An automotive supplier requires frames in order to perform comprehensive pressure, heat and emission tests on fuel tanks and for storing these tanks. The frames are to be used to install the tanks just like in an actual vehicle. The aim is to simulate the installation situation as realistically as possible. The frames must be adaptable to the different tank geometries and fitted with rating plates for the individual projects. In addition, the frames for different tank types must have the same external dimensions to enable stacking and to prevent the frames from tipping or falling when stacked. The frames must also be fuel-resistant and able to withstand temperatures ranging from -40 to +100°C as well as the vibrations produced during testing.
In addition to the frames, the customer also requires trolleys for transporting the frames to the different test stations and storage locations. It must be possible to transport up to three frames stacked one on top of the other. This corresponds to a weight of approx. 140 kg per frame, including a full tank.
To meet these requirements, we constructed robust, convertible frames made from series 40 aluminium profiles and equipped with accurately positioned mountings for the fuel tanks. Thanks to the open T-slots, additional connection points can be set at virtually any position on the profile. Rubber buffers at the relevant points provide secure, damage-free support for the tanks if no accurately positioned mountings are available. To enable safe and easy stacking of the frames, stacking lugs have been applied to the upper corners. The upper framework is removable and can be locked with clamping levers, thereby ensuring easy installation of the tanks in the frames.
The trolleys were also constructed from series 40 profiles. They feature swivel castors for ease of movement and integrated locking devices for maximum security. The castors are electrically conductive to prevent the build-up of electrostatic charges.