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


JLR heads to LA with I-Pace

LV

Engineer Simon Patel takes potential I-Pace customer Ann Voyer on a long-distance real world road trip from Sunset Boulevard, Los Angeles to Morro Bay, San Luis Obispo to test the vehicle's range and durability

Click here to watch the video


Waymo unveils self-driving cars

LV

Waymo, which started as the Google self-driving car project in 2009, is ready for the next phase. Fully self-driving vehicles are currently being tested on public roads, without anyone in the driver’s seat.

Click here to watch the video


As vehicle developers and suppliers continue to advance their software programs, ATTI wants to know, has simulation software established itself as the single most vital piece of equipment during a development program?

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
RECEIVE THE
LATEST NEWS


Your email address:



Web Exclusives

Safer analysis of onboard chargers

How Keysight's compact, two-quadrant, regenerative power converter test solution with integrated safety features accelerates test time, and protects both users and devices under test
Click here to read more



SEAT uses HBM autonomous DAQ system

SEAT and Polytechnic University of Catalonia (BarcelonaTech) have jointly developed a unique data acquisition enabling more precise control over instrumented parts and the entire data acquisition process  
Click here to read more



Modern calculation management

The engineering department at Hitachi Construction Truck Manufacturing is taking steps to improve its rigid-frame hauling truck design through improving its analysis tools
Click here to read more



Traveling in a Volkswagen that is still to be developed

Volkswagen Group’s IT Virtual Engineering Lab has developed a virtual concept car using digital future technology
Click here to read more



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




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.

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