When it comes to developing a moving system, be it a car, a bicycle, or even an airplane, the first thing you want to test are the brakes. But even during in-vehicle test runs, no one wants to perform in-vehicle tests with a braking system that has not yet been verified or validated.
dSPACE offers a range of test systems, including test benches with real braking system components. They let you test an electronically actuated braking system (e.g., brake-by-wire or electric brake booster) and its individual power electronic components under realistic operating conditions.
Challenges
There are innovative technologies and concepts for electric vehicles (EV) and hybrid electric vehicles (HEV).
Regenerative braking, for example, allows kinetic energy from the wheels to be converted to electric energy that can be stored for later use.
Electronic brake boosters and brake-by-wire systems make it possible to reduce the pedal power required and adjust it, independently from the required pressure. This enables the recovery of a large part of the braking energy (recuperation). If the electrical energy of the drive motors is not sufficient for the intended braking operation, braking is immediately supported by the brake discs. For this purpose, the brake booster transfers the braking energy from the electric drive motor to the brake discs. However, these systems also allow for fully automatic braking intervention in autonomous driving.
While the electric brake booster approach uses a conventional hydraulic brake system combined with an electronically controlled brake booster, the concept of brake-by-wire allows electric drives to operate the brakes with no mechanical connection between the braking actuators on each wheel and the brake pedal.
For testing such complex systems, comprehensive validation is key to ensuring their proper operation. Simulation-based approaches have to be complemented by highly dynamic mechatronic test benches to ensure that all components under test behave realistically.
dSPACE Solutions for Braking Systems
dSPACE offers a wide portfolio of solutions for testing complete braking systems under realistic operating conditions. Our products support the entire development process from SIL testing to prototyping, code generation, and testing at the signal level, the electrical power level, and the mechanical power level. Our test systems are flexible and highly scalable – from compact off-the-shelf-solutions to modular customized options. Our highly dynamic mechatronic test benches include real brake components that let you create the perfect test environment for virtual test drives at an early stage.
Rapid Prototyping
HIL Testing
Central Test Method for Validating ECUs
The dSPACE HIL test systems provide a simulated environment for efficient and reproducible validation of real ECUs in the laboratory 24/7. This increases test coverage and shortens validation times significantly. Our HIL solutions cover all vehicle domains from autonomous driving to zero emissions – starting with component testing and up to virtual vehicle testing.
Power HIL Testing
Closing the Gap Between HIL and Dynamometer Testing
With our power HIL systems, we offer ready-to-use solutions for testing any kind of inverter, including the controller and power electronics, at full power. Using real voltages and currents, our systems enable you to complete exceptionally rigorous tests. Our systems behave like a digital twin of the real system and allow for easy configuration with just a few clicks, which significantly reduces setup times.
SIL Testing
Software-in-the loop (SIL) testing with the powerful dSPACE solution for PC- and cloud-based simulation
With the dSPACE solution for software-in-the loop (SIL) testing, you can significantly accelerate your software development process by testing and validating virtually. dSPACE offers you a complete, modular, scalable development and test solution. You can conveniently simulate a device-under-test on a PC, connect it to physics-based models, run scalable tests in the cloud, and then easily reuse test scripts on hardware-in-the-loop (HIL) systems.
Bus & Network Communication
Mechatronic Test Benches
Turn-key solutions – optimally adapted to your requirements
ECUs that cannot be accessed by means of their electrical interfaces can be tested with the highly dynamic dSPACE test benches. The turn-key solutions can be optimally adapted to your specific requirements, letting you use highest performance and most complex control for electric drives providing ideal mechanical interfaces for testing. The mechatronic test benches allow for virtual test-drives including real components in real time, 24 hours a day, 7 days a week.
Production Software Development
Optimized Production Software Development
The central challenges in production software development include the optimization of RAM resources, run time, and integration into the overall system. Furthermore, it must be possible to split the software in such a way that regular software updates are possible. And before the final software release, special validation and often a release process are required.
Simulation Modeling
Development support from start to finish
Developing complex E/E systems and software with ever more safety-critical functions, especially in the area of autonomous systems, raises the question of guaranteeing function reliability. That's why dSPACE offers end-to-end expertise in functional safety, test strategy development as well as verification and validation in complex E/E processes - to support you from the earliest project stages to homologation.
dSPACE systems are easy to get up and running – however, if a project is more complex, if individual solutions are needed or if there is high time pressure, you can also trust dSPACE's fast, competent and reliable engineering services.
