Table of contents
- PS guide ABE approval Acceptance of the Magura HC3 brake pump
- HC3 brake pump for road drivers
- Documentation on documentation
- From theory to the test laboratory
- Climatic chamber and dirty bath
- Technology radial brake pump HC3
Jahn
14th pictures
Jahn
1/14
Because Magura do not want to offer the new HC3 brake pump as a pure racing accessory, but also for all road drivers, this ABE was organized. The pump can then be entered directly after it has been correctly installed.
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2/14
Brake records via GPS with a Tellert system.
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3/14
Max Hohler checks the changeable lever bearing point in all variants and later even checks the operating instructions.
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4/14
The practical test is as simple as it is effective. Lever widths, risk of entrapment, malfunction: the list of possible errors is huge.
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5/14
With the new HC3 radial brake pump, the traditional Swabian company is presenting a top-class radial brake pump.
Jahn
6/14
If you move the HC3 to position 15, you operate the brake with little manual force over a longer lever path. If you prefer the 16 position, you have to pull a little harder, but only with a shorter lever path.
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7/14
The secondary seal of the master piston is designed in an X-shape. This double seal ensures that even with critical engine vibrations, no air bubbles can penetrate the brake system.
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8/14
Testing on the living object. Here, the HC3 radial pump is carefully examined when it is attached to a BMW HP2 Megamoto. Touching is expressly allowed!
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9/14
At one of the Magura test stands: Alex Pohle, Product Manager at Magura, risks a shoulder glance while the rest of the developer crew waits and relaxes.
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10/14
Magura is silent about the composition of the standardized dirty liquor.
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11/14
Bend, press, measure forces. Clean notepads and shirt collars are an examiner’s obligation.
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12/14
Stefan Fritschle (left), head of innovation management at Magura, and test master Markus Buck (center) explain the “Bad Urach dirt pan” to Max Hohler from TuV Sud.
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13/14
Construct, test a lot, check and document properly.
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14/14
While test technician Bernd Bossler whizzes towards the data logger, Aftermarket Sales Manager Conor McRory offers TuV man Hohler extra driving time: “You can drive until the lights go out!”
counselor
technology & future
PS guide ABE approval
PS guide ABE approval
Acceptance of the Magura HC3 brake pump
Content of
With a regular general inspection, the fun hangs lower than a knee slider. But what happens when a company like Magura demonstrates its new HC3 brake pump for ABE approval?
Markus Jahn
05/20/2014
Imagine a company has to go to the TuV to have a new component checked. Immediately memories pop up from your own TuV experiences, suffered in countless tests of the beloved two-wheeler, always accompanied by the legendary blue “TuV smock”, right? In the past, this fashionable cape usually contained a bad-tempered, quirky figure – an outdated eggshell on its head – gurgled across the TuV-Hof on a “customer motorcycle” and braked man and machine with respect.
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Ha, we knew you knew him! But what does this have to do with a Magura brake pump and an ABE? Except for the TuV stamp, nothing at all, and that’s what makes it so exciting. So let’s forget about the old blue squirrel and grab a cup of coffee in the present.
HC3 brake pump for road drivers
The clock in a quiet conference room at Magura shows ten sharp. Anyone who was still able to experience Kreidler, Hercules and Maico knows Magura As a dashboard manufacturer and producer of the legendary M handlebar, the younger generation of bicycle brakes and BMW drivers have their hands on it without even knowing it.
So now a product offensive with “hardcore tech” and new patents. Conor McRory, thanks to his Irish-Bavarian origins and his grandiose dialect, is the only one able to pronounce Magura with four “uuuu”, explains the meaning of today. “Because we don’t want to offer our new HC3 brake pump as a pure racing accessory, but also for all road drivers, we are organizing this ABE approval. Then you can have the pump entered directly after it has been correctly installed. ”Anyone who stumbles over Europe’s mountains of paragraphs on the subject of general operating permits, E-marks or certification could contact the main person on this test day directly, assuming the appropriate budget.
Documentation on documentation
Max Hohler is an engineer and officially recognized expert at TuV SuD, with an impressive 27 years of professional experience. The expert explains the labyrinth of regulations and possibilities in a friendly, calm and completely without blue coat mentality. “We, TuV SuD and of course our competitors like TuV Rheinland or Dekra, are a service between the authorities and the manufacturer. Our range of tests extends from the creation of a motorcycle component ABE and homologation to the complete certification of an accessory manufacturer. “
Magura has such a classification and has applied for an ABE from the Federal Motor Transport Authority (KBA) for a new product, such as the HC3 radial brake pump here. In our case, the Bad Urachers received KBA number 91441 and ordered Max Hohler to have an inspection carried out. This person is then personally named in the ABE for the test result.
That sounds simpler than it is, because up until then a few tree trunks had to be put on paper in Scandinavia, and Stefan Fritschle and Alex Pohle are now sorting out the results and tables in the Magura documentation that resulted from this. Above all, Stefan Fritschle won the award for the longest business card title: “Head of Innovation Management and Testing.” That clearly beats Alex Pohle’s project management. However, the gentlemen don’t seem to be really excited at the TuV appointment. So says Stefan Fritschle, who already did his diploma thesis at Magura on the subject of brakes: “The factory standards of Magura are significantly higher than the required ECE guidelines, so that doesn’t give us a stomach ache.”
From theory to the test laboratory
Max Hohler first lets the Magura troop go ahead. “We call this a witness process,” he explains. “We could also test such a pump in our test center, or just take a look at everything here.” A mixture of school questionnaires and pants down: conception, construction, materials, tools, test stands, standards, guidelines, the entire back and forth.
11.28 a.m. It’s relaxed. Motorcyclists are only too happy to get lost in technical discussions. “Wouldn’t it be possible to use normal oil instead of brake fluid?” So now, gentlemen, don’t waste any time – it goes from theory to the test laboratory. Cameras usually have to stay completely outside here, but with certain restrictions, such as the brake test bench, it works today. A very exciting thing for TuV man Hohler, of course. It is his first visit to Magura and he is interested in every little detail.
Climatic chamber and dirty bath
Pffft, tock, pffft, tock. Pneumatic cylinders continuously press on the handbrake pumps and their levers installed in the test bench. They simulate load peaks and all forms of tensile, compressive, hand and so-called abuse forces. It continues to the climatic chamber and the dirty bath, where the new component is exposed to heat, cold and dirt. Experimental master Markus Buck explains and Max Hohler systematically ticks off his catalog of questions.
Last but not least, there is a practical test on a motorcycle on a closed-off area. A BMW HP2 Megamoto and a KTM 1290 Super Duke R serve as rolling laboratories. Before starting, the attachment, manual forces and security against twisting are checked. The TuV man makes it clear: “I’m not here to test how well the brakes work, just to check function, safety and permissibility.” Then Stefan Fritschle and Max Hohler thunder down the test track. Up, down – brake, record, remodel. As soon as test engineer Bernd Bossler has brought the respective data to safety on the computer, it continues with defined braking. After the different lever hinge points, the ABS suitability and everything else have been checked, this day comes to an end – the practical check was also successful! Now there is a lot of paperwork for Max Hohler, for Magura the step to the start of series production and the till rings at TuV Sud. And all of that without the unfortunate TuV smock.
Technology radial brake pump HC3
Jahn
The secondary seal of the master piston is designed in an X-shape. This double seal ensures that even with critical engine vibrations, no air bubbles can penetrate the brake system.
With the new HC3 radial brake pump, the traditional Swabian company is presenting a top-class radial brake pump. The specialty of this brake fitting is the possibility to change the lever ratio of the brake lever to the primary cylinder in three positions and thus to simulate three different sized brake piston diameters. This idea isn’t new in and of itself, but Magura’s implementation is brilliant. Because only with the HC3 fitting is the brake cylinder’s piston always applied centrally with the braking force of the lever. This creates constant friction within the valve and thus the same braking feeling on the lever, regardless of whether the 14, 15 or 16 piston diameter is simulated.
Another advantage of the central loading of the brake piston in the pump is the high durability of the seals within the valve. In addition to its full ABS suitability, the HC3 also impresses with another innovation that is of particular interest to racers. The secondary seal of the master piston is designed in an X-shape. This double seal ensures that even with critical engine vibrations, no air bubbles can penetrate the brake system. Soft pressure points or fading are a thing of the past with this fitting – at least from the pump side.
What are the benefits of three simulated piston diameters? If you move the HC3 to position 15, you operate the brake with little manual force over a longer lever path. If you prefer the 16 position, you have to pull a little harder, but only with a shorter lever path.
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