects installing

water pipelines and pumping stations in the Sudan.

“We deliberately hire people with a diverse background to ensure we have a pool of experienced talent,” continues Terry. “And that’s what makes us good. We don’t always look for industry experience, we look for skills and character traits that may have applied in a completely different way in other situations. We don’t try to style our operations on our industry, we seek role models from other

industries whose methods and performance excel.

As an example, to speed up our machine repair turnaround, we used the garage system as a basis of our DYNOHAUL ‘fixed price for fixed scope service.’”

The whole department is greater than the sum of its parts, and delivers consistently excellent support to our customer base whether global or local.

“In the time that we have been working with Froude Hofmann, the company has consistently offered the highest levels of professionalism and reliability. We are currently jointly working on two projects, and from the beginning, Froude Hofmann has met all of the stringent technical and commercial requirements to which we work, particularly within its commercial area.”

antonio squillaro (fiat group purchasing s.r.l. a s.u.) europe region capital equipment & indirect material

“We set up service infrastructures around the world by finding a common approach, and we strive for perfection”

13 Froude Hofmann

products 12

products:turbine (aero)With 60 years of experience in the Aerospace and Gas Turbine industry, Froude Hofmann is the world’s leading supplier offering the most comprehensive range of dynamometers, control systems and test stands for testing aerospace and industrial gas turbines.

Hydraulic dynamometers are supplied for low and high speed applications, they all use the Froude design of vaned internal power absorption elements which together with the use of high response servo controlled inlet and outlet valves provide a stable and high transient load change capability. ProDuCTSThe ‘F’ range of dynamometer is supplied for testing small to heavy turboprop engines and indirect drive turboshaft engines, up to 30 MW in power. The ‘HS’ dynamometers provide the solution for testing

this wealth of experience enables us to provide our customers with dynamometers and dynamometer control systems tailor made for

the application of testing gas turbine prime movers. The Texcel VX100 digital dynamometer control system provides the user with the very latest in controls technology, providing the highest levels of accuracy in measurement and control. They come equipped with a comprehensive health monitoring and safety systems to ensure that the engine on test is always protected.

direct drive turboshaft engines and are capable of operating at speeds of 30,000 RPM and up to 30 MW in power.

To compliment the dynamometers we also provide a range of high and low speed flywheels when there is a need to test the engine with the same level of inertia as it would experience when connected to the airframe transmission.

To complete the in-cell equipment offered we also provide complete engine test stands and for smaller engine applications mobile test stands, integrating the dynamometer, flywheel and engine mounting

system. Additional flexibility in test cell use can be provide by using pre-aligned interchangeable engine cradles (adaptor frames) for same engine or different engine types this allowing out of test cell pre-rigging reducing engine turn around time.CuSToMErSOur worldwide customer references include: Avio SpA, GE, Mtu aero engines GmbH, NPO Saturn, Pratt & Whitney Canada, Rolls-Royce, Turbomeca.

F84D dynamometer and flywheel

15 Froude Hofmann

products 14

Froude Hofmann supply state-of-the-art, highly accurate and extremely reliable Chassis Dynamometers to the automotive and commercial vehicle markets. The range of vehicles that can be tested included motor cycles passenger cars, light to heavy duty trucks, buses and agricultural vehicles.

P roducing Powertrain test facilities requires the combination of our expertise and experience

in engine and chassis dynamometer design and control, incorporating the advanced techniques developed for our own state-of-the-art robot driver systems we are able to provide the

Froude Hofmann’s “48” Chassis Dynamometer range has been designed on a modular basis configurable for 4x2, 4x4 and 4x4 independent

configurations. These are compliant to worldwide Emission and fuel economy standards and are fully U.S.E.P.A. compliant. The configurable design and distributed I/O control hardware provides many benefits including; full system testing before despatch and greatly reduced installation and commissioning times. Many automated sub-systems are provided to assist test set-up and safe operation including integrated centralising systems, auto-roll guards and automated floor covers.

Special, advanced design solutions are available for a variety of applications that demand attention to detail and refinement of the chassis dynamometer due to the unique demands of the application:

Fully integrated, automated >endurance testing with our robot driverPowertrain testing including >Hybrid vehiclesEnvironmental and climatic >windtunnels – extreme temperature testing and altitude simulation Noise, Vibration and Harshness – >performed in a Semi Anechoic chamber; the Froude Hofmann chassis dynamometer has unique design solutions for noise attenuation and containment to provide extremely low noise operation.

ProDuCTS48” Roll diameter chassis >dynamometersEndurance/Automated test >facilities (MACD)Large roll chassis dynamometers >for special applications: Climatic, NVHMotorcycles to Passenger cars >to TrucksAutomation systems >

very best solutions for your Powertrain and transmission testing requirements.

Experience drawn from our record of providing first-class Chassis and Engine Dynamometers allow us to provide the hardware and software that leads the way in Transmission and Powertrain testing.

Control systems include full road load simulation as well as advanced features such as full journey replay and simulation for rapid development of Powertrain systems and components.

Systems can be provided to accommodate both 2 and 4 wheel

drive systems as well as additional replacement of prime movers for transmission only tests.

Whether the requirement is for long term durability, emissions, NVH or drivability testing the Froude Hofmann systems provide the right solution.

products:vehicle

AuToMATED roBoT DrIvErFroude Hofmann’s Automatic robot Driver System provides the unique ability to supply a fully integrated automated test facility for any of the test applications. The robot is designed for rapid installation and with a fully automated learn utility the robot driver is quickly ready for testing in the vehicle. Together with high accuracy of drive cycle control and high repeatability, the robot is ideally suited for many test demands including; emission calibration and development, extended automated testing, climatic and special chamber testing.

With the latest developments providing “real driver” simulation and route replay capability the system brings many more advanced benefits to our customers.CuSToMErSOur worldwide customer references include all key OEM’s, Tier 1 suppliers, research centres including: Renault, Ford, GM, Hyundai, Honda, Jaguar, Kia, VW, Idiada.

products:powertrain

Main picture: 4x4 48˝ independent chassis dynamometer

17 Froude Hofmann

products 16

products:end-of-line

As a worldwide expert in the design and supply of End-of-Line test equipment for the automotive industry, Froude Hofmann offers a wide range of roll Test Stands (rTS), Shake roll Test Stands (S-rTS), Wheel Alignment Machines (WAM) with Headlight Aiming Tester (HAT) and if required also a universal Test System (uTS).

until recently the Wheel Alignment Machine was designed specifically for the adjustment of

toe and camber angles and the Roll Test Stand was designed for vehicle functionality and brake tests. Now, these are combined into a single test stand which also includes a significant number of additional functions for new features being added to modern vehicles. Most modern vehicles are equipped with

a large number of electric components, in order to recognize and correct potential errors at an early stage, the vehicle and those safety critical components are tested following the final assembly. Advances in the design and performance of the Froude Hofmann test machines have led to increased flexibility, with the replacement of many mechanical functions by electric or electronic solutions.

Our Products are applied to the following markets:

roll Test Stand >Wheel Alignment Machine >Headlamp Aiming Tester >universal Test System >Shake roll Test Stand >

Specialist Testing including:ABS, EDS, ESP, FAS, ACC, >ASr or AWD etc.EoBD >ECoS >Driveline Balance System >Brake Inertia Testing >

roLL TEST STAnD Froude Hofmann’s computer controlled vehicle test systems can be arranged to provide a total test package at the end of the production line or to meet the need for a stand-alone test station for example; development, quality audit or post rectification tests.

Test stands are available for passenger and commercial vehicles, motorcycles (including quads) as well as agricultural machinery and can be configured for different kinds of tests, typically: Shake, Functional, Brake, ABS, EDS, ESP, ASR or AWD. All of this is available on a single machine.WHEEL ALIGnMEnT MACHInE Froude Hofmann offer different configurations of Wheel Alignment Machines. These machines measure

toe, camber, and caster angles of all four vehicle wheels and they then provide data for the optimum adjustment of the wheel angles. Rear-view cameras and ACC Systems fitted to the vehicle can also be calibrated and certified as part of the Wheel Alignment Machine.

Modular machines are available with two different types of measuring heads: either contacting rollers on the tyre sidewall or non-contacting lasers which view the tyre sidewall as required. The laser systems are available in 2 or 3 sets per wheel configuration.

All Machines have wheel drive rollers with a floating feature to ease the wheel adjustment process.unIvErSAL TEST SySTEMAs a unified automation and measuring system the Universal Test System (UTS) can control Roll Test Stands, Wheel Alignment Machines and Headlight Aiming Testers. This covers the whole range of test applications in the End-of-Line area up to complex tasks like ABS or motor management testing. Normally the test device will be connected via the central diagnosis interface in the vehicle. The UTS provides programming

Froude Hofmann GmbH at Elze, Germany is the design centre for our range of End-of-Line products. The products are manufactured in Germany and the uK, as required.

and diagnosis of vehicle control units (EOBD) and test of electronic components (ECOS) by measuring and evaluating the voltage profile and current profile of electrical components.EoL ACCESSorIESAs a supplier of turnkey solutions, Froude Hofmann will supply the main test stands, booths for noise protection, ventilation systems for exhaust extraction and fresh/conditioned air supply In order to provide an acceptable working environment.

Vehicles equipped with an Adaptive Distance Radar (ADR) to give the driver the maximum safety in heavy traffic situations require an exact orientation position of the vehicle on the test stand to allow adjustment. Froude Hofmann can supply a high-precision centering system as a single stand solution.

For simpler test requirements and low production a single axle Brake Tester can be provided. Simple functionality and brake tests including ABS tests with communication to the vehicle’s ECU can be carried out.

For the quick examination of the chassis alignment, a Side Slip Tester can also be provided.

TrAnSMISSIon SoLuTIonS & CoMPonEnT TESTSDrIvELInE BALAnCEBased on an increase in demand for drive comfort, Froude Hofmann developed the Drive Line Balance (DLB) System which will balance the drive shaft of a completely assembled vehicle on a Roll Test Stand or on a dedicated test rig. The imbalance is measured by a non-contact measurement system and the automatic balancing unit removes or applies material as required resulting in the ultimate in balanced drive systems.BrAKE InErTIA DynAMoMETErTo fulfill the demand for more comfort and efficiency, environmental simulation, noise and vibration are some of the most important factors in the recent brake development. To meet the requirements of our customers, Froude Hofmann supply a wide range of Brake Inertia Dynamometers for testing the components of passenger cars, light and heavy commercial vehicles, and railway and aircraft applications.CuSToMErSWe have extensive references with many of the major OEMs including Volkswagen, Skoda, Seat, Daimler, Ford, Scania, CNH, Iveco, Triumph, Avtotor, Avtovaz, Frendo and Lucas.

19 Froude Hofmann

products 18

products: marine

The LS-2 range has cast main carcase sections, incorporating the power absorption stator elements directly into these casings provides simplified construction and improved reliability over the original stator inserts.

The bedplate is a robust fabrication designed to be clamped at any position on its perimeter and to protect all pipework and electrical fittings/cabling from normal shipyard rigours. Independently controlled

jacking systems provide a simple and easy method of alignment.

Control of the power absorbed by the dynamometer is by the unique fast response characterised outlet valve mounted directly on the casing. This configuration provides a faster response to load change demands typically required for marine propulsion system development. For reversible dynamometers, logic within the control system can pre-charge the non-working

m any of today’s high-power, low-speed heavy fuel

engines used in Marine propulsion systems have been developed and refined against our equipment. In 1979 with the market developing more sophisticated drive systems including Turbine and Nuclear fuelled prime movers, Froude Hofmann replaced the ever popular FA machine and launched the innovative LS range. These new machines

provided improved low speed control and a number of additional features specific for development of this new breed of marine propulsion systems.

The Industrial and Marine Diesel industry is well served by the FB and LS ranges of dynamometers. The smaller FB machines are available in either unidirectional (AFB) or bidirectional (BFB) versions whilst the larger LS range comprises machines available in unidirectional (LS), direct reversible versions (RLS)

and double capacity (DLS) versions covering a duty range in excess of 100,000kW

LS Dynamometers have continued to be a key part of this ever developing area of the marine market and many of the original machines are still providing reliable service to Research and Development facilities world wide. As part of the continuous improvement program of this key area of business, Froude Hofmann continue to invest in the further

development of these machines and control systems, this has resulted the LS-2 range of Hydraulic Dynamometers released this year.

All torque-transmitting components are assembled using the oil injection technique, eliminating stress raising keys, keyways and associated operating problems. This technique also assures that subsequent removal of components, even after many years of service, is simple, quick and non-destructive.

Dynamometers, control systems and ancillary equipment are available to test a wide range of engines

from the latest automotive Hybrid power units to large industrial and marine diesel engines. Applications range from Hot Test Production, End-of-Line Quality Assurance through to full Research & Development.

DynAMoMETErSThe dynamometer range includes:

AC transient machines rated up to >1.2 MW providing the most flexible solution for advanced R&D or power saving durability testing.

Eddy current dynamometers rated >up to 750kW for cost effective testing of automotive or industrial engines.Hydraulic dynamometers rated up >to 50 MW for medium to large industrial and marine diesel engines.

ConTroL SySTEMSGenysis software running on the latest generation Texcel V12 CAN networked control and data acquisition hardware platform results in a highly flexible, advanced test solution which meets the most discerning customer requirements. For systems not requiring the sophistication of the V12 package there is the Texcel VX4 for simple manual control of

products:engineWith over hundred years of experience, Froude Hofmann is providing innovative solutions for testing the next generation of quieter, cleaner and more fuel-efficient engines.

dynamometer and throttle actuators.AnCILLArIESWhen combined with the Froude Hofmann range of ancillary equipment, such as engine oil and water cooling modules, engine stands, fuel meters etc; a total test solution can be provided.

From the planning and specifying of the engine test facility to the installation, commissioning and training, we provide the total solution.

THE TEAMOur team of experienced multi-disciplined engineers form the core skill base on which our business is built. From mechanical and electrical design of dynamometers to the

development of sophisticated software systems for control and data acquisition, we can meet your requirements.

THE AIMCost competitive >On-time delivery >Total customer support >High-quality reliable products >Customer satisfaction. >

CuSToMErSWe have extensive references with many of the major OEMs including: Tier 1 suppliers, research institutes and test centres, Bosal, Ford, Bentley, ProCat Testing, Dongfeng, Honeywell, Mahle.

Since the Hydraulic dynamometer was invented back in 1877, Froude Hofmann have been providing state of the art machines suitable for testing some of the largest Diesel engines in the world.

compartment to allow smooth transition from ahead, through zero load, to astern for direct reversing tests. For absolute control through zero the LS dynamometer may be fitted with an optional friction brake, controlled by the dynamometer control system. This servo control system makes the machine inherently suitable for automation and permits constant speed, constant torque as well as the conventional ‘power law’ modes of control.

For major maintenance the rotors can be supported by means of jacks in the bottom half casing, enabling the coupling, bearing and water seals to be removed from the end of the machine and re-fitted without dismantling the casing. This can be carried out rapidly due to the use of

oil injection techniques considerably reducing downtime and maintenance costs.

Comparison of the Froude LS dynamometers with any other conventional type of hydraulic dynamometer of a similar duty will clearly show why Froude are world leaders in the production and design of large dynamometers for testing piston, turbine and electric prime movers.

21 Froude Hofmann

quality and 20the environment

between teams and working closer together, blurring the boundaries between these, has given us greater fluidity enabling us as a company to react to any diversity quicker and more effectively. With the nature of this business where much of the products are tailored to the customers requirement, every time we build a machine its almost like building it for the first time and this always presents challenges that need to be dealt with, ensuring that we deal with the problems as quickly and effectively as possible, whilst maintaining the highest quality standards.

HoW WE WorK“We develop our products and operations in a systematic way. Our product development feeds from thorough research into our customers’ future requirements. Our product managers regularly meet customers to discuss their current needs, future needs and any improvements they would like in our products or services. This allows us to move in the direction that is required and not waste time and resource on projects that don’t give value to our customers. Additionally we aim to improve our operations through continuous improvement groups, and lean events such as 5S and kaizen activities. This allows individual areas to own their processes and change these rapidly if better methods are identified or become available”.

quality is not an act, it’s a habit

r ight first time, on time, every time. This is the ethos that Matt is working to as Continuous Improvement

Manager at Froude Hofmann. ““My job is a dual role that

encompasses Continuous Improvement and Quality which are intrinsically linked, on the Continuous Improvement side it’s about improving every aspect of the company. This is not only the processes that make up our day to day work but also improving the products and services. Our quality philosophy goes all the way from the quality of our ideas through to the service provided to a customer after they have had a machine running for 15 years”.

After spending nearly 10 years in a blue chip automotive manufacturer Matt understands what is required to optimise and maintain a World Class manufacturing business and says that the biggest changes to be made are in the people and the culture. “People are what make your company work well, and teamwork between these people ultimately defines how well you work as a company. On the rugby field if I didn’t know what my team mates were doing and thinking then I couldn’t move and change my position to best support them, and this is what we have succeeded to bring in at Froude Hofmann. Better communication

ACCrEDITATIonSAlong with ensuring that the company complies with the quality management systems of ISO9001:2000, Tickit (Software Quality Assurance) and ISO14001, part of the role is also ensuring that the company complies with the Investors in Excellence standard, “Based around the EFQM framework (European Foundation for Quality Model). This ensures that we are achieving consistently good results for all stakeholders with a customer based approach. The EFQM model ensures that we cover all the bases of good business practice and don’t lose sight of the ultimate aim of excellent customer satisfaction whilst achieving sound financial results”.

Froude Hofmann is truly proud of its established environmental record with no incidents

reported and a clean slate from all relevant auditing bodies. The job of consolidating health, safety and environmental issues is constantly changing, but also constantly challenging. We maintain a preventative outlook whilst working to clearly defined KPIs, ensuring that every member of the team is kept informed of the standards that we have to work to. We are able to boast a unique and exemplary record of environmental responsibility and continual improvement, in all aspects of daily operations.

“To support our customers we aim to improve our operations through continuous improvement groups, and lean events such as 5S and kaizen activities.”

“our quality philosophy goes all the way from the quality of our ideas through to the service provided to our customers”

ISo 14001

23 Froude Hofmann

people 22

we’re connecting the worldwide market

Production Manager, John has been working for the company for 23 years and exemplifies the company’s ethos of embracing all disciplines. From apprentice to test engineer, test manager through to his current position, his extensive knowledge of the engineering industry spills over into his out-of-office passion – auto grass. His engineering background has been invaluable in helping him to build and maintain his custom made Fiesta with two specially adapted 900CC motorbike engines which he races whenever he can. This dedication to perfection is part of John’s determination to keep the production department producing the same high quality components that he demands for his car.

Asia Regional Sales Manager, Paul spends his life working with vehicles, enjoying racing off-road cars in the National French Championships. Paul is used to travelling the length and breadth of the globe developing the Froude Hofmann presence in the Asian market. Currently involved in China, Paul has been instrumental in developing the Asian market. “This is a hugely influential area,” he comments. “It is not just about offering the highest quality product at competitive prices, it’s also about understanding and adapting to different traditional cultural diversities. China is one of the largest developing markets and with a physical presence in the country now, we are in an excellent position to capitalise upon its significance.”

German born, Antje is a Project Manager, a job she relishes. “When a job lands on my desk, it’s my complete responsibility until it is signed off by the customer,” she explains. Her native German language has been invaluable in liaising with continental customers as well as further afield, such as the

Russian market. Married to an Englishman, Antje has made her home in Worcestershire, adapting to the English way of life, which has been made easier with the support of her colleagues at the UK headquarters.

Sales Engineer, Ian has every reason to be pleased at Froude Hofmann – supporting him through his degree, and promoting him to Germany where he met his future wife. Ian has spent the past eight years expanding our product range in the German market. “As a chartered engineer, I find it is important to be able to explain the technical details of our products,” he says. “Through building up relationships with the customer, I can really understand their needs, enabling us to offer the correct products for their needs.” Ian enjoys challenge and this is evident in his spare time which is spent running marathons, triathlons and riding over the Alps.

from boardroom to factory floor, Froude Hofmann’s value lies in the people it employs

to represent the company on every level in every country. Dedicated to supplying a

comprehensive and specialist range of top quality technologically advanced solutions,

the team is committed to providing customer service that is second to none,

which is why the Froude Hofmann name is the only one that matters in the automotive

and aerospace industries.

Sebastian is one of our newest members of the team, appointed Sales Manager for France. Sebastian recently trained at Worcester and has hit the ground running in the French and Benelux countries. Having ten years experience in the industry behind him already, he is familiar with the Froude Hofmann brand and is enjoying working with the team. “This is an excellent opportunity for me and I look

forward to expanding the Froude Hofmann name throughout my new area,” he says. “What I respect most about the company is the willingness and capacity to invest in its people. I look forward to constantly returning to England and re-acquainting with the terrific people I have met here.”

Keeping Froude Hofmann moving forward in the America’s which includes the United States, Canada, Mexico and the newly created office in Brazil, is the responsibility of Andrew. As Sales Manager for Froude Hofmann Inc, with 10 years experience with the company focusing on engine, vehicle and gas turbine testing. “For me, I feel I have the best position in the company, offering a combination of developing the North and South America market along with the opportunity to be actively involved with new technologies and applications which are specific to a particular region, the important aspects for working at Froude Hofmann are the talented team and our commitment to complete our obligation to the customer”.

For over two years, David has been the company’s technical support engineer which sees him completing installations and commissioning on site. In addition, the company utilises his cultural background as in the role of customer support for the Chinese market. After graduating from Tsinghua University in China, he pursued a career in the R&D centre of Dongfeng automotive company for two years, experience which he brought with him to Froude Hofmann. David relaxes by travelling and spending time with other families, learning about their traditions and cultures, as well as participating in as many sports as time allows.

Anthony enjoys drawing as a hobby. His day job is commissioning engineer which is a far throw from his previous employment with the Royal Navy and as a member of the elite Parachute Regiment. In fact, after achieving a degree

in engineering, Anthony has moved around the country before settling in Worcester and bringing his mechanical and electrical engineering experience to Froude Hofmann. As well as the arts, he also enjoys spending what spare time he has with his children, entertaining them with his musical skills on the saxophone.

Sports figure heavily in Dave’s social life. Froude Hofmann’s very own Marathon Man took part in this year’s London Marathon with a very respectable finish time, and has competed in numerous half marathons. In addition, he is often found hanging from cliffs with his hobby of rock climbing. This endurance stands him in good stead in his day job. Dave is often found abroad in various locations from India to the Far East as well as all over Europe in his role as Applications Engineer. With a background in mechanical engineering, Dave deals with the chassis business and having been with the company for over ten years, he is obviously still enjoying the challenge.

rachael is secretary to the Manufacturing Operations Director and the Technical Director, and has been with the company for 22 years. A far throw from her first job of working at a local horse stud, she deals with the administration within the manufacturing department, and within shop services as well as purchasing and general health and safety issues this leaves her with little spare time but she still finds time to travel the country at weekends, showing Bullmastiff dogs at shows. Rachael’s success in her hobby is reflected in the many awards she has won and includes qualification and exhibiting at Crufts.

Mickey is the Company’s Sales and Marketing Manager and with a global working background, her experience and motivational skills are proving invaluable at Froude Hofmann. Fluent in Italian, Mickey

previously held senior executive roles in Italian and American businesses in a sales and marketing capacity, bringing her into contact with many diversified area’s where her outstanding presentation and communication skills have laid many foundations for future and real prospects. From living and working in Singapore, Italy and USA with her family, Mickey’s role in the company is diverse and challenging but one that she is facing head first with innovation, determination and experience.

Andy is the company’s Software Manager, co-ordinating the activities of a team of software engineers that has grown significantly during the last 12 months. In addition to working on the development of new software he also has responsibility for contract related software and providing assistance to the Technical Support Desk. Andy has been with Froude Hofmann for eight years and previously worked in the fields of accountancy and insurance but fancied a software role in a manufacturing company, for the satisfaction of seeing his own software controlling a physical product. Previously Andy would have been found out and about on two wheels, either as a motorcyclist or getting some exercise under pedal power. He also counts dinghy sailing as a hobby which he hopes to return to when the boys are older.

the future 24

froude hofmann – the future

Froude Hofmann is a business on the rise, based on the firm foundation of customer service excellence. Let us help you improve your R&D and production performance by working with us to develop new products, wherever and whoever you are.

Froude Hofmann maintains a policy of continuous research and development and specifications are subject to alteration without notice.

Photograph: compliments of Applus Idiada Spain (NVH Chassis Dynamometer)