IAAPS is a research and engineering organization that designs, develops and tests future propulsion systems, technologies and advanced validation methods for the global automotive, aerospace and marine industries. Building on a technical cooperation agreement with Ansible Motion that began in 2024, this second phase, set to be operational from February 2026, supports the development of advanced powertrain methodologies.

By directly connecting the Delta S2 DIL simulator to one of IAAPS’s existing AVL 1800kW full four-wheel-drive powertrain dynamometers, the partnership will create the companies state will be a “unique vehicle-in-the-loop/driver-in-the-loop (VIL-DIL) environment” that bridges the virtual and physical world for more accurate and sustainable vehicle development of ICE, hybrid and electric powertrains.

The integration of a driver-in-the-loop (DIL) simulator with a full powertrain dynamometer will facilitate seamless, real-time interaction between human drivers and actual powertrain systems. This will enable engineers, researchers and drivers to experience realistic vehicle dynamics while the dynamometer precisely controls and monitors powertrain inputs and outputs within a controlled lab environment.

A benefit of this configuration is the ability to capture human-in-the-loop behavior during active powertrain operation – without subjecting personnel or hardware to undue risk when replicating complex or hazardous driving scenarios. This capability will accelerate driveline calibration and validation across a broad spectrum of powertrain systems, including internal combustion engines (ICE), hybrid and battery-electric platforms, even ahead of full vehicle availability.

Additionally, it will enable early-stage evaluation of advanced driver assistance systems, autonomous driving transitions and edge-case scenarios in a repeatable, resource-conscious and environmentally responsible manner.

Dan Clark, managing director at Ansible Motion, commented, “This next stage of collaboration provides IAAPS, its partners and the wider UK automotive industry with access to a world-class simulator environment that advances research methods for all forms of powertrain in controlled and repeatable lab conditions. The project also highlights our shared ambition to advance validation and testing techniques for increasingly complex vehicle powertrains.”

IAAPS selected the Delta S2 DIL simulator for its compact, high-fidelity capabilities and easy integration with its powertrain dynos. The system includes a six-degrees-of-freedom motion base, immersive projection visuals, interchangeable cockpits and advanced control systems, with Ansible Motion providing full support and maintenance.

Prof. Rob Oliver, IAAPS managing director, added, “We are delighted to announce the deepening of our collaboration with Ansible Motion, a global leader in driving simulator technology. This partnership represents a powerful alignment of capabilities, combining IAAPS’s cutting-edge propulsion system engineering and research expertise with Ansible Motion’s advanced simulation systems. This is a milestone moment for both organizations and a testament to our shared commitment to innovation.”

Under the new agreement with IAAPS, Ansible Motion will also have scheduled access to the simulator lab and IAAPS’s wider research ecosystem for internal R&D purposes, customer demonstrations and professional driver evaluations. In addition, Ansible Motion will set up a dedicated office space for four people within the IAAPS facility.

In related news, Hyundai opens €150m Square Campus R&D center in Germany

Tyrone Johnson, managing director at Hyundai Motor Europe Technical Center, said, “The investment at Square Campus is a clear sign of our commitment to the region and reflects the importance of Europe in our long-term growth strategy. The extensive new capabilities at HMETC give us more independence and flexibility, while creating exciting new opportunities for collaboration between our brands. Fundamentally, Square Campus will also support us as we continue to grow our market share in Europe, developing new vehicles and technologies designed around the needs of our customers.”

New capabilities

The 25,000m² site is equipped with the largest semi-anechoic chamber within the Hyundai group, enabling unrestricted noise, vibration and harshness (NVH) and drive-by noise testing with complete independence from weather conditions.

Highly advanced dyno facilities at Square Campus play a key role in development, enabling the comprehensive testing of vehicles and individual components, compatible with all-electric, hybrid and internal combustion engine (ICE) powertrain applications. The facility is also equipped with an EV charging laboratory, a state-of-the-art driving simulator and new facilities for extended electronics system development – including over-the-air-updates (OTA), cybersecurity, and advanced driver assistance systems.

In related news, Site visit: Inside Mercedes-Benz’s light testing tunnel

The Future of Automotive Testing Conference

This day of high-level content will explore various topics and provide an engaging opportunity to learn from and connect with industry peers. Situated among the exhibits, it will have a relaxing atmosphere, and visitors will be able to dip in and out at their leisure. A highlight will be ATTI’s on-stage interview with Jon Quigley, who worked for Volvo for many years and now runs his own company, Value Transformation. With his broad experience and portfolio of contacts, he’s a very good person to know. He loves sharing his thoughts, too, hence his new gig as ATTI’s regular columnist.

Read Quigley’s latest column on p36 of the September issue.

Also during the conference, Venkat Adusumalli, software engineering manager at Stellantis, will reveal how Stellantis is using AI to accelerate E/E system testing and validation workflows. Click here for a pre-show interview with him.

Innovation Showcase

The free-to-attend Innovation Showcase also provides an interactive platform for learning about new technologies. Speakers will welcome questions and discussion after their presentations, making it a great way to explore ideas together. Like the conference, it will take place within the main hall, so it will be very easy to listen in while wandering through the exhibits, or to come and go throughout the day.

Technology debuts

The industry is moving quickly and it can be a challenge to keep up. Every year there is an abundance of new technologies on display. Some are incremental improvements to existing products, others are entirely new. It’s always surprising how companies find ways around bottlenecks. Often, these developments emerge from ongoing conversations between supplier and customer, ultimately benefiting multiple companies.

Read ATTI‘s comprehensive expo preview in the September issue.

Face-to-face discussions  

It sounds obvious, but the most fruitful conversations are usually the ones that happen in person – it’s how journalists find the best stories. Year after year, exhibitors and visitors report having forged unexpected collaborations at the show, in the form of technology tie-ups or service partnerships.

Detroit’s revival 

A lot of money has been plowed into Detroit in recent years, as evidenced by the stunning renovation of Michigan Central Station, which is well worth a visit. Much of the investment has been in the tech sector. Eleven years ago – when the station was still derelict – ATTI took a tour of some of the labs at GM and what was then the FCA headquarters (see The right wave length, November 2014, Seasonal highlights, September 2015, and Powerbase, March 2015). The facilities were impressive then and are even more so now, thanks to several years of investment in innovation leading to Detroit’s resurgence as an automotive powerhouse.

Visit the Automotive Testing Expo North America website to secure your FREE pass, which will give you access to the expo, the Future of Automotive Testing Conference and the Innovation Showcase

TEES supports Texas A&M University by conducting engineering and technology-oriented research and educational collaborations. The new test cell will be used in cooperation with the Texas Department of Transportation.

The large dynamometer was installed below ground and is contained in two rooms. The rolls section is in a climate-controlled room to simulate Interstate driving in different road conditions and temperatures. The inertia wheel, load-simulating power absorption unit (PAU) and AC electric motor are in a separate room where the temperature created by the load will not affect the test.

“This project was unique in that there was an existing dynamometer at the university from which Mustang was able to reuse some existing parts and elements, which was a cost-reducing factor in the project,” said Michael Caldwell, senior account manager at Mustang. “MAE is more than capable of producing test stands at any scale. Our rugged design philosophy, along with state-of-the-art control technology, provides our customers with unparalleled performance in these challenging applications.”

The system can handle 80,000-pound gross vehicle weight rating (GVWR) trucks, as per state maximum limits.

In related news, Applus Idiada recently announced an investment in an Integrated Vehicle Dynamics & Ride Comfort Simulation Platform that will upgrade its existing VI-grade DiM250 driving simulator at its Santa Oliva facility in Spain, extending its capabilities into high-frequency vibration comfort and NVH development. Click here to read the full story. 

With its full-range steering function, the company’s latest steerable dynamometer enables precise, real-time simulation of vehicle motion and positioning for scenarios such as straight line driving/cruising, acceleration/deceleration, s-curve navigation, dynamic braking and lane changes, parallel parking maneuvers and road load simulation.

The front axle has a steering angle of ±45° and a rated tractive force of ±7,760N, with a rated power output of 178kW. The rear axle provides a rated tractive force of 11,684N and a rated power output of 300kW. Both axles offer an overload capability of 150% for up to 60 seconds. Additionally, the dyno is equipped with Burke Porter D4 4X4 torque vectoring software and includes an interface to Simcenter Prescan software for autonomous driving simulation.

During operation, the dyno combines two interfaces: one for scenario simulation system and another for intelligent connectivity. It is specifically designed to test the functions, sensors, actuators and controller hardware and software of autonomous vehicles. This facilitates quick, repeatable validation of a vehicle’s autonomous driving capabilities – a process currently performed primarily on proving grounds.

Ascential Technologies’ hub dynamometer includes four wheel hubs, each connected to a shaft linked to an electric motor that provides resistance – enabling road conditions to be emulated accurately while eliminating the inconsistencies of the tire patch interface. Since range anxiety is a key concern with EVs, Ascential Technologies expects automotive manufacturers to use its hub dyno for hardware-in-the-loop simulations. According to Ascential Technologies, the directly coupled hub dyno enables engineers to simulate vehicle component modifications like never before, facilitating a vast range of testing variations for the vehicle’s electric drivetrain.

Each axle has a rated torque of 16,370Nm and a rated power of 600kW. The system features an overload capability of 150% for up to 60 seconds. It also offers an adjustable wheelbase range from 80-184in and supports a vehicle axle load of up to 10,000 lb. The hub dyno is equipped with Burke Porter D4 torque vectoring software and includes an interface to dSPACE and CarMaker for HIL simulation.

“Ascential Technologies has a legacy of producing top-of-the-line, customized and groundbreaking dyno products that solve customers’ most pressing problems. We have always been on the leading edge of innovation and these new additions to our dyno portfolio are no different. Our new hub and steerable dynos are crucial in setting the industry up for success and shaping the industry standard for the next five to 10 years,” said Uwe Krueger, executive VP of the global transportation business unit within Ascential Technologies’ Test & Measurement Systems division.

Expect a feature on hub-coupled versus roller dynos in the June issue of ATTI.

Vice president Robert Camp explained the motivation behind launching the new facility: “We reached out to our customer base and the response was overwhelming. People were asking, ‘When can you be up and running?’ That pushed us to start operations in August 2023.”

The facility is equipped with two flexible powertrain dynos, capable of handling different powertrains. It features battery simulation up to 1,600V and 1,600A, which Camp noted is above the industry standard. “Most battery simulators on dyno test stands run up to 1,000V. We had requests for 1,200V, so we decided to spec ours at 1,600V,” he said.

The systems can achieve axle output torques of 35,000Nm. They are also capable of high-speed electric motor testing beyond 12000rpm. Both dynamometers are modular, facilitating configurations with two, four or five motors. Camp stressed that adaptability is critical in today’s powertrain development, especially as the focus shifts from electrification, bringing hydrogen internal combustion engines into the mix.

Since the new asset became operational, Eden Engineering has seen significant growth across all three tiers of its service portfolio: on-site services, equipment and test services. “We’re planning to bring a couple more test cells online next year,” Camp added.

One challenge the company faces is managing the automation and data analysis systems of each customer. Due to a lack of standardization, this requires careful planning to ensure that the right data package is created for each use case, including data acquisition, transmission, management and storage. “We’re working with one of the big OEMs here in the US to integrate their automation system into their test cell hardware to enable different types of tests. They need to move fast and don’t have time to get bogged down,” said Camp.

Meet Eden Engineering at Booth 12065.

It’s not too late to attend the only show truly dedicated to automotive testing and development! See the latest vehicle and component testing and validation technology – everything you need to build better cars and accelerate testing and development programs. Click here to register for your FREE expo entry pass.

The sophisticated 738m², two-story facility is equipped with cutting-edge testing technology such as advanced simulation capabilities for road grades, load and wheel slip and robotic driving systems capable of handling both manual and automatic transmissions.

Jonathon White, VP of engine business engineering, emphasized the significance of the new facility: “This center enables us to develop and test a broader range of vehicles and machinery powered by hydrogen, renewable natural gas, advanced diesel or battery-electric. It is a key element of our destination zero strategy, aimed at reducing greenhouse gas emissions and improving air quality while aiding our customers in their transition to cleaner energy solutions.”

The facility represents a major upgrade for Cummins’ engineers, who are now learning how to harness the advanced dynamometers to analyze chassis-installed powertrains. This advance enables the development of full drivelines for a variety of applications, from compact SUVs and 44-ton trucks to double-decker buses and off-road machinery for construction and agriculture, with both two-wheel and four-wheel drive options.

White further noted, “Our extensive powertrain engineering expertise is driving the adoption of cleaner technologies, enhancing driveability, performance, efficiency and sustainability while keeping operational costs manageable. Additionally, the facility is designed to meet forthcoming regulatory standards, such as Euro 7 and CO₂  heavy-duty vehicle regulations.”

Each of the dynamometers features energy recovery systems that generate electricity for use across the Cummins site, reducing the strain on the local grid. The facility also utilizes rainwater harvesting to minimize water consumption, reflecting a system already implemented at the company’s engine plant.

The forum will be a vibrant hub where enthusiasts, experts and newcomers alike can converge to explore, share and connect on all things automotive testing and development. You can expect discussions on cutting-edge analysis technologies and industry trends, and passionate debates. The program will offer an afternoon of high-level content and will be followed by the first-ever live ATTI Awards ceremony.

Here’s what’s in store:

2:30pm
Welcome

2:40pm
Panel discussion – Exploring the future of automotive testing
Moderator: Dr Huw Davies, senior lecturer at Coventry University’s Centre for Future Transport and Cities

Gemma Hatton, freelance technical writer
Phil Durston, technical manager, Volkswagen
Nils Katzorke, project manager, Mercedes-Benz

3:20pm
In conversation

Jahee Campbell-Brennan, director, Wavey Dynamics
• AI-driven simulation is revolutionizing vehicle development
• How to gain actionable insights by using AI in testing
• The challenges in adopting AI-driven testing solutions

Plato Pathrose, CTO and technical director, ADAS and AD, Vinfast Germany
• The key hurdles of connected, software-defined and autonomous vehicle simulation
• How to formulate a successful simulation program
• Mature simulation platforms vs the latest collaborative platforms

4:00pm
ATTI Awards ceremony
Drinks and canapés will be served.

For more information, visit the Automotive Testing Expo Europe website.

The dynamometer test stand is designed to be a training tool for automotive technical schools and for the research and development of future vehicles.

Magna has a partnership with Marco’s Pizza, an American pizza brand, to explore the autonomous delivery method in specific locations within North America. Therefore, the company approached MAE about creating a testing system for its recently developed autonomous three-wheeled delivery vehicle.

Traveling at speeds of up to 32km/h, the autonomous driving system uses cameras, radar, lidar and other hardware to navigate. The AV is an all-electric, lightweight robotic vehicle and according to Magna it will reduce last-mile delivery costs and carbon emissions in urban environments.

MAE designed and created the test stand according to Magna’s timeline and testing parameters. It is equipped with features such as permanent restraints, a turntable for measuring turning radius during dynamic testing, an adjustable wheelbase and an AC motor power absorber and flywheel for extra inertia.

Michael Caldwell, senior account manager at MAE, said, “Thanks to MAE’s history of providing sophisticated test stands in an extremely economical manner as well as our ability to create testing systems for autonomous vehicles, we were able to provide a great, simple testing solution for our customer.”

For more on dynamometers, please click here.

Menny Shalom, the company’s CEO, revealed that the dynamometer runs the motor for “just a few seconds, testing it during its acceleration and deceleration phases, sampling and analyzing the inputs and outputs. They are run through a proprietary algorithm that calculates the different performance parameters as opposed to the traditional method that only tests the motor during the steady state. Algorithm-based testing provides three main advantages: the testing bench is much smaller and cheaper, as no loading motor is required. Testing time is dramatically shorter as there is no need to bring the motor to full speed and then start testing it; a minor acceleration is required. Algorithm-based testing is not dependent on loading the motor. The MEA IDS dynamometer can test many motors that cannot be tested with the traditional method using an external load, due to the size or speed of the motor under test, such as very high speed (200,000rpm), very high torque/speed/density (EV), very small (smaller than the diameter of a coin) and very large (room-sized MV and HV used in power plants).”

Shalom continued, “The MEA IDS takes millions of samples during the complete acceleration and deceleration process, and these samples are processed with MEA’s algorithm-based analysis to provide accurate and reliable measurements of an electric motor’s dynamic performance. Finally, the MEA PdM is MEA’s predictive maintenance solution, which uses the unique patented MEA IDS technology to achieve faster and more reliable test results of the motors in the field. This can be applied to EVs such as a fleet of e-trucks, e-cars, e-bikes; machines (manufacturing plants), cranes (warehouses, docks, ports), turbines (wind farms), etc.”

Daniel Levy, the company’s senior sales manager, said, “EV automotive, aerospace and industrial applications require testing motors with extreme torques, speeds and densities. With clear advantages at different stages of the design process, motor efficiency and performance can be measured multiple times in a short period of time, allowing you to improve and optimize design during R&D by testing different materials and comparing results; in EOL (production testing), to test 100% of the production, before it leaves the assembly line; in QA, to test the final application; and post-production.”

Shalom concluded, “Automotive Testing Expo is an excellent platform to present and introduce the MEA IDS to the automotive and EV industries, and India is a powerhouse in these industries. MEA has a great number of solutions already working in the Indian EV market, with many satisfied returning customers. We are looking to meet all the team players in design, manufacturing, testing, quality assurance and maintenance because we can help them with their daily tasks.”

Meet MEA Testing Solutions at Booth 5003.