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Functional Test Benches

We plan and implement your functional test bench

The use of mechatronic systems (e.g. electromechanical steering systems, active drive dynamic systems) can resolve in conflicting objectives for vehicle development, enable new functionalities or create additional degrees of freedom for optimization. The development efforts and innovations are shifting from solely mechanical systems to electronics and software. The development of such systems therefore requires mechatronic HIL test benches that enable the characterization and validation of the overall mechatronic system (mechanics, electric drive, electronics and software).

Customised and fully automated test benches

In addition to mechanical load units, test benches for mechatronic systems always include the option of controlling the test specimens via the vehicle bus (e.g. CAN, FlexRay, Ethernet) and via a suitable electrical power supply for the systems to be tested (vehicle battery simulation). In addition, different temperature and climate conditions are often simulated on the DUT. In principle, the higher the safety integrity level (ASIL level) to be achieved in accordance with ISO 26262, the greater the testing effort.

Suitable automation of the development test benches is therefore of central importance for the efficient development and functional validation of mechatronic systems. This concerns both the joint and synchronous operation and control of the individual subsystems of the test bench and the test object via a higher-level test automation system and the integration of the test bench into existing processes and tool chains as well as the automation of test procedures.

We therefore coordinate suitable functional architectures and interfaces as well as software and hardware modules for your specific application individually.

Flexible functional and development test benches

Our test stands are typically designed for testing during early development stages (e.g. structure-borne noise analysis), performance tests (e.g. determining efficiency levels or friction tests) and automized functional validation of the system, including the simulation of electrical faults (e.g. short circuit or bus breakdown).

Automated release tests of software versions, driver in the loop test, virtual test driving and endurance tests are further applications for our hardware in the loop test benches. Our aim is always to work with you to develop a solution that offers you the greatest possible flexibility with regard to current and future testing demands.

Benefit from IABG Mechatronic Test Benches

Customized software and hardware solutions

We offer you customised software and hardware solutions for your system test bench - tailored to your individual tasks and wishes. When designing suitable system and functional architectures, we naturally take into account your existing automation solutions, processes and toolchains in addition to your standards and preferred lists and operating equipment regulations. If necessary, we implement individual interfaces, e.g. for the integration of further peripheral devices, communication with higher-level automation systems or for the integration of the test environment into your database systems.

For you, this means uniform, standardised solutions in your test field, short training periods, flexible personnel deployment and the greatest possible flexibility with regard to current and future testing tasks.

Custom-fit actuator and control technology

Mechatronic systems are usually characterized on the basis of differing load cases, ranging from tests in a blocked state to very slow movements at constant speed (e.g. for measuring friction forces), tracking signals from driving operation measurements and highly dynamic tests (e.g. determining step responses for controller tuning). While most tests are carried out with an active, controlled test specimen, some of these tests (e.g. determination of friction forces or determination of dynamic stiffness) are also carried out on a passive test specimen. The resulting conflicts of objectives are aggravated by the fact that test specimens with very different mechanical properties generally have to be characterized. Examples of this are component stiffnesses, transmission ratio, a wide variety of geometries and different installation positions. The different load cases and the widely varying properties of the test specimens result in a huge spectrum of differing requirements for the actuators and the control of the test bench.

In the case of active test specimens, the interactions between the control of the test stand and the control loops of the test specimens present a further challenge.  Here, too, it must be taken into account that the dynamic behavior of the test specimens can vary greatly depending on the operating modes and the software version installed. Iterative approaches, which are used on test benches for conventional, passive test specimens to improve the control quality, are often unsuitable for the functional testing of electromechanical systems due to the highly time-variant behavior of the active test specimens.

We therefore design the actuators and control algorithms of your new HiL test bench based on models to meet your specific requirements. For moderate dynamic requirements, we mainly use electric servo machines with ball screw drives or energy-efficient hydrostatic drives. For even higher requirements, we primarily use electric direct drives. The latter offer significant advantages over servo-hydraulic drives, particularly in terms of performance, energy consumption, operating and maintenance costs, the realization of safe operating states (e.g. for set-up) and the required infrastructure.

Reliable test results across the entire range of applications

It goes without saying that functional test benches have to perform significantly better than the test specimens. This results in high demands on dynamics, measurement accuracy, rigidity and structural dynamic behavior. The design of rigid structures is often made more difficult by large set-up and adjustment ranges. These are necessary in order to enable a wide variety of geometries and mounting positions of the test specimens.

With our expertise, we design your system test bench using various numerical tools to precisely meet your individual requirements. We identify potential conflicts of interest, discuss them with you and suggest suitable solutions.

The result: a test system that fulfils your individual requirements and delivers test results you can rely on.

Variability and extendibility

New development projects often require the procurement of new test systems. As the conceptualization and design of the test systems usually begins in early development phases of the test specimen, the requirements for the functional test benches are often still unclear at the start of development or change during the course of the project. This is aggravated by the fact that, due to the high level of investment, sufficient performance reserves must be held in reserve for future product generations with as yet unknown properties.

This can be achieved through partnership-based cooperation in the projects and professional requirements management. Our aim is to work with you to develop the optimum solution for your task, to take contingencies into account and to provide for expansion options.

For you, this means investment security.

Simple and safe operation

We implement the test automation of your test bench according to your specific requirements. We develop the user interfaces required for this together with you during the project. It goes without saying that we take the future users and your in-house experience into account. With the aim of enabling simple, fast, safe and ergonomic set-up, we develop suitable set-up concepts - also together with you or the future operators. We coordinate the safety concept of the test bench with the users and your occupational safety department at an early stage. Where possible, we use actuators with proven and easy-to-implement safety functions.

The result is test benches that are simple and safe to operate.