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Road-to-lab replication on the testbed

Optimization of Real-World Electric Range

Validating and optimizing real-world electric driving range in the lab environment

Whether it’s a battery electric (BEV), plug-in hybrid (PHEV) or fuel cell electric vehicle (FCEV), one of the biggest factors influencing the decision to purchase is driving range. This single issue is influenced by many different factors, such as component optimization, powertrain efficiency and operation strategy.

It is common practice to optimize powertrain components on components testbeds with the operating strategy pre-designed using simulation models. Driving range is finally validated and optimized on the test track and under special conditions. But this process is lacking in many areas.

For example, with a human driver, test repeatability is nearly impossible. Real world conditions are changeable, with environmental conditions such as weather, traffic and a multitude of other factors being difficult to predict. This makes comparing test runs and optimizing the operating strategy extremely difficult.

Predicting the Unpredictable.

To tackle these challenges our advanced robot system replicates and reproduces real-life vehicle road testing on the chassis dyno and the powertrain testbed. Featuring a superior driver algorithm, our system enables you to bring real-world testing into the lab, with reproducible, comparable and representative results.

Employing a high level of automation, our system lets you conduct exhaustive testing, 24 hours a day, seven days a week. You can repeat maneuvers and replicate driving styles to ensure robustness of results, and compare different vehicle types under the same conditions.


Reducing Effort, Saving Time, Cutting Costs

Our approach allows you to frontload electric vehicle range optimization, by bringing these tasks into the lab. By guaranteeing repeatability and reproducibility, you can explore different configurations and scenarios without being dependent on real world conditions.

Our system also enables you to optimize driving performance and comfort, and allows you to increase prototype utilization by up to a factor of 16. This is thanks to the removal of battery charging requirements during optimization.

Higher test throughput supports increased product validation which leads to higher product quality. We have already proved our approach with a large number of different customers, all with very different requirements. Ultimately, the real validation comes from end-user satisfaction, which this approach is designed to deliver.