System Integration - Test Systems

Design and development of an Adjustable Brake/Accelerator Test Station (freestanding, with vision) dedicated for the testing of adjustable automobile pedals. The general functions are to manually receive pedal assemblies, test pedal assemblies, log test data and print barcode labels. The HMI screens are designed ergonomically around a touch screen interface only. All data reporting for results of operational tests, test tolerances, test station faults and calibration have also been incorporated into this Test System.

The Pedal Test Station test system was designed and developed to target the following operational tests:

• Track Time: time it takes for the pedal to travel its entire distance.
• Motor Current: current of the motor during full travel of the pedal.
• Load and Permanent Set: 150 lb. load is applied to the brake pedal and a 50 lb. load is applied to the accelerator pedal. While the load is applied, measurements are collected at 10% of load before and after maximum load is applied.
• Swing Test: free motion of the full swing of the brake pedal.
• Pedal Offset: offset distance of the brake and accelerator pedal relative to each other.