Test bench development

At PGM GmbH, customer-specific test bench development from the manufacturer begins with a precise task analysis. We record the test specimen, test parameters, load profile, cycle requirements, measured variables and interfaces before our engineering department designs the test bench planning and test bench concept.

Our project engineers develop test benches for gearboxes, special gearboxes and drive systems with measurement data acquisition, test bench control, sensors, actuators, torque measurement, speed measurement, temperature measurement and vibration measurement.

Special test benches, machine test benches and gearbox test benches for functional testing, series testing, endurance testing, load testing and quality assurance are created in our production facility. We validate real load conditions, automated test sequences, data visualization and data evaluation through to commissioning.

This testing technology is relevant because it provides technical decision-makers with reproducible results, stable processes and reliable product validation.

At PGM GmbH, we combine measurement data acquisition, sensor technology and control to create a technically coordinated test bench system for reproducible test processes. Our engineering defines measuring points, signal paths, limit values, load cycles and interfaces so that mechanical, electrical and thermal test values can be recorded reliably.

For digital test bench development, our project engineers integrate measurement and control technology, test bench software, signal processing, data evaluation and data visualization into a uniform system architecture. Industrial PCs, multi-channel technology, drive control and open interfaces enable short reaction times and transparent test sequences.

We manufacture test benches, special test benches, machine test benches and drive test benches for endurance testing, durability testing, end-of-line testing and product validation. We validate test bench development for realistic load conditions so that gearboxes, drive units and assemblies are tested under realistic loads.

This test bench technology is crucial because developers receive reliable measurement data and purchasers can evaluate a scalable solution with automation, retrofit capability and a clean interface connection.

Automated test benches from PGM GmbH combine mechanical test setup, control technology, sensor integration and software to create resilient systems for series testing and endurance testing. We design the test process in such a way that test specimens are reproducibly evaluated over defined load cycles, speeds, temperatures and operating conditions.

Our project engineers develop test systems for gearboxes, drive units and machine components in which real-time measurement, data connection, visualization and data evaluation are integrated directly into the test sequence. This results in reproducible measurement series for quality assurance, service life assessment and technical approvals.

In our production, we implement automated test bench development, test bench automation and test bench software for automated test systems with industrial PC, interface connection and optional MES connection. Materials such as steel, aluminum and stainless steel are selected depending on the load, rigidity and environment.

We validate stable test conditions, especially for high-speed applications, test bench construction and retrofitting, so that technical teams can make reliable decisions on function, load capacity and series release.

When retrofitting existing test benches, PGM GmbH renews mechanical assemblies, electrical equipment, sensors, controls and test bench software without unnecessarily replacing the existing basic structure. We analyse wear, measuring chains, safety functions, interfaces and the current load cycle before our engineering department designs the technical modernization.

Our project engineers integrate new drives, industrial PC systems, data acquisition, visualization and automation into existing test systems. This allows older test benches to be used again for reproducible measurements, documented test sequences and digital data connection.

We adapt steel frames, aluminum superstructures, stainless steel components, control cabinets and cabling to the new test environment in our production facility. Particularly for endurance tests, gearboxes, drive systems, mechanical engineering, special machine construction, automotive and aerospace, a resilient modernization is more important than a completely new construction.

This test bench construction is technically relevant because we reduce downtimes, safeguard existing investments and expand test capacities in a targeted manner.

With test bench software, visualization and data connection , PGM GmbH makes measured values from test benches evaluable, controllable and traceable. We link sensors, actuators, measuring channels, controllers and industrial PC systems to create a stable digital architecture.

Our experts develop user interfaces, limit value logic, test programs, data exports and interfaces to higher-level systems. This allows speed, torque, temperature, vibration, runtime and status signals to be recorded, displayed and documented during the test sequence.

In test bench engineering, our project engineers take signal quality, real-time capability, user guidance, rights concepts and process reliability into account. This results in reproducible test sequences instead of isolated measurement islands, particularly in the case of a customer-specific test bench.

The software also supports test bench integration, remote analysis, fault diagnosis and subsequent expansions. This is relevant for gearboxes, drive systems, machine components, test systems and the test bench for special applications, because technical teams can evaluate measurement data more quickly and make more reliable approvals.

Test bench development is all about technology that allows test benches to work reliably and precisely. At PGM GmbH, we develop everything ourselves. We make sure that we develop the test bench technology that you really need. This also includes solutions with a modular platform. Depending on the area of application, this results in a system for test bench development for special gearboxes or for concept development for test bench systems. We also implement individual test bench development for mechanical engineering or the planning of test benches in a technically sophisticated manner for you.

During test bench development, we start with a discussion about your requirements. The test bench project planning then takes place in close coordination with your team. In the next phase, we plan the components that will later interact precisely. Our test bench development covers everything from the measurement concept to the control system. Whether a simple solution or test bench development with a modular platform, we build precise systems. We also implement special requirements from special gearbox construction or test bench development for gearboxes in a technically sound manner for you.

In test bench development, we rely on software that is precisely tailored to test processes. We use programs for control, visualization and data acquisition. Depending on the test bench, we combine solutions such as LabVIEW, Codesys or structured PLC programming. The aim is always to ensure reliable communication between sensors, actuators and the measurement software. Test bench development requires flexible tools for real-time data. We also use individually adapted systems for special tasks. The result is a test bench development that fits seamlessly into your processes and functions reliably.

A great deal of flexibility is possible when developing test benches. You can expand systems in stages or adapt them to new components. Even if test specifications change, the control system can often be reprogrammed without much effort. Our test bench development is structured in such a way that subsequent adaptations are technically easy to implement. Depending on the application, we combine modules, interfaces and software individually. As a result, we achieve test bench development that pays off in the long term and responds precisely to your requirements. Even with complex test procedures, the test bench development remains adaptable.

The integration of the control system is a central part of test bench development. The systems are designed for the desired test strategy at an early stage. Depending on the design, the test bench is developed with a suitable combination of sensors, actuators and software. This allows processes to be adapted directly and values to be processed in real time. Test bench development ensures that all components work together reliably. Modern control systems enable safe and fast testing. Test bench development results in precise and controllable processes.