Performance & Consumption Test System

This solution is designed to perform complete vehicle or component endurance tests in order to develop or confirm specified characteristics.

AVL Approach

AVL ROADSIM combined with a robot driver drives the test vehicle. For testing over several days a refueling system supplies the vehicle with fuel. For repeatable testing conditions a vehicle cooling fan is used.  External signals can be recorded via the baseline measurement module.


Benefits at a Glance

  • Proven vehicle test system for safe operation with one user interface
  • Simple solution for refueling the vehicle
  • Integrated data acquisition system with interfaces for various sensor types
  • Application specific workflow for mileage accumulation testing

Technical Data

Vehicle types supported

Range from all-terrain over light-duty and medium-duty up to commercial vehicles with front wheel and/or rear wheel driven axle:

The following specification shows the typical values of the product AVL ROADSIM 48" MIM LIGHT TRUCK and is subject to change. For more detailed information concerning this product or other products of our mileage accumulation product range please click here. Alternative technical configurations are available upon request.

 

Nominal power in motor mode (per axle)

150kW @ v≥92km/h

 

Nominal tractive force in motor mode (per axle)

5,870N @ v<92km/h

 

Max. speed

200km/h

 

Max. axle load

4.5t

Test conditions

Environmental conditions:
Temperature: -30°C … +60°C
Rel. humidity, not condensed: max. 95%

Fuel type and properties

Diesel and gasoline fuels with up to
20 % alcohol (M20 or E20) and 6 % biodiesel

 

Tank capacity

≈ 4x100l

 

Pump flow rate

≈ 10l/min

 


System Scope

Robot Driver
The easy to install robot driver, with its control unit which is also part of the central control cabinet, represents an essential part of a mileage accumulation test system. This robot driver makes it possible to operate the accelerator (gas) pedal, the gear shift lever of manual or automatic transmission, the brake and the clutch pedal. The system is designed to be failsafe: in case of emergency the clutch is pressed and the accelerator pedal released. Software is included for closed-loop speed control of the vehicle under test. It can be extended by a human drive style upgrade and/or a keyboy to start/stop of the vehicle.

Chassis Dynamometer
The chassis dynamometer is designed for transient testing requirements. It includes an AC dynamometer specifically designed for vehicle testing. An encoder mounted on the dynamometer shaft provides highly accurate speed measurement. Tractive force is measured using a load cell. It can be upgraded by a second axle for all wheel-driven vehicles. The AVL ROADSIM chassis dynamometer includes a calibration device for the accurate tractive force measurement system, a fan for the AC-drive and a special metal roller surface for simulating realistic road load conditions. The chassis dynamometer controller VECON provides the fundamental control function for transient testing modes and monitors the vehicle.

Baseline Measurement
The baseline measurement includes thermocouples, temperature sensors, pressure and a speed input as well as digital I/O to cover basic vehicle measuring tasks. Those transducers are connected to AVL I/O modules, which also belong to the module baseline measurement. They are specifically designed for the demanding operating conditions of vehicle outdoor testbeds and are housed in a boom box mounted on a movable cable boom, which can be positioned close to the vehicle.

Refueling System
Of special importance is the refueling system. The manual refueling system basically consists of a fuel tank with hood, pump, hose nozzle and a fuel dipstick. The test vehicle is prepared to provide a digital signal of minimum (reserve) fuel. Alternatively, the extension to a manual fuel dispenser unit is foreseen for comfortably refueling a vehicle under operation on a chassis dynamometer.

Vehicle Cooling
For repeatable testing conditions a vehicle cooling fan is used. The rotational speed of the fan is controlled. It is mounted on a support structure with four moveable rollers. This allows the fan to be aligned with the front of the vehicle in order, for example, to cool the engine radiator. The fan control cabinet sets the speed dependent flow rate via a frequency converter.

Test System Mechanics
The test system mechanics include a suitable sized and robustly designed vehicle restraint system and an optional vehicle monitoring system. The vehicle position monitoring system alerts the user of any movement of the test vehicles position. The restraint system on front and rear of the vehicle allows high dynamic acceleration and deceleration during test runs. On a 2WD layout the wheels of the non-driven axle are firmly fixed on the floor using the wheel-holding devices. The driven vehicle axle is fixed with belts as standard. Alternatively, a bar system is available.

System Integration and Start-Up Service
The system integration services contain all services for an efficient project execution from project kick-off until final acceptance. In addition, a pre-acceptance on AVL site and FOB packing and transport can be chosen. With the 'extended start up services' extension, the user can be supported in achieving their initial knowledge level for optimal system operation.