When Hyundai Mobis required a reliable test solution to verify its Hybrid eCall system, the company selected Anritsu for its proven expertise in automotive communication testing.

As the automotive industry transitions from the conventional eCall emergency call system operating on 2G and 3G networks, where vehicles automatically contact emergency services in the event of an accident, to the next-generation (NG) eCall system using 4G networks, Hybrid eCall is crucial in bridging the gap.

Hyundai Mobis has adopted Hybrid eCall and overcome significant challenges, including acquiring test equipment, mastering the advanced 4G and 5G mobile protocols required for call initiation, and addressing the limitations of network simulation environments in the early stages of development.

Anritsu’s eCall Tester MX703330E and Signalling Tester MD8475B provided an effective solution to these challenges. By establishing a comprehensive test environment and using automated conformance testing and log analysis functions, Hyundai Mobis promptly identified the root causes of operational issues. Furthermore, sharing the test environment between the development and verification teams improved consistency, reliability and operational efficiency.

Hyundai Mobis integrates Hybrid eCall functionality into its data connectivity unit (DCU). Conformance testing is conducted to EU regulations and ETSI (European Telecommunications Standards Institute) standards to verify the system’s functionality across various network conditions as well as ensuring interoperability with public safety answering points (PSAPs).

In addition, Hyundai Mobis was required to design test scenarios, perform error analysis, prepare detailed test reports and develop technical verification documents necessary for certification. These processes were supported by Anritsu’s simulation and functional testing capabilities.

There were two primary reasons why the company selected Anritsu’s test solution.

First, it enables comprehensive Hybrid eCall testing with an all-in-one tester. Previously, separate testers were required to verify Hybrid eCall, NG eCall and eCall. By integrating Anritsu’s MX703330E software-based tester with the MD8475B hardware tester, all three types of eCall functionality can be tested using a single solution. This integration reduced initial investment requirements and operational workload, improving overall verification efficiency.

The second reason was enhanced collaboration and efficiency using the same test environment as the development team. This alignment facilitated accurate issue reproduction and streamlined root cause analysis. Additionally, Anritsu’s clear setup documentation contributed to more efficient software updates and debugging activities.

With Anritsu’s technical support, Hyundai Mobis teams gained early access to the MX703330E, MD8475B and beta firmware versions. This enabled them to verify Hybrid eCall‑related software updates prior to official release, and perform conformance testing during the development stage.

Anritsu’s test solution also helped Hyundai Mobis build expertise in 4G and 5G mobile communications and Session Initiation Protocol (SIP) signaling. Analyzing the operation of the SIP using the sequence log feature provided a practical understanding. Furthermore, the setup procedures were based on the provided manuals, and network simulations were repeatedly conducted with on-site support and phone consultations with Anritsu’s staff. With this support, the teams steadily acquired the knowledge of mobile communications required for eCall verification.

The teams also needed to simulate various network conditions. Using the handover and cell configuration features of the MX703330E and MD8475B, including signal strength control, ECL settings and service controls, they were able to effectively reproduce real-world network conditions. This enabled prompt and effective software verification.

Since implementing Anritsu’s test solution, compatibility between the DCU and the test environment has remained consistently high. The teams experienced no notable issues when integrating the product with existing hardware. The test environment was configured efficiently, and stable operation was achieved from the initial stage of deployment.

Hyundai Mobis has been able to conduct reliable, repeated testing in the laboratory, building a normal testing environment. It has also automated conformance testing and network simulations. Test scenarios were created using Anritsu’s SmartStudio Manager (SSM) MX847503A, which supports the generation of rapid and reliable test results, thereby contributing to improved development efficiency and product quality.

When issues arise, reviewing the sequence and message logs of the tester allows immediate determination of whether the problem is due to device settings or the hardware itself. This enables the verification team to provide accurate and timely feedback to the development team, reducing the time required for root cause analysis and problem resolution.

During the implementation process, Anritsu supported the teams from the program installation stage, which allowed them to establish the test environment smoothly. One unexpected issue was that the USIM card initially provided for the device was not compatible with performing the test eCalls required for functionality verification. Anritsu promptly provided a compatible USIM card, allowing the verification activities to continue without interruption. No additional compatibility issues were observed with the existing DCU verification setup.

Another challenge was the provision of a reporting tool, including testers’ logs. The initial conformance test reports could not be presented as objective evidence to certification bodies and relevant departments, necessitating further improvements. In response, Anritsu updated the reporting tool to create highly reliable reports that included logs from the MX703330E. As a result, verification results could be presented more clearly and convincingly.

Anritsu’s tester is stable and reliable, enabling the Hyundai Mobis teams to focus on analyzing hardware issues during the verification processes. On-site support and telephone and email communication from Anritsu – along with the manuals provided by Anritsu’s representatives – enabled the Hyundai Mobis teams to acquire the skills to operate the tester.

With Anritsu’s technical support, Hyundai Mobis plans to expand automation within its verification processes.

Beyond the eCall functions, the Anritsu test solution supports verification capabilities, including SMS transmission and throughput measurement. Although the details of these functions are still being finalized, Hyundai Mobis hopes to use them to increase the value of the equipment by broadening the scope of verification, enabling a more multifaceted analysis of product performance and, ultimately, contributing to the development of even higher-quality products.

Need to know

• Anritsu’s test solution enables comprehensive Hybrid eCall testing with an all-in-one tester
• Real-world network conditions can be reproduced, enabling effective software verification
• Hyundai Mobis recently sought a reliable partner to test its Hybrid eCall technology
• It chose Anritsu for the supplier’s expertise in automotive communications testing

Signal Plot is a free, downloadable extension for CanKing 7.4.0 or later that allows engineers to track multiple signals simultaneously, zoom into events, compare values using cursors and switch between live and pause modes. The extension provides engineering-unit graphing directly within the CanKing workspace, making it particularly useful for HIL bench bring-up and on-site debugging.

“Our goal with Kvaser CanKing has always been to give engineers the clarity they need with as little friction as possible. Signal Plot does exactly this; turning raw CAN and LIN data into clear, meaningful visuals in real time. It’s a simple yet powerful upgrade that delivers an immediate boost in understanding and efficiency,” said Martin Sventén, CEO of Kvaser.

The update is designed to provide engineers with faster, more intuitive insights into system behavior, making real-time monitoring and debugging of automotive networks simpler and more efficient.

The extension is the first built on Kvaser’s CanKing Extensions SDK, which was launched last year, to enable users to create web-based GUI extensions such as dashboards, gauges and custom interpreters without modifying the core application. The SDK leverages React and is compatible with both Windows and Linux systems.

CanKing 7.4.0 also adds support for LIN message logging and replay using MDF4.x files. Improved MDF4.x compatibility ensures that LIN data frames are correctly recognised, enabling the Message Logger and Message Replay nodes to function seamlessly across both CAN and LIN traffic.

CanKing 7.4.0 was unveiled at at Embedded World 2026 in Nuremberg, Germany.

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The lab’s high-current capability is designed to test large automotive cells and other high-power, high-capacity battery technologies, including those used in eVTOLs, data centers and stationary battery energy storage systems (BESS). Its extensive channel count is useful to companies with high-volume testing requirements, enabling hundreds of cells to be tested simultaneously under varying conditions. High-precision cyclers and advanced EIS tests also enable accurate long-term analysis and performance characterization, including cell ageing and end-of-life simulation, with modeling and calibration expertise provided by CamMotive’s specialist engineers.

The facility offers additional technical capability and services, including dynamic climatic chambers to replicate varying temperature conditions, and process thermostats for real-world thermal management testing. For high-power module and pack testing, the lab provides capability up to 1MW.

The primary purpose of the new laboratory is to support automotive OEMs and accelerate development timelines by gathering data for modeling, compliance and improved understanding, leading to enhanced performance, longer useful life and faster charging strategies.

In addition to the main facility, the laboratory also houses several lower current cyclers for testing of smaller capacity cells. In this way, the company aims to support innovation in battery technology, including startups working on the latest chemistries and organizations exploring battery options for new applications.

Bruce Campbell, director at CamMotive, said, “The launch of our new test facility marks the latest phase of CamMotive’s commitment to advancing battery technology and its applications. We provide solutions across the entire battery ecosystem, from early concept to end-of-line validation.

“Working with UK cell developers and digital modelers, manufacturers and integrators, we combine world-class testing infrastructure with decades of powertrain expertise to help our partners deliver sustainable solutions for road, air, sea transportation and stationary applications.”

Related news, BeyondMath raises US$18.5m to scale foundational physics AI model

By using the web-based engineering platform Aqira, CETIM has sped up its e-mobility R&D, addressing the challenges of managing, analyzing and sharing large volumes of prototype electric equipment data.

“To catch the real-life duty cycles CETIM has to realize multiphysics testing campaigns on a wide range of equipment and machinery under diverse operating conditions, enabling comprehensive coverage of all product lifecycle scenarios. We needed a software platform capable of synthesising large volumes of data to optimize mechanical system design and validation,” said reliability engineer Denis Chojnacki, who is heading the mission profile project.

CETIM selected Aqira for its advanced features, nCode analytics capabilities and user-friendly web interface. The platform has been applied to numerous projects, including key mission profiles for electrifying mobile equipment such as mini-excavators and telehandlers.

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Founded in 2022 by AI industry veterans Alan Patterson and Darren Garvey, BeyondMath has developed the world’s largest foundational physics model, which is capable of simulating complex physical phenomena, from aerodynamics to thermal management.

In automotive engineering specifically – where BeyondMath works with an F1 team – the platform supports real-time testing of thousands of design combinations to identify optimisations in aerodynamics and thermal management.

The funding will be used to scale up the commercial deployment of BeyondMath’s generative physics technology and increase its research capacity.

Alan Patterson, CEO of BeyondMath, said, “Engineering teams require ever-faster, more flexible simulation, but do not have the technology to deliver on these demands. Generative physics introduces a fundamentally new approach to engineering, unlocking innovation across fields ranging from aerospace and automotive to data-center design. We now have the capital and investor support to accelerate our research roadmap and scale commercial adoption. This could be the ChatGPT moment for physics.”

Edward Inns, principal at Cambridge Innovation Capital, added, “BeyondMath is tackling one of the hardest and most valuable problems in engineering. By combining first-principles physics with modern AI, the team has built a platform that can redefine how complex systems are designed across multiple industries. We look forward to supporting Alan, Darren and the team as they continue to scale.”

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The first quarter of 2025 saw a key milestone in the program as the team, together with Mahle Powertrain, fired up Mjølner – the world’s most powerful production V12 engine – for the first time. Since then, technical partnerships with Ricardo and Castrol have been confirmed. The progress across the drivetrain system has seen the integration of the hybrid powertrain, which will eventually deliver up to 1,850hp.

The first validation prototype entered service as summer approached, and global events bookended the biggest brand activations for Zenvo Automotive to-date. The VP0 prototype ran up the hill at Goodwood Festival of Speed. From there, it has been used across the powertrain, electronics, suspension and dynamics testing phases.

The test program has continued at the Præstø factory and at facilities across Europe, with successful crash, dynamics and performance testing completed, both as simulations and real world tests. Further prototypes have also come online as the testing phases spread through different teams and departments, accelerating toward the plans for 2026.

Jens Sverdrup, chairman and CCO of Zenvo Automotive said, “We come to the end of 2025 with the technical and development phases of the Aurora program driving forward with real momentum. It has been a very proud year of firsts, one of real progress, and one which has firmly put Zenvo on the map, with our biggest activations and achievements over Goodwood and Monterey.

“It hasn’t been all plain sailing, by any means – which is expected from a program of this magnitude and when working with the latest advances in technologies and systems that have never been seen or used before. We always set out for Aurora to be something more than had gone before, and we now have the team in place to deliver what we set out to achieve. 2026 will be another year of firsts and of relentless pursuit of improvement as we keep building towards production.”

CTO Jon Gunner said, “It has been a big challenge for every member of the team over this year, working through a long list of firsts. The team is now at its strongest, and Aurora is delivering or overachieving at each phase. We are determined and dedicated to getting the results, and we have put the pieces in place with our team and partners to ensure that Aurora is everything that we have set out for it to be. There is still a job list to be completed, but it is an exciting journey to be on.”

Meet the team behind the Mjølner powertrain in this behind-the-scenes video

This milestone comes in anticipation of evolving global regulatory standards, including the EU’s CEN EN 17240:2024 and China’s GB 45672-2025, which will mandate standardized speech quality testing for in-vehicle emergency call systems by 2027 as defined by ITU-T P.1140 and GB/T 45314, respectively.

As the automotive industry moves toward 5G-enabled emergency call systems, manufacturers need to ensure reliable, high-quality communication across different network technologies. The successful interoperability between Keysight’s test platform and Head Acoustics’ acoustic test setup helps meet this need, enabling OEMs and system suppliers to confidently validate speech quality, network connectivity and compliance with emerging NG eCall standards.

According to Keysight, the test, conducted at the company’s facility in Germany, verified seamless integration between its one-box RF test solution and Head Acoustics’ measurement environment with Acqua and LabCore. Together, the systems enable comprehensive validation of NG eCall functionality across 4G and 5G networks. Fallback solutions via 2G and 3G networks were also successfully analyzed. Key achievements from the interoperability test include verified 4G/5G IMS-SIP server connection and end-to-end audio with NG eCall, successful legacy eCall audio verification over 2G/3G networks, and calibration of delay and audio levels for compliance testing.

Thomas Goetzl, VP of automotive and energy solutions, Keysight Technologies, said, “This milestone underscores Keysight’s commitment to enabling the automotive industry’s transition to next-generation emergency call systems. By combining our comprehensive RF test capabilities with Head Acoustics’ expertise in acoustic validation, we are delivering a futureproof solution that meets global regulatory demands and supports safer mobility.”

The managing director of Head Acoustics, Dr Matthias Wegerhoff, commented, “Customer satisfaction drives everything we do. That’s why we’re committed to offering a broad, flexible range of NG eCall solutions. The interoperability with Keysight technology brings valuable technical expertise to this mission, enabling us to jointly develop future-ready tools for next-generation voice and audio quality testing.”

In related news, Keysight has launched an optical automotive ethernet transmitter test solution

Among the disruptive forces that are reshaping the automotive industry, electrification is entrenched and unrelenting. Market demands as well as safety and environmental legislation are calling for all cars – from entry-level to premium models – to become smarter, more assistive, more connected and sustainability conscious. To deliver these values, car makers are adding more sensors, computing power and communication capabilities, and electrifying more subsystems, from water pumps and power steering to the entire drivetrain.

It’s a trend that presents opportunities for electronic component manufacturers and assembly builders in the automotive supply chain. Among the challenges, the industry’s high-quality expectations and unit-volume demands call for test capabilities that are fast and extremely accurate, and able to correctly identify good units and any that have defects. This needs to be accomplished with minimal errors or time-consuming rechecking to rectify false NG results.

Improving tests of advanced electronics  

Contact test solutions for advanced equipment using probes could prevent suppliers from meeting their objectives, as test contact points are becoming smaller, more closely spaced and more difficult to reach with conventional sprung test probes (Figure 1).

Furthermore, connecting with the DUT at a single point creates an unreliable solution. All types of electronic devices are affected, from semiconductor wafers to ECU modules, as component geometries are being reduced and PCB assemblies are more densely populated. Also, intricately designed vibration-proof connectors used within the automotive industry present difficulties for probes to achieve contact when placed on the test fixture (Figure 2).

Problems with sprung test probes or pogo pins are already common. The pins often fail to make proper contact with the test point. Based on actual research, only 80% of occasions when tests are performed using standard pogo pins result in the DUT being correctly classified. Such errors result in high false NG rates that require investigation and re-testing. In addition, the typical lifetime of a pogo pin can be about 100,000 cycles. At automotive mass-production volumes, this can demand frequent stoppages for replacement. Inaccurate results and frequent stoppages both impair productivity and cause delivery delays.

Also, the contact resistance due to conventional pogo pin structure can be inconsistent and is not usually less than 70mΩ, which can prevent testing of assemblies where contact resistance needs to be low. A generally accepted practicable minimum diameter for conventional sprung pins is about 0.35mm. Reducing the size can prevent reliable contact with test points as the probes can become fragile, leading to more frequent malfunctions and breakages. And yet, smaller test pins are required to meet future demands. An alternative is needed to ensure efficient, fast and accurate contact testing.

Pin limitations

Conventional pogo pins are carefully designed to possess compliance that allows tolerance for a small amount of positioning error, as well as spring force to press against the DUT test point and ensure a robust electrical connection with low ohmic resistance. However, the mechanism adds complexity to the design and seizing or other malfunctions are possible as the DUT is placed on the test fixture. The pin can break or the spring may fail if positioning error or force is excessive. Further reducing the mechanism size to permit closer positioning needed to test densely populated boards results in the pin being more fragile and more easily broken.

Creating an alternative that overcomes these limitations while also supporting the drive toward smaller geometries is not easy or trivial. A suitable pin must provide adequate compliance to let the pin find its place against the test point as well as ensuring adequate and consistent contact force. At the same time, durability needs to be improved to minimize stoppages to replace broken pins and prevent false NG results that can result from poor electrical contact and inconsistent contact resistance.

A new type of test pin made with a specially developed electroformed (EFC) metal alloy and fabrication process now presents a solution to meet these demands. The custom material provides mechanical properties comparable to 304-grade stainless steel (SUS304/SS304) and meantime electrical properties achieving great conductivity at copper level. The combination of alloy properties and dedicated pin design (Figure 3) enable one-piece pins that eliminate the size restrictions and potential for seizing associated with the conventional spring mechanism.

Optimized electrical parameters 

The pins enable test engineers to create high-reliability test fixtures with a pitch down to 0.175mm. Because the pins have been shown to make proper contact with the test point on over 99.8% of test operations, the risk of false NG results from poor pin contact is greatly reduced. Also, with a lifetime easily reaching 500,000 cycles depending on application and design, their longevity improves efficiency and reduces stoppage time. The one-piece design ensures consistent electrical parameters and extremely low-contact resistance, typically about 30mΩ, which is suitable for testing products like OLED panels. Moreover, flexibility to optimize all aspects of the pin size, shape and tip design mean the pin properties can be adapted for a wide variety of applications.

EFC pins are suited to pin blocks and complete custom sockets for board-level testing and are also used in optimized fixtures for IC and other component testing, or even device test. They have been designed for testing high-end modules with high transmission speeds, as well as high-power electronics at levels much above 2A per pin for unique bundle structure, meantime reaching the highest testing durability.

There is also an off-the-shelf product. The unique test socket for USB Type-C connections combines EFC pins with resin pin tips and a special floating head mechanism that enables 1° of tolerance in X-Y positioning (Figure 4). The floating head ensures fast and faultless insertion to avoid stoppages when used in test equipment while the special internal pin structure extends the endurance of testing sockets compared to existing means.

Conclusion

Pogo pins have a long and distinguished record in the history of electronics testing and can continue delivering high levels of performance in many applications. At the cutting edge, however, the geometries of the latest components and assemblies are becoming too small for conventional pins.

Creating a suitable solution has demanded innovation both in materials science and electroforming production processes. New one-piece EFC pins allow test-point spacing as small as 0.175mm, with lower contact resistance than pogo pins, and enhance positional accuracy, resilience and reliability. Using custom shapes and tip profiles, these pins can reach difficult areas such as inside complex connectors, and can meet demanding applications such as high-frequency or high-current testing. Product manufacturers can experience fewer false NG calls and fixture repairs, raising efficiency, productivity and delivery performance.

Look out for a feature in the November issue of ATTI on how Stellantis ensures the robustness, reliability and compliance of EE components and systems through systematic validation and virtualization. Read the September edition for FREE here

One year after its inception, the Rivian and Volkswagen Group Technologies (RV Tech) joint venture is pushing forward with the development of a zonal architecture for software-defined vehicles, which will be sold in Western markets. RV Tech is preparing reference vehicles from the Volkswagen, Scout and Audi brands with the SDV architecture for winter testing early next year. The hardware and electronic architecture specifications for these reference vehicles have been defined since spring.

Among the vehicles is the Volkswagen ID.Every1. Since the summer, work with engineering prototypes has been in full swing at RV Tech’s sites in Palo Alto and Irvine in California. The series model is scheduled to launch in 2027 as the first group vehicle featuring a version of the SDV architecture.

With more than 250 solution providers, The Future of Automotive Testing Conference and the Innovation Showcase, it’s the ideal place to discover new solutions, share ideas and build valuable connections.

There will truly be something for everyone, whether you’re an NVH specialist seeking new acoustics testing tools, an EV engineer in need of high-voltage test equipment, an ADAS expert looking for the latest lab systems, or a simulation specialist in need of a tool or a test driver searching for a new vehicle rental partner.

The Innovation Showcase will take place on day one and day three, enabling visitors to learn more about some of the latest technologies on display. Its interactive format is always a big hit. On day two, ATTI will host The Future of Automotive Testing Conference, beginning at 9:55am with an onstage interview featuring ATTI columnist Jon M Quigley, and with a program that features a wealth of influential industry figures.

Serving as the testing sector’s foremost communications platform, ATTI will also report live news throughout the show and gather intelligence for upcoming magazine issues. Don’t hesitate to share your ideas or news with ATTI.

For a comprehensive preview, see the September edition of Automotive Testing Technology International magazine.

Automotive Testing Expo North America will take place at the Suburban Collection Showplace in Novi, Michigan, on October 22-23. Visit the expo website to register for your free expo pass.