Dr Malte Zur Managing director Testxchange GmbH GERMANY
Digitisation is a mega-trend that greatly affects the market for industrial testing and certification. For outsourced testing at third-party test providers, there is still some catching up to do when it comes to the digital collaboration of test labs with their industrial clients, such as automotive OEMs or suppliers.
In the context of Industry 4.0, an increasing degree of automation and digitisation will be needed in test labs to support the clients' needs for more efficiency, cost savings and process transparency. Testxchange is an initiative to support the process of digitisation in industrial testing.
Using big data to ensure safe autonomous vehicles
Manuel Hofmann Field marketing team lead - automotive National Instruments GERMANY
Big data acquired on the road and throughout the test process will help make autonomous vehicles a reality. Testing strategies of the past are inadequate for the autonomous vehicles of the future. To meet external safety and customer demands and internal time-to-market and cost pressures, you need a platform able to fully emulate and test ADAS, V2X, infotainment, powertrain, and body and chassis hardware and software as integrated systems instead of just discrete subsystems. The data and systems management technology is an example of the Industrial Internet of Things that is changing the way autonomous vehicles are designed, tested and trained.
Rest bus simulation in test bench
Amine Bajnati Intersystem integration specialist in testbed Renault SAS FRANCE
Christian Andagnotto Solution manager electronics Altran FRANCE
The automotive industry is undergoing a very important evolution, due to massive integration of new functions such as AD/ADAS, mechatronics and intersystem in vehicles. The resultant impact on the testbed is very important for two reasons: the organ and system validation is very dependent on the embedded software and ECU for representativeness; the intersystem communication between the ECUs is increasingly complex. To meet these challenges, Renault and Altran have collaborated to develop a new intersystem module for rest bus simulation in different test benches.
BIA extends road simulation possibilities with its newly developed HexaWheel
Matthieu Driat Project manager BIA FRANCE
To meet the increasing demand for performance and to accelerate product development time, BIA has developed a spindle/wheel-coupled road load simulator: the HexaWheel. This newly developed test system can be used for quarter-car tests, axle tests and full-vehicle tests. The HexaWheel control system can perform road load replications and can also be included in HIL/MIL simulations.
Boost productivity of durability load data acquisition and the analysis process
Gert Frans Senior business developer Siemens PLM Software BELGIUM
More vehicles brought to market combined with engineering requirements for lighter and stronger vehicles, directly increases the workload for durability testing. Since these tests are usually large scale and mostly happen at the end of the development cycle, they are often conducted under huge time pressure. Hence, it is of crucial importance that automotive test teams can collaborate in a productive way to get all this work done. Durability engineers therefore need an integrated end-to-end platform that guides them through all the different steps of a typical durability testing campaign, combining load data acquisition, load data analysis and fatigue life estimation.
To test traction and auxiliaries in e-mobility and hybrids, the speed and torque of test rigs are constantly increasing. Power ratings above 250kW and speed in the region beyond 20k rpm are the current talk of the town. This presentation will explain how to get there by using a unique cooling concept.
RoboPIV: how robotics enable PIV on an industrial scale
Frank Michaux Managing director ILA_5150 GmbH GERMANY
Particle image velocimetry benefits from the developments in the field of industrial robotics, especially for automated, large-scale industrial environments. An example of a typical automotive wind tunnel application is used to show the flexibility and the complete automation of stereo PIV measurements. Three robots are individually used as a 6D traversing unit for the laser and for the two cameras. The control of the synchronised movements of the robots is integrated in the wind tunnel control system. Measurements can be requested through the interface. The RoboPIV system automatically starts the measurement and the results are already available after the run.
Onboard electronics testing for tomorrow’s automotive industry
Gregory Lechki Project manager materials testing services SGS SA FRANCE
New mobility, connectivity and environment are topics of innovation for onboard electronic systems in the automotive industry. Driven by regulations on CO2 reduction, ongoing projects like autonomous (ADAS) and electrical vehicles are plentiful. This is why SGS, the world’s leading inspection, verification, testing and certification company, provides customised services for tomorrow’s products. This presentation will explain how SGS deals with testing of electronic components by giving and sharing its expertise.
Technology Demonstration Area - HALL 8 PM
Psychoacoustic tonality analysis
Dr Julian Becker Research engineer Head Acoustics GmbH GERMANY
Quantifying tonalities in technical sounds according to human perception is a task of growing importance. Existing tonality metrics, such as tone-to-noise ratio or prominence ratio, do not quantify tonality according to human perception since they are not (completely) based on psychoacoustics. Thus, they require listening in addition to the metric. A new psychoacoustic method for evaluation of tonal sounds is presented, which is based on Sottek's model of human hearing . Thus, it automatically considers several psychoacoustic effects and enables automatic, intervention-free determination of tonalities according to how they would be perceived.
The aerodynamics of the Cronuz concept car
Paul Marston CFD engineer IDIADA Automotive Technology SA SPAIN
Cronuz is an electric compact SUV concept car with breakthrough aerodynamic solutions designed and engineered by Applus IDIADA. The Cronuz incorporates active and passive aerodynamic enablers that focus on key areas such as the wheelhouses and underbody. The objective of the Cronuz project is to study EV aerodynamics, focusing on the underbody and wheelhouses. The Cronuz design started from a blank page and ended in a full-scale wind-tunnel mock-up. Thanks to its innovative passive and active systems, such as active rockers and front wheel fairings, the Cronuz provided an outstanding Cx value of 0.19 in the wind tunnel measurements.
Application of UN38.3 transportation testing requirements for EV batteries
Rich Byczek Global technical director Intertek USA
The UN 38.3 transportation tests are a globally harmonised requirement for all lithium batteries. Large-format electric vehicle batteries present many challenges and misconceptions as to how the UN 38.3 requirements apply to EV battery packs, modules and cells. Here we provide some interpretations and discuss some common misconceptions related to these transportation and shipping requirements to help ensure that manufacturers, dealers and auto makers are able to demonstrate compliance when shipping these batteries globally by air, sea or ground transport.
The future is here today: digital transformation – automate your end-of-line testing with COBOT solutions
Andreas Schlipf Commercial manager consumer industries, global solutions Rockwell Automation GERMANY
End-of-line testing evaluates not only the quality of the product, but also the steadiness and yield of the production process. Precise detection of non-working units is a key objective of the test. Reducing the elimination rate and maximising the output are the ultimate key goals. Come and learn how to automate your end-of-line testing with COBOT solutions that will decrease your operational cost and increase your test quality.
Fast transient emissions from gasoline, diesel and hybrid vehicles
Dr Mark Peckham Director of products Cambustion Ltd UK
Real World Driving Emissions presents challenges for engine and vehicle OEMs largely because of the unpredictable transient inherent in real-world driving conditions. Fast-response emissions analysers measuring on board vehicles can accurately identify the short-duration 'spikes' of emissions, and these can be correlated with engine parameters such as air fuel ratio, exhaust mass flow, etc. Such transients are greatly smoothed by standard portable emissions measurement systems.
Technology Demonstration Area - HALL 10 AM
Big test data: measurement data mining without the need for Hadoop
Dr Bernhard Sünder General manager AMS GmbH GERMANY
AMS presents a complete toolchain for management, analysis and visualisation of test data. Thirty years of experience in measurement data analysis are used for extracting information out of thousands or millions of test data files, reducing the complexity of the data by using measurement-specific analysis, reducing the analysis time by parallel analysis in a cluster and bringing the analysis to the data. An evolution-type approach for big test data analysis.
Digitisation changed the consumer business. What about automotive testing?
Kieran McAleer Department manager AVL List GmbH AUSTRIA
The rapid pace of digitisation is transforming the typically hardware-driven automotive sector into a software - and solutions-focused industry. As the automotive development needs shift towards more complex solutions, it is certain that most of the industry will adopt this transition. New technologies such as artificial intelligence, combined with new approaches to data management, will help reduce development times and enable a more responsive and effective approach to the development requirements. Here we will look in more detail at the impact this digitisation is having on the automotive testing environment, and the solutions required to support this transition.
Characterising the physical layer of automotive CAN FD networks
Johnnie Hancock Product manager Keysight Technologies USA
CAN is the workhorse protocol used for automotive powertrain control. With demands for increased electronic content in next-generation automobiles, many systems are migrating to CAN FD. This shift in technology to transmit and receive more bits in less time over relatively long distances brings with it new design and test challenges. During this presentation you will learn how to perform critical dynamic pulse parameter measurements, including transceiver loop delay and recessive bit width, using an oscilloscope. Also discussed during this presentation is eye-diagram mask testing, which provides a physical layer analogue signal quality test in one composite measurement.
Bringing the test bench on board the vehicle
Enrico Corti Founder Alma Automotive Srl ITALY
The need for real driving emissions testing and for actual onboard scenarios during the calibration process are changing the approach to powertrain experiments. Many tests usually carried out on the test bench for component behaviour identification and ECU parameters optimisation may be performed on the road. The idea is to develop a real driving calibration approach, so that real driving emissions performance can be better optimised. Obviously, total costs should be carefully addressed too: vehicle testing is notoriously expensive, but 4WD powertrain test rigs are extremely expensive as well. Finally, lab-grade sensors compatible with onboard installation need to be used.
Objective evaluation of engine and transmission drivability
Rajesh Reddy Product manager ETAS GmbH GERMANY
The Engine and Transmission Drivability Toolboxes support the calibration engineer in measuring and evaluating the vehicle’s drivability. The aim of the Engine Drivability Toolbox is to obtain objective criteria like response time, jerk, etc., to compare vehicles or calibration datasets. The Transmission Drivability Toolbox is used to evaluate different events (shift, launch, etc.) by identifying physical criteria from data measured. These can be visualised and compared with reference results. This is accomplished either in real time in the vehicle or offline in the office. In online mode, signals from the vehicle’s sensors and additional external sensors are recorded; in offline mode, saved measurement files are analysed.
ADwin Real-Time in HIL models, test stand automation and innovative production line solutions
Heinz Beimert Manager international sales Jaeger Computergesteuerte Messtechnik GmbH GERMANY
ADwin Real-Time systems are used for automotive applications in component design, product verification in test stands and for innovative production line solutions. ADwin systems have a scalable concept, and are built for fast, precise, deterministic real-time applications, such as HIL test stands, complex Simulink models, ADbasic control and analysis solutions, any many more. ADwin systems have a free user-programmable CPU core, and offer additional analogue, digital I/Os and bus interfaces (CAN, CAN-FD, LIN, SENT, SPI, etc.). This presentation demonstrates the necessity and benefit of fast real-time systems for automotive tests.
Actionable insights across the development cycle
Michael Rietvelt Power and energy measurement specialist Yokogawa Europe BV NETHERLANDS
In pursuit of greater efficiencies and longer driving ranges for hybrid/electric vehicles, auto makers move through a variety of testing applications across various stages of development. These include analysis of communication buses, control signals, electromechanical efficiency of the powertrain or provable accuracies for compliance with standards. Using application examples across the automotive system, this session will explore the varying test requirements across the development cycle and the capabilities needed to address them.
Endoscopic visualisation systems for the automotive industry – trends and advances
Patrick Eckert Product manager visual inspection Schölly Fiberoptic GmbH GERMANY
HD visualisation systems today play an important role within the field of automotive quality control and testing. For use in static or dynamic applications, numerous cameras are available, often with high-speed capabilities or measurement functionalities. Challenges arise when it comes to image acquisitions inside complex assemblies or during high-temperature operation. In such situations, endoscopic visualisation systems with small geometries and outstanding features are needed. The presentation will highlight the latest trends in terms of visualisation systems for the automotive industry, including high-temperature borescopes and solutions with smart functionalities or real-time 3D visualisation.
Technology Demonstration Area - HALL 10 PM
Harvesting your production data for 4.0 profitability
Derek Kuhn Senior vice president Sciemetric Instruments CANADA
Leveraging data to drive the productivity and efficiency of a line or a plant is nothing new in the automotive industry, but the type of data that can be collected, how it should be collected and what you can and should do with it is evolving more quickly than ever before. Derek Kuhn will discuss how powertrain and other automotive OEMs can use the reams of manufacturing process and test data they generate from the parts/assemblies being produced to succeed in a sector that is rapidly being redefined by the principles of Manufacturing 4.0 and the Industrial Internet of Things.
Altitude effects on emissions in RDE cycles
Diego Impinna CEO and technical director Control Sistem Srl ITALY
Altitude has a big effect on emissions generated by modern engines, so this parameter has become extremely important in RDE development. It is very complicated to develop new solutions working directly on the road, so it is necessary to find a way to perform realistic tests in the laboratory. Is it possible? The answer is 'yes'. Control Sistem has patented an altitude simulation system (EACS) that demonstrates a very good correlation with on-road results. The presentation will show real data obtained using the EACS in a standard chassis-dyno laboratory.
Exhaust temperature and NOx monitoring in stationary and biogas engines
Stefan Carstens General manager EngineSens Motorsensor GmbH GERMANY
The presentation will discuss EGT monitoring to detect failures in turbochargers, injection systems and fuel quality. Biogases differ very much regarding content and possible sensor and catalyst poisons. The presentation will examine different poisons and correlating failures. NOx sensors are sensitive to moisture. Users have to take into account the dew-point before heating up the sensor. A newly developed transmitter translates CANbus messages of NOx sensors into a 4-20mA signal to be read by all PLC systems. This is an easy-to-install system for all stationary and even mobile combustion engines. Sensor poisons and cross-sensitivities will also be considered.
RDE test and simulation
Alexander Arzt Application engineer, test automation Horiba Europe GmbH GERMANY
The European RDE surveillance legislation requires vehicles to be compliant with the emission limits in a wide range of boundary conditions such as altitude, temperature and driving dynamics. To better understand this challenge and develop new methods and tools, Horiba conducts its own research to test vehicles with different powertrain concepts under a wide range of conditions on the road and on dyno. The presentation will contain results of the tests and the comparison of road to dyno. Additionally, a number of simulation and testing tools that have been developed to increase the efficiency of road and dyno testing will be presented.
VR system for efficient, immersive annotation of 3D point clouds
Patrick Grüner Development engineer CMORE Automotive GmbH GERMANY
Sensors like radar and lidar provide 3D point cloud data that represent the environment around them. We will present a new system to deal with such data in an efficient, immersive way by utilising VR technology. A prominent application for our system is the annotation of the point cloud data to prepare it for machine learning algorithms or for validation. Our system avoids the difficulties that arise at the 3D/2D border on a computer monitor. Instead it allows many new possibilities to navigate and process the 3D data in a very natural and therefore efficient way.
Energy-saving testing of battery packs in e-cars
Bernhard Rill Vice president Gustav Klein GmbH & Co KG GERMANY
Gustav Klein invented a multichannel system for testing and simulation of battery packs for electrical cars as well as fuel cells. The system has up to four channels each with maximum 1,000V and 1,000A.
Gustav Klein has already delivered more than 1,000 high-power testing and simulation systems worldwide.
Day 2: Wednesday 6 June
Technology Demonstration Area - HALL 8 AM
Demonstration of component reliability statement by accelerated life testing
Václav Verner Reliability analyst Ingersoll Rand s.r.o; Engineering and Technology Centre Prague CZECH REPUBLIC
The presentation is intended to highlight differences between ALT (Accelerated Life Test) and RDT (Reliability Demonstration Test) to demonstrate specified survival ability percentage. It will cover electromechanical and electronic components tested in a high-temperature and temperature cycling environment, which, along with vibration, is the most critical stress factor to reduce component life. A combination of ALT (Arrhenius and Coffin Manson model) and WeiBayesan approach will be presented, which enables accelerated test base on environmental stress and component degradation over time. Calculated test time and sample size is applicable for bench testing of the components.
Reduction of prototype vehicles via front-loading of drivability-related development
Rainer Schantl Project manager IODP AVL List GmbH AUSTRIA
Drivability calibration causes up to 50% of the overall calibration effort and is performed late in the process with massive usage of prototype vehicles. By enabling powertrain or chassis-dyno testbeds in combination with simulation and smart automation, the efficiency of prototype vehicle usage can be increased by a factor of 12. In combination with DOE methodologies, further improvements are possible. Furthermore, powertrain testbeds enable the possibility to begin drivability-related optimisation six months in advance of the availability of the first prototype vehicle. During the presentation, technical insights, prerequisites and customer projects with proven benefits will be shown.
Crash performance of magnesium and TRIP steel
Dr Robert Szlosarek Researcher TU Bergakademie Freiberg GERMANY
This presentation will focus on the crash performance of lightweight materials. First of all, drop tower tests of tubes made of magnesium will be shown. Using the tapering mechanism, the mass specific energy assumption is considerably better than aluminium. Subsequently, crash simulations of a crash absorber made of TRIP steel will be shown. TRIP steel is characterised by high strength in combination with great plasticity. The numerical examples show the potential of this kind of steel in crash structures.
The increasing number of car design variants that are delivered to customers worldwide it taking its toll on NVH engineers. Test results are expected much more quickly, which puts additional pressure on the development and validation teams. Engineers, regardless of their level of expertise, need tools that will let them work more quickly and easily, at the same time ensuring confidence in the quality of the results and methods applied. To successfully deliver good-sounding vehicles or subsystems, analysis tools must combine easy-to-use acquisition, clear and intuitive processing, interactive replay and state-of-the-art NVH and sound quality metrics.
Real-world emissions results from independent PEMS testing programme EQUA Index
Nick Molden CEO Emissions Analytics UK
Emissions Analytics has independently tested almost 1,000 passenger cars in Europe using PEMS equipment. The cars have been tested on an RDE equivalent EQUA Index cycle. Emissions Analytics will share the results and demonstrate whether WLTP and RDE legislation is doing enough, fast enough, to save the internal combustion engine.
Faster setup of measurements and more precision by using TEDS
Thomas Kleckers Product manager Hottinger Baldwin Messtechnik GERMANY
TEDS (transducer electronic data sheet) is a little electronic chip that is integrated in sensors. As the properties of the sensor are stored on that chip, the data acquisition system can read out the data. This technology allows measurement to be set up in an automatic way, which saves time and avoids typing errors. With modern instruments it is also possible to do a mathematical correction of the linearity error of the characteristic curve of sensors, and set up warnings for requested recalibration. Standard 1451.4 is currently under revision. The new version covers more sensors.
Modular e-pump testing solution
Michael Haug Managing director EUtech Scientific Engineering GmbH GERMANY
Electric pumps are a central component in the development of modern drive systems. EUtech has developed a modular test platform that allows quick and easy adaptation of the test solution to the requirements of development, endurance or end-of-line testing. The modular concept allows on the one hand different layouts and configurations (air-conditioning from -40°C to 150°C) and on the other hand, several modules can be operated independently of one other. The pumps can be controlled via any interface (LIN, CAN, PWM, etc.). Special attention is paid to data management.
HCM of DCT, 48V e-machine/BSG test solution, conceptional test platform
Stephane Pfeffer Sales manager Dam Group FRANCE
The next engineering challenge is to reduce project lead time and the process cost. We have to think out of the box in order to meet the production needs. As a result of our expertise and knowledge, we have developed a new way of working in order to provide successful solutions for our customers. At Dam Group we have found and realised a solution to overcome that challenge: a platform approach for test bench.
Technology Demonstration Area - HALL 8 PM
Proving-ground safety and optimised management combined with optimised utillisation solutions
Tom Elworthy CEO SHPG NEW ZEALAND
The presentation will discuss everyday life on the proving ground, and the optimised workflow benefits of using a safety tool incorporating driving and resource safety with proving ground management. Subjects to be covered: introduction to SHPG; SHPG leading the way in safety, security and confidentiality; research into existing management solutions; personalised development; safety, security, confidentiality, efficiency and management; roll-out of 150 OBUs along with smart TV; advantages – live view and overview of all PG activity, scheduling of resources – efficiency, safety rules developed together, emergency response, new legislation; remote management; database, encrypted stored data reports; easy installation/supportive development.
Comparison HALT & HASS test with a random vibration test
Holger Boller Sales manager Vibration Research European Office GERMANY
For electronic products, in addition to a vibration test, a HALT & HASS test is also required during the development and for a product release. The test times for vibration tests in practice are getting longer and longer. We wanted to find out whether a HALT & HASS can provide an indication of whether the vibration tests will be passed. The question of whether the generated mechanical loads are comparable was also very interesting. For an electronic board we have made a comparison of the introduced fatigue stress during a HALT & HASS test with the required random test.
LiB technology trends and practical challenge on all-solid-state batteries
Dr Jaesik Chung CTO and executive VP of technology PCTEST Engineering Lab USA
Much attention has been focused on the technology of 'all-solid-state batteries' since Toyota Motor announced its launching plan for EVs powered by that technology from year 2022. This presentation will focus on reviewing the developing status and trends of 'all-solid-state batteries' and their solid electrolytes. The practical technical challenges to its mass production for EV will also be discussed, and new technologies on the current LiB and their recent trends will be reviewed.
Big data and vehicle acoustics – chances and challenges
The amount of collected measurement data is steadily growing with the rising number of derivates and variations of vehicles, and hence the effort involved in conducting the tests is rising. To enhance the R&D process, conclusions should be made fully automatically using current and existing data as a baseline. This could be trends, targets or a prediction of the interaction of components. Hence, it seems reasonable to integrate methods from big data into the development process, as these are applied successfully in other applications. This talk will give an insight into current projects and the challenges we faced.
A model-based product reliability process
Franz X Langmayr Managing partner Uptime Engineering GmbH AUSTRIA
Product verification and validation are highly interdependent, distributed long-term activities. Quantitative assessment of product family synergies is particularly challenging. A common platform for storage and evaluation of data and results is presented here. It supports product reliability throughout the lifecycle, from concept to fleet operation. Physics of failure models, developed for test assessment and programme optimisation, are further used for fleet analytics to provide recommendations for condition-based maintenance. The presented consulting and software approach generates a transparent basis for decision making. It drives efficiency in co-development of product variants and allows for condition-based fleet maintenance.
Using psychoacoustics indicators for go/no-go acceptance in production testing
Guillaume Cousin Product manager OROS FRANCE
The efficiency of go/no-go tests is key in the demanding automotive industry. Classical indicators such as sound pressure levels are often not discriminative enough. The use of new indicators such as psychoacoustics parameters have proved to be much more efficient for testing automotive components such as pumps and motors. In parallel, the development of EV/HEV vehicles lets some components, silent until now, emerge against other standard engine contributions, making their sound quality and globally their NVH characteristics very important. Discover in this presentation how loudness, sharpness, roughness and others can contribute efficiently to the go/no-go acceptance decision.
Technology Demonstration Area - HALL 10 AM
Contact-free testing of welding spots using laser-excited ultrasound
Bernhard Nussbaumer Vice president sales Xarion Laser Acoustics GmbH AUSTRIA
To ensure lasting reliability and stability of the vehicle body, the quality of welding spots is crucial for the automotive industry. To pave the way for an automated test system, we present a novel air-coupled method based on an optical microphone and a fibre-coupled excitation laser source. The broad measurement bandwidth, sub-mm detection volume and high sensitivity of the optical microphone in combination with laser excitation enable contact-free monitoring of welding spots with high resolution and robust detection of weld defects. C-Scans recorded with the Optical Microphone will be presented, and results are discussed in comparison with state-of-the-art methods.
Improving business operations by applying big data and machine learning
Jörg Schönbach Business development manager automation Horiba Europe GmbH GERMANY
Horiba is working on comprehensive solutions to master challenges via fleet data and its evaluation in cooperation with partners. With new regulations regarding RDE data and evaluation, the automotive industry cannot announce reliable information on actual fleet consumption and emission values.
Big data or mass data transfer handling, storage and evaluation is one solution being employed to collect and evaluate data from large vehicle fleets. Although machine learning processes these data sets and generates knowledge from them, interpretation of the results requires expert knowledge. Artificial and human intelligence build a strong team for businesses to improve their operations.
How will machine learning and AI affect the way we test?
Marcus Monroe Principal systems engineer – real-time test National Instruments GERMANY
We are on the verge of a revolution in the way computing is performed. Instead of logic algorithms, machine learning and artificial intelligence are finding their way in self-driving cars and ADAS systems. From a testing perspective this poses several challenges in meeting safety standards like ISO 26262, as inputs and outputs are loosely correlated.
Vehicle aerodynamics effects on sports car handling and steering performances
Matteo Sacchi Performance engineer Fiat Chrysler Automobiles SpA ITALY
Handling behaviour is a fundamental aspect of modern cars. Aerodynamics permits further degrees of freedom, changing car response at high speeds. The presentation shows a synthesis of criteria used in the development of a former FCA sporty vehicle: from correlation between on-track and wind tunnel tests, forecast with simulation tools and bench tests, to analysis of high-speed vehicle dynamics manoeuvres, changing some aerodynamic configurations. The whole method was shown to be robust in terms of correlation, repeatability and objective parameters. Its use on future applications will allow faster tuning of sport and racing vehicles.
Parametric, modular and highly automated testing framework used for automotive front video camera system test
Karoly Livius Bakos Test automation engineer Robert Bosch Ltd HUNGARY
Balázs Tiszai Test engineer Robert Bosch Ltd HUNGARY
The Bosch Front Camera System Test Team will present a test automation framework capable of running complex ECU testing tasks in a hardware-in-the-loop environment using a continuous-integration-based workflow. We present our data-driven test definition IDE and a full modular and adaptive tool chain built using our pre-existing tools and Jenkins CI platform. The framework allows our test engineers to focus exclusively on test definition, while all other aspects of system testing, such as test execution, evaluation and reporting, are automated. The solution is able to handle distributed and dedicated test hardware too. Co-author: Dániel Balogh, system test engineer, Robert Bosch Ltd
Mobile data acquisition for RLDA, ride and handling
Finn Lange Product manager Hotting Baldwin Messtechnik GmbH GERMANY
Mobile data acquisition requires a high degree of flexibility and functionality of data acquisition systems and software. Nowadays, one system is used for many different types of tests such as RLDA or ride and handling. This presentation will cover the following topics: synchronous integration of analogue and digital signals (GPS, vehicle bus, videos); usability enhancements for the test engineer coming from new technologies like cloud services; vehicle testing and validation on proving grounds.
Better testing using advanced control loop techniques
Erwin Frederiksen Test consultant Moog NETHERLANDS
Modern test controllers have many features to help improve testing. Using different control loops or advanced control loop features allow users to run their tests more quickly, easily and accurately.
Smart sensor evolution for automotive testing
David Change Technical director, VP Dytran Instruments USA
Dytran Instruments Inc has introduced a smart bus-based sensor for solving a multitude of measurement and monitoring challenges across many automotive applications including: end-of-line testing, test-cell shut down and autonomous vehicle monitoring. Distributed processing is finally here. Each standalone sensor in the network is actually a powerful microcomputer capable of processing data and actually returning the condition of a machine via digital information on the bus in the form of a 'condition indicator'. The end result is a great savings in system cost and weight. Additional advantages include the elimination of a central computer.
Technology Demonstration Area - HALL 10 PM
Leak test of electronic control units with compressed air
Dr Joachim Lapsien Sales manager CETA Testsysteme GmbH GERMANY
Electronic control units (ECU) are used in every automobile. Therefore these components have to fulfil a variety of requirements. This includes leak tightness against dirt and moisture, because the penetration of liquids or humidity can cause serious malfunction of the ECU and the associated electronics. The leak testing of the ECUs as an end-of-line test integrated in the production line is of particular importance. The presentation will cover the basics of leak testing and important practical aspects of the leak test of ECUs using compressed air as a test medium.
Delivering high-speed, non-contact volume measurements with smart sensor technology
Johannes Beyer Territory manager LMI Technologies GERMANY
In this talk, learn how 3D smart sensors can be used effectively for non-contact, high-tolerance inspection applications. Specific examples in the automotive market will be shared, including a unique approach for inspecting cylinder heads and piston bowls by combining a standard 3D smart snapshot sensor with customised volume measurement tools. Gain insight on how to sync multiple sensors to inspect complex parts, and how a PC can be used to accelerate your data acquisition speed.
Revolution in fuel cell R&D infrastructure and toolchain
Tomas Dehne Application manager fuel cell test systems AVL List GmbH AUSTRIA
The presentation will discuss how the partnership of Greenlight Innovation and AVL is pushing fuel cell R&D to a game-changing level.
Design, test and debug automotive electronics
Darshan Mehta Product manager, automotive Tektronix INDIA
In its 130-year history, the automotive industry has never experienced a revolution such as is currently unfolding. Driven by electrification, automation, connectivity and mobility, manufacturers are having to re-evaluate hitherto unquestioned practices and technologies. Indeed, the very foundation of the car is mutating from a mechanical device to a mini-datacenter on wheels, driven by the rapid advances in electronics. We are using high-speed standards in the automotive segment, such as Automotive Ethernet, SDRAM, Flash Memory, MIPI, USB, HDMI, etc. Automotive parts require 0ppm failure rate, and need to work in harsh automotive environments. This calls for special care at the design stage, more tests and a need to validate parts beyond compliance. Automotive Ethernet is a classic example of how many tests are required for compliance. This presentation will cover different test aspects for automotive parts, and test and measurement solutions from Tektronix.
Using slip-ring assemblies in automotive testing
Michael Castiglione Vice president Michigan Scientific Corporation USA
This presentation will include a discussion on making rotating measurements for vehicle development and innovation. It will cover the different types of slip rings and methods for using slip-ring assemblies to measure torque, thrust, strain and temperature. The discussion will focus on how slip rings aid in the development of engine and drivetrain components.
Automation of durability and fatigue tests under harsh conditions
Harald Unterrainer Director business unit SnIP Westcam Technologies GmbH AUSTRIA
Initial situation: Test benches involve high operating costs for OEMs and test service providers. In the ideal world a test bench should run 24/7. Requirements: Shorten test cycles, deliver high quality in result interpretation and test documentation, reduce test costs. Solution: Automated image processing and crack detection online direct at the test benches, even under harsh conditions in climate chambers and on shakers; automation of brake disc test benches is under development. Advantage: Precise definition of the events; reduced runtime, less manual inspection; crack formation and propagation is documented, automatic test stop at predefined crack length.
Day 3: Thursday 7 June
Technology Demonstration Area - HALL 8
Simulated pass-by noise for prediction and homologation
Louis-Ferdinand Pardo NVH expert UTAC CERAM FRANCE
For decades now, pass-by noise testing has been performed on outdoor vehicles for homologation tests. However, concerns were raised regarding measuring exterior noise under wide driving behaviour in a controlled environment. Therefore, various facilities were designed and constructed to support pass-by development and – some day – homologation. 'Some day' has come: ISO 362-3 was published and UN51.03 implements indoor testing as an alternative to outdoor. Thanks to more reliable results, indoor testing allows the implementation of advanced pass-by noise engineering techniques. This presentation aims to present the results of indoor testing for correlation with outdoor, and methods for virtual testing.
Airbag compliance testing using the new FINAL test system
Bodo Streich Senior manager HuDe GmbH GERMANY
Inspection of airbag inflators and performance tests based on standard tank tests are not sufficient for decisions related to real behaviour in case of a crash. Too many differences are visible in sled and crash tests even if the tank tests show similar inflator behaviour. The new FINAL test system is a different approach to evaluating the power and time performance of airbag inflators. Based on the inflator part only, the results of the FINAL test system show the same differences as those observed in sled and crash tests. Compliance tests broken down for the inflator part now became possible.
Optimising wheel force transducer accuracy, durability and efficiency
Hans-Peter Beggel Systems engineer MTS Systems GmbH GERMANY
Deployed on proving grounds for RLDA and on lab-based road simulators to support drive file iteration and testing, wheel force transducers fulfil key roles throughout the vehicle durability testing process. Because all excitations from roads and lab-based rigs travel through these wheel force transducers, their accuracy and durability are crucial to achieving and maintaining high levels of data measurement and test integrity. This presentation recounts several initiatives pursued jointly by MTS and PCB engineers to maximise accuracy, durability and efficiency as they adapted legacy transducer technology for reintroduction to the automotive market as the new SWIFT Evo product line.
Avoiding common pitfalls in validation testing plans and DVP&R
Rich Byczek Global technical director Intertek USA
To demonstrate the reliability and durability of automotive components, suppliers must successfully complete the DVP&R design validation plan and report. By understanding the common pitfalls and validation test planning challenges, product development teams can reduce delays and improve product launch timelines, as well as mitigate the effects of actual product failures during testing. This talk addresses the limitations of test and measurement equipment, sample availability and design level, human resources, as well as communication and reporting breakdowns. Communication guidelines and test plan development techniques are provided, from the viewpoint of the validation engineer and the testing laboratory.
Real-world altitude simulation for cost and energy savings
Javier Gómez Product manager conditioning - altitude simulation Horiba Europe GmbH GERMANY
New directives require homologation at altitude to approach standards for actual driving conditions, thus closing the gap between regulated and real-driving emissions. However, common tools consume many resources and lack repeatability of results. In this presentation, we will compare measurement results of an altitude chamber and an altitude simulation system using the example of performance and emissions of a turbocharged diesel engine at different altitudes. Although the measurement results of both variants are similar, the main advantages of the altitude simulator are cost savings, and a considerable reduction in space requirements and energy consumption combined with greater flexibility.
Instruments used for characterising fuel injectors and urea dosers
Dr Germano Ragosta Representative - Europe region En'Urga Inc USA
This presentation discusses two methods of characterising fuel injectors and urea dosers. The first is optical patternation using extinction tomography (SETscan). The optical patternator provides quantitative planar information on plume and spray angles, plume centroids, drop surface areas and spray pattern. The SETscan patternator is used by leading injector manufacturers for the quality audit of urea dosers, where spray angle and drop surface areas determine the performance of the exhaust system. The second method is velocity estimation using statistical pattern imaging (SPIvel), which enables the determination of transient and mean velocities in high-speed GDI and diesel injectors.
Hardware-in-the-loop test bench for electric single-wheel-drive vehicles
Gabrielius Jakstas Research associate Universität Rostock GERMANY
The Chair of Transmission Technology and Drive Engineering has developed and commissioned a hardware-in-the-loop test bench to investigate and further develop electrified vehicle drivetrains. It consists of a driving machine, a braking system and a load machine. A homokinetic driveshaft connects both machines. The load machine is controlled by a virtual vehicle model, which simulates the road-tyre contact and driving resistances. The behaviour of different vehicle braking system hardware is reproducible. This system allows us to induce torsional vibrations in the drivetrain and optimise the coordination between the vehicle drive unit and the braking system regarding functional safety.
Technology Demonstration Area - HALL 10
Mechanical hardware-in-the-loop test bench in chassis development
Florian Löcken Research associate Helmut Schmidt University GERMANY
This presentation introduces a mechanical hardware-in-the-loop test stand (mHiL), which was recently designed and put into operation at the Helmut Schmidt University. The test bench combines an in real-time-calculated virtual vehicle model with two biaxial, digitally controlled servohydraulic test benches for suspension components. This offers the possibility to combine the system behaviour of physical components (e.g. prototypes) with the vibration behaviour of vehicles in a reproducible way in the laboratory and without a test vehicle. This is a great advantage, especially in the early stages of development, particularly for the supplier industry and service providers.
An enterprise test architecture for your test challenges
Lorenz Casper Senior field marketing engineer - automotive National Instruments GERMANY
Total cost of test, higher test coverage and new changing requirements are a huge challenge for test engineers. A holistic approach to software-centric automated test solutions that facilitate teams with the right workflows, including automated processes to test, verify, validate and deploy your application, prepare you and your team to face these challenges. Learn from our experience with our customers on how they use these processes to achieve greater reuse from validation into production, decrease the time to perform root cause analysis and keep track of their deployed systems.
NVH end-of-line test of components with high revolution speed
Olaf Strama Head of NVH department Saab Medav Technologies GmbH GERMANY
NVH assessment at the end-of-line test has been established in recent years. In terms of sound quality and error detection, the focus has been on frequency range perceptible by human beings. New applications in the field of turbocharger testing and e-mobility make higher demands on NVH measurement technology in terms of bandwidth and speed range. Based on the physical relationships in vibration and noise generation, a measurement chain for objective feature extraction and assessment will be described. Attention is paid to the new demands of machinery with high revolution speeds and the challenges of reliable production measurements.
Six-phase power analyser for test rig or mobile data acquisition
The presentation will introduce a multiphase power analyser and data acquisition system for testing electrical drives from three to 21 phases. With the capabilities for real-time analysis e.g. space vector and DQ0 transformation or customised analysis, it offers R&D huge possibilities to understand the electric drive and its losses in less time. All test-relevant signals can be acquired and stored in real time continuously or point-controlled. Efficiency mapping will be accelerated by shortest measuring times per set point. Depending on the system configuration, it can be used for test rigs or mobile data acquisition.
Inspiring innovation in powertrain NVH testing
Bart Verrecas Business development manager NVH and durability testing Siemens PLM BELGIUM
The continued push to develop new powertrain architectures, in response to the ever-increasing demand for greener and cleaner transportation, without compromising on NVH performance, leads to many challenges for powertrain NVH engineers. Use of smart technologies and electronics is an important element of innovation, but makes it ever more complicated to balance and control different attributes. This requires NVH engineers to go beyond the pure NVH testing. Furthermore, electrification of the powertrain leads to new requirements on the instrumentation side, as well as in processing. Also, test and simulation are increasingly going hand in hand to have a dramatic impact on the total development time.
How to develop a perfect test facility
Manuel Rubow Senior civil engineer Tilke GmbH & Co KG GERMANY
Tilke is the world's largest and most influential designer of racetracks and automotive facilities. It is renowned for its state-of-the-art racetracks and has completed more than 1,000 projects in over 50 countries. There is a wide range of elements you can choose from to establish a test facility that will meet the specific user and market demands. Tilke helps you find the right elements to develop your perfect test facility.
Efficient testing strategies for quality control of automotive materials
Frank Walther Prof. Dr.-Ing. TU Dortmund University GERMANY
Parts made from metals, light metals, polymers, composites and hybrid materials are exposed to quasi-static and cyclic loading under service conditions, which leads to a need for sufficient assessment of automotive materials and structures. Conventional testing procedures require high time and energy efforts and are limited in extent of results, since tensile tests and Woehler curves don’t show a sufficient measure to describe deformation and damage processes. Testing strategies are presented for efficient performance determination, deformation and damage propagation evaluation and lifetime prediction, combined with climatic influences.
How to improve your competitive advantage with time-synchronised multi-bus simulation and testing
Carmelo De Mola Manager sales and marketing K2L GmbH & Co KG GERMANY
In the automotive industry, a highly competitive environment is important for the success of a technology. The ability to generate competitive advantage drives car manufacturers to innovate in hopes of a generous return on investment (ROI) in terms of customer interest and eventual sales. Competitive advantage is dependent on shortening time to market, optimising total system costs, and providing high-quality products. In today’s vehicles, different bus systems such CAN, LIN, CAN-FD, FlexRay, MOST and Automotive Ethernet are used and connected to effectively and efficiently perform the complex tasks of the onboard electronics. This very complex in-car network must be developed, tested and validated within the relatively tight car development schedule. The challenge here is to start the testing and validation tasks as early as possible in the development process without having the real hardware available. However, how to start testing a system that does not yet exist? The key is of course smart simulation that allows simulation of time synchronisation in the multi-bus environment as well. The presentation will show how you can improve your competitive advantage through simulation and testing of time-synchronised multi-bus systems using K2L solutions.
Please Note: This programme may be subject to change