Custom Test Solutions

Test Stands for Battery-Powered Hydraulic Devices

in the Energy Sector

Klauke, an Emerson company and leading provider of specialized solutions for the energy and utility sector as well as electronic tools and connection technology, was looking for a tailor-made solution to test its battery-powered hydraulic crimping and cutting tools under extreme stress conditions. The goal is to evaluate the durability and performance of the products and to identify long-term improvement opportunities. For this, Klauke requires a test system that simulates various environmental conditions and provides detailed measurement data on pressure, temperature, voltage, and current.

The NOFFZ Solution

NOFFZ Technologies developed, in close collaboration with Klauke, a freely configurable test system that includes both customized hardware and software components:

1. Test setup with multiple scenarios:

The system is designed to test the product until failure – a procedure that replicates realistic wear conditions. The tested products are stressed to their limits and beyond. Using a user-friendly sequence editor function, Klauke can create and flexibly adjust individual test scenarios. To accurately document sources of failure, cameras record the critical moments of product failure, providing additional valuable visual information for analysis alongside the recorded measurement data.

2. Advanced software functions:

The standalone software developed enables Klauke to define and independently further develop its own test procedures. During the tests, precise sensors continuously collect measurement data. An active cooling system (air conditioning) ensures that the ambient temperature in the test cell is kept constantly at a safe level. In the event of an incident, an integrated fire protection system intervenes and automatically shuts down the test stand. At the same time, responsible persons are notified via email or SMS.

3. Results: Further development and quality improvement

Thanks to the tailor-made test solution, Klauke identifies optimization potential in its products at an early stage and can continuously increase the quality of its tools. The close collaboration with NOFFZ enables Klauke to precisely trace errors and comprehensively analyze test data. With the user-defined features, the tools can be tested in a way that meets the high requirements of the energy sector. Today, five test systems are already in use at Klauke, supporting the very high quality standards of Klauke products.

Key features of the test systems:

• Customizable test sequences via a sequence editor
• Safety functions including fire protection and emergency shutdown
• Transparent lab experience for customers

“After the specification phase, the coordination and approval of
the design and system concept, we successfully
commissioned the prototype and its replicas in our laboratory. The close and constructive collaboration with NOFFZ
Technologies has resulted in a tailor-made test solution that sustainably supports our testing processes
and provides a solid foundation for future developments in the
demanding environment of the energy sector.”– Team Klauke