Motorcycle Switchgear Actuation Forces

Solution

• MultiTest 2.5-i test stand with ILC intelligent cell
• Event input connectivity cable
• Specially engineered fixtures for switchgear actuation testing

Benefits

• Integrated testing setup for multiple switch evaluations
• Customisable features to suit varied and complex designs

Requirement

One of the largest German motorbike manufacturers had a need for a testing setup to measure the actuation forces of controls located on the handlebars. It is critical for safe riding that the switches can be reliably operated regardless of weather conditions and also offer a distinctive tactile feedback. Whether activated by thumb or fingers, the controls must deliver consistent performance and a definite confirmation of engagement.

The company needed a versatile system capable of testing different types of controls, regardless of their mechanical operation, placement, or orientation on the motorcycle assembly.

Solution

Presto’s engineering team collaborated closely with the manufacturer to develop a dedicated fixturing arrangement that fulfilled multiple testing requirements. The first step involved securely positioning the switch module so that the direction of actuation aligned precisely with the probe’s axis, made possible through multiple mounting positions on the test stand platform.

Push-button, toggle, rocker, and lever-type switches could be actuated with a small compression plate. Support fixtures were designed to allow the testing of entire assemblies representative of sub-assemblies. The final setup functioned as a comprehensive workstation for evaluating hand-operated switchgear.

The testing process was managed through advanced software, which controlled the compression cycle and captured the peak force required for actuation. Integration with event input signals enabled correlation between applied force and movement, allowing precise measurement of displacement during operation

This solution supports the development of ergonomically efficient and high-quality control systems, enabling manufacturers to enhance rider comfort, safety, and accessibility of both essential and advanced motorcycle functions.

Test equipment

• MultiTest 2.5-i test stand
• 250 N ILC intelligent loadcell
• Event input cable
• Compression plate
• Custom lower fixture for switchgear modules