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Automotive Testing > Testing equipment
automotive industrial_automation gebauedetechnik

System test beds

Everything integrated

Testing of complete systems, integration of control units, simulation of components, accurate and synchronous data acquisition and processing up to 10 kHz.

KS system test beds combine our best products and extensive expertise from all the disciplines in the company. They enable the greatest possible flexibility in the tests to be performed and configurations to be used, both in relation to the setup and the possible scenarios for the unit under test. All the subassemblies, control units and other components in the unit can be actually integrated in the test bed or simulated with appropriate hardware and software, depending on the setup.

Technology

Our innovative R2R technology means that the conditions for the unit under test are identical to real road testing. To simulate the load on the powertrain even more realistically, drive units that do not actually exist on the test bed (e.g. an internal combustion engine) are replaced with highly dynamic prime movers including characteristics of speed vibrations up to the highest order.

Applications

In the area of hybrid drive systems in particular, a KS system test bed provides previously unknown opportunities for developing, applying, verifying and testing all the relevant components. There is the option of either using real batteries or a battery simulator as the energy source. In addition, the inverter in the vehicle can also be replaced by a universal inverter that can be used with your own models (e.g. MATLAB/Simulink). All the physical and electrical data is recorded using highly accurate instruments and then evaluated and stored in the Tornado automation system.

Integration & interfaces

Due to the use of HIL systems and accurately timed residual bus simulation, all the components installed are supplied with information, ensuring smooth operation. When connected to an integration and test platform and a virtual driver model, a closed-loop environment is created with the option of conducting manoeuvre-based tests.

Layout

  • Schema Systemprüfstand

Functions:

  • ICE simulation including torsional vibrations
  • Variable setup
  • Hybrid drive systems
  • Performance analysis
  • Residual bus simulation
  • HIL integration
  • Integration of MATLAB/Simulink models, e.g. for the vehicle, wheel/tyre, powertrain components, ICE, battery, inverter, etc.
  • Interfaces to integration and test platforms (e.g. CarMaker )
  • Interfaces to control units
  • Interfaces to DoE systems (e.g. ICT)

Components:

Power analysis

AC/DC Box

Voltage measurement 100 kHz, 1-1,500 V

Current measurement 100 kHz, 0-1 kA

TRMS conversion

Performance analysis

Phase shifting

Short circuit and no-load testing

Safe changeover and shutdown

Simple contacting options

Flexible high and low voltage taps