Proposal for test simulation to support the transition away from reliance on real vehicle testing for automotive drive systems.
In the field of research, development, and testing related to automotive drive system components, performance verification and reproduction of defects through actual vehicle test drives are still important evaluation methods. On the other hand, in the field: - Repeated driving by test drivers requires a lot of time and cost. - Variability in test conditions and measurement deficiencies lead to the occurrence of retests. - It is difficult to reproduce transient phenomena and defects that only appear under specific conditions multiple times. These challenges constrain the improvement of development efficiency and the advancement of quality verification. Seagoat Inc. supports addressing these field challenges by constructing "test simulations" that replicate actual vehicle behavior in a test bench environment. By integrating the analysis of actual driving data, generation of command waveforms, deterministic control using real-time OS/FPGA, and reproduction of actual loads through inverters into a single application, we provide a highly reproducible testing environment even for individual components.
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basic information
The generated command data is sent to the inverter, and the speed, torque, and position of the motor (dynamo) are controlled in real-time. As a result, the specimen physically reproduces "speed changes and load conditions equivalent to those at the start of actual vehicle operation," enabling component-level testing under conditions close to actual driving. This series of processes is established by integrating: ■ Data generation and visualization via HMI ■ Deterministic control using real-time OS and FPGA ■ Physical load reproduction through the inverter In other words, our company enables the creation of an environment where the verification of starting behavior, which previously required actual vehicle testing, can be reproduced in bench tests.
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Applications/Examples of results
In the performance evaluation of components related to the automotive drive system, such as engines, transmissions, hybrid systems, and motors, inverters, and batteries for EVs, verification through actual vehicle testing is still used. However, this method often requires a significant amount of time and cost due to repeated driving by test drivers, preparation of measurement equipment, and addressing variations in testing environments, which can be a burden in terms of development efficiency. Additionally, in the analysis of defects and recall responses after product commercialization, it is necessary to reproduce and repeatedly verify transient behaviors where problems occur. However, tests that rely on actual vehicle driving often require long periods of driving before phenomena occur, making it difficult to conduct repeated tests. Therefore, in development settings, there is a demand for environments that can reproduce loads and behaviors close to those during actual vehicle driving, allowing for repeated tests under the same conditions with individual components. In recent years, there has been a growing effort to construct testing conditions using simulation technologies that utilize real driving data and mathematical models, as well as control software/applications, to reproduce behaviors including transient changes on test benches.
Detailed information
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An example of a test simulation that reproduces crank start behavior As an example, we will focus on a test simulation targeting the start behavior of the crankshaft. At the moment the crankshaft transitions from a stopped state to idling, a specific waveform appears, characterized by continuous and complex changes in speed. In the development field, there is a need to faithfully reproduce the actual measured speed waveform during startup on the test specimen itself.
Company information
Our company is engaged in measurement and control applications, test simulation proposals, replacement and functional enhancement of test equipment and measurement, and the provision of original hardware. With the mission of "making the world simpler and better" through software and electronics technology, we create value through technological development and will continue to contribute sustainably to various industrial fields. Please feel free to contact us when you need our services.