BLACK FOREST POWER STATIONS

The essentials of a testing machine is the correlation with the actual loads on the road and in the field. From my past in a big American company, I know that there is a big discrepancy here. The requirement to reconcile practicality and at the same time simulate the existing standards has been done with in-house engineering work. In other words,

Our requirements usually go beyond the current standard (ISO 4210). Our Schwarzwald power plants are the most important part to determine the operational strength of hubs, wheels, handlebars, stems and seatposts. For further evaluation of the operational strength, additional criteria such as corrosion resistance, UV resistance, extraordinary loads, etc. are of interest. And for those interested: The heart of each machine is a processor connected to a pneumatic system. The machines are modular. According to reality, the processor is power-driven and not path-controlled.
It controls a pneumatic cylinder, records the measured values ​​of a load cell, compares the setpoint and actual force, processes it and transmits it to a computer via a serial interface.

Schwarzwaldkraftwerke 1 and 2. They enable statements on the products for which tune is known and recognized – hubs and wheels.

BLACK FOREST POWER STATIONS 1 and 2:
These enable assurances on the products for which Tune is known and recognised – hubs and wheels. Power unit 1 measures the force that the brake’s disc attachments can tolerate. Reassuring to know:
Significantly more than double the maximum braking force. This is roughly equivalent to the torque of a 1.6 litre diesel engine.

 

Power station 2 checks the load capacity of the freewheel. Tune was a pioneer in aluminum freewheels with narrow bridges. Good to know they work.

Both power stations simultaneously measure the complete wheel, so we get data about the torsional strength of the hub body, flange, spoke, nipple and spoke hole at the rim.

 

BLACK FOREST POWER STATION 3
is a kind of guillotine for rims. This is most importantly for carbon rims which can not be bent.

The falling axe can either hit both flanges simultaneously and vertically, or only laterally on one side of the flange.
Like the French doctor Joseh-Ignace Guillotin, the guillotine separates the good from the bad rims.

BLACK FOREST POWER STATION 4
simulates both downhill (1000N double-sided load) and sprint (300N unilateral load) by pulling and pressing.

For those who are reassured by how much the carbon bar can bend, allowing us to call it ‚Wonderful‘.
Of course, as in the case of the power stations 1 and 2, the entire system is tested together, so we also test with the stem attached too.
However, we can only fully stress a stem if we use a steel rod instead of a handlebar.

BLACK FOREST POWER STATION 5 
ensures that all our Seat posts are true to the name, both a strong and a light piece of equipment. The refined design was only possible after countless cycles of computation and testing.

We assume the rider is a ruthless 90kg man descending a mountain, and the power plant even simulates 100,000 instances of 120kg on the seat post.

More than enough for the average 70 kg rider.

BLACK FOREST POWER STATION 6 
relentlessly sits on saddles. A solid foam „butt” presses down 200,000 times with 100kg of force on the saddle. There are machines for everything…..

 

BLACK FOREST POWER STATIONS 7 

Tries with all its force to break our quick releases.
After unsuccessfully trying to destroy the AC and DC variants, we turned to the U20 and U30s skewers.
In order to break them apart, we had to hang over 3.5 tons on them – which is lacking in practical relevance, we know.
So we´re studying the creeping behavior of the adhesive for weeks and months at 400 kg. Just as as if your bike sits in your cellar.