Millbrook Group

Leyland and NVH – A real customer example

October 2018 – CRITT M2A

© Millbrook Proving Ground Limited 2017 1 www.millbrook.co.uk

Leyland Test Facility Overview
.

© Millbrook Proving Ground Limited 2017 2 www.millbrook.co.uk

Millbrook’s Leyland Test Facility

Built in 1980 as Leyland DAF Technical centre

© Millbrook Proving Ground Limited 2017 3 www.millbrook.co.uk

Powertrain

Engine and
Electric Machine Driveline Testing
Testing
Axle Testing

Engine Noise
Testing

© Millbrook Proving Ground Limited 2017 4 www.millbrook.co.uk

Engine and Driveline Testing
Millbrook’s Leyland Applications:
test facility offers ten • General engine durability: high
torque passenger car engines,
engine test cells. commercial vehicle engines, off-
highway engines
They are suitable for • Durability with emissions
engine capacities of • Exhaust after-treatment durability
• Passenger car exhaust system
up to 50 litres; the
durability: hot resonance testing,
dynamometers are thermal fatigue and manifold
150kW to 2100kW. cracking type tests
• General driveline durability
• Driveline development: complete
control of load and driveshaft speed
and extensive instrumentation
opportunities, making the rig an ideal
tool for development work

© Millbrook Proving Ground Limited 2017 5 www.millbrook.co.uk

Electric Machine Testing
Millbrook delivers a
complete range of
test solutions to
characterise, validate
and support
development and
certification of
electric driveline
components and
systems for various
applications.

Applications
• Initial / post-test electrical and
mechanical performance
characterisation
• Environmental
• Vibration
• Durability
• Witness testing and certification

© Millbrook Proving Ground Limited 2017 6 www.millbrook.co.uk

Axle Testing
The axle test rig at
the Leyland test
facility can be used
for the performance,
efficiency and
durability testing of
axles, transmissions
and differentials.

The motive power is

provided by an
electric motor and
multi-speed gearbox
for full speed and
torque control. Applications
• Efficiency measurement
• Lubrication studies
• Speed and torque characteristic
• Temperature surveys
• Durability running to fixed cycle,
block programme or RLD (Road Load
Data)

© Millbrook Proving Ground Limited 2017 7 www.millbrook.co.uk

Engine Noise Testing
Millbrook’s semi-
anechoic chamber
provides a quiet,
non-reflecting
environment for noise
assessment of
engines and their
ancillaries.

Multi-channel noise
and vibration data
acquisition
equipment is used to
acquire data straight
into LMS data Applications
processing and • Standard NVH benchmarking
analysis equipment. • Noise source ranking
• Operational vibration analysis
• Torsional vibration
• Mechanical noise/vibration
• CAN interface (Plus INCA)

© Millbrook Proving Ground Limited 2017 8 www.millbrook.co.uk

Interior Systems
Seat Vertical Pitch and
Robot Test Roll System
Testing
Laboratory
Materials
Testing
Environmental
Chambers

Airbag
Corrosion Testing
Laboratory

© Millbrook Proving Ground Limited 2017 9 www.millbrook.co.uk

Vertical Pitch and Roll System
Millbrook’s Vertical
Pitch and Roll facility
allows users to
conduct BSR
assessments on a
range of
components,
including seats and
IPs. It offers a high
capacity frame that
can achieve realistic
conditions through
simultaneous
excitation.
Applications
• Buzz, Squeak and Rattle (BSR)
• Assessment on cockpits and other modules
• Vibration durability testing
• Testing to OEM and international standards
• Subjective and objective assessments
using BSR sound quality
• Road Load Data

© Millbrook Proving Ground Limited 2017 10 www.millbrook.co.uk

 Vehicle Systems
Chassis
Multi Axis Dynamometer
Ride Simulator
Shake Table
Structural Test
Laboratory

Vibration
Laboratory

Vehicle Semi
Anechoic
Chamber

© Millbrook Proving Ground Limited 2017 11 www.millbrook.co.uk

Ride Simulator
The ride simulator is
used for accelerated
durability testing 2
and 3 axle vehicles,
with axle loads of up
to 12 tonnes and
gross vehicle weights
of 36 tonnes.

The 18m x 11m x 8m

test hall is ideal for
full sized commercial
vehicles and is
equally capable of
running simulations Applications
right down to small • Passenger cars
passenger cars and • Trailers, cabs, caravans, tractor units
off-road vehicles. • Wheeled military vehicles
• Ride comfort benchmarking and
development
• Modal analysis of complete vehicles to
identify resonant responses
• Rigid body modes and flexible body
modes
© Millbrook Proving Ground Limited 2017 12 www.millbrook.co.uk
Multi Axis Shake Table (MAST)
The MAST is used to
support durability,
Key Life Testing and
the development of
seats, instrument
panels and other
products.

Millbrook can support

the whole testing
process by collecting
all the relevant RLD
from a given
surface/condition,
iterating drive signals Applications
for the rig, running • Seats and IP testing
the test and • KLT (Key Life Tests)
analysing the results. • Durability
• Off-highway cab systems
• EV battery systems
• Up to 300kg payload

© Millbrook Proving Ground Limited 2017 13 www.millbrook.co.uk

Structural Test Laboratory
The structural test
laboratory at Leyland
has an area of 800m2
and is one of the
most sizeable and
well equipped in
Europe. It is
supported with two
electro-hydraulic rig
mains, a reinforced
concrete strong floor
grid and a dynamic
modular beam
system. The
laboratories can
Applications
accommodate test
• 4 or 6 point beam axle testing
samples from
• Air suspension axle testing
components to full
• Axis testing
HGV vehicle bodies
• Hub fatigue testing
and even bigger.
• Steering system testing
• Static strength, torsion, bending, fatigue,
5kN to 500kN load durability and ultimate strength testing
capability • One-off custom rig tests, rapid turnaround

© Millbrook Proving Ground Limited 2017 14 www.millbrook.co.uk

Vibration Laboratory
The vibration
laboratory features a
range of electro-
magnetic shakers
and electro-hydraulic
shakers that can
operate at a variety
of frequencies.

The range of shakers

covers rating from
5kN to 32kN thrust.
Most are coupled
with slip tables to
allows 3 axis testing. Applications
• Sine and Random
Testing can also be • Sine-on-Random
• Random-on-Random
conducted under
• Shock
various
• Road Load Data
environmental
• Data Acquisition and Analysis (incl. Strain)
conditions
• Squeak and Rattle
• Resonance Search / dwell

© Millbrook Proving Ground Limited 2017 15 www.millbrook.co.uk

Vehicle Semi-Anechoic Chamber (VSAC)
Millbrook’s VSAC
enables vehicle
performance and
noise development to
be concluded in a
controlled and
repeatable
environment with
very low levels of
background noise
(<20dB(A))

The chamber is a
single large concrete
structure weighing Applications
over 1200 tonnes, • Vehicle internal and external noise
mounted on springs development/analysis
to isolate it from the • Investigation of noise transmission paths
main building and • Noise and vibration data analysis
lined with sound- • Powertrain noise investigation
absorbent wedges. • Vehicle performance
• Exhaust brake tests
• Fuel consumption tests
(19m x 9m x 5m)
© Millbrook Proving Ground Limited 2017 16 www.millbrook.co.uk
NVH Testing – Engine NVH
Millbrook has
experience of
conducting engine
NVH testing within its
SAC

This covers:
- Vibration data
collection to
support operational
vibration analysis
- Standard 1m noise
measurements
including sound
power
measurements
- Noise source
ranking using
Acoustic Camera /
Windowing
technique

© Millbrook Proving Ground Limited 2017 17 www.millbrook.co.uk

NVH Testing – Vehicle NVH
Millbrook has
experience of
conducting vehicle
NVH testing within
our Semi Anechoic
Chamber in Leyland

This covers:
- Internal noise tests
- Exhaust orifice
noise tests 90 90
Baseline exhaust Conservative
- Exhaust 80 80

disconnects 75 75

70 70
- Transfer function 65 65
measurements 60 60
dB(A)

dB(A)
(NTF / VTF)
Pa

Pa
55 55

50 50

45 45

40 40

35 Overall level FRLH_inner (A) 35

30 Order 2.00 FRLH_inner (A) 30

Order 4.00 FRLH_inner (A)
20 20
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 1000 1500 2000
rpm
90 90
Aggressive Single Outlet Aggressive D
© Millbrook Proving Ground Limited 2017 80 18 www.millbrook.co.uk
80

75 75
NVH Testing – Component testing
Millbrook has extensive experience of
conducting component NVH testing.

This covers:
- Operational Deflection Shape analysis
- Operational Modal Analysis
- Component noise testing
- Seat power functions
- Exhaust transmission loss
- Squeak & rattle assessments
- Sound power measurements
- Modal response measurements using
calibrated impact hammer
- Off-site data collection

© Millbrook Proving Ground Limited 2017 19 www.millbrook.co.uk

 CLAAS works a lot to improve the
comfort of its customers,
especially regarding noise level in
cab

✓ Family business founded in 1913 ✓ CLAAS Tractor in France :

✓ One of the world’s leading manufacturers • Vélizy (78) : R&D, administration and purchasing
of agricultural engineering equipment • Le Mans (72) : Factory, Test Center
Test campaign on roller bench in semi-anechoic chamber
to better understand noise sources and transfer paths

✓ Search of a testing facility designed for tractors

✓ Contact with CRITT M2A and Millbrook
✓ 6 weeks of test at Millbrook, Leyland (UK)
✓ Test bench in accordance with our needs
✓ Very good reactivity, availability and assistance from
Millbrook team

© Millbrook Proving Ground Limited 2017 21 www.millbrook.co.uk

Summary
Millbrook is a
strong, growing
business

New ownership
underpins long
term investment

Clear focus on
providing value
to customers

© Millbrook Proving Ground Limited 2017 22 www.millbrook.co.uk