Actuators for controlling powertrain components

Actuators are drivetrain elements that convert electric signals into motion. They are excellently suited for automated testing of manual transmissions. The actuators from ATESTEO are specially designed for use in test benches for transmissions, gearboxes, drivetrains, and powertrains. At first created only for use in ATESTEO’s own test benches, these actuators have since been further developed into products that you can use right at your premises. In the process, the requirements of the user flow directly into the development process. All actuators are exactly customised to your needs. For conducting highly dynamic tests, ATESTEO offers you a wide range of actuators and robots with their key functions.

Range of service of ATESTEO actuators:

  • Delivery of highly-dynamic actuators for throttle valve, clutch as well as gear lever for automatic transmission
  • Various gear-shifting robots for the operation of manual gearboxes in the test bench
  • Objective shifting quality analysis of synchronised transmissions within complex development projects with the GSA gear shift analysis system
  • Safety-tested and certified technology

Contact

Do you have questions about our actuators and specifications? Please contact us. We are at your disposal.

Your message to ATESTEO

GSE 4.0 gear shifting systems

The product family GSE 4.0 from ATESTEO offers you highly dynamic shifting actuators for use on drivetrain and transmission test benches. The high-frequency control of the actuators enables the fully automated shifting of vehicle transmissions. Depending on the model of the system, the mechanical connection occurs via the original shifting cables or the gear lever. The use of state-of-the-art interfaces (EtherCAT, CAN) enables seamless integration of the actuator into your testing environment. Numerous safety functions assist in implementing the safety concept of the entire test bench facility. The use of exclusively industrial-strength components assures high availability of the actuators and allows fail-safe operation worldwide on numerous test benches from ATESTEO and its customers.

ATESTEO has developed two different GSE shifting actuators to meet the different demands and requirements of gear shifting in testing. The highly dynamic GSE 4.0 Highline shift actuator realistically reproduces the human shifting behaviour and thus enables realistic, fully automatic shifting of all vehicle transmissions. The highly functional GSE 4.0 Function shift actuator is a durable alternative that allows for simple, economical and flexible gear positions on the transmission.

GSE 4.0 – characteristics of our actuators

Software

GSE 4.0 HighlineGSE 4.0 Function
Synchronous force controlClosed loop control (force sensor)Open loop control (motor current)
Speed controlYesYes
Position controlYesYes
Human shift behaviorYesNo
Automated learningNoNo
Number of positions (waypoints, gear positions)6464
Number of parameter sets1010
Post-process shift quality analysisOptionalNo

Electronics and mechanics

GSE 4.0 HighlineGSE 4.0 Function
Force measurementYesOptional
Travel measurementYesYes
Force decouplingYes (by lifting the gripper)Optional (for shift cable)
Height adjustmentYesNo
Digital outputsOptionalOptional
Power supply230 VAC230 VAC
Mechanical interfaceShift knobShift/Select cables

Specifications

GSE 4.0 HighlineGSE 4.0 Function
Shifting force (max.) (Peak load/Continuous duty)500 / 300 N2000 / 750 N
Selecting force (max.) (Peak load/Continuous duty)500 / 300 N2000 / 750 N
Shifting travel280 mm200 mm
Selecting travel320 mm200 mm
Z-axis travel70 mmNo
Shifting speed (max)1200 mm/s1200 mm/s
Position accuracy0,1 mm0,1 mm

Interfaces for automation

GSE 4.0 HighlineGSE 4.0 Function
CANYesYes
EtherCATOptionalOptional
AnalogueOptionalNo

Safety

GSE 4.0 HighlineGSE 4.0 Function
Emergency offYesYes
Safe torque off (STO)YesYes

Highly dynamic gear shifting robot GSE 4.0 Highline

The challenges of modern transmission testing place ever growing demands on modern shift actuators. While a few years ago, enabling a secure shift of gears was sufficient, these days, realistically simulation of human gear shifting behaviour takes priority. The ATESTEO shifting actuator GSE 4.0 Highline supports the entire spectrum of gear shifting. The gear shifting unit GSE 4.0 Highline from ATESTEO is a highly dynamic shifting actuator for use on drivetrain and transmission test benches. The high-frequency control of force, position, and speed enables fully automatic and realistic shifting of all types of vehicle transmissions.

Highly dynamic simultaneous control of force and speed

The GSE 4.0 Highline shifting actuator consists of two linear motion units driven by servomotors for the shifting and selecting direction. Speed and position values are collected by the absolute encoder integrated in the servomotors. The determination of the shifting forces takes place through a customised force measuring device integrated in the gripper axis. To recognise the gear lever, the gripper is additionally equipped with a magnetic sensor. The height of the gear shifting actuator foot can be adjusted to adapt the robot to various assembly situations.

Displaying human shifting behaviour with the shifting actuator GSE 4.0 Highline

Experience from analysing human behaviour when shifting gears with the ATESTEO GSA system was the basis for developing gear shifting patterns of the force-controlled GSE 4.0 Highline. The highly dynamic simultaneous control of force and speed during the shifting event enables the simulation of how human drivers change gears.

GSE 4.0 Highline Servo

The servo amplifier for the shifiting actuator GSE 4.0 Highline contains a 19-inch industrial rack to drive the motors and the necessary hardware for capturing and processing signals. The back of the servo rack contains all electrical power connections, the EtherCAT slave interface, and other interfaces for the higher-level automation.

Highly functional shifting actuator GSE 4.0 Function

The gear shifting actuator GSE 4.0 Function offers an affordable and durable solution. With the GSE 4.0 Function, ATESTEO offers a flexible and economical gear shifting actuator for use on drivetrain and transmission test benches. The high-frequency control of position and speed of this actuator enables the fully automatic shifting of vehicle transmissions with shifter/selector cables.

Safe gear engagement with high safety and economy

The GSE 4.0 Function actuator consists of two linear motion units driven by servomotors for the shifter and selector direction. Speed and position values are acquired by absolute encoders integrated into the servomotors. The shifting forces can optionally be determined with the actuator GSE 4.0 Function by load cells integrated into the ends of the linear motion units. With the aid of adapters, the original cables can be attached to the actuator. An automatic learning process, which lasts only a few minutes, concludes the logical integration of the test specimen.

Electronics of the GSE 4.0 Function

Components such as servo amplifiers to control the motors and hardware necessary for signal acquisition are part of the GSE 4.0 Function system electronics. The electronics are integrated into the actuator. Routing wires and cables is therefore reduced to a minimum.

The automated learning process of the GSE 4.0 Function shifting actuator

The automated learning process of the GSE 4.0 Function actuator seeks all available gear shift positions. The shift gates and interlocks (reverse) are automatically recognised by the shifting actuator. The zero-force end positions of the gears are automatically determined by the control software. After the learning process has finished, the user can make corrections to the gear positions if needed and connect the gear positions to each other by foot point (routing). Further, the optional extension set “mechanical force decoupling,” with its mechanical play, can create disengagement between the actuator and the shifting system of the transmission. After a gear has been engaged, even strong vibrations or movements of the test specimen and underdeveloped inner shifting systems do not prevent a gear end position without load at the shift forks.

Equipment of the GSE 4.0 actuators

GSE 4.0 Controller

The GSE 4.0 Controller is an industrial computer in 19-inch format. The GSE 4.0 control software, which runs on a real-time operating system, controls the gear shifting process using the EtherCAT master interface, simultaneously controlling forces (Highline model only), position, and speeds. The system communicates via CAN interface with the higher-level automation and communicates via a network interface with the GSE 4.0 App.

GSE 4.0 Tablet

The industry-strength GSE 4.0 Tablet is designed for use in rough environments. It has a high-resolution touchscreen. Mounted on the accompanying docking station, the tablet is used for parameter setting and displaying outside the test room. When directly connected to the GSE 4.0 Highline shifting actuator, the tablet serves to teach the gear positions.

GSE 4.0 App

The intuitive user interface of GSE 4.0 App makes all necessary parameters available, clearly arranged. All characteristic values such as the shifting forces and speeds can be set gear by gear and stored as projects in any required number. Besides the numerical representation of current measurement values and parameters, the software also makes additional graphics windows available. Displaying the gear lever positions “learned” by the robot enables the visual control of the learning phase, while presenting the shifting force over the shifting travel serves the rapid analysis of the individual phases of the shifting event. Optionally, the GSE 4.0 App can additionally be executed on a connected Windows® PC.

Download

To perform shifting operations on other transmissions, such as trucks, ATESTEO also develops special solutions in the GSE system according to customer requirements. Learn more about the ATESTEO shift actuators in our current performance brochure.

Brochure GSE actuators

Test bench actuator LMC3 Linear Motion Control

During the automation of test benches, actuators take on various tasks; for example, controlling the clutch pedal, adjusting the drive positions of an automatic transmission, and simulating an electric gas pedal (accelerator). With the LMC Linear Motion Control actuator, ATESTEO offers you a test bench actuator that has mastered it all — from operating the accelerator to activating the clutch and gear lever.

The actuator system consists of a controller with a highly dynamic servo amplifier including microcontroller control, a synchronous servo actuator with absolute value device, and a linear guide with specific mechanics. The controller has a high-resolution colour touch display, the intuitively operable menu-driven interface of which enables the entering of all parameters. Independently of the actuator, the various types of operation are a component of the LMC3 software, which offers a uniform user interface for all applications. To communicate with higher-level vehicle automation systems, there is a CAN interface, along with digital and analogue input-output (I/O) channels. The LMC3 remote control is handy and is for mobile operation of the actuator. The remote control is equipped with a touchscreen display which ensures that all functions of the LMC3 actuator are also available through this mobile operating device.

Actuator LMC3 Linear Motion Control — features

  • Highly dynamic brushless servomotor
  • Durable industrial linear guides with microcontroller-controlled servo amplifiers
  • Highly accurate travel measuring device; resolution < 0.05 mm
  • High control speeds
  • Pivotable drive unit and stable installation plate enable easy adjustment at the test bench
  • Pressure roller with ball bearing permits connection to any pedal geometry (KBE/TPC)
  • Adaptable to all standard shift cables (AGS)

Actuator LMC3 Linear Motion Control — software

The control software is the operating system of the Linear Motion Control LMC3 actuator. This software provides the user with a convenient and easy-to-use interface to enter and control all parameters. All necessary functions and input dialogues of the LMC3 can be dealt with using the touchscreen. Depending on how it is used, the main monitor offers the possibility of entering and changing control input (set points) or manually driving to the desired position.

Variants of the LMC3 Linear Motion Control

The actuator series Linear Motion Control (LMC) handles all the functional tasks for fully automated linear movement processes on vehicle and drive train test benches. This system is available in two variants: as a clutch actuating device KBE for operating vehicle clutch pedals, plus the throttle valve actuator TPC, and as an automatic transmission shifting device for operating selector levers on automatic transmissions.

KBE3 clutch activation device (clutch actuator)

The actuator KBE3 automates the clutch processes at the test bench. Optionally, the KBE3 actuator can also measure the clutch characteristic curves with a force measurement device. To operate the clutch pedal, the KBE actuator is equipped with a pressure roller with a ball bearing. The actuator can be adjusted to various installation situations by adjusting the angle of the torsion-resistant foot. Capturing the force of the pedal takes place through an optionally available load cell. With the additional motor brake, the KBE can hold the pedal securely in position disengaged even in a condition without current.

KBE clutch actuator — features

  • Suitable for any clutch system up to 500 N of actuation force
  • Communication with higher level automation systems via CAN bus or analogue input
  • High control speeds
  • High-precision path measurement device, resolution < 0.05 mm
  • Integration via the series-produced clutch pedal
  • Pressure roller with ball bearing permits integration with any pedal geometries
  • Swivelling drive unit and stable mounting plate enable simple adaptation to the test bench
  • Remote control
  • Durable industrial linear guides with microcontroller-controlled servo amplifiers
  • Optional climate resistance to -30°C

KBE clutch actuator – software

  • Parameterisation and monitoring of the forces and paths
  • A special position can be configured in case of errors
  • Intuitive operation with plain text menu

KBE clutch actuator – details

  • Linear thrust stat./dyn.: 700/1,700 N
  • Force measurement range: 2,000 N
  • Speed: 1,300 mm/s
  • Position precision: ±0.1 mm
  • Mechanical travel range: 200 mm
  • Weight: 25 kg

TPC throttle valve actuator

As with the clutch actuator, the gas pedal (accelerator) is operated directly via a pressure roller containing ball bearings. Because of the lower pedal forces, the foot is lighter and more slenderly built than with the KBE. To control an electronic gas pedal (accelerator), the LMC3 controller has two additional analogue and digital outlets.

TPC throttle valve actuator – features

  • High control speeds
  • Durable industrial linear guides
  • High dynamic servo motor
  • Easy adaptation to the test stand via swivel drive unit and stable mounting plate
  • Displacement measuring system with resolution < 0.05 mm
  • Connection to KBE and TPC by means of ball bearing mounted pressure roller
  • AGS adaptable

TPC throttle valve actuator – software

Control software with user-friendly interface for both input and control of the relevant parameters via touch screen. It is also possible to set the setpoints and move to the targeted position.

TPC throttle valve actuator — details

  • Linear thrust stat./dyn.: 300/500 N
  • Speed: 1,300 mm/s
  • Position prescision: ±0,1 mm
  • Mechanical travel range: 200 mm
  • Weight: 15 kg

AGS automatic gear shifting actuator

The actuator AGS automatic gear shifter is used to shift automatic transmissions in the test bench. The adaptation to the automatic transmission takes place via the original cable control. For this, the actuator is outfitted with an universal cable holder that can be adjusted using the included adapter. During the set-up process, the chosen lever positions are fed into the LMC3 controller and can be driven to automatically by entering the position numbers. Chosen lever positions that lie outside of the axis of actuation can be controlled directly via additional electronic outputs (tip/sport).

AGS automatic transmission shifting device actuator — features

  • Adaptation to all typical shifting cables
  • Communication with higher level automation systems via CAN bus, digital input (BCD code), or analogue input
  • High control speeds
  • Highly accurate travel measuring device, resolution < 0.05 mm
  • Remote control
  • Durable industrial linear guides with microcontroller-controlled servo amplifiers
  • Optional climate resistance to -30°C

AGS automatic transmission shifting device actuator — software

  • Parameterisation and monitoring of the forces and paths
  • 16 storable positions
  • A special position can be configured in case of errors
  • Intuitive operation with plain text menu

AGS automatic transmission shifting device actuator — details

  • Linear thrust stat./dyn.: 300/500 N
  • Speed: 1,300 mm/s
  • Position precision: ±0.1 mm
  • Mechanical travel range: 200 mm
  • Storage positions: 20
  • Weight: 15 kg

Download

All further information on our test bench actuators can be found in our current brochure.

Brochure LMC3 Linear Motion Control

This might also interest you