Clutch Testing Machine – UK & USA

Client: Automotive Tier 1 supplier

Challenge

Traditional clutch testing machines relied on a dual-layer architecture:

A PLC for machine and servo drive control, as well as line integration

An IT-based system for measurement and ECU communication

This setup was complex, expensive, and hard to maintain. Even minor changes to test profiles required external IT support, costing the customer thousands of dollars per adjustment. Cycle times were critical, as large volumes of torque data needed to be processed and transferred to the MES system for every test.

AG Controls Approach

AG Controls was contracted to deliver software development and commissioning, supporting all stages of the project in both the UK and US. The team identified opportunities to simplify and optimise the architecture by removing the IT layer entirely.

Key steps and achievements included:

  • PLC-only architecture: All measurement and control functions were brought into the PLC, eliminating the need for a separate IT system.
  • High-speed measurement: Torque data was captured at 0.25 ms resolution using Profinet iRT, guaranteed at both software and hardware levels.
  • Optimised control: A custom PID loop for clutch torque ran every 10 ms, enabled by highly optimised PLC code.
  • Data handling: Each test generated around 3 MB of measurement data, packaged and sent to the MES system without impacting cycle times.
  • Flexibility: Test profiles became fully configurable via PLC recipes, with fingerprint scanning protecting against unauthorised changes.
  • Communication: Integration complied with strict General Motors specifications, including CAN bus communication with the ECU.

Results

  • The new solution delivered tangible business value:
    Reduced costs: No external IT intervention needed; process engineers can configure test profiles independently.
  • Increased flexibility: Engineers have full control over testing recipes, enabling rapid adaptation to new requirements.
  • Improved maintainability: Maintenance staff can diagnose and resolve issues directly in the PLC environment.
  • Performance: The machine achieved the required cycle times and was successfully deployed at the customer’s US site.

This project demonstrates how AG Controls can replace complex, costly IT systems with streamlined, industrial-standard PLC solutions, delivering both technical performance and business efficiency.