Braking Test Benches

Testing electronic brake systems using realistic braking forces

For testing electronic brake systems under realistic operating conditions, dSPACE offers test benches with real brake components. 

  • Using real parts, such as brake pedal, iBooster, and ESP with the necessary hydraulic components
  • Modular system for easy adaption to more ECUs by exchanging the ECU I/O box
  • Fault simulation

Key Benefits

This mobile mechanical test bench is designed to test electronic brake systems under realistic operating conditions. Therefore, the vehicle dynamics are simulated and the effective braking forces are applied to the brake by a linear actuator drive.

The whole setup consists of a brake robot, an ECU I/O box for installing real components, such as a caliper and ESP, and the hardware-in-the-loop system for computing the simulation models, among others.

Parameter Ball Screw Actuator Linear Actuator
Motor
  • Synchronous motor with ball screw transmission
  • Synchronous linear motor
Motor encoder
  • Absolute motor feedback system (multiturn)
  • Absolute motor feedback system (linear)
Servo amplifier
  • KEBA ServoOne
  • KEBA ServoOne
dSPACE Real-Time Interface
  • TWINsync
  • TWINsync
Control strategy force
  • Overlay feedback control (force transducer and disturbance variable compensation)
  • Overlay feedback control (force transducer and disturbance variable compensation)
Control strategy position
  • Cascade control with subsidiary speed and force control
  • Cascade control with subsidiary speed and force control
Maximum continuous force [N]
  • 2000
  • 2000
Maximal displacement [mm]
  • ±50
  • ±50
Actuating mass [kg]
  • 200
  • 20
Maximal velocity [m/s]
  • 0.4
  • 0.9

 

  • Customized Mechatronic Test Benches Product Information, PDF, English, 1431 KB
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