Mustang Advanced Engineering recently supplied three automated end-of-the-line test systems to Harley-Davidson Motor Company. The project, dubbed the “Keystone Project”, called for Harley-Davidson to build a new $145 million, 350,000-square-foot manufacturing facility on the site of its existing assembly plant in York, Pennsylvania. The York plant provides machining, fabrication, paint and final assembly of the Dyna, Softail and Touring models and builds limited edition custom models.
For this project, Mustang supplied all equipment, software and engineering requirements including system design, installation, start-up and training for three self-contained end-of-line test cells. The new test systems were installed in late 2002 and will began testing in early 2003.
Each of the three test cells contained a multi-function chassis dynamometer capable of variable wheelbase adjustment, vehicle load testing, brake testing, road simulation and function testing. A front and rear wheel restraint system limits the motorcycle’s movement while under test. All of these tests are performed while the motorcycle is on the build cart.
In addition to the dynamometers, the test systems also were outfitted with exhaust removal systems, motorcycle cooling systems, fuel control systems, ECM read/write control interfaces, charging and starting systems, boom arm closed interconnect and operator interface panels, conveyor system interfaces, factory automation system interfaces, as well as fire and sound suppression systems.
“The unique testing approach of these systems enabled Harley-Davidson to test all motorcycles while on the build cart attached to the conveyor line, removing the requirement and liability of manually moving motorcylces in and out of the testing and packaging stations. This is the only motorcycle production line that I am aware of that completely builds, test and packages a motorcycle while on the conveyor build cart” said Donald Ganzhorn, Executive Vice President and Chief Engineer for Mustang Dynamometer.
“Mustang is extremely proud to have worked with Harley-Davidson for this project” said Dean Ganzhorn, Mustang President and CEO. “Mustang’s experience with this type of tightly integrated, advanced end-of-line test system was key to us winning this contract and Mustang looks forward to a long working relationship with Harley-Davidson on future production and related R&D projects.”