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R2R Road to Rig

In-house application

In-house vehicle testing and application under real driving conditions. Integration of vehicle, road and tyre model, testing and tuning of driver assistance systems.

Ever shorter innovation cycles in developing new, complex drive systems, such as automatic or hybrid transmissions, previously meant that extensive, time-consuming tests and trials had to be performed on the road. The KS-R2R 4x4 test rig has now revolutionised testing. Testing of complete powertrains can therefore be shifted to the test bed at every stage of development. We have thus achieved three strategic goals: improving the quality of development services, substantially reducing the development costs and significantly saving on development time.

Given the revolutionary inertia compensation system, any powertrains from small cars to SUVs can be tested on one and the same rig without having to change the setup. The unit under test is thus subjected to identical conditions as in real road testing. You can configure any type of roads and surfaces on the KS R2R 4x4’s host computer - such as dry, rainy or snowy conditions.

Carrying out special misuse tests is also possible: idiot start, parking lock and chessboard tests, turning with the hand brake on, manhole covers, off-road driving and much more. As an alternative to frontloading real test drives, native data acquired from simulation programs (e.g. win-EVA, CarMaker, ve-DYNA) can also be used as references.

This now also enables test configurations that could not previously be simulated on test beds: for example real drivetrains in combination with virtual bodies. With the extremely user-friendly KS-R2R you can therefore test the powertrain’s true behaviour throughout the entire development process: independently of time, place and weather conditions, reproducing tests and changing parameters as you require.

The reality of the road on the rig

Key benefits

  • Reproducibility
  • Time saving
  • Personal safety

The unit under test is subjected to conditions just like on real roads in all situations

  • From dry to icy roads
  • From an “idiot start” to top speed
  • Also slow uphill starting and rolling downhill from a standstill
  • Also with real vehicle brakes (“hot braking”)
  • Also intervention from assistance systems (ABS, ASR, ESP…)

Possible scenarios

  • Gear and load changes (tip-in, tip-out)
  • Changing road conditions (µ-low, µ-split, tiled surface)
  • Acceleration and brake tests, cornering
  • Idiot start, misuse tests


Only one test bed for

  • All vehicle variants
  • All off-road profiles
  • All friction coefficients, different left and right
  • All load conditions
  • All driving conditions including standardised test cycles for road driving
  • NVH development, e.g. optimising torsional vibrations in the vehicle’s powertrain
  • Application for engine, gearbox, assistance systems in relation to
    • Drivability
    • Exhaust emissions
    • Fuel consumption
  • Combined rig: powertrain and complete vehicle testing

Schematic of control

Example of control quality and measuring accuracy

Torque fluctuation side shafts

Initial situation

  • Unit under test with 8-cylinder ICE

Test procedure

  • Steady-state load mode

Special feature

  • Misfiring can be identified and assigned to individual cylinders from the axle torque

Cell design

Variant with strip foundation and pit

  • Recommended for new build
  • Testing at ground level
  • Vehicle underside easily accessible

Variant on level test rig base

  • Easy integration in existing environment
  • Ramps
  • For combined rig (vehicle and powertrain)



Optimisation of the entire powertrain and assistance systems in the complete vehicle on the KS-R2R test bed.

  • Powertrain loading identical to on the road
  • Assistance systems in the vehicle enabled on the test rig
  • One test bed for all performance classes