From One Source: Complete Vehicle Test Rig for Steering Systems
Customer: Premium manufacturer
Sector: Automotive
Requirements: Design and implementation of a complete vehicle test rig for steering systems
Implementation: Mechanical and electrical components; control, measurement and regulation technology; operating application, evaluation system X-Frame; control program, measurement and automation system LabVIEW/LabVIEW RT; data management ASAM-ODS
Complete Test Rig with High Flexibility
The inital situation
To comprehensively test steering systems in a static state, the Mercedes-Benz Technology Center in Sindelfingen required a new functional test rig for complete vehicles. The previously used test facility was outdated and no longer met the requirements for test diversity, quality, and throughput.
The task
With the exception of the structural engineering, all components had to be replaced: test rig mechanics and electrical systems, control and safety technology, measurement and automation systems, as well as measurement data analysis and the database. The requirements included automated processes for various tests and an integrated system for the entire test—from planning in the office through measurement on the test rig to report generation.
The solution
The steering test rig was developed and implemented within a year in collaboration with partners specializing in test rig mechanics. At its core are freely movable turntables equipped with sensors and actuators that simulate realistic forces and movements. The application software, based on X-Frame, integrates the planning, preparation, and execution of tests as well as data analysis and report generation. All relevant data regarding the test vehicle is automatically imported into the software via an interface to the vehicle database. The testing process runs automatically. Online screens display raw data, status information, and the measured parameters. At the push of a button, the system generates a report in PDF format.
In practical use
The steering test rig enables the efficient characterization of steering systems under static conditions. A nearly complete assessment of steering kinematics is now available within a few hours. Furthermore, the test bench is an important tool for preparing and validating vehicles that undergo test drives to fine-tune the steering feel. Thanks to its modular design, every component—mechanics, hardware, and software—can be flexibly adapted, allowing for a rapid response to the requirements of new vehicles and technologies at any time.
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Introductory image: © Mercedes-Benz