Supplier Spotlight

Show Reviews

Automotive Testing Expo Europe 2017 Show Review

Click here to read

 

Automotive Testing Expo Europe 2016 Show Review

Click here to read

 

Automotive Testing Expo Europe 2015 Show Review

Click here to read

 

Automotive Testing Expo North America 2014 Show Review

Click here to read

 

Automotive Testing Expo India 2014 Show Review

Click here to read

 

Latest Video


World's largest test ground for autonomous cars

LV

ATTI visits K-City in Seoul, Korea. Expressways will be available for evaluation later this month, with the rest of the facility due to open in early 2018

Click here to watch the video


Fishhook / roll stability testing

LV

AB Dynamics explains a steer and counter-steer manoeuvre, which might be applied by a panicked driver avoiding an obstacle in the road.

Click here to watch the video

If you could pick only one, where would you prefer to perform climatic testing?

Articles

« back to listing

New test program approach

Drive Design Systems has devised a new approach to developing a realistic test program from limited real-world data

 

Automotive engineering consultancy Drive System Design (DSD) has overcome one of the biggest challenges facing companies developing new products for completely new applications – devising a realistic test program to validate a product early in its development in order to avoid costly revisions later.

Taking accelerometer data from prototype field trials, DSD configured a comprehensive vibration test program to provide accelerated life testing for a custom-designed battery system.

DSD’s client, Hyperdrive Innovation, develops powertrain systems for electric, hybrid and conventionally powered vehicles, including robotics, off-highway and automotive applications.

“Accelerated testing undertaken independently was attractive to us as it meant we could run a program in a short time frame to give both ourselves and our customer added confidence that our battery system was robust and ready for series production,” explains Hyperdrive’s engineering director, Robin Shaw, of the reasoning for the test.

“We appreciate the professionalism and expertise demonstrated by DSD in designing an optimum test regime using real-life data and then running this test in its independent facility for one of our custom-designed battery packs.”

Unlike derivations of previous products or revisions to existing applications, which can use historically proven tests, the new product required DSD to devise the test specification from scratch. The key objective was to have a representative regime for testing both the complete battery system and Hyperdrive’s own Battery Management System (on a PCB) to a short a timescale as possible.

DSD validated Hyperdrive’s battery pack for a new application with limited field data

“Any all-new product or application creates a validation challenge; early confirmation of the design is vital to minimize development risk, but established test regimes are often inappropriate,” explains DSD’s managing director, Mark Findlay.

“The methods developed by our engineers to overcome this barrier have the potential to help clients across a wide range of industries, products and applications, where no relevant baseline data exists.”

The raw data was collected from two accelerometers sampling at different frequencies, with DSD’s first task being to convert the data into a meaningful format. Appropriate vibration amplitudes, frequencies and durations were taken from the field data to create a duty cycle with the required factor of safety, using Labview and Matlab software.

A test profile based on the frequency content of the data was defined to represent an average of many repeated tests. DSD rejected simply replicating the field data on a shaker rig as this would only have simulated the previous test, not provided an accelerated test capability.

DSD designed the fixtures and frames for the test rig to ensure loading was applied through the standard system mounting points. Testing was carried out in three perpendicular axes, under ambient conditions, and was completed within five days.

Hyperdrive then took back the battery pack to test the integrity of all systems and electronic parts.
 

DSD analyzed, created and carried out a test program using its independent test facility

February 10, 2016

 

Read Latest Issue
Read Latest Issue

Web Exclusives

The importance of software engineering

Tier 1 supplier GKN’s software and electronics manager, Michael Schomisch, discusses how software development is becoming increasingly important in vehicle testing
Click here to read more



Daimler reveals how the GLC F-Cell went from testing to production

With the Mercedes GLC F-Cell SUV unveiled at Frankfurt this week, Daimler has revealed the extensive testing process the first production plug-in hydrogen-powered car was put through
Click here to read more



Speaker Q&A: Jerry Beeney, FLIR Systems

The business development manager, who will be presenting at Automotive Testing Expo in Novi, Michigan, discusses current measurement tools and techniques used to measure high-speed targets, including thermal cameras and contact and non-contact temperature measurement systems.
Click here to read more



Conti celebrates 50th anniversary of the Contidrom

The German tire giant looks back on 50 years of testing and development at its flagship facility
Click here to read more



Cruden launches new simulator technology

The system designed for ADAS and autonomous vehicle testing enables engineers to add as much hardware- or software-in-the-loop as they wish
Click here to read more




Supplier Spotlight

Supplier SpotlightClick here for listings and information on leading suppliers covering all aspects of the automotive testing industry. Want to see your company included? Contact jason.sullivan@ukimediaevents.com for more details.

فروشگاه اینترنتی فروشگاه اینترنتی سیستم همکاری در فروش ماهواره آنلاین اندروید کانال تلگرام چت روم دانلود فیلم فروشگظ;ه اینترنتی

Submit your industry opinion

Industry BlogDo you have an opinion you'd like to share with the automotive testing community? Good or bad, we'd like to hear your views and opinions on the leading issues shaping the industry. Share your comments by sending up to 500 words to john.thornton@ukimediaevents.com

Advertising

Recruitment AdTo receive information on booking an advertising banner please email jason.sullivan@ukimediaevents.com