Component fatigue testing on electrodynamics vibration machines Hall 8
Dr Jaromír Kejval Team manager testing and simulation department Altran CZ AS CZECH REPUBLIC
This paper describes a different approach to component fatigue testing on standard electrodynamics vibration machines. Fatigue testing uses loading of tested components under their resonance frequency with suitable modification of initial condition – especially geometry, fixing points and additional mass. The combination of FEM simulation and experimental validation of this method will be presented. A detailed description of more experimental examples shows the advantages and limitations of these methods, which are mainly suitable for small components with high rigidity.
Using hybrid simulation tools to accelerate vehicle development Hall 8
Thomas Stachel Principal staff engineer MTS Systems Corporation USA
Driven by the growing deployment of active systems for ADAS and autonomous vehicles, rapidly increasing vehicle complexity poses significant test and validation challenges for developers. Moreover, to achieve competitiveness, these challenges must be overcome within condensed development cycles, using fewer human resources and physical prototypes. This presentation will explore industry examples of an innovative hybrid simulation approach that has been proved effective by MTS and its partners. It integrates computational models, physical hardware under test and human occupants into the simulation loop to extend the advantages of lab-based testing into early-stage development, facilitating more efficient, earlier acquisition of meaningful objective and subjective data.
Challenges and opportunities of electric vehicles and electricity grid integration Hall 8
Thijs van Wijk Manager Testlab ElaadNL NETHERLANDS
Do you want to learn about the opportunities and challenges of integrating electric vehicles with the electricity grid? And learn what tests should be performed to ensure an issue-free experience for customers? We welcome every test organization and EV(SE) manufacturer to join our presentation about smart charging, the impact charging can have on the grid power quality and why it is necessary to test on those subjects. EV(SE) manufacturers will learn how to prevent charging issues and get the most out of the electricity grid. Test houses will learn about new types of tests to add to their portfolios.
Dynamic real-time power measurement on complex drive systems Hall 8
Klaus Lang Business development manager HBM GmbH GERMANY
Power measurements are challenging when it comes to complex hybrid systems consisting of various different components, such as multiple e-machines with more than three phases, gearboxes, inverters, batteries and a combustion engine. At the same time, other important signals like temperature and vibrations need to be acquired and stored as well. All power measurements should not only be doable at static set points to do a motor map, but also at highly dynamically changing loads like in WLTP testing processes. The paper presents a solution to these challenges: a modular dynamic drive power analyzer.
Electrical testing in vehicle manufacturing Hall 8
Andreas Huber Head of OE-services Mahle service solutions Mahle Aftermarket Inc USA
Today’s vehicle manufacturing testing needs to address a variety of use cases to increase efficiency and reduce cost. Mahle’s TestLogiq, VAT, DL3 and NanoKernel offer a suite of hardware and software products to help increase the speed of vehicle testing (reduced cycle time) in plants by offering features such as location-based testing, tester software management and options for automated embedded test sequences. Such solutions need to minimize the use of vehicle battery charge, especially during downtime. Another major challenge is to implement data architecture that enables authored data reuse across various solutions, thereby minimizing overall system and labor costs.
Car components – pressure, vibration and temperature testing Hall 8
Jiri Samsonek Director of Testing Division Institute for Testing and Certification CZECH REPUBLIC
ITC Zlin is a private testing and certifying organization in the Czech Republic, with historic links to the Research Institute of Rubber and Plastic Technology, founded in 1956. ITC has historically focused on testing and certification of plastic and rubber products for various industries which include automotives, construction and building, toys, PPE, etc. Its physical laboratory offers services mainly for automotive and building products. Key activities include pressure, vibration and temperature testing of car components, such as cooling systems, evaporators, sensors, etc. The lab can also offer tailor-made solutions for combinations of various stress factors on products during testing.
Qualification and failure analysis on highly stressed CFRP components Hall 8
Matthias Popp Global vice president of testing services SGS GERMANY
After their introduction in the aerospace industry, carbon-fiber materials (CFRP) are also becoming increasingly important in the automotive industry. CFRP components have a very low density with high stiffness and strength, which is an important advantage over metallic materials. Challenges in process reliability during manufacturing and assembly, however, require high testing and qualification standards. In addition to non-destructive testing (NDT), destructive tests and chemical analysis methods are used. If CFRP components fail despite extensive qualification, their cause must be clarified in a damage analysis. The lecture gives an overview of automotive and aerospace qualification strategies and presents results of damage analyses on CFRP components.
NVH assessment and optimization of EVs and HEVs Hall 8
Guillaume Cousin Product manager Oros FRANCE
Electric and hybrid vehicle development opens a new field of noise and vibration challenges. First, a quieter cabin environment, relieved from the ICE noise, lets new sources emerge. Those sources often generate low sound levels but with unworked sound design, thus providing a poor sound experience for passengers. The main propulsion motor plays a major role in the overall sound: its vibroacoustic behavior can be assessed and improved using the appropriate technology. Globally, e-NVH requires a wide scope of dedicated skills and high-end tools: from simulation to testing.
Tuesday, May 21 PM
Moderator Hall 8
Anette Schaefer Sales engineer Horiba Europe GmbH GERMANY
Efficient testing strategies for quality control of automotive materials Hall 8
Frank Walther Professor of materials test engineering TU Dortmund University GERMANY
Dr Olesia Khafizova Responsible Innovation Center Composites Shimadzu Europe GmbH GERMANY
Parts made from metals, light metals, polymers, composites and hybrid materials are exposed to quasi-static and cyclic loading under service conditions, which results in a need for sufficient assessment of automotive materials and structures. Conventional testing procedures require high time and energy efforts and are limited in the extent of the 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.
Combining simulation and testing: a case study of electric sports car Hall 8
Jan Debille Go-to-market manager Siemens BELGIUM
To successfully develop high-quality products in the automotive industry, manufacturers need to leverage the synergies of testing and simulation in the product development cycle. That is why engineers need efficient ways to bridge the gap between the two. The modal survey of electric sports car frames shows how simulation feeds test and how test feeds back simulation. The optimal locations of shakers and accelerometers were defined from the structural FEM by pre-test analysis, and the FEM was updated by correlating with modal test results. Tips on how to improve the efficiency of your modal survey will also be given.
Winter testing of electric vehicles – in the summer Hall 8
Andrew Beach Business development director Test World Oy FINLAND
Cold-environment testing in the northern hemisphere has traditionally been carried out between November and April, to coincide with the winter season and avoid high shipping costs. Test World has recently extended the world’s first dedicated indoor winter test facilities to offer a valuable resource for year-round electric vehicle testing; for example, to test systems where battery performance is adversely affected by low ambient temperatures. This presentation will show a range of cold-weather test scenarios that can be successfully carried out on electric vehicles at Test World – every day of the year.
Analyzing field environments to understand product failure causes Hall 8
Holger Boller European managing director Vibration Research GERMANY
Product failures often require expensive repairs or replacements. Over-engineering adds to recurring costs, and its success is uncertain if the failure’s cause is not understood. Engineers need in-depth knowledge before attempting a redesign. This case study focuses on bus seat failures not predicted by industry standard tests. The goal was to collect comprehensive field vibration data and analyze it to understand the cause of the failure. The study used accelerometers placed at various points in multiple seating configurations and across multiple field environments. Analysis identified transmissibility issues between axes of motion, as well as higher-reliability seat configurations.
Material sampling process in the automotive supply chain Hall 8
Marco Theunissen Sales and business development manager - automotive and polymers Intertek Polychemlab BV NETHERLANDS
A robust supply chain is one of the most important criteria in an OEM leadership’s approval for material qualification. The process of material qualification not only differs between car companies, but also is dependent on the type of material in question and the OEMs’ business and technology goals. OEMs do not want a risky single source of material for the product in question. This presentation addresses the challenges for material development and validation throughout the supply chain, and how to improve speed-to-market.
AI- and cloud-based testing process applied to battery tests Hall 8
Dr Thomas Freudenmann CEO EDI GmbH - Engineering Data Intelligence GERMANY
Lithium-ion batteries (LIB) are the state-of-the-art technology for traction batteries in electric vehicles. However, determining the aging and performance of the LIB remains a challenge, since these essential parameters are highly dependent on the vehicle, user behavior and environmental conditions. Therefore, LIB have to be tested in an efficient and sustainable way. The presentation introduces a fully automated, cloud-based process that includes measurement of the LIB during operation, generation of load profiles at cell level and transfer to battery test benches.
Tuesday, May 21 AM
Moderator Hall 10
Lorenz Casper Principal field marketing manager - automotive National Instruments GmbH GERMANY
Wireless measurement systems for rotating and reciprocating components Hall 10
Paul LaVigne Vice president / co-owner IR Telemetrics Inc USA
The presentation will discuss the design, manufacture and use of custom-built real-time data transfer systems for rotating and reciprocating components operating in harsh environments. This will include wireless measurement systems used to transmit data from internal engine components, transmission components and driveline components from a number of transducer types, including embedded thermocouples, surface thermocouples, heat flux probes, piezo-resistive pressure transducers and accelerometers, foil and semiconductor strain gauges, inductive non-contact proximity sensors and IRT quadrature rotation sensors and gear rotor flow meters.
Test systems optimization with advanced process data monitoring Hall 10
Christoph Kappacher Manager test systems Hainzl Industriesysteme AUSTRIA
Automotive testing applications, especially in in-line or end-of-line systems, need to maintain a high level of availability. Therefore, it is essential to know the exact condition of the testing equipment. With its process data monitoring system, Hainzl provides a comprehensive monitoring solution based on existing data from the automation system and additional sensors as well as automatic data analytics. The system can be extended with vibration analysis and fluid monitoring of hydraulic units as well, and can also be easily retrofitted to existing equipment. Long-term trend analysis and data correlation ensure on-time alarms in case of recognized deviations, and enable cost-reduced maintenance and optimized testing procedures.
Making better decisions with your test data Hall 10
Lorenz Casper Principal field marketing manager - automotive National Instruments GmbH GERMANY
No matter the size of your application, on average only 5% of the data being collected is analyzed. This data could be anything from system configuration files, through metadata up to your final acquired values and further calculations. When it comes to deriving knowledge, all your data is key to gaining a competitive edge. In this session, learn how you can increase your efficiency in analyzing and visualizing engineering data that scales from an individual user to the enterprise.
Remote testing solutions for non-road mobile machinery Hall 10
Marijn Hollander Product manager calibration solutions AVL List GmbH AUSTRIA
Development needs are shifting toward more complex solutions and it is certain that most of the industry will adopt this transition. Emission legislation is also pushing for more testing in real conditions. A concrete example here is the in-service-monitoring testing for the current Stage V legislation. For the test to be valid, boundary conditions must be taken into account. Machines often operate in remote locations with a specifically trained operator. Therefore, the testing engineers want to monitor the testing remotely and in real time, as well as to be able to guide the operator in case action must be taken.
Beyond RDE – virtual tools and advanced climatic testing techniques Hall 10
Richard Adams Head of international sales Horiba-MIRA Ltd UK
The regulatory and ethical demands of RDE result in increased levels of development activity that make it impractical and non-viable to sustain planned new product introduction programs within reasonable commercial expectations. The use of virtual tools, advanced testing techniques and test hardware will provide relief from the automotive industry’s latest headache. Powertrain and vehicle simulation, linked directly to engine hardware, will allow development and calibration to cover the new, wider boundaries of the RDE universe. Coupled with new climatic testing technology, physical validation can be accomplished within the laboratory, leaving the road for final verification and delivering RDE in good time.
Increasing test coverage by selection of affordable test bench equipment Hall 10
Norman Puch General manager PTS-Power Test Solutions UG (Haftungsbeschraenkt) GERMANY
Achieving full test coverage of all new products related to new powertrain technologies requires very high investment. As testing often does not produce a noticeable advantage for the end-user experience, the demands of managers and decision makers to decrease investments in this field are very high. Therefore, Power Test Solutions is constantly looking for the world's most competitive and forward-looking companies and testing solutions in the field of power electronics testing. As an example, Power Test Solutions presents new capacities for testing equipment, introducing some of Kewell Power Systems' products available for the European market.
Hyperspectral x-ray imaging for non-destructive testing of automotive composites Hall 10
Max Wunderlich Sales and business development Polytec GmbH GERMANY
The merging of x-ray and (hyper)spectral imaging technology enables the next generation of non-destructive testing (NDT). A new generation of x-ray imagers is now able to deliver very high contrasts and dynamics, as well as element differentiation due to energy (spectral) sensitivity of the pixels. Unlike traditional hyperspectral imaging, this generates an insight into the measured objects beyond the surface area. This talk will discuss how this new generation of imagers can be utilized in automotive testing for identifying defects and material distribution in composites and other mixed-material structures for in-line quality control and research and development.
Tuesday, May 21 PM
Moderator Hall 10
Jörg Schönbach Global business development manager automation Horiba Europe GmbH GERMANY
HIL testing in agile development with continuous testing Hall 10
Michael Beine Lead product manager dSPACE GmbH GERMANY
Hardware-in-the-loop simulation is well established and widely applied for verification and validation of automotive software. Furthermore, most OEMs and suppliers are introducing virtual validation using software-in-the-loop simulations. At the same time the whole automotive industry is moving toward agile processes and introducing continuous integration and testing workflows. What is the role of hardware-in-the-loop simulation with regard to the shift to continuous integration and testing? How can hardware-in-the-loop simulation be applied in agile organizations and support agile development processes? And how does this move toward agile affect the introduction of software-in-the-loop simulations? This presentation will discuss these questions.
Measuring emissions inside the vehicle in real-world conditions Hall 10
James Hobday Business development director Emissions Analytics UK
Vehicle thermal management and air-conditioning systems play an important role in protecting the driver and passengers from pollution ingress into the vehicle, and from the build up of carbon dioxide in the cabin. With air pollution in excess of legal limits and World Health Organization guidelines in many areas across Europe, drivers may be particularly susceptible. Emissions Analytics will present test results from testing over 100 passenger cars, measuring ultra-fine particulates entering the vehicle, and CO2 levels which can cause drowsiness.
Get ahead of the infotainment industry with signal testing Hall 10
Mette Bertelsen Account manager Averna BELGIUM
Today’s infotainment, telematics and car radio systems are increasingly sophisticated, offering mobile users a wide range of connectivity, navigation and audio options. With all the new technology and features appearing on the market, OEMs and auto makers are racing to integrate them. A key to leading this growing market is fast, comprehensive and efficient parallel testing of all the integrated technologies. This presentation gives a high-level overview of some of today’s major infotainment trends and presents how a renowned car maker gets ahead of the market by relying on a signal tester and Averna’s test expertise.
High-frequency characterization and modeling of elastomeric mounts Hall 10
Johannes Käsgen Group manager Fraunhofer LBF GERMANY
Elastomeric mounts are a key component of NVH control, especially in the automotive sector. They decouple high-frequency vibration coming from the tire-street contact or vibrations from the (electric) engine. Electric drivetrains boost the demand for high-end elastomeric components because the combustion engine as main noise emitter is obsolete and other noise-emitting sources come to the fore.
This speech presents the state-of-the-art testing technology of those mounts for high-frequency characterization of dynamic stiffness. Common advantages and limitations of this method will be addressed. Finally, an approach for modeling of elastomeric mounts will be presented.
RF testing of automotive Ethernet cables in manufacturing Hall 10
Harshang Pandya General manager AEM SINGAPORE
With increasing bandwidth and noise immunity demand from automotive Ethernet cables, it is increasingly important to test the RF performance of the cables before installation in the vehicle. Stringent requirements for signal balance parameters as well as transmission parameters necessitate a sophisticated test setup. This talk covers the issues related to cable performance testing and practical implementation of test systems in manufacturing floors.
Wednesday, May 22 AM
Moderator Hall 8
Axel Breuer Product manager, thermal testbeds AVL List GmbH AUSTRIA
Usage of FEA to determine the vibration behavior of the base plate Hall 8
Sascha Döhler Engineer Framag Industrieanlagenbau GmbH AUSTRIA
Test benches are placed on base plates that are decoupled from the ground. Therefore, the base plate is a very important part of every test bench. Test devices, frames, dynos, motors and more are directly connected to the base plate. The static, dynamic and vibration behavior of the whole test bench is significantly influenced by the base. This means that the performance of a test bench is influenced by the mass, stiffness and damping properties of the base plate. This presentation will show how numerical tools can be used to observe and improve the static and dynamic behavior of base plates for test benches.
Source characterization using blocked forces and experimental dynamic substructuring Hall 8
Dr Dennis de Klerk Managing director Müller-BBM VibroAkustik Systeme BV NETHERLANDS
Vehicle development processes require a more modular approach in NVH engineering where simulation and testing merge. Experimental dynamic substructuring introduces a new era for testing, as measurements may serve as an input to simulation rather than a validation process. Depending on the component complexity and the prototype availability, a component model is generated either from simulation (FEM model) or test (test-based model). Experimental substructuring combines all component models to obtain a virtual acoustic model of the vehicle from, for example, the driveline components up to the driver's ear.
Digital ADAS – camera and radar calibration
Andrea Cantadori Head of engineering and product management Mahle Service Solutions Europe Mahle Aftermarket Italy SpA ITALY
ADAS (advanced driver assistance systems) technologies can detect and classify various objects, inform the driver of dangerous road conditions and, in some cases, apply the brakes or bring the vehicle to a stop. Installation is increasingly no longer limited to higher class vehicles. ADAS is a combination of different sensors, cameras and software. This complex network of vehicle systems must also be recalibrated during routine maintenance work to ensure that ADAS functions are all ready to run. With Mahle's intuitive, future-proof TechPRO Digital solution, ADAS is setting new benchmarks in maintaining and calibrating these driver assistance systems.
Sensor data analytics to support predictive maintenance Hall 8
Thomas Kemmerich Technical software expert HBM Prenscia GERMANY
IIoT uses sensors to gather information for the understanding of usage, maintenance and operations. A Health and Usage Monitoring System (HUMS) monitors the health state of a fleet of vehicles; it also monitors the usage and targets the improvement of its availability, reliability and performance. This presentation will describe the practical use of descriptive and predictive analytics in an industrial case study, where an automotive component is monitored. This case study required the collection of usage data off the vehicle such as digital bus data, vibration, temperature, strain, etc. The challenge is to turn measured data into actionable knowledge.
Solving the unique challenges of testing electric vehicles Hall 8
Joergen Etter Business development manager – electric vehicle validation National Instruments GmbH GERMANY
Electrification of vehicles is the need of the hour. Vehicle electrification brings in test challenges including high-fidelity simulations and higher-power operations. There are various building blocks of an EV such as the charging infrastructure, storage and traction – and all of them need to be tested. These tests may include performance tests of batteries, HIL validation of the BMS or software validation of the traction inverter. The partnership between NI and Opal-RT provides world-class solutions to customers, including high-fidelity simulations for validating the electric powertrain.
Latest innovations for electrical vehicle NVH testing Hall 8
Mobility is evolving. The evolution toward electric vehicles is without doubt a positive one for a healthier planet. Vehicle NVH testing teams are shifting their focus toward reducing the imprint of road, wind and completely new noise sources, and are challenged with new minimum pass-by noise level regulations. This presentation provides an overview of the latest innovations in Simcenter Testlab and Simcenter SCADAS for electric vehicle NVH testing. A combination of classical and completely new innovative methodologies will be presented, illustrated by real examples.
Optical metrology in automotive testing Hall 8
Gunter Sanow Regional manager GOM GmbH GERMANY
Due to rising development costs in the automotive industry, innovative and cost-reducing development methods are becoming increasingly important. Validating new products' durability, crash behavior and visual requirements is essential for safety and lifecycle prediction. Optical metrology for static and dynamic deformation measurement supplies point-based or full-field information based on digital image correlation (DIC), for example, for material and component testing. This fast, easy-to-apply optical method replaces a multitude of LVDTs and accelerometers and enables visual presentation of measuring results, which makes test evaluation easy and intuitive. Furthermore, optical measurement methods allow for precise and efficient validation of simulations.
Wednesday, May 22 PM
Moderator Hall 8
Rich Byczek Global technical director Intertek USA
Understanding the goals and challenges in on-road vehicle test programs Hall 8
Rich Byczek Global technical director Intertek USA
When developing an over-the-road durability, benchmarking or field evaluation program, many variables can greatly affect the quality of data collected. Multi-month durability as well as short-duration, focused test drives require upfront planning as well as flexibility during the program. Technical as well as logistical challenges need to be addressed throughout a test program, especially when evaluating driving conditions across global markets. The presentation will discuss specific data to be collected and questions to be answered, driving route development and prioritizing test parameters, logistical challenges and driver/personnel safety training, including real-world examples from various test programs.
Development support of active bonnet systems and sensor signal simulation Hall 8
Dr Gernot Pauer Head of engineering/simulation Altran Concept Tech AUSTRIA
The presentation will show how the implementation of active bonnet systems can be efficiently supported by FE simulation. The basis of the development process comprises realistic and predictive modeling of the vehicle front, including a sensor system based on silicone pressure tubes for pedestrian detection. Simulations of impacts with pedestrian dummies (coupled FE and multibody simulation), lower-limit impactor and FE models of various misuse objects (small animal, basketball, etc) are used to evaluate and optimize the detection system performance at an early stage in the vehicle development.
Impact of connected and autonomous cars on testing facilities Hall 8
Yves Rebuel Strategy and business development director Aries SPAIN
The presentation will give insights into the impact of connected and autonomous cars on testing facilities. It will discuss the specificities and differences of connected and autonomous cars versus conventional ones. It will also outline the future of test benches dedicated to connected and autonomous cars.
Digital pressure sensing for automotive test applications Hall 8
Ian Abbott Product manager - industrial sensors Druck UK
Recent advances in high-speed processors are resulting in digital sensors being preferred to analog systems. Druck has integrated newly available processing power into a piezoresistive pressure sensor called DPS5000 CANbus, which has a CANopen protocol enabling best quality data availability on an easy-to-interface CANbus system. This presentation explains how automotive companies who are performing on-vehicle and engine cell testing, as well as other forms of automotive testing, can benefit from the adoption of digital sensors as part of their testing systems in order to enjoy productivity improvements and reduce their cost of ownership while operating in tough environments.
Next generation of data-oriented test benches Hall 8
Martin Albers Manager EUtech Scientific Engineering GmbH GERMANY
Modern test benches collect large volumes of data in various formats that must be managed professionally to retrieve and utilize information with maximum efficiency. The presentation will show how EU-MDM, a dedicated data management and analysis framework, provided with a test bench, automates and standardizes analysis and reporting. The tool enables fully automated and customizable data handling (automatic tagging, extended searching, processing and feeding modeling applications), expanding the value proposition of the test bench: benchmarking, creating a 'digital twin' for predictive maintenance, or identifying the device under test.
Wednesday, May 22 AM
Moderator Hall 10
Willem Toet Senior manager and professor Sauber Aerodynamics Ltd and University of Bolton SWITZERLAND
Cloud-native test automation Hall 10
Pete Staples CEO Blue Clover Devices USA
Everyone attending Automotive Testing Expo subscribes to the importance of testing, especially when 2-ton vehicles are traveling at lethal speeds. A core problem is that the people designing the tests are often disconnected from the people doing the tests. This problem can be mitigated by using test automation. This type of solution has long been very expensive and hard to apply when the production volumes are measured in thousands instead of millions. Today is possible to leverage open-source software, cloud-native infrastructure and off-the-shelf hardware to do robust test automation for about one-tenth the cost of competing methods.
Cover all angles of sensor validation Hall 10
Edward Levack Product engineer OxTS UK
ADAS test engineers need reliable reference data for the position, range and field of view of multiple sensors on their test vehicles. This process can often be time-consuming given the number of sensor configurations on Level 3 or Level 4 vehicles. This presentation will outline a new method for validating up to 12 sensors on a test vehicle at once, each sensor having an individual range and field of view configuration. Using this method, test engineers can measure target range and visibility in real time, removing the need for expensive, complicated post-processing techniques.
Automotive Ethernet testing Hall 10
Marty Gubow Product planner Keysight Technologies USA
Curtis Donahue Senior manager University of New Hampshire InterOperability Laboratory USA
Vehicle manufacturers are looking to automotive Ethernet as a next-generation communication bus. This presentation will introduce the testing requirements for automotive Ethernet including current standards such as 100BASE-T1 IEEE 802.3bw. It will also discuss emerging standards such as 1000BASE-T1 IEEE 802.3bp and future variants being defined in IEEE 802.3ch and IEEE 802.3cg. Discussions will include transmitter testing, receiver testing and channel characterization.
Aerodynamic testing and aero research challenges in Formula 1 Hall 10
Willem Toet Senior manager and professor Sauber Aerodynamics Ltd and University of Bolton SWITZERLAND
The presentation will provide a summary of how aerodynamic testing is done in Formula 1 from concept to detailed research. Aerodynamic research had been moving toward CFD combined with full-scale, high-speed wind tunnel testing until rules put the brakes on CFD (or so it seemed) and eliminated full-scale wind tunnel work. So teams found ways to conduct effective research within these restrictions. The results are clear for all to see. For example, limiting CFD computer power has led to better software, and model tests have become races against the clock. A glimpse into the dark arts!
Innovative testbed solutions for thermal management Hall 10
Peter Drage Global business segment manager thermal testbeds AVL List GmbH AUSTRIA
Vehicle thermal management is widely accepted as one of the key development topics for future vehicle concepts, as it directly influences the vehicle range, component lifetime and passenger comfort. Huge effort goes into optimizing development processes to implement innovative solutions focusing on coupled CAE methodologies as well as interactive testing approaches. One drawback when it comes to front-loading during development is the inability to perform certain development and validation tasks on a testbed rather than in the vehicle itself. This presentation focuses on testbed solutions for thermal management applications that close the gap between virtual development and physical validation by taking into consideration the best of both worlds. These testbeds comprise highly dynamic conditioning units that are controlled via customer-specific CAE tools and thermally emulate heat sources like ICE or battery, or heat sinks such as single radiators or the entire cooling system of an engine. It will be shown how CAE models as well as virtual prototypes can be integrated in the testbed via an independent coupling platform, and how that approach is used to fulfill validation as well as control development tasks. One example is the use of a model that is implemented in a dynamic coolant conditioning unit to emulate the cooling system of a battery while the battery – including the BMS – is tested in hardware. By means of this approach it is possible to directly test the effect of adapting, for example, radiator sizes, pump power or cooling air inlets, etc to the thermal behavior of the battery.
Trendsetters for automotive power amplifier test systems
Helmut Rohrer CEO/managing director Rohrer GmbH GERMANY
In the automotive industry, testing standards such as LV124 and LV148 have been established to ensure proper operation of the electronic components throughout their lifetime and all expected supply conditions. HEROpower has developed a new system: PA-LV124-148. Its main advantages are: 3x higher in-rush current, 100% power dissipation, regulation of the voltage on the DUT even at 200kHz under load, switchable power ranges, voltage and current regulation, symmetrical/asymmetrical or unipolar construction, remote control for all functions, stored test curves, and remote operation via internet and interfaces. The presentation takes a critical view and demonstrates the behavior life.
Software-defined machine: a pragmatic approach for testing hybrid vehicles Hall 10
Laurent Brunel Product manager DAM Group – DACTEM Développement FRANCE
The emphasis on cost within the automotive industry has gradually drifted from production to project lead time and future-proofing. DAM Group has successfully developed a novel approach for designing testing facilities. This platform approach based on an SDM (software-defined machine) enables a test bench to be stacked full of new functionalities. DAM developed HydroCore to test transmission components including the solenoid, gearbox module for DCT, CVT, AT, dual clutch and triple clutch. The company's second development, LabScript, is based on the same principle; DAM has developed its 48V rotating machine test Script, enabling complete ranges of products and applications.
A new concept of brake for dynos: the hybrid hydroelectric Hall 10
Enrico Corti Founder Alma Automotive Srl ITALY
Water brakes have been used for a long time due to their compactness, low inertia and reliability. However, the control accuracy is usually an issue. Furthermore, water brakes are passive machines which cannot be used to drive the engine under test. Lately, the large majority of test brakes have been based on electric machines, which are accurate and can work in motor and generator modes but require an expensive and bulky infrastructure (dedicated powerhouse, wirings, drive system, etc). A solution based on the coupling of the two machines may be effective in terms of total cost and performance.
Wednesday, May 22 PM
Moderator Hall 10
Anette Schaefer Sales engineer Horiba Europe GmbH GERMANY
Test-data mining – visualizing the invisible content of your test data Hall 10
Dr Bernhard Sünder Managing director AMS GmbH GERMANY
When analyzing vast amounts of data, one term inevitably becomes relevant: data mining. By applying statistical methods, countless data points are processed by algorithms for the recognition of patterns, coherences and clusters, among other things. AMS – a Kistler Group company – offers a toolchain that covers the complete workflow necessary for analyzing big data – from data storage with MaDaM to parallel evaluation with jBEAM-Cluster and even including statistical analysis of these evaluation results (test-data mining).
How to include tire temperature in the tire testing control loop Hall 10
Claude Rouelle Founder and president OptimumG USA
Air, carcass and compound tire temperatures have a huge influence on tire performance and durability. OptimumG president Claude Rouelle will show the results of tests performed on flat-track test benches, and explain how and why the tire temperature needs to be introduced in flat-track testing. He will also present the influence of tire models created with this new tire-temperature-dependent methodology and their influence on vehicle performance.
ADwin-X compact OEM real-time system for signal analysis and control applications with ADbasic/C/Simulink Hall 10
The presentation will introduce ADwin-X, a new real-time system, as a standard version with various options, or as a fully customized, tailored version in terms of type and number of I/Os for OEM applications. OEM versions can be scaled in any number, as analog and digital I/Os, interfaces like CAN/CAN-FD, SENT, LIN, PROFIBUS/PROFINET, etc. ADwin-X has a local RT-CPU for fast and precise real-time applications with RT software ADbasic or Simulink. Measurement and control; fast open/closed-loop control; signal generation; within R&D test stands, production lines, end-of-line or HIL models: ECUs, sensors, actuators, brakes, shock absorbers, engines, transmissions, gearboxes, and vibration test stand control. ADwin is an expert with more than 25 years' experience in deterministic real-time applications.
High-resolution camera strain sensors for fatigue testing Hall 10
Ralf Lichtenberger General manager Limess Messtechnik u. Software GmbH GERMANY
Fatigue testing of components is the key for long-lasting, high-quality products. Camera sensors are able to, for example, measure tiny deformations and strains, identify weak areas, find defects and track cracks during mechanical loading of the components. New developments expand the application range of high-resolution camera sensors to fatigue testing with up to 1kHz excitation frequency. This presentation gives an overview of the current state-of-the-art technologies, their capabilities and typical application examples.
Hybrid testing – numerical simulation meets testing Hall 10
Stefan Kirschbichler Head of occupant and VRU safety Virtual Vehicle AUSTRIA
Hybrid testing is an innovative approach to combine testing with numerical simulation to provide cost- and time-efficient engineering solutions. We will show how this can be done on two use cases. The first use case is about an efficient approach for validating the B-pillar crash behavior by using numerical simulation to set up a B-pillar test bench as a replacement for a full-vehicle crash test. The second use case shows how numerical crash simulation can be used to extend the capabilities of active safety testing by combining them into one hybrid test.
Thursday, May 23
Test of high-voltage battery packs in a production environment (EOL) Hall 8
Markus Zacherl International manager HVSP/MCB Berghof Automation GmbH GERMANY
HV storage systems must meet increasingly heavy demands. They are becoming more and more powerful, with higher capacities and higher charging voltages or currents, thanks to appropriate source-sink systems as well as state-of-the-art programs to test this new technology. HVSP records and evaluates measured values so that they can be reproduced at any time and used for the necessary quality control. Security-relevant data is precisely logged and can be transferred to various database systems. The safe and simple operation of the test system guarantees worker safety and prevents possible sources of error.
Mechanical components life assessment Hall 8
Václav Verner Reliability analyst Ingersoll Rand Engineering and Technology Center Prague CZECH REPUBLIC
The use of real-time or accelerated life tests in new component development is intended to identify potential weakness of the design during service life. The presentation will discuss the methodology of durability assessment and testing based on the application of Miner’s cumulative damage approach for poly V belt (thermal fatigue) and tensioner (bearing contact fatigue). The approach is applicable for durability assessment and testing of bi-directional drive subsystems applied in hybrid solutions operated in different modes e.g. diesel and electric motor–generator. A typical automotive application is the belt starter generator to provide start, electricity generation and power assistance functions.
Calibration of particle measuring devices Hall 8
Kevin Auderset Technical expert Federal Institute of Metrology METAS SWITZERLAND
Accurate measurement of the aerosol particle number concentration is becoming increasingly important in many areas and has been recently introduced in vehicle emission legislation. Number concentration measurements are also integrated in particle size distribution measurements. The increasing importance of aerosol metrology implies the need for traceable calibration services for particle measuring devices. METAS has developed traceable calibration methods and performance tests for particle counters, particle analyzers, dilution systems, volatile particle removers. In this presentation we will convey the basic principles of aerosol instrument calibration and report on the measurement uncertainties that can be experimentally attained.
More efficient automated HIL testing through better test bench utilization Hall 8
Andreas Petermüller Lead engineer in-tech GmbH GERMANY
Modern HIL systems are significant investments and therefore demand the highest grade of utilization, meaning high uptime and low idle time. Yet many HIL systems can’t make efficient use of all available testing time overnight and at weekends, due to a lack of test case numbers for one specific variation of ECU hardware. By allowing the connection of a multitude of different ECU variations to one HIL at once, and enabling the remote-controlled changeover of automated testing tools, orangeSwitch offers a solution for maximizing overnight and weekend test time per HIL. Several different ECUs can be tested with one HIL during one overnight run.
Nitrogen on-site production for inertization of testing environments Hall 8
Benjamin Popp Representative INMATEC GaseTechnologie GmbH & Co KG GERMANY
Nitrogen is needed to prevent explosions when potentially hazardous appliances are being assessed. Examples include the testing of powertrains, vehicle electronics or batteries, to name a few. What is the most convenient nitrogen source available for these tests? Conventional liquid nitrogen needs to be stored in tanks or bottles, filled up and carried even when empty. The most convenient and nearest N2 source is the ambient air all around. This is what INMATEC offers: on-site nitrogen production out of compressed ambient air with customized quality and quantity.
The new reality of crash testing with M=Brake Hall 8
Philipp Hoffmann Safety testing systems expert Messring GmbH GERMANY
With over 50 years' expertise in the field of automotive safety, Messring wants to drive the future of advanced safety testing and safer mobility. That’s why the company is pushing modern technologies to make them fit for active safety. One of these developments is the M=Brake system. The main objective of the system is to simulate emergency braking before a collision in non-destructive sled tests and standard crash tests with vehicles. Testing with the M=Brake system results in more realistic test data due to the extra car pitching and dummy displacement, as in a real traffic accident.
Thursday, May 23
Handling authenticated CAN messages with testing and analysis tools Hall 10
Carmelo De Mola Manager marketing K2L GmbH & Co KG GERMANY
Modern cars contain different automotive bus systems such as CAN, CAN FD and LIN, which were defined and developed before cars were connected to the internet and cloud services. As a result, most automotive bus systems have been developed without considering aspects of security such as authenticated communication. In today’s vehicles, the lack of authentication methods for communicating across automotive bus systems has made the connected car a potential target for easy hacker attacks. Car makers and Tier 1 suppliers have meanwhile recognized the importance of having authenticated communication within the car, and are supporting it in new developments to prevent unauthorized access to vehicles. This presentation will demonstrate a set of tools that simplify testing, analyzing or verifying devices that use CAN-authenticated communication.
High-quality testing: trend monitoring as a tool Hall 10
Erwin Frederiksen Test consultant automotive Moog NETHERLANDS
Test laboratories perform a wide variety of tests including static strength, dynamic performance characterization and fatigue life. With fatigue life tests, components and systems made up of different materials may degrade or wear out at different times, which then causes secondary part failures. Understanding this process, and recording information to track the changes, is necessary to document high-quality test results. The presentation will cover example test methodologies beginning with data acquisition, through to road data reproduction and tools used to run and monitor a well-documented test.
Stress measurement of PCB in the electronic vehicle era Hall 10
Takahiro Hara Overseas sales engineer Kyowa Electronic Instruments Co Ltd JAPAN
A printed circuit board is integrated in every kind of electronic device. In this era, 'electricity' has been a key term in the automotive industry. As the technology for electrically powered vehicles and internet-connected cars has developed, the reliability of core battery parts, and the development and assembly process for PCBs, has been a concern for automotive quality assurance. In this presentation we will show our development of a data acquisition and analysis system that is particularly useful for PCB stress and failure analysis in the assembly and development phase. By showing our specific application example, we will reveal how our product can be used for quality assurance of printed circuit boards.
Record and play back field data to validate ADAS algorithms Hall 10
Daniel Riedelbauch Automotive go-to-market manager, EMEIA National Instruments GmbH GERMANY
Although scenario simulation tools are good for virtual testing, 3D rendered scenes can be misinterpreted by algorithms designed for the real world. Record field data from ADAS sensors that can be played back in the lab to simulate driving and increase test repeatability and coverage; stream up to roughly 15GB/s of data within a single system, using RAID storage options; synchronize interfaces such as automotive networks, camera interfaces, radar, etc, down to microseconds by leveraging a modular hardware platform: ultimately, this platform allows the same system architecture to be used to play back the recorded field data to validate algorithms through HIL.
V2X testing: seamless from bench test to field test Hall 10
Manfred Miller CEO Nordsys GmbH GERMANY
Testing of V2X systems is challenging OEMs and Tier 1 supplier because the testing environment is becoming more and more complex when connecting cars with other cars and the infrastructure.
Among other things, the presentation explains how V2X systems can be tested in HiL setups in the lab, and how the same test cases can be reproducibly performed in real driving scenarios, seamlessly and without the need of extensive and expensive infrastructure equipment. Smart simulation of V2X nodes reduces the complexity of the test setup and can significantly speed up the test cycles.
Please note: this program may be subject to change