Whole vehicle testing
- Driving performance measurements on the roller test stand and on the road
- Fuel consumption measurements on the roller test stand and on the road
- Driving dynamics measurements on test circuits and on the road
- Functional and service life investigations on individual assemblies (tyres, wheels...) on appropriate assembly test benches
- Investigations on suspension and suspension elements, e. g. wheel kinematics, suspension characteristics and vibrational behaviour.
Whole vehicle simulation
- Simulation technology
- System simulation
- Hardware-in-the-loop simulation
- Vehicle-system dynamics
- Multi-body dynamics
- Component modelling (chassis and suspension, shock absorbers, tyres)
Tests on the roller test stand
Laboratory experiments on the performance and torque characteristics of motor vehicles are conducted on the roller test stand. As part of performance data measurements, the characteristics of drive motors are worked out, and the energy efficiency and emission characteristics, where appl., are assessed. In driving simulation mode, the test vehicles can be driven under almost realistic conditions on the test stand. Various standardised and in-house test cycles are carried out and compared. The investigation of operating strategies on complex drive trains, e. g. in hybrid vehicles, is carried out as project work. The results are then used to improve simulation models, among other things, which can then in turn be validated on the test stand.
To supplement the experiments on the roller test stand, fuel consumption measurements are conducted in on-road tests on real roads or test circuits. The acceleration and braking behaviour of vehicles with and without assistance systems is investigated in experiments on longitudinal vehicle dynamics. The steering performance of vehicles is objectively assessed and discussed with the aid of standardised tests (such as VDA lane-changing test – “elk-avoidance test”, steady-state circular-course driving, sudden steering-angle change...).
Experiments on the tyre test stand
The lateral force behaviour of tyres on the non-powered wheel is recorded on the tyre test stand. The effects of wheel loading, slip angle, tyre pressure and temperature on forces and moments on the wheel (e. g. the cornering force required to drive through corners), are measured and explained. The findings obtained here are necessary for the dimensioning of the vehicle, suspension and tyres. The data obtained at the tyre test stand can be used to scale simulation models for vehicle development.
Experiments on the vibration test stand/road simulator
The vertical vibration behaviour of a complete vehicle can be investigated on the servo-hydraulic four-poster test rig. The influence of loading, vibration damping and road excitation on comfort and driving safety are recorded experimentally by parameter variation and analysed. Characteristic parameters and curves of individual chassis components, such as springs or shock absorbers, are measured on component test rigs.
Equipment Whole vehicle testing
- Single-axis roller test stand for vehicle investigations with roller diameter 1.91 m, up to 250 km/h speed, 5,000 kg axle weight and 12 kN circumferential force; variable DC motor with 232 kW.
- RoadSim road simulator: servo-hydraulic 4-poster test rig to simulate vertical vehicle excitation. Max. piston force 40 kN, travel 250 mm, frequencies up to 50 Hz.
- Servo-hydraulic test facility with shock absorber testing machine and single-axis modular test stand for component tests.
- EUREPA - three-axis, hydraulically controlled tyre test stand for measurements on the non-powered wheel. Rim size from 13" to 17”, wheel loads up to 2,000 kg, slip angle up to ±18°, inclination angle up to ±8°; force measurement with piezo-electric recording hub; non-contact IR temperature measurement of the tyre surface.
- Mobile measurement acquisition systems and data loggers for on-road testing. Acquisition of analog and digital measuring signals, CAN nodes. Measurement of driving speed with optical correlation systems; sensors to detect vehicle motion; fuel consumption measurements with universal fuel flow measuring device.
- Vehicle diagnostic systems.
- Test vehicles (incl. Mercedes B180, Toyota Prius PlugIn, Honda Accord Type R, driving dynamics modular vehicle and poss. project-related vehicles).
Equipment Whole vehicle simulation
- 13 networked PC workstations with corresponding periphery and presentation system.
- Software (available at all workstations): MSC.ADAMS, MATLAB/Simulink with all important tool boxes, PSpice (electronics simulation), FTire, COSIN/mbs, AMESim (hydraulics simulation).
- dSpace HiL workstation.