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Open Technology Forum

The Open Technology Forum showcases a series of free-to-attend presentations from some of the leading figures in the industry – all visitors are welcome. Simply pull up a free seat and watch any session you wish.


Day 1

Tuesday 25 October

10:00 - 16:20 - DAY 1

Moderator
Jeff Warra, technical specialist, Spirent Communications, USA

10:00 - Developing network, surPASS your expectations, active monitoring vs datalogging
Jeff Warra, technical specialist, Spirent Communications, USA
OEMs in the automotive, off-highway and heavy-duty truck industries are running out of bandwidth for autonomous driving. Industries are turning to Ethernet for their in-vehicle communications networks to deliver high-bandwidth data from sensors to systems. There is a vision to have one Ethernet backbone connecting components by the end of 2018. Standard OABR (Open Alliance BroadR-Reach) is now accelerating the development of Ethernet components. Classic bus systems like CAN or Flexray were designed to deliver critical control messages in real time. The real-time requirements need to be addressed for the Ethernet architectures, since Ethernet technology was not created to be a real-time communications bus.

10:20 - imc revolutionizes vehicle-testing: easier, faster and more flexible than ever
Andrew Jesudowich, application sales & operations manager, imc DataWorks LLC, USA
The presentation will discuss how the expanded imc test and measurement portfolio enables faster, more efficient vehicle testing. New imc CANSASflex measurement modules can be used in spatially distributed configurations or as central units. With the imc click-mechanism, modules mechanically and electrically connect. New imc CANSASfit is well-suited for mobile testing in harsh environments. The robust housing offers reliable protection against water-spray, dirt and vibrations. A temperature range from -40° to +125°C allows for testing year round and in climate chambers. New imc WAVE sound and vibration analysis software allows customers to perform noise measurements, structural analyses and vibration examinations and simultaneously detect other measurement variables.

10:40 - “ETAS EHANDBOOK - New Interactive Documentation Tool Makes ECU Calibration Easier”
Jayesh Patel, program manager, ETAS Inc, USA
Over the past decade, fiber-optic sensors (FOS) have advanced and are emerging as a fitting alternative to traditional electrical sensors, yet few people realize the potential and advantages of this technology. Composed only of glass, FOS are intrinsically safe and offer advantages over electrical sensors; they are not sensitive to electromagnetic interference (EMI) and can achieve higher measurement accuracy. This presentation will highlight optical sensor manufacturing, and real-world applications of FOS versus conventional strain gauges in industries including automotive, oil and gas, and aerospace. Attendees will leave the session understanding fiber-optic sensors and the advantages they offer.

11:00 - Testing automotive security and testing despite security
Philip Lapczynski, program manager, Vector CANtech Inc, USA
We all are aware of the growing need for cybersecurity in automotive. This presentation focuses on two things: 1) The growing need for security testing in automotive; 2) The challenges in testing created by the introduction of security mechanisms. We will discuss secure engineering practices such as automated functional testing (white box), fuzz testing (black box) and testing a system with security mechanisms in place.

11:20 - MaDaM – the measurement data management solution
Dr Bernhard Sünder, managing director, AMS GmbH, GERMANY
Based on practical use cases at large OEMs, the advantages and limitations of modern measurement data-management systems are shown. Indexing technology (Lucene) and enhanced search capabilities, highly interactive HTML5 and traffic-minimizing EnCom are new technologies developed during the last five years. With samples from the AMS product MaDaM, the advantages of these new technologies are demonstrated. The measurement data-management system MaDaM combines modern approaches to data storage and indexing with web technologies for mobile and desktop access. It provides server-based report on demand or interactive data analysis in a web-based environment with easy-to-use full text search. This enables big data solutions.

11:40 - The effect of tire data quality on vehicle performance prediction
Henning Olsson, director, R&D, Calspan Corporation, USA
Laboratory tire testing provides tire data that, when used appropriately, can help accelerate the vehicle development process. With tire data and tire models being used for many different applications, the effects of data quality and accuracy must be considered. A study has been carried out to quantify the impact of these effects on vehicle performance predictions. Examples from passenger car and truck applications are presented and conclusions discussed.

12:00 - Technology of a diagnostic tester with cybercrime protection
Peter Subke, director business development, Softing AE GmbH, GERMANY
The presentation will introduce a state-of-the-art diagnostic tester consisting of an MVCI D-Server (ISO 22900) that processes data that is described in ODX format (ISO 22901) and sequences that are described in OTX format ( ISO 13209). Particularly for diagnostic communication over the air, e.g. for a software update, measures must be taken to protect against cyberattacks. Examples include but are not limited to the encryption of data and sequences, and signature technologies.

12:20 - New techniques for automating analysis for technical data
Stephanie Amrite, senior product manager, National Instruments, USA
You are collecting a lot of data, but industry research shows that on average only 5% is analyzed. This is due to a combination of reasons such as poorly documented data, and the variety and volume of data sources that customers use. To help you overcome this problem, NI is investing in technologies to help make automating the analysis of engineering data easier than ever, including the ability to standardize metadata from any data source and smartly choose which analysis routine to run based on the data.

12:40 - DC fast charging testing at various temperatures
Rich Jacobson, operations manager, Intertek Phoenix, USA
The plug-in electric vehicle (PEV) industry commonly markets DC fast charging as a method to provide up to 80% of a full charge in 20-30 minutes. However, the charge rate will vary greatly depending on the ambient and energy storage system (ESS) temperatures. In this study, the charge acceptance rates of a variety of PEVs are compared, and the effects of the thermal management system (TMS) on the charge event are explored. Tested PEVs include the 2011 and 2013 Nissan Leaf, 2012 Mitsubishi i-MiEV, Volkswagen e-Golf, Kia Soul EV, Chevrolet Spark EV and BMW i3.

13:00 - Road to LTE: connected cars, LTE roadmap and test solutions
Craig Hendricks, senior technologist, Anritsu US Automotive Focus Team, Anritsu Company, USA
Cory White, North America Business Development Mgr, Automotive Sector, Anritsu Company,, USA
With the long product development cycle of automobiles and increased utilization of LTE for connectivity, it is critical to understand the roadmap for new LTE developments in networks and chipsets. Auto makers will need to invest in these technologies to stay ahead of the technology curve and offer consumers the most up-to-date connectivity. This presentation will provide LTE technology roadmaps from 4.5G to 5G and explore the test solutions available to ultimately bring the technology into the marketplace through connected cars.

13:20 - Next-generation PEMS (smaller, lower cost, more energy efficient)
Andrew Burnette, science advisor, 3DATX, USA
The in-use emissions testing industry, academic research and other sectors have been pushing for smaller, lighter, lower-cost and, ever more importantly, lower-energy-consumption portable emissions measurement systems (PEMS). Although there is an understandable natural tension here for the more established PEMS technology manufacturers, it is worth both acknowledging this and considering the routes and barriers for such a next-generation system. Recent test results for a next-generation PEMS system will be presented, along with current thinking on where it may reasonably be applied to cost-effectively help reduce emissions.

13:40 - Advanced power emulators for power system development and testing
William Peterson, vice president/CTO, E&M Power, USA
High-fidelity DC power system and motor drive inverter testing is made achievable with the use of advanced power emulation. An active load emulator can mimic all the characteristics of a motor/generator at full power in all four quadrants with no moving parts. A DC emulator can provide wideband – to 20kHz – simulation or emulation of the DC power system. The ability to sweep at full power, to frequencies above the switching frequency provides for full characterization of system resonances and characteristics.

14:00 - Advanced physics-based sensor simulation approaches for testing ADAS systems
Tony Gioutsos, director sales and marketing, TASS International, USA
To provide a 'due care' testing approach to automated and connected vehicle technology, an advanced sensor simulation must be involved. However, to provide the most accurate and best validation, sensor simulation closest to 'raw data' would be preferred. Advanced physics-based sensor models with deterministic and probabilistic components are introduced. The models described include: camera, radar and V2X.

14:20 - An open systems approach to BMS HIL testing
Peter Blume, president, Bloomy, USA
Hardware-in-the-loop (HIL) testing is an essential approach for validating the hardware and firmware of an automotive ECU, including the battery management system (BMS) electronics of hybrid and electric vehicles (xEVs). A HIL simulator is used to simulate the xEV battery including cell chemistry, drive cycles and numerous fault conditions, without the hazards of real batteries, or the cost of prototype vehicles and track time. In this session, Peter presents an open systems architecture approach to HIL test systems implementation using commercial off-the-shelf hardware and software, including battery simulators.

14:40 - RDDS, state-of-the-art control system for easy upgrading of existing test stands
Jörg Cordes, president, Renk Systems Corporation, USA
The presentation will discuss a software/hardware concept to control new or existing test systems. The required hardware: PC and Ether-CAT bus; electrical wiring in general and connection of instrumentation, new or existing; electrical connection of actuating elements; software setting to make it match the actual or future test stand application. General features in limit monitoring, control loops, datalogging, fault history logging (post-mortem dump). Display configuration. Users, operators, engineering level protection by pass codes and much more.

15:00 - Torque and power measurement – auto case studies and approaches
Brian Carr, US sales manager, Binsfeld Engineering Inc, USA
Throughout history, mankind has relied on rotating shafts and torque to power society. That ideal has never been more prominent than during the advent of the automobile. Measuring the torque and mechanical output produced by a shaft-driving system is critical to understanding, and optimizing, multiple processes within the industry. This paper provides an overview of various torque measurement tools, as well as the benefits and limitations of each approach. Finally, we’ll examine application stories that illustrate one preferred method. While the examples are different, they highlight the potential that condition monitoring presents for a wide breadth of automotive professionals.

15:20 - How Siemens' high-performance drive can enhance your testing equipment
Ulrich Weinhart, business development, test stands, Siemens Industry Inc, USA
Test stand applications are increasingly realizing benefits like noise reduction, energy recovery and improved time to market with Siemens SINAMICS drives. Join Siemens for a glimpse into the test stand specific capabilities built into the standard, off-the-shelf SINAMICS drives. Features such as torque pulse engine simulation, automatic disturbance compensation and connectivity with National Instruments' LabVIEW or MATLAB’s Simulink will simplify your testing requirements. Siemens will discuss various test stand applications including battery simulation, and how the exceptionally high-performance SINAMICS drives can streamline and increase the productivity of your applications.

15:40 - VOC environmental testing automotive applications – what you need to know
Ben Pipher, application engineer - automotive business unit, Weiss Envirotronics, USA
Volatile organic compounds (VOC) must be limited in personnel vehicle applications. Understanding the product and the interaction with other vehicle components and the surrounding environment is essential to product development and product and air safety. Environmental testing chambers play a critical role in testing of vehicle interior components and VOCs. Safety requirements will need to be in place in testing vehicle interiors, such as particle measurement, absorption rates, contaminations from the vicinity and venting systems. This presentation will give relevant information and guidance on what to look for in the product testing phase with interiors, and how to limit the VOC elements. We will review industry test requirements including ASTM VDA, ISO and other test specifications. The presentation will also review how to get the most out of your environmental test equipment, and proper test applications with VOC materials.

16:00 - Create test profiles correlated to multiple end-use environments utilizing FDS
Kevin Van Popering, application egineer, Vibration Research Corp, USA
The initial design of your product is done; now it’s time for vibration testing. Vibration levels the product will experience have been collected from field measurements taken at the end-use environment (EUE). The amount of time the product will experience these vibration levels throughout its lifespan is known. Why not take these field measurements and target lifespans and convert them into a vibration profile correlated to the EUE? Fatigue Damage Spectrum (FDS) does just that. This presentation will describe the theory and demonstrate the process of creating a test profile from multiple EUEs utilizing FDS from start to finish.

16:20 - Adding HIL to your driving simulator
Ken Jackson, senior vice president, Linux/Real-Time, Concurrent, USA
The simulation world is evolving into a more complete environment that can simultaneously test and verify the vehicle dynamics and a new design of the vehicle's controllers. In the past, ECU testing was more singular in its reach and was relegated to testing individual components. The new thought is to fully integrate all aspects of the vehicle prior to production release. Connecting the ECUs to the driving simulator provides the complete test of the car's abilities and functionality. To expand this to autonomous vehicles requires a multi-model simulation sharing interdependent data while maintaining a high frame rate.

Day 2

Wednesday 26 October

10:00 - 16:00 - DAY 2

Moderator
William Doelle, director North American operations, Berghof Group North America, USA

10:00 - Fiber Optic Sensing, a visible alternative
Nicholas Burgwin, Founder, fibos, CANADA
Over the past decade, fiber optic sensors (FOS) have advanced and are emerging as a fitting alternative to traditional electrical sensors, yet not many realize the potential and advantages of this technology. Composed only of glass, FOS are intrinsically safe and offer advantages over electrical sensors; they are not sensitive to electromagnetic interference (EMI) and can achieve higher measurement accuracy. This presentation will highlight optical sensor manufacturing, and real-world applications of FOS versus conventional strain gauges in industries including Transportation, Oil and Gas, and Aerospace. You will leave the session understanding fiber optic sensors and the advantages they offer.

10:20 - Aftertreatment testing equipment that replicates real-world transient exhaust gas conditions
Jonathan Stewart, technical specialist, Catagen, UK
This study describes a synthetic gas reactor capable of producing a wide range of RDE testing scenarios including WLTC, SULEV and NEDC test cycles. The system has the capability of reproducing transient cycles for a wide range of engine types, with test sample temperatures from -10°C to 800°C. The approach is inherently accurate and repeatable; it also is ideally suited to sensitivity, calibration and performance testing, and is designed to help customers meet emission targets. Results of the system performance are presented for the WLTC cycle for a light-duty diesel vehicle, and compared with real engine data.

10:40 - PIA – economic injection testing for every environment
William Doelle, director North American operations, Berghof Group North America, USA
The PIA family is a testing equipment family designed for fuel-injector and pump research, manufacture and validation, controlling piezo and solenoid injectors. Profiles created in the R&D lab can be used to calibrate injectors or pumps in an EOL (end of line) test station, confirmed by PIA in validation testing. Before the background of recent trends in automotive testing, PIA and its development together with customers and suppliers will be our focus – development that led us to set up a forum dealing with the future of the powertrain‘s engine section: the Berghof Testing Powertrain Innovation Day.

11:00 - An enterprise approach to engine test analysis: requirements for implementation
Bruce Thomason, director of technology, SGS, USA
Engine and vehicle OEMs have complex product development requirements that call for capable and standardized post-test analysis while simultaneously dealing with high levels of product technology and test diversity. Many organizations rely on shared spreadsheets or distributed desktop tools, which can produce inconsistent and non-traceable results. This presentation addresses enterprise-scale post-processing requirements, features and implementation considerations in addition to providing lessons learned that can help move an organization to an efficient, standardized and maintainable professional process. The presentation will cover how to address diversity of product topology, physical components, fluid properties, measurement uncertainty, naming conventions, traceability and IT architecture.

11:20 - Guided and automated calibration using ETAS INCA-FLOW
Rajesh Reddy, product manager, ETAS, GERMANY
ETAS INCA-FLOW is a revolutionary approach for automating and guiding calibration. It facilitates the graphical specification of calibration procedures without requiring programming skills. Calibrating gasoline and diesel engine management systems is a challenging task that is largely repetitive with regard to specific customer projects. Using INCA-FLOW, the calibration process can be set up for one ECU variant and then reused for others, which can significantly increase calibration efficiency. In addition, measurements can be easily reproduced, leading to clear improvements in calibration quality. The same standardized calibration methods can be used for any calibration infrastructure.

11:40 - ADAS – automotive radar test challenges and solutions
Greg Kregoski, automotive market segment manager, Rohde & Schwarz, USA
To keep transmission power levels low and range resolution of automotive radars high, FM modulated continuous wave signals of high bandwidth are typically used in automotive radar applications. Operating in the 24 and 77GHz frequency bands, automotive radar takes advantage of these frequencies and their high atmospheric attenuation, allowing many automobile radar systems to operate concurrently without impacting one another. This presentation provides an overview of current automotive radar technology, test and measurement technologies used for automotive radar and new radar target simulation devices.

12:00 - The correlation of rolling resistance and tire liner temperature profiles
Alan Bennetts, director, Bay Systems Ltd, UK
The presentation will discuss the development of a remote sensor that accurately (+/- 0.2ºC) measures an array of points stretching from bead to bead. Data from a range of tires will be presented, showing where heat is being generated and correlating the final temperature with the classical derived rolling resistance. Questions posed will include the effect of excessive temperature on the number and size of particulates shed by the tire.

12:20 - Testing composites using high-definition fiber-optic sensing
Naman Garg, field applications engineer, Luna Innovations, USA
Luna Innovations of Blacksburg Virginia, has developed a high-definition fiber-optic sensing (HD-FOS) system that is perfectly suited for measuring strain of composite materials and structures. A single fiber sensor can replace thousands of strain gauges and, with its flexibility and light weight, can be used to instrument in hard-to-access locations. The fiber, at only 150 microns in diameter, can also be embedded within composite parts. The use of composite materials in automotive design will continue to grow, and its imperative that test engineers understand the unique challenges with testing composite parts and structures.

12:40 - Piezoelectric measurement made easy – powerful signal conditioning from Kistler
Bill Zwolinski, SBU manager, acceleration, Kistler Instrument Corporation, USA
Kistler’s charge amplifier module Type 5171A is directly plugged into National Instruments’ CompactRIO platform. The signals of one or four piezoelectric sensors are digitized and then processed in real-time. Everything is programmed with the familiar LabVIEW development tools, allowing users to create customized solutions. The Type 5165A Kistler LabAmp dual-mode amplifier not only amplifies the dynamic signals with very low noise, but also provides the digitized data via Ethernet interface. Thanks to its advanced signal processing, it offers outstanding flexibility and ease of use. With GUI control or use of LabVIEW development tools, users can create customized solutions.

13:00 - Problems with kurtosis as a random vibration specification
Dr Benjamin Shank, engineer, Thermotron Industries, USA
This talk is a summary of lessons learned while developing kurtosis algorithms for a vibration controller. The past decade has seen a trend of dealing with non-stationary vibration power by controlling the kurtosis of random tests. Based on Miner’s Rule and fatigue damage spectra, testing with kurtosis is shown to always deliver damage more slowly than SRS-equivalent tests without kurtosis. Furthermore, there are many non-equivalent ways to meet a kurtosis specification, meaning products tested to the same specification by different controllers will likely receive significantly different amounts of fatigue damage.

13:20 - Success through failure: using accelerated stress testing for product reliability
Rich Byczek, global technical lead, Intertek, USA
Failure is good for success, and Intertek has the means to prove it. This presentation will show how to use accelerated stress testing (AST) to achieve high product reliability for mission-critical components. This program will cover a variety of elements, including: how to get the 'right stuff' for a product development effort, avoiding failed validation, conventional testing vs. accelerated stress test, what AST test methods are available (FMVT, HALT and more), a deeper dive into HALT and FMVT, how to develop a smart test plan, and more.

13:40 - Simplifying conformance testing of all new in-vehicle networking standards
Thomas Schulze, head of testing, automotive, Spirent Communications, GERMANY
Ethernet as the new in-vehicle networking standard for infotainment and advance driver assistance systems comes with a bunch of new standards that need to be tested on your device or software under development. The test process should be simple but reliable, repeatable, and must be well documented. This presentation will show methodologies and tools to implement these test procedures on existing test benches or how to set up a new one to reduce the cost of testing and the time to market with improved product quality.

14:00 - Development of an energy distribution diagram for door durability tests
Dr Yanwu Xu, senior engineer, Ford, USA
Energy distribution among components during door slam close is one of the important design parameters for product development and durability performance testing. During vehicle usage, the customer input energy is mainly distributed onto door sheet metal, dynamic seal, check, hinge and latch, as well as the body and cabin air. The energy distribution on each of the components varies with the design parameters and physical properties of the door. This presentation gives a methodology of energy distribution diagram establishment with mathematical models. As one of the diagram applications, inside handle durability tests in different levels are demonstrated.

14:20 - Digital image correlation non-contacting strain measurement systems
Alistair Tofts, director of sales & marketing, Correlated Solutions Inc, USA
Digital image correlation (DIC) is a non-contacting measurement technology that has gained widespread popularity due to the overall robustness, versatility, ease of use, accuracy and cost savings. DIC utilizes digital cameras to measure full-field 3D surface displacements and strains, eliminating the need for strain gauges and other measurement devices. Due to its full-field measurement capability and high spatial resolution, DIC has been particularly popular for applications that require finite element model (FEA) validation. An overview of the latest turnkey systems available with some automotive testing applications will be presented.

14:40 - Achieving power measurement accuracy of dynamic PWM signals
Jack Christensen, manager, technical support - Americas, Newtons4th NA, USA
The presentation will discuss the importance of proper ranging techniques, the requirement for precise voltage and current phase angle measurements, and acquisition synchronization of multi-phase systems in determining correct mechanical and electrical efficiencies.

15:00 - Innovative electrically and mechanically filtered sensor technology
David Change, vice president/technical director, Dytran Instruments Inc, USA
Dytran presents the industry's first case-isolated, mechanically and electrically filtered IEPE triax – 3603A. The internal sensing element is suspended inside the housing by a set of specially designed supports designed to stop high-frequency propagation into the element structure, causing the sensing element to resonate in relation to the housing at around 10kHz. The built-in electrical filter is capable of smoothing the sensor output to a flat line up to 8kHz region. The attenuation of mechanical resonance plus the two-pole electrical filter provide effective -24dB/octave signal reduction with a corner frequency near 10kHz.

15:20 - Very slow-speed and angular position control for dynamometer systems
Richard Rumer, senior application engineer, Horiba Instruments Inc, USA
With vehicle electrification, the engine has become a complex propulsion system requiring validation, verification, calibration and durability testing at an extended operating range, which includes standstill and rotational speeds below 50rpm. Maintaining accuracy and stable controls throughout a speed range of 0 to 24,000rpm without changing instrumentation has been accomplished by Horiba’s dynamometer controller, called SPARC, by adding additional control modes that take advantage of the position sensing inherent in incremental encoders. Unique signal processing methods are discussed to circumvent the 'no pulse' at zero speed. Improvements in settling time and reduced overshoot to a step disturbance will be shown.

15:40 - X-ray and optical extinction tomography for drop size estimation
Jason Green, engineer, En'Urga, USA
En'Urga Inc has developed a new diagnostic tool for dense sprays such as high-pressure diesel injectors and GDI systems. The new diagnostic, SETxvue, uses soft x-rays to obtain the planar mass concentrations in high-pressure fuel injectors. Conventional optical techniques cannot study these high-pressure sprays because they are optically dense. En'Urga will present x-ray and optical tomography results obtained from a GDI injector at high pressures. Full planar drop size distribution can be obtained using the SETXvue system. Results were validated using a diffraction-based drop-sizer system.

16:00 - Numerical/experimental approach for ejection mitigation testing
Paolo Cavallo, technical director, AMET USA Inc, USA
In the last two years CSI and AMET have started a partnership to develop an integrated numerical/experimental approach to deal with the testing of vehicles w/r/t ejection mitigation requirements. The approach is based on vehicle dynamics and integrated biomechanics simulations that allow a reduction in the number of physical tests to be held at CSI's proving ground and provide the ECU suppliers with DOE plans results to test ECU logics behavior. This approach has been successfully adopted for the development of ECUs of several vehicles for different OEMs.

Day 3

Thursday 27 October

10:00 - 13:40 - DAY 3

Moderator
John Tyson, president, Trilion Quality Systems, USA

10:00 - Measurement microphones in theory and practice
Udo Wagner, sales director, Microtech Gefell GmbH, GERMANY
The presentation will discuss applications of measurement microphones, indoor and outdoor microphones, car acoustics (interior noise, array technology, sound intensity, tire noise measurement on a driving car), plus how to find the right microphone type, microphones in theory, calibration, and accuracy of measurement.

10:20 - End-of-production-line measurement systems for automotive components
Steve Johnson, sales engineer, Signalysis, USA
The presentation will offer an overview of the different types of automotive components that have Signalysis measurement systems on production lines for end-of-line testing for sound and vibration. It will cover ways these systems are implemented and how they can be utilized to deliver better-quality products.

10:40 - A holistic diagnosis of airborne sound sources
Dr Sean Wu, CEO & president, Signal-Wise LLC, USA
This presentation discusses an innovative technology that enables users to acquire comprehensive knowledge of airborne sound sources, including their Cartesian coordinates, sound pressure spectrum, sound pressure level, sound intensity vector and sound intensity level distributions on an arbitrarily shaped 3D source surface, and radiation pattern in the surrounding fluid medium over the entire audible frequency range. In particular, this technology allows users to correlate five physical quantities – time, space, frequency, visual, and hearing effects – resulting from the captured sound sources at user-defined time steps and frequency bands. All these tasks can be accomplished using six microphones.

11:00 - Optical metrology for improved quality
John Tyson, president, Trilion Quality Systems, USA
Optical metrology is fast becoming the measurement method of choice for real-time measurements. 3D digital image correlation is finite element measurement, and allows users to intuitively understand the material response of complex structures, providing CAE engineers with powerful tools to understand their structures and designs, especially for advanced materials and structures. Photogrammetry provides 6DOF (degrees of freedom) measurement of structures with the same hardware, from robot motion to NVH, from materials studies to manufacturing quality control. This paper will discuss these advanced capabilities.

11:20 - Implementing quality inspection systems to battle 'other-objectionable-noise' requirements
Neil Coleman, president, Signalysis, USA
Automotive OEMs are constantly driving suppliers to deliver a quieter ride. Almost every component that is powered, moves or spins has a 100% inspection requirement for dB(A) and/or Loudness (Sones). And just in case that isn't enough, they add the subjective requirement of 'no objectionable noises'. This subjective specification is very difficult to meet because the bar can move daily based on the weather or who is inspecting the parts. Signalysis has been working side by side with suppliers since 1987 and has an entire toolbox of metrics designed to win the battle and deliver the sound of silence.

11:40 - Signal-based fault detection and diagnosis based on using noise and vibration
Prof Saeid Habibi, professor and director, McMaster University, CANADA
This presentation is on the implementation of a fault detection and diagnostic (FDD) strategy for electric starters jointly developed by McMaster University and D&V Electronics. Due to the vehicle electrification trends, electric motors are playing an increasingly important role in the powertrain of vehicles. These are continuously evolving into complicated electromechanical systems that require more advanced testing equipment. As one of the leading test system suppliers, D&V Electronics has put great effort in advancing test cell technologies. The presentation is on advanced signal-based algorithms that provide a unique capability of detecting and diagnosing faults using noise and vibrations.

12:00 - BIA’s next-generation multiaxial acceleration sled
Nick Jaksa, managing director, BIA North America, USA
Crash test protocols continue to evolve with new, expanding and more rigorous conditions that require more and more functionality and precision. BIA’s new multiaxial acceleration sled offers a modular-based system that allows users to have a multistep implementation including horizontal testing, pitching simulation, yaw simulation, or a combination of the three. The system integrates an innovative numerical control strategy with real-time closed-loop control during the entire duration of pulse creation, in parallel with real-time predictive system modeling algorithms. This fully servohydraulic system provides advanced high payload, with excellent pulse-matching capability.

12:20 - The woes of plant environment seat testing
Andrew Whitely, solutions engineer, Signalysis, USA
Often laboratory results are not easily achievable in plant environments. Stamping, welding and various other plant noises and vibrations can degrade or interfere with measurements. The presentation will explain some ways to combat these issues, and cite examples of good and bad choices.

12:40 - New NSI processing technique – CleanSC with Reference Contribution
Scott Hunt, product specialist - automotive, Brüel & Kjær, USA
Historically, beamforming, a far-field NSI technique, has been limited to showing only sources with the highest radiated sound levels from a single plain. Recently it became possible to show levels that were the most impactful to the experience of a product. Brüel & Kjær has developed a new method called CleanSC with Reference Contribution, which allows these array tools to very accurately map sources with respect to the level that is taken from a reference transducer. This method will be discussed and example data presented

13:00 - Indoor test for a car with radar-based pre-crash safety systems
Hirosuke Suzuki, president, Keycom Corp, JAPAN
Awareness of driving safety has led to the need for pre-crash safety systems to be installed on a vehicle. Things like steering wheel movement, cross-entering human and braking for pre-crash avoidance should be tested on a real car test course. But sometimes the test driver is tired and dangerous. We therefore developed a moving collision target simulation system using digital delay for long distance, optical fiber for middle distance, jamming noise to realize human cross-entering and a dielectric waveguide for short distance. It allows for indoor testing of radar-based automatic brake systems.

13:20 - Combining inertial and GPS data for accurate vehicle brake testing
Dr Martin Hill, director, Race Technology Ltd, UK
For a number of years companies have been relying on the use of GPS-only systems to perform vehicle brake testing. Over the last few years this has been demonstrated to be the source of significant errors in certain tests. This presentation explains the source of these errors, including their likely impact on the results of brake tests, and shows how, by using inertial data combined with GPS data, this source of errors can be eliminated while also improving the robustness of the data to poor GPS conditions.

13:40 - Don't be a dummy: body forms for seat testing
Terry O'Bannon, chief scientist, OBannon Technologies, USA
Many body forms are used in testing vehicle seats and interiors, but specifications and requirements for the forms are usually lacking (except in the specialized area of crash testing). Therefore the test result often doesn't relate to the real test objective: 'What happens when a human interacts with this seat?' We will look at various classes and examples of body forms and discuss what tests they are appropriate for, and show errors that result from using the wrong form.

*This program may be subject to change

Day 1

Tuesday 25 October

10:00 - 16:20 - DAY 1

Moderator
Jeff Warra, technical specialist, Spirent Communications, USA

10:00 - Developing network, surPASS your expectations, active monitoring vs datalogging
Jeff Warra, technical specialist, Spirent Communications, USA
OEMs in the automotive, off-highway and heavy-duty truck industries are running out of bandwidth for autonomous driving. Industries are turning to Ethernet for their in-vehicle communications networks to deliver high-bandwidth data from sensors to systems. There is a vision to have one Ethernet backbone connecting components by the end of 2018. Standard OABR (Open Alliance BroadR-Reach) is now accelerating the development of Ethernet components. Classic bus systems like CAN or Flexray were designed to deliver critical control messages in real time. The real-time requirements need to be addressed for the Ethernet architectures, since Ethernet technology was not created to be a real-time communications bus.

10:20 - imc revolutionizes vehicle-testing: easier, faster and more flexible than ever
Andrew Jesudowich, application sales & operations manager, imc DataWorks LLC, USA
The presentation will discuss how the expanded imc test and measurement portfolio enables faster, more efficient vehicle testing. New imc CANSASflex measurement modules can be used in spatially distributed configurations or as central units. With the imc click-mechanism, modules mechanically and electrically connect. New imc CANSASfit is well-suited for mobile testing in harsh environments. The robust housing offers reliable protection against water-spray, dirt and vibrations. A temperature range from -40° to +125°C allows for testing year round and in climate chambers. New imc WAVE sound and vibration analysis software allows customers to perform noise measurements, structural analyses and vibration examinations and simultaneously detect other measurement variables.

10:40 - “ETAS EHANDBOOK - New Interactive Documentation Tool Makes ECU Calibration Easier”
Jayesh Patel, program manager, ETAS Inc, USA
Over the past decade, fiber-optic sensors (FOS) have advanced and are emerging as a fitting alternative to traditional electrical sensors, yet few people realize the potential and advantages of this technology. Composed only of glass, FOS are intrinsically safe and offer advantages over electrical sensors; they are not sensitive to electromagnetic interference (EMI) and can achieve higher measurement accuracy. This presentation will highlight optical sensor manufacturing, and real-world applications of FOS versus conventional strain gauges in industries including automotive, oil and gas, and aerospace. Attendees will leave the session understanding fiber-optic sensors and the advantages they offer.

11:00 - Testing automotive security and testing despite security
Philip Lapczynski, program manager, Vector CANtech Inc, USA
We all are aware of the growing need for cybersecurity in automotive. This presentation focuses on two things: 1) The growing need for security testing in automotive; 2) The challenges in testing created by the introduction of security mechanisms. We will discuss secure engineering practices such as automated functional testing (white box), fuzz testing (black box) and testing a system with security mechanisms in place.

11:20 - MaDaM – the measurement data management solution
Dr Bernhard Sünder, managing director, AMS GmbH, GERMANY
Based on practical use cases at large OEMs, the advantages and limitations of modern measurement data-management systems are shown. Indexing technology (Lucene) and enhanced search capabilities, highly interactive HTML5 and traffic-minimizing EnCom are new technologies developed during the last five years. With samples from the AMS product MaDaM, the advantages of these new technologies are demonstrated. The measurement data-management system MaDaM combines modern approaches to data storage and indexing with web technologies for mobile and desktop access. It provides server-based report on demand or interactive data analysis in a web-based environment with easy-to-use full text search. This enables big data solutions.

11:40 - The effect of tire data quality on vehicle performance prediction
Henning Olsson, director, R&D, Calspan Corporation, USA
Laboratory tire testing provides tire data that, when used appropriately, can help accelerate the vehicle development process. With tire data and tire models being used for many different applications, the effects of data quality and accuracy must be considered. A study has been carried out to quantify the impact of these effects on vehicle performance predictions. Examples from passenger car and truck applications are presented and conclusions discussed.

12:00 - Technology of a diagnostic tester with cybercrime protection
Peter Subke, director business development, Softing AE GmbH, GERMANY
The presentation will introduce a state-of-the-art diagnostic tester consisting of an MVCI D-Server (ISO 22900) that processes data that is described in ODX format (ISO 22901) and sequences that are described in OTX format ( ISO 13209). Particularly for diagnostic communication over the air, e.g. for a software update, measures must be taken to protect against cyberattacks. Examples include but are not limited to the encryption of data and sequences, and signature technologies.

12:20 - New techniques for automating analysis for technical data
Stephanie Amrite, senior product manager, National Instruments, USA
You are collecting a lot of data, but industry research shows that on average only 5% is analyzed. This is due to a combination of reasons such as poorly documented data, and the variety and volume of data sources that customers use. To help you overcome this problem, NI is investing in technologies to help make automating the analysis of engineering data easier than ever, including the ability to standardize metadata from any data source and smartly choose which analysis routine to run based on the data.

12:40 - DC fast charging testing at various temperatures
Rich Jacobson, operations manager, Intertek Phoenix, USA
The plug-in electric vehicle (PEV) industry commonly markets DC fast charging as a method to provide up to 80% of a full charge in 20-30 minutes. However, the charge rate will vary greatly depending on the ambient and energy storage system (ESS) temperatures. In this study, the charge acceptance rates of a variety of PEVs are compared, and the effects of the thermal management system (TMS) on the charge event are explored. Tested PEVs include the 2011 and 2013 Nissan Leaf, 2012 Mitsubishi i-MiEV, Volkswagen e-Golf, Kia Soul EV, Chevrolet Spark EV and BMW i3.

13:00 - Road to LTE: connected cars, LTE roadmap and test solutions
Craig Hendricks, senior technologist, Anritsu US Automotive Focus Team, Anritsu Company, USA
Cory White, North America Business Development Mgr, Automotive Sector, Anritsu Company,, USA
With the long product development cycle of automobiles and increased utilization of LTE for connectivity, it is critical to understand the roadmap for new LTE developments in networks and chipsets. Auto makers will need to invest in these technologies to stay ahead of the technology curve and offer consumers the most up-to-date connectivity. This presentation will provide LTE technology roadmaps from 4.5G to 5G and explore the test solutions available to ultimately bring the technology into the marketplace through connected cars.

13:20 - Next-generation PEMS (smaller, lower cost, more energy efficient)
Andrew Burnette, science advisor, 3DATX, USA
The in-use emissions testing industry, academic research and other sectors have been pushing for smaller, lighter, lower-cost and, ever more importantly, lower-energy-consumption portable emissions measurement systems (PEMS). Although there is an understandable natural tension here for the more established PEMS technology manufacturers, it is worth both acknowledging this and considering the routes and barriers for such a next-generation system. Recent test results for a next-generation PEMS system will be presented, along with current thinking on where it may reasonably be applied to cost-effectively help reduce emissions.

13:40 - Advanced power emulators for power system development and testing
William Peterson, vice president/CTO, E&M Power, USA
High-fidelity DC power system and motor drive inverter testing is made achievable with the use of advanced power emulation. An active load emulator can mimic all the characteristics of a motor/generator at full power in all four quadrants with no moving parts. A DC emulator can provide wideband – to 20kHz – simulation or emulation of the DC power system. The ability to sweep at full power, to frequencies above the switching frequency provides for full characterization of system resonances and characteristics.

14:00 - Advanced physics-based sensor simulation approaches for testing ADAS systems
Tony Gioutsos, director sales and marketing, TASS International, USA
To provide a 'due care' testing approach to automated and connected vehicle technology, an advanced sensor simulation must be involved. However, to provide the most accurate and best validation, sensor simulation closest to 'raw data' would be preferred. Advanced physics-based sensor models with deterministic and probabilistic components are introduced. The models described include: camera, radar and V2X.

14:20 - An open systems approach to BMS HIL testing
Peter Blume, president, Bloomy, USA
Hardware-in-the-loop (HIL) testing is an essential approach for validating the hardware and firmware of an automotive ECU, including the battery management system (BMS) electronics of hybrid and electric vehicles (xEVs). A HIL simulator is used to simulate the xEV battery including cell chemistry, drive cycles and numerous fault conditions, without the hazards of real batteries, or the cost of prototype vehicles and track time. In this session, Peter presents an open systems architecture approach to HIL test systems implementation using commercial off-the-shelf hardware and software, including battery simulators.

14:40 - RDDS, state-of-the-art control system for easy upgrading of existing test stands
Jörg Cordes, president, Renk Systems Corporation, USA
The presentation will discuss a software/hardware concept to control new or existing test systems. The required hardware: PC and Ether-CAT bus; electrical wiring in general and connection of instrumentation, new or existing; electrical connection of actuating elements; software setting to make it match the actual or future test stand application. General features in limit monitoring, control loops, datalogging, fault history logging (post-mortem dump). Display configuration. Users, operators, engineering level protection by pass codes and much more.

15:00 - Torque and power measurement – auto case studies and approaches
Brian Carr, US sales manager, Binsfeld Engineering Inc, USA
Throughout history, mankind has relied on rotating shafts and torque to power society. That ideal has never been more prominent than during the advent of the automobile. Measuring the torque and mechanical output produced by a shaft-driving system is critical to understanding, and optimizing, multiple processes within the industry. This paper provides an overview of various torque measurement tools, as well as the benefits and limitations of each approach. Finally, we’ll examine application stories that illustrate one preferred method. While the examples are different, they highlight the potential that condition monitoring presents for a wide breadth of automotive professionals.

15:20 - How Siemens' high-performance drive can enhance your testing equipment
Ulrich Weinhart, business development, test stands, Siemens Industry Inc, USA
Test stand applications are increasingly realizing benefits like noise reduction, energy recovery and improved time to market with Siemens SINAMICS drives. Join Siemens for a glimpse into the test stand specific capabilities built into the standard, off-the-shelf SINAMICS drives. Features such as torque pulse engine simulation, automatic disturbance compensation and connectivity with National Instruments' LabVIEW or MATLAB’s Simulink will simplify your testing requirements. Siemens will discuss various test stand applications including battery simulation, and how the exceptionally high-performance SINAMICS drives can streamline and increase the productivity of your applications.

15:40 - VOC environmental testing automotive applications – what you need to know
Ben Pipher, application engineer - automotive business unit, Weiss Envirotronics, USA
Volatile organic compounds (VOC) must be limited in personnel vehicle applications. Understanding the product and the interaction with other vehicle components and the surrounding environment is essential to product development and product and air safety. Environmental testing chambers play a critical role in testing of vehicle interior components and VOCs. Safety requirements will need to be in place in testing vehicle interiors, such as particle measurement, absorption rates, contaminations from the vicinity and venting systems. This presentation will give relevant information and guidance on what to look for in the product testing phase with interiors, and how to limit the VOC elements. We will review industry test requirements including ASTM VDA, ISO and other test specifications. The presentation will also review how to get the most out of your environmental test equipment, and proper test applications with VOC materials.

16:00 - Create test profiles correlated to multiple end-use environments utilizing FDS
Kevin Van Popering, application egineer, Vibration Research Corp, USA
The initial design of your product is done; now it’s time for vibration testing. Vibration levels the product will experience have been collected from field measurements taken at the end-use environment (EUE). The amount of time the product will experience these vibration levels throughout its lifespan is known. Why not take these field measurements and target lifespans and convert them into a vibration profile correlated to the EUE? Fatigue Damage Spectrum (FDS) does just that. This presentation will describe the theory and demonstrate the process of creating a test profile from multiple EUEs utilizing FDS from start to finish.

16:20 - Adding HIL to your driving simulator
Ken Jackson, senior vice president, Linux/Real-Time, Concurrent, USA
The simulation world is evolving into a more complete environment that can simultaneously test and verify the vehicle dynamics and a new design of the vehicle's controllers. In the past, ECU testing was more singular in its reach and was relegated to testing individual components. The new thought is to fully integrate all aspects of the vehicle prior to production release. Connecting the ECUs to the driving simulator provides the complete test of the car's abilities and functionality. To expand this to autonomous vehicles requires a multi-model simulation sharing interdependent data while maintaining a high frame rate.

*This program may be subject to change

Day 2

Wednesday 26 October

10:00 - 16:00 - DAY 2

Moderator
William Doelle, director North American operations, Berghof Group North America, USA

10:00 - Fiber Optic Sensing, a visible alternative
Nicholas Burgwin, Founder, fibos, CANADA
Over the past decade, fiber optic sensors (FOS) have advanced and are emerging as a fitting alternative to traditional electrical sensors, yet not many realize the potential and advantages of this technology. Composed only of glass, FOS are intrinsically safe and offer advantages over electrical sensors; they are not sensitive to electromagnetic interference (EMI) and can achieve higher measurement accuracy. This presentation will highlight optical sensor manufacturing, and real-world applications of FOS versus conventional strain gauges in industries including Transportation, Oil and Gas, and Aerospace. You will leave the session understanding fiber optic sensors and the advantages they offer.

10:20 - Aftertreatment testing equipment that replicates real-world transient exhaust gas conditions
Jonathan Stewart, technical specialist, Catagen, UK
This study describes a synthetic gas reactor capable of producing a wide range of RDE testing scenarios including WLTC, SULEV and NEDC test cycles. The system has the capability of reproducing transient cycles for a wide range of engine types, with test sample temperatures from -10°C to 800°C. The approach is inherently accurate and repeatable; it also is ideally suited to sensitivity, calibration and performance testing, and is designed to help customers meet emission targets. Results of the system performance are presented for the WLTC cycle for a light-duty diesel vehicle, and compared with real engine data.

10:40 - PIA – economic injection testing for every environment
William Doelle, director North American operations, Berghof Group North America, USA
The PIA family is a testing equipment family designed for fuel-injector and pump research, manufacture and validation, controlling piezo and solenoid injectors. Profiles created in the R&D lab can be used to calibrate injectors or pumps in an EOL (end of line) test station, confirmed by PIA in validation testing. Before the background of recent trends in automotive testing, PIA and its development together with customers and suppliers will be our focus – development that led us to set up a forum dealing with the future of the powertrain‘s engine section: the Berghof Testing Powertrain Innovation Day.

11:00 - An enterprise approach to engine test analysis: requirements for implementation
Bruce Thomason, director of technology, SGS, USA
Engine and vehicle OEMs have complex product development requirements that call for capable and standardized post-test analysis while simultaneously dealing with high levels of product technology and test diversity. Many organizations rely on shared spreadsheets or distributed desktop tools, which can produce inconsistent and non-traceable results. This presentation addresses enterprise-scale post-processing requirements, features and implementation considerations in addition to providing lessons learned that can help move an organization to an efficient, standardized and maintainable professional process. The presentation will cover how to address diversity of product topology, physical components, fluid properties, measurement uncertainty, naming conventions, traceability and IT architecture.

11:20 - Guided and automated calibration using ETAS INCA-FLOW
Rajesh Reddy, product manager, ETAS, GERMANY
ETAS INCA-FLOW is a revolutionary approach for automating and guiding calibration. It facilitates the graphical specification of calibration procedures without requiring programming skills. Calibrating gasoline and diesel engine management systems is a challenging task that is largely repetitive with regard to specific customer projects. Using INCA-FLOW, the calibration process can be set up for one ECU variant and then reused for others, which can significantly increase calibration efficiency. In addition, measurements can be easily reproduced, leading to clear improvements in calibration quality. The same standardized calibration methods can be used for any calibration infrastructure.

11:40 - ADAS – automotive radar test challenges and solutions
Greg Kregoski, automotive market segment manager, Rohde & Schwarz, USA
To keep transmission power levels low and range resolution of automotive radars high, FM modulated continuous wave signals of high bandwidth are typically used in automotive radar applications. Operating in the 24 and 77GHz frequency bands, automotive radar takes advantage of these frequencies and their high atmospheric attenuation, allowing many automobile radar systems to operate concurrently without impacting one another. This presentation provides an overview of current automotive radar technology, test and measurement technologies used for automotive radar and new radar target simulation devices.

12:00 - The correlation of rolling resistance and tire liner temperature profiles
Alan Bennetts, director, Bay Systems Ltd, UK
The presentation will discuss the development of a remote sensor that accurately (+/- 0.2ºC) measures an array of points stretching from bead to bead. Data from a range of tires will be presented, showing where heat is being generated and correlating the final temperature with the classical derived rolling resistance. Questions posed will include the effect of excessive temperature on the number and size of particulates shed by the tire.

12:20 - Testing composites using high-definition fiber-optic sensing
Naman Garg, field applications engineer, Luna Innovations, USA
Luna Innovations of Blacksburg Virginia, has developed a high-definition fiber-optic sensing (HD-FOS) system that is perfectly suited for measuring strain of composite materials and structures. A single fiber sensor can replace thousands of strain gauges and, with its flexibility and light weight, can be used to instrument in hard-to-access locations. The fiber, at only 150 microns in diameter, can also be embedded within composite parts. The use of composite materials in automotive design will continue to grow, and its imperative that test engineers understand the unique challenges with testing composite parts and structures.

12:40 - Piezoelectric measurement made easy – powerful signal conditioning from Kistler
Bill Zwolinski, SBU manager, acceleration, Kistler Instrument Corporation, USA
Kistler’s charge amplifier module Type 5171A is directly plugged into National Instruments’ CompactRIO platform. The signals of one or four piezoelectric sensors are digitized and then processed in real-time. Everything is programmed with the familiar LabVIEW development tools, allowing users to create customized solutions. The Type 5165A Kistler LabAmp dual-mode amplifier not only amplifies the dynamic signals with very low noise, but also provides the digitized data via Ethernet interface. Thanks to its advanced signal processing, it offers outstanding flexibility and ease of use. With GUI control or use of LabVIEW development tools, users can create customized solutions.

13:00 - Problems with kurtosis as a random vibration specification
Dr Benjamin Shank, engineer, Thermotron Industries, USA
This talk is a summary of lessons learned while developing kurtosis algorithms for a vibration controller. The past decade has seen a trend of dealing with non-stationary vibration power by controlling the kurtosis of random tests. Based on Miner’s Rule and fatigue damage spectra, testing with kurtosis is shown to always deliver damage more slowly than SRS-equivalent tests without kurtosis. Furthermore, there are many non-equivalent ways to meet a kurtosis specification, meaning products tested to the same specification by different controllers will likely receive significantly different amounts of fatigue damage.

13:20 - Success through failure: using accelerated stress testing for product reliability
Rich Byczek, global technical lead, Intertek, USA
Failure is good for success, and Intertek has the means to prove it. This presentation will show how to use accelerated stress testing (AST) to achieve high product reliability for mission-critical components. This program will cover a variety of elements, including: how to get the 'right stuff' for a product development effort, avoiding failed validation, conventional testing vs. accelerated stress test, what AST test methods are available (FMVT, HALT and more), a deeper dive into HALT and FMVT, how to develop a smart test plan, and more.

13:40 - Simplifying conformance testing of all new in-vehicle networking standards
Thomas Schulze, head of testing, automotive, Spirent Communications, GERMANY
Ethernet as the new in-vehicle networking standard for infotainment and advance driver assistance systems comes with a bunch of new standards that need to be tested on your device or software under development. The test process should be simple but reliable, repeatable, and must be well documented. This presentation will show methodologies and tools to implement these test procedures on existing test benches or how to set up a new one to reduce the cost of testing and the time to market with improved product quality.

14:00 - Development of an energy distribution diagram for door durability tests
Dr Yanwu Xu, senior engineer, Ford, USA
Energy distribution among components during door slam close is one of the important design parameters for product development and durability performance testing. During vehicle usage, the customer input energy is mainly distributed onto door sheet metal, dynamic seal, check, hinge and latch, as well as the body and cabin air. The energy distribution on each of the components varies with the design parameters and physical properties of the door. This presentation gives a methodology of energy distribution diagram establishment with mathematical models. As one of the diagram applications, inside handle durability tests in different levels are demonstrated.

14:20 - Digital image correlation non-contacting strain measurement systems
Alistair Tofts, director of sales & marketing, Correlated Solutions Inc, USA
Digital image correlation (DIC) is a non-contacting measurement technology that has gained widespread popularity due to the overall robustness, versatility, ease of use, accuracy and cost savings. DIC utilizes digital cameras to measure full-field 3D surface displacements and strains, eliminating the need for strain gauges and other measurement devices. Due to its full-field measurement capability and high spatial resolution, DIC has been particularly popular for applications that require finite element model (FEA) validation. An overview of the latest turnkey systems available with some automotive testing applications will be presented.

14:40 - Achieving power measurement accuracy of dynamic PWM signals
Jack Christensen, manager, technical support - Americas, Newtons4th NA, USA
The presentation will discuss the importance of proper ranging techniques, the requirement for precise voltage and current phase angle measurements, and acquisition synchronization of multi-phase systems in determining correct mechanical and electrical efficiencies.

15:00 - Innovative electrically and mechanically filtered sensor technology
David Change, vice president/technical director, Dytran Instruments Inc, USA
Dytran presents the industry's first case-isolated, mechanically and electrically filtered IEPE triax – 3603A. The internal sensing element is suspended inside the housing by a set of specially designed supports designed to stop high-frequency propagation into the element structure, causing the sensing element to resonate in relation to the housing at around 10kHz. The built-in electrical filter is capable of smoothing the sensor output to a flat line up to 8kHz region. The attenuation of mechanical resonance plus the two-pole electrical filter provide effective -24dB/octave signal reduction with a corner frequency near 10kHz.

15:20 - Very slow-speed and angular position control for dynamometer systems
Richard Rumer, senior application engineer, Horiba Instruments Inc, USA
With vehicle electrification, the engine has become a complex propulsion system requiring validation, verification, calibration and durability testing at an extended operating range, which includes standstill and rotational speeds below 50rpm. Maintaining accuracy and stable controls throughout a speed range of 0 to 24,000rpm without changing instrumentation has been accomplished by Horiba’s dynamometer controller, called SPARC, by adding additional control modes that take advantage of the position sensing inherent in incremental encoders. Unique signal processing methods are discussed to circumvent the 'no pulse' at zero speed. Improvements in settling time and reduced overshoot to a step disturbance will be shown.

15:40 - X-ray and optical extinction tomography for drop size estimation
Jason Green, engineer, En'Urga, USA
En'Urga Inc has developed a new diagnostic tool for dense sprays such as high-pressure diesel injectors and GDI systems. The new diagnostic, SETxvue, uses soft x-rays to obtain the planar mass concentrations in high-pressure fuel injectors. Conventional optical techniques cannot study these high-pressure sprays because they are optically dense. En'Urga will present x-ray and optical tomography results obtained from a GDI injector at high pressures. Full planar drop size distribution can be obtained using the SETXvue system. Results were validated using a diffraction-based drop-sizer system.

16:00 - Numerical/experimental approach for ejection mitigation testing
Paolo Cavallo, technical director, AMET USA Inc, USA
In the last two years CSI and AMET have started a partnership to develop an integrated numerical/experimental approach to deal with the testing of vehicles w/r/t ejection mitigation requirements. The approach is based on vehicle dynamics and integrated biomechanics simulations that allow a reduction in the number of physical tests to be held at CSI's proving ground and provide the ECU suppliers with DOE plans results to test ECU logics behavior. This approach has been successfully adopted for the development of ECUs of several vehicles for different OEMs.

*This program may be subject to change

Day 3

Thursday 27 October

10:00 - 13:40 - DAY 3

Moderator
John Tyson, president, Trilion Quality Systems, USA

10:00 - Measurement microphones in theory and practice
Udo Wagner, sales director, Microtech Gefell GmbH, GERMANY
The presentation will discuss applications of measurement microphones, indoor and outdoor microphones, car acoustics (interior noise, array technology, sound intensity, tire noise measurement on a driving car), plus how to find the right microphone type, microphones in theory, calibration, and accuracy of measurement.

10:20 - End-of-production-line measurement systems for automotive components
Steve Johnson, sales engineer, Signalysis, USA
The presentation will offer an overview of the different types of automotive components that have Signalysis measurement systems on production lines for end-of-line testing for sound and vibration. It will cover ways these systems are implemented and how they can be utilized to deliver better-quality products.

10:40 - A holistic diagnosis of airborne sound sources
Dr Sean Wu, CEO & president, Signal-Wise LLC, USA
This presentation discusses an innovative technology that enables users to acquire comprehensive knowledge of airborne sound sources, including their Cartesian coordinates, sound pressure spectrum, sound pressure level, sound intensity vector and sound intensity level distributions on an arbitrarily shaped 3D source surface, and radiation pattern in the surrounding fluid medium over the entire audible frequency range. In particular, this technology allows users to correlate five physical quantities – time, space, frequency, visual, and hearing effects – resulting from the captured sound sources at user-defined time steps and frequency bands. All these tasks can be accomplished using six microphones.

11:00 - Optical metrology for improved quality
John Tyson, president, Trilion Quality Systems, USA
Optical metrology is fast becoming the measurement method of choice for real-time measurements. 3D digital image correlation is finite element measurement, and allows users to intuitively understand the material response of complex structures, providing CAE engineers with powerful tools to understand their structures and designs, especially for advanced materials and structures. Photogrammetry provides 6DOF (degrees of freedom) measurement of structures with the same hardware, from robot motion to NVH, from materials studies to manufacturing quality control. This paper will discuss these advanced capabilities.

11:20 - Implementing quality inspection systems to battle 'other-objectionable-noise' requirements
Neil Coleman, president, Signalysis, USA
Automotive OEMs are constantly driving suppliers to deliver a quieter ride. Almost every component that is powered, moves or spins has a 100% inspection requirement for dB(A) and/or Loudness (Sones). And just in case that isn't enough, they add the subjective requirement of 'no objectionable noises'. This subjective specification is very difficult to meet because the bar can move daily based on the weather or who is inspecting the parts. Signalysis has been working side by side with suppliers since 1987 and has an entire toolbox of metrics designed to win the battle and deliver the sound of silence.

11:40 - Signal-based fault detection and diagnosis based on using noise and vibration
Prof Saeid Habibi, professor and director, McMaster University, CANADA
This presentation is on the implementation of a fault detection and diagnostic (FDD) strategy for electric starters jointly developed by McMaster University and D&V Electronics. Due to the vehicle electrification trends, electric motors are playing an increasingly important role in the powertrain of vehicles. These are continuously evolving into complicated electromechanical systems that require more advanced testing equipment. As one of the leading test system suppliers, D&V Electronics has put great effort in advancing test cell technologies. The presentation is on advanced signal-based algorithms that provide a unique capability of detecting and diagnosing faults using noise and vibrations.

12:00 - BIA’s next-generation multiaxial acceleration sled
Nick Jaksa, managing director, BIA North America, USA
Crash test protocols continue to evolve with new, expanding and more rigorous conditions that require more and more functionality and precision. BIA’s new multiaxial acceleration sled offers a modular-based system that allows users to have a multistep implementation including horizontal testing, pitching simulation, yaw simulation, or a combination of the three. The system integrates an innovative numerical control strategy with real-time closed-loop control during the entire duration of pulse creation, in parallel with real-time predictive system modeling algorithms. This fully servohydraulic system provides advanced high payload, with excellent pulse-matching capability.

12:20 - The woes of plant environment seat testing
Andrew Whitely, solutions engineer, Signalysis, USA
Often laboratory results are not easily achievable in plant environments. Stamping, welding and various other plant noises and vibrations can degrade or interfere with measurements. The presentation will explain some ways to combat these issues, and cite examples of good and bad choices.

12:40 - New NSI processing technique – CleanSC with Reference Contribution
Scott Hunt, product specialist - automotive, Brüel & Kjær, USA
Historically, beamforming, a far-field NSI technique, has been limited to showing only sources with the highest radiated sound levels from a single plain. Recently it became possible to show levels that were the most impactful to the experience of a product. Brüel & Kjær has developed a new method called CleanSC with Reference Contribution, which allows these array tools to very accurately map sources with respect to the level that is taken from a reference transducer. This method will be discussed and example data presented

13:00 - Indoor test for a car with radar-based pre-crash safety systems
Hirosuke Suzuki, president, Keycom Corp, JAPAN
Awareness of driving safety has led to the need for pre-crash safety systems to be installed on a vehicle. Things like steering wheel movement, cross-entering human and braking for pre-crash avoidance should be tested on a real car test course. But sometimes the test driver is tired and dangerous. We therefore developed a moving collision target simulation system using digital delay for long distance, optical fiber for middle distance, jamming noise to realize human cross-entering and a dielectric waveguide for short distance. It allows for indoor testing of radar-based automatic brake systems.

13:20 - Combining inertial and GPS data for accurate vehicle brake testing
Dr Martin Hill, director, Race Technology Ltd, UK
For a number of years companies have been relying on the use of GPS-only systems to perform vehicle brake testing. Over the last few years this has been demonstrated to be the source of significant errors in certain tests. This presentation explains the source of these errors, including their likely impact on the results of brake tests, and shows how, by using inertial data combined with GPS data, this source of errors can be eliminated while also improving the robustness of the data to poor GPS conditions.

13:40 - Don't be a dummy: body forms for seat testing
Terry O'Bannon, chief scientist, OBannon Technologies, USA
Many body forms are used in testing vehicle seats and interiors, but specifications and requirements for the forms are usually lacking (except in the specialized area of crash testing). Therefore the test result often doesn't relate to the real test objective: 'What happens when a human interacts with this seat?' We will look at various classes and examples of body forms and discuss what tests they are appropriate for, and show errors that result from using the wrong form.

*This program may be subject to change

 
 
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Future show dates:

Automotive Testing Expo North America 2018
Dates: 23-25 October 2018
Location: Halls A,B & C (149,00ft2), Suburban Collection Showplace, Novi, Michigan, USA

Future show dates:

Automotive Testing Expo North America 2019
Dates: 22-24 October 2019
Location: Halls A,B & C, Suburban Collection Showplace, Novi, Michigan, USA