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Europe Expo yet another massive success

Automotive Testing Expo Europe 2010 was another huge success as the many visitors have come to expect, and as in previous years, visitors flocked to the event seeking solutions. Whatever their need, whether developing vehicles with greater power, more safety features, lower emissions, superior durability, shortened development times or greater cost efficiency, there were experts on hand with the technology and expertise needed to optimize any vehicle program.

Couple this with the sister events taking place at the same venue – Engine Expo, Vehicle Dynamics Expo, European Automotive Components Expo, and Automotive Interiors Expo – and Messe Stuttgart was undoubtedly a ‘must-attend’ event for the automotive-engineering community.

However, for those who didn’t make it, or who didn’t make it all the way round the show, here are a few highlights.

AVL reveals Real-Life Testing

One of the busiest stands at the Expo was that of AVL, and that wasn’t just the draw of its Astroturf floor and enormous screen showing World Cup fixtures! No, the real draw was the company’s latest launch, the ethos of which is that one must learn from one’s mistakes, whether in personal development, or in recreating real-life driving conditions for the development of vehicles.

AVL Real-Life Testing is designed to bridge the gap between simulation and reality. This learning platform provides a consistent framework for the entire development process, transforming simulation knowledge into practical know-how on a methodical basis. This technology enables AVL to improve quality and process efficiency, and to shorten development cycles.

The integrative learning platform generates a continuous framework over the entire course of the vehicle-development process to systematically turn simulation knowledge into validated know-how. An additional development, AVL InMotion, enables virtual vehicle integration under simulated real-life conditions. Step-by-step simulation results are validated and models improved by integrating real-life data from AVL M.O.V.E onboard measurement systems.

By systematically closing the loop between simulation and reality, AVL Real-Life Testing is claimed to enable maneuver-based testing and continuous learning throughout the development process.

Height and position in vehicle testing

‘Optimized and highly precise data’ was the promise at GeneSys Elektronik’s stand. A test vehicle’s position must be precisely determined during road tests, with planar coordinates, as well as height profiles, accurately recorded during driving. This is where the company’s ADMA (automotive dynamic motion analyzer) is applicable.
A combination of GPS and inertial sensors provides accurate position data, which improves with the GPS-reception conditions. The GPS and inertial sensors complement each other. Disturbances in the GPS signal reception, for example when the vehicle passes under a bridge, are compensated by the inertial measurement. In return, the GPS signal prevents long-term drifts by the inertial-sensor system. Thus the system is able to supply accurate position data with a high bandwidth of several hundred hertz. Working with additional DGPS-correction data enables real-time positioning accuracies down to a few centimeters.

Originally developed for vehicle dynamics testing, developers can use the ADMA for validating driver-assistance systems such as lane-departure warning systems. Another function of ADMA is to provide road data, including realistic height profiles, valuable for optimizing powertrain design.

Measurement of rotational vibrations

The RLV-5500 Rotational Laser Vibrometer, an advanced non-contact angular velocity-and-displacement sensor being demonstrated at the show by Polytec, is designed around high-performance digital decoding techniques for an improved signal/noise ratio, an expanded rpm range to 20,000, and a compact measurement head.

By implementing a new optical configuration, the company’s designers have reduced the sensor-head size, making it easier to get close to the measurement object. For industrial environments, a robust design is combined with an integrated air-purge system to cool the sensor head and prevent contamination from oil spray and dust. Taken together, these features make possible on-vehicle measurement of an operating drivetrain, under real driving conditions.

Test-bench software

ThyssenKrupp released a modular software package for creating, configuring, and safely operating test applications. The package, dubbed UPS64, features a runtime manager that permits interactive editing of test sequences, the scope of testing, and evaluation parameters. This capability enables characteristics such as speed profiles, function-test sequencing, and test control to be defined.

A runtime system is also featured, incorporating the runtime application with measured-value recording functionality. It forms the basis for reliable quality data acquisition on the line. When added to the evaluation parameters, edited using runtime manager, this system delivers reproducible quality control.

The sound of science

Visitors were getting into the mood before they even entered the hall, with the sound of a screaming flat-six greeting them by the doors. This was no boy racer – it was a Porsche Carrera being put through its paces on a Rototest VPA-RX complete vehicle dynamometer.

Eagle-eyed visitors noticed the lack of wheels on the car. This was because the dyno features direct hub connection to eradicate slip between the tires and dynamometer rollers, aiding accuracy and safety. Other benefits of the system include near-zero system inertia and an extremely accurate front-end mounted calibratable torque transducer. The system is also very portable – set-up takes just a few minutes.

Portable measuring equipment

Portability was also a theme at Gantner’s stand, where the new Q.brixx product line, conceived for portable measurements with high demands on flexibility, reliability and accuracy, was being demonstrated.

Up to 16 plug-in modules in any desired combination, together with the test controller, provide a high-performance package. This incorporates PAC functions, synchronized data logging, test sequences and an Ethernet TCP/IP interface for configuration and output of the measured data. The variety and flexibility of the measuring and I/O modules makes the Q.brixx a real all-rounder, offering dynamic signal logging up to 100kHz, inputs and outputs for all types of signals, selectable input connectors, electrical isolation of I/O signals, power supply and interface, as well as flexible multiple-channel solutions with high-packing density, and comprehensive signal conditioning.

The system also enables IRIG-based synchronization and time marking for all measured values, and PAC functions with a comprehensive module library. Applications range from standalone solutions all the way to networked multiple-channel applications for stationary and mobile component testing, as well as long-term monitoring.

Climatic/acoustic chamber news

Ipetronik made a major announcement on its stand. Walter Zipp, an acoustic specialist at the company, explained: “In order to be able to help our customers perform increasingly complex test and measurement tasks, we have put a new climatic/acoustic test chamber into operation that is among the most modern of its kind within the European automotive industry.”

The project marks an expansion of the company’s consulting and engineering services, and has been undertaken to meet the test needs of electric and hybrid powertrains. Together with its range of peripherals for testing and measurement, the climatic/acoustic test chamber makes it possible to acquire data on all the relevant variables with regard to climate and NVH. A multitude of suitable sensors makes it possible to measure – in addition to pressures and temperatures – such aspects as airborne and structure-borne noise, and pulsation in the climate-control system’s wiring, as well as the vehicle’s operating parameters.

Quantum Cascade laser technology

A hot topic at this year’s Expo was emissions regulations, and how manufacturers and suppliers can meet these tough limits. The latest solution, launched at Automotive Testing Expo Europe, is the MEXA 1400 QL-NX emission-measurement system from Horiba. This test system utilizes four Quantum Cascade lasers (QCL) to analyze nitrogen components in the exhaust gas. It enables engineers to evaluate the performance of after-treatment devices.

Horiba representatives informed visitors that, compared with other exhaust emission measurement technologies, QCL is able to analyze ultra-low concentrations of NO, N2O, NO2 and NH3, and also shows excellent measuring performance over a very broad spectrum. This enables all test cycles used in emission measurement to be performed with the MEXA 1400 QL-NX system. Internal combustion engines, hybrid powertrains, and electric drive systems can all be tested, and accurate measurements can also be obtained, even with eco-fuel and CNG-fuelled vehicles.

Mobile front-end series launched

Another major point of interest for the 2010 event was the trend towards tighter test program deadlines with reduced resources. In response, LMS has extended its testing portfolio with the SCADAS Mobile 02 16-channel data-acquisition front-end.

Designed for day-to-day usage in the field or the lab, this rugged, mid-sized front-end can be directly connected to numerous noise, vibration and strain transducers, as well as the CANbus system for streamlined test data. It also has a built-in GPS receiver that collects time, speed and position data. The two-slot mainframe can be set up in a master-slave configuration, with parallel signal processing to cover high channel-count tests.

Convoy guidance technology

Visitors to last year’s event will recall mm-lab’s launch of the proving ground management and security system (PGTS). For the 2010 event, the company has unveiled the convoy guidance service (CGS), designed to support vehicle tests based on the Advanced Telematics Platform.

CGS aids the dynamic supervision and assistance of test vehicles performing tests within a convoy on public roads. The service is based on vehicle positioning by means of a global-navigation satellite system, with all vehicles in the convoy equipped with mobile vehicle computers, transferring tracking data via radio to the telematics server. The server provides vehicle-tracking data to the other convoy vehicles in real time. CGS displays the positions of a defined group of vehicles on a street map, relative to their own position, and the visualization on a geographical street map, without manual interaction, enabling the driver to easily recognize his/her own position, and the positions of others.

F1 driving simulator technology

Moog representatives were very proud of their association with Ferrari, and the most recent product of this association is a new testing simulator at Scuderia Ferrari’s Gestione Sportiva F1 facility at Maranello, Italy.

Ferrari selected Moog to provide an integrated flexible motion control and testing system designed to meet specific and highly demanding requirements. The project development entailed a bilateral exchange of expertise to overcome technical challenges. In particular, addressing the latency and high-bandwidth requirements of the simulator led to advances in the use of carbon fiber-composite materials in the structure to create more stiffness and lower weight.

Two years in development, the Ferrari F1 dynamic-driving simulator features a customized motion-control solution, with combined motion mechanism, control loading system, complete software package, cockpit, and dedicated operator workstation. A crucial requirement was that the system needed to operate at a higher frequency bandwidth compared to conventional systems.

The test driver sits in front of a screen providing a viewing angle of more than 180°. Ten multiprocessor computers control the system with a total 60GB of RAM producing around 5GB of data per day. The setup also features a 3,500W Dolby Surround 7.1 sound system.

“We are delighted with the success of this dynamic driving simulator for Ferrari,” said European business manager for Moog, Pim van den Dijssel. “Engineering hardware and human-in-the-loop (H2IL) testing solutions in a driving simulator is an area in which we have over 20 years experience, since Moog pioneered advanced cueing technology. Using Ferrari’s software model, we can achieve enhanced fidelity through advanced platform kinematics and optimized motion cues.”

Dynamics measurement

Visitors to CFM Schiller’s stand were interested in the vehicle-inertia measuring machine (VIMM) servo-hydraulic test bench. VIMM is designed to measure all inertia parameters of vehicles for vehicle-dynamics applications. Areas of operation are full vehicles up to the SUV class, and also components such as engines.

VIMM consists of a servo-hydraulic-actuated testing table, which can move with respect to a defined routine in three degrees of freedom. Sensors are mounted to measure the table motion and the acting forces, and the sensor data is fed to a post-processing unit, which calculates all 10 inertia parameters of mass, centre of gravity, moments of inertia, and products of inertia. Although there is a range of different testing systems available for the determination of vehicle inertia, almost none of these systems are able to perform a simple and rapid measurement of all 10 inertia parameters in one sequence. Most inertia testing equipment is limited to the measurement of some parameters, and major modifications, or series of different test runs are needed to determine all relevant parameters.

This device can be used to judge the dynamic behaviour of a vehicle, to support the development of simulation models, or to determine safety criteria, such as rollover performance.

Rapid prototyping platform

dSpace used the Expo to introduce visitors to MicroAutoBox II, the next generation of the company’s compact rapid-prototyping platform for in-vehicle use.

MicroAutoBox II is designed to give ECU-function developers fast real-time computation of their controller models. This boost to processing power comes from a new processor board, equipped with an IBM PowerPC processor running at 900MHz.

In addition, MicroAutoBox II has a new host connection for direct connection to the host PC's Ethernet interface. A further Ethernet interface is for connecting to external devices by standard Ethernet technology. This opens up potential uses in a whole series of new application areas, such as driver-assistance systems. To develop these systems, embedded PCs are often used for processing video data or controlling analog or digital displays. MicroAutoBox II now offers direct connection to these embedded PCs via an Ethernet bus interface. In addition, dSPACE has made the MicroAutoBox's boot much faster so that in ECU networks, it can perform immediate boot-up like a real ECU.

Early detection of damage

The MIG16-SFE shown by red-ant is a measuring system to establish the limits of the vibration signature of a tested device under various load conditions such as speed, torque, and temperature. After a short learning phase, MIG16-SFE switches automatically to monitor the tested device. When the vibration signature exceeds the learned limits, a pre-alert is triggered. The pre-alerts are logic filtered, and when necessary, a shut-down signal is sent to the test stand. The system can detect bearing faults, gear pitting, shaft fractures, abuse wear, valve-spring fractures, and piston-ring faults.

Benefits of the system include saving on prototypes for an almost instant return on investment, cost-effective test-cell operation, a clear diagnosis and history of any damage, detection of the cause of the damage, and constant monitoring.

Universal data-acquisition system

Many test and measurement tasks require measured physical parameters to be output as a standardized voltage. For these applications, HBM now offers the MX878 output module - a new module for the QuantumX data-acquisition system. The output module has eight analogue voltage outputs which can be individually configured. The module enables system signals to be output as scaled and filtered values in the range of ±10V. All signals supplied by the amplifiers can be used as signal sources, which makes individual monitoring or forwarding of system signals such as measured values very easy.

In addition, the module offers integrated local intelligence that enables measured values to be analyzed or set off against each other in real time, using algebraic operations. The module also features functions for the computation of peak value or root mean-square value. Computed signals can be made available in the system in real time or they can be output directly.

Typical fields of application for the MX878 QuantumX module include test-bench applications involving conversion of various transducer signals.

High g piezoresistive shock accelerometers

Meggitt Sensing Systems launched the Endevco model 72 series, a new family of high-g SMT-mountable piezoresistive accelerometers designed to support a variety of high-reliability acceleration, vibration and shock measurements.

Available with a 20,000g measurement range and a soon-to-be-released 60,000g version, the model 72 series offers broad frequency response, minimum zero shift post-shock event, and a Class 3 rating for electrostatic-discharge protection. Its low-profile, miniature, hermetically sealed LCC package weighs just 0.16gm for significantly minimized mass-loading effects. The LCC package can be SMT mounted using production pick-and-place machines and reflow solder for easy installation.

The monolithic, four-active arm bridge-circuit design of the model 72 series incorporates a MEMS sensing element with light gas damping to attenuate resonance. Mechanical stops are included to increase ruggedness and reduce the likelihood of breakage under overload conditions, with stability and reliability to four times over-range. With a frequency response extending down to dc (steady-state acceleration) and a minimum post-shock zero shift, this accelerometer is ideal for measuring long-duration shocks.

Wheel force transducer for small and light cars

Two key factors in the development of fuel-efficient vehicles are weight and rolling resistance. The RoaDyn S615, launched at the Expo by Kistler, is a wheel-force transducer, tailored to the small, light cars needed in the future. Reduced vehicle masses and narrower tires enable further reduction of the weight of the CFRP (carbon fibre-reinforced plastic) components of the transducer. It is optimized for recording load spectra for durability, vehicle dynamics and powertrain investigations.

The design of the RoaDyn S615 is based on a three load-cell concept. Saving one cell and its mounting screws shaves 400g off the weight of the established RoaDyn S625 lightweight wheel-force transducer system. There is another potential saving of 400g available in the design of the inner part, where the CFRP construction offers a reduction of up to 20% compared with the S625 model. The design of the RoaDyn S615 enables a maximum vertical load Fz of approximately 15kN.

The CFRP/aluminum-composite rim consists of an aluminum-rim ring and matching wheel disk, manufactured from carbon fibre-reinforced plastic. The positive and frictional connection of these components ensures great strength. The inner part represents the connection with the hub, and is also made of CFRP. The three load cells connect the rim to the inner part. To minimize local stresses all the relevant components were optimized using FEM.

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