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Motorcycle Switchgear Actuation Force Testing
Motorcycle switch force testing machine
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switch testing machine
Solution
- Zeus Ultimo 3.0 software-controlled test stand
- Event input interface
- Custom fixtures designed for handlebar switchgear modules
With motorcycle switches and control modules rapidly evolving, the Presto Stantest software-controlled actuation force testing system has enabled the determination of motorcycle switch performance, an important factor in evaluating handlebar switchgear modules. It is equipped with accessories consisting of a Zeus Ultimo 3.0 test stand, an intelligent load cell, and custom-made fixtures, allowing push-button, toggle, and rocker switches, as well as lever mechanisms, to be tested in their actual positions. Peak actuation force and displacement information are recorded in real, real-time and recorded on the workstation, enabling engineers to explore tactile response, rider comfort, and switch performance consistency. Thanks to its modular fixture design, it ensures the testing of entire switchgear designs and thus adapts to ever-widening control layouts, heated grips, cruise control, and infotainment. Laboratory testing has been automated to provide greater repeatability, easier ergonomic assessment, and facilitation for manufacturers to keep motorcycle cockpit controls responsive, safe & high-quality.
Benefits
- Comprehensive workstation capable of performing a complete suite of actuation tests
- Expandable, adaptable design for testing unique or evolving switchgear configurations
Requirement
A leading German motorcycle manufacturer sought to evaluate the actuation forces of its handlebar-mounted controls. Riders must operate switches comfortably and safely in all conditions, with each control providing a positive tactile response and clear feedback. The company required a testing system capable of assessing any type of control, regardless of mechanism type, mounting position, or orientation.
Solution
Presto Stantest engineers collaborated with the manufacturer to develop a bespoke fixturing system. The switchgear modules were secured so that the actuation motion aligned precisely with the probe axis, using multiple locating points on the test stand’s anvil plate. The system accommodated push-buttons, rockers, toggles, and lever mechanisms, ensuring each component could be tested in its functional orientation. Supporting fixtures were included to allow testing of complete sub-assemblies, providing results representative of actual manufactured units.
Software controls the test, recording the peak force required to operate each switch. The system also allows the linear displacement required to actuate the system and plot it onto the graph of the results by integrating the Zeus Ultimo 3.0 interface. This has made the manufacturer to be able to retain ergonomic and high-quality cockpit controls without compromising the safety and comfort of introducing more features like the heated grips, cruise, and infotainment devices. The workstation has made sure that all the switchgear is easily controlled and reactive to the touch of the rider.
Test Equipment
- Zeus Ultimo 3.0 software-controlled test stand
- ILC intelligent cell
- Event input interface
- Compression plate
- Custom lower fixture station for handlebar switchgear modules
Test standards
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