Systems are getting smarter. This poses new challenges for the test environment. Realistic simulations of vehicles and their surroundings require dynamic interaction between the test bench and the test object. Count on our cross-domain expertise to meet your demands for high availability, reproducibility, traceability, and more. We draw on this diverse skill-set to optimize test environments in accordance with ISO 26262, integrate solutions into legacy architectures, and ensure flexibility and modularity.
A holistic approach to developing test systems
We take a holistic approach to development that factors individual industries and customers’ challenges into the equation. These services cover everything from definition and conceptualization to end-to-end systems (software and hardware) engineering and field support.
In the conceptual phase, we tackle requirements engineering tasks such as tool qualification and standards conformity – and all other demands associated with determining specifications, building machines, designing tests, and consulting on technologies. As a vendor- and systems-agnostic service provider, we always puts the customer’s needs first. We rely on modular software architectures and state-of-the-art data management for overall systems engineering. Once the project wraps up, we will be happy to provide follow-on services and support to cover maintenance, lifecycle management, and the like. Whatever you need – a development or a manufacturing test bench – your requirements are always our focal point.
Also listen to our data analytics expert Marcus Weber in the Factory21 Pocast, talking about how companies can use data-based decisions to increase quality in production and reduce costs.
You can actually verify and validate mechanical components, actuators, sensors, control units, and the way they interact in one and the same test environment. With this integrated testing method, a hydraulic or other actuator generates the desired load profiles for the mechanical component while a residual bus simulation tests the electronic function. The test bench controller is crucial to capturing very accurate results.
– Model-based test bench layout for early validation of the system’s design based on test specifications – Fully automated testing – Professional real-time software and optimal system architecture for test bench controller sampling rates up to 20 kHz
Steering test benches
Powerful algorithms and an automated controller ensure high-quality control and very accurate test results
Scales integrated into the mechanical design for a fully reproducible test setup (adjustable for the tested object and actuator)
Haptic testing even without vehicles, with fewer road trips to cut costs
Wide range of use cases from conventional steering systems to (semi) autonomous EPS applications and steer-by-wire systems
Custom test benches
We serve as your general contractor for specific challenges. Anything goes, from optimizing legacy systems to delivering turnkey component test benches.
– End-of-line quality assurance using computer visio (optical and tactile) – Steering, breaking systems and active vehicle components – Power packs – Actuators with position sensors
Our reference projects
Automated EOL testing of intelligent actuators
The challenge: Develop an automated, robust, and fast test system to validate product attributes in the final manufacturing step, while factoring part traceability into the equation. Our customer tasked us to develop a new software architecture to enable robust automation at the end of line (EOL). The brief was to facilitate test configuration, accommodate diverse variants, automate error handling, and ensure comparability of development and production. Before we were called on board, there were so many actuator variants that tests, actuators, and sensors’ traceability could not be assured.
Our solution: Provide hardware consulting and test bench software development services. This modular, adaptable test bench management tool was designed for systems with and without an external motor and for use in development/validation and in manufacturing. Configurations and variants can be managed from the office rather than on the shop floor. Its database-driven design, user management with rights administration, and quality management with tool-based approvals ensure traceability.
Added value for the customer: This test bench software features sophisticated error handling to automatically eliminate various faults. Assistance is provided to help the user troubleshoot more serious errors. This decreases downtime and increases availability.
Platform development for EOL testing of intelligent sensors
The challenge: Develop a test field for assessing sensors with many variants. The brief for this project was to develop and establish in various global plants a versatile platform / software solution to map test objects’ most diverse requirements with functional safety (ISO 26262) serving as the test standard. The customer had bespoke software for testing each variant, but it lacked the consistency necessary to trace and retrace tests and tested sensors. On top of that, the software’s quality, maintainability and extensibility was not assured.
Our solution: Develop a platform. Opting for a combination of IPC, industrial measuring instruments, and COTS hardware, we developed the following software functions for the platform: user, configuration and variant management, HW abstraction (measuring instruments, external devices & actuators, DUT), test sequencing, event logging, measurement data storage, and a plug-in concept for new sensor types.
Added value for the customer By building an architecture with plug-ins for the various application components, we were able to minimize the verification and validation effort for tool qualification. Only the affected plug-ins need to be qualified in the event of changes or extensions.
Optimizing quality control for manufactured mechanical components
The challenge: Taming complexity in quality assurance. Shipping defective parts out from a factory is a no-go, which is why the quality assurance bar is set so high – and rises with increasing complexity. A top priority for this customer was to keep the company’s factories in Germany competitive with components manufactured on various shop floors in several plants and countries. Despite the challenging cycle time demands, the customer was still running many systems with outdated hardware.
Our solution: Camera- and sensor-driven end-of-line control. We developed a camera- and sensor-based solution for end-of-line inspection of mechanical components. Then we retrofitted 25 machines with this solution to achieve the expected standard of quality. Several 1D, 2D, and 3D laser sensors were used to this end.
Added value for the customer Featuring algorithms and sensors at the cutting edge of technology, the overall solution works with replicable accuracy. We also provided operation and management software for the entire test bed.
