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Vehicle testbeds 4x4 for Advanced Applications in R&D

Advanced Applications 4x4 Test System

The development of new drive concepts and powertrain functionalities entails new requirements for test systems. For this, AVL offers high-end solutions which fulfill the challenges.

AVL Approach

All four highly dynamic load units of the vehicle testbed can be controlled separately or synchronously. This is not only possible for generic analyses, but also forms the basis for the basis for real­life testing in connection with AVL InMotion. Previously recorded 3D road  profiles, including curves, can be modeled. Along with the conventional method (by means of coast-down coefficients), the road simulation is implemented through an advanced approach on the basis of a physical multi­body simulation model in connection with an environment, road, and driver model. This easily allows for the most  different parameter variations, e.g. air resistance, vehicle weight, trailer, style of driving, etc. Additionally, a comprehensive residual bus simulation on the basis of the simulation model can also be implemented (e.g. simulation of acceleration or traffic for ACC systems).


Benefits at a Glance

  • Highly dynamic four­motor vehicle testbed for modeling different pulling forces and speeds on all four wheels
  • Future­proof development platform for intelligent drive concepts such as electric drives as well as complex powertrain functions (e.g. torque/speed vectoring)
  • Maneuver­based real­life testing on the vehicle testbed
  • Parameterizable simulation models for driver, road and topology, environment, and residual vehicle

Market Requirements

The application field of 4x4 vehicle testbeds for Advanced Applications is broad:

  • Real consumption and emission analyses on customer-specific roads (e.g. Auto Motor and Sport track)
  • Development of advanced driver assistance systems, e.g. advanced driver assistance systems by free maneuver, road, and traffic definitions
  • Analysis of different (virtual and reproducible) driver types in connection with operating strategies

Technical Data

Criteria

Value

General

 

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. Alternative technical configurations are available upon request.

Nominal power in motoring mode1

150kW @ v≥92km/h<189km/h

Nominal tractive force in motoring mode1

5,870N @ v<92km/h

Max. speed

200km/h

Max. axle load

2,500kg

 


System Scope

Chassis Dynamometer
The chassis dynamometer is suitable to perform various road load conditions, control modes and legislative quality assurance procedures. It is designed to test the vehicle in twin axle operation at various road speed settings. Therefore the chassis dynamometer is equipped with four rollers driven by four motors.

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.

Optional 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.

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. 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.