The development and optimization of complex mechanical and mechatronic systems requires practical tests to handle the overall complexity resulting from the interaction of different components and the lack of accurate simulation models. Test benches allow the evaluation of complex systems in real time 24 hours a day, 7 days a week.
Mechanical test benches are capable of applying mechanical load torques or forces to those parts of the real system which are physically incorporated into the test setup. If this is just the real electric motor, a simple rotational load is sufficient. Incorporating parts of the mechanics like brake boosters, gearboxes, rack-and-pinion systems, etc., leads to much more complicated configurations, partly requiring more than one load drive or linear drives.
dSPACE’s hardware offers the required scalability, real-time performance, I/O interfaces and a powerful tool chain to control a complete test bench out of Simulink®. dSPACE provides interfaces to all automotive buses like CAN, CAN FD, LIN, FlexRay, and K-/L-Line. In addition, automation interfaces like EtherCAT and PROFIBUS as well as proprietary interfaces and protocols, e.g., LTi TWINsync for electric motor control, are also available.
The TWINsync Solution from dSPACE for controlling electric drives in perfect synchronicity from a dSPACE HIL simulator makes it possible to use the TWINsync protocol from LTI Motion. This protocol enables synchronous communication between two or more LTi ServoOne motor controllers and the dSPACE hardware.
The solution’s main features include:
The typical components comprise:
The dSPACE ASM Vehicle Dynamics Library provides tailored open simulation models for testing vehicle dynamics ECUs, such as ESP, steering and active damping ECUs, with a test bench. All of the Simulink blocks in the model are visible, so it is easy to add or replace components with custom models to adapt the properties perfectly to individual projects. The ASMs’ standardized interfaces allow the vehicle dynamics models to be easily expanded to meet specific requirements and even let you create a virtual vehicle.
For test benches, dSPACE offers comprehensive support from the first planning days to the delivery of the turn-key system to on-site support.
Until now, a wide range of test bench projects have been completed. For example:
Test system for ECUs with integrated sensors and actuators, with a 3-D motion platform that moves the ECU and thus creates the same forces that occur in a vehicle.
Rotary steering test bench for electronic power steering (EPS) systems, including the steering column and assistance motors or for testing superimposed steering systems.
No-load steering test bench to drive a steering system in closed-loop mode for integration tests of the complete vehicle.
Brake test bench with the complete real hydraulic system, e.g., brake line and pedal, for testing energy recovery during braking, for example.