Turn-key test benches for mechatronic components and systems can be used for testing and developing functions, automated software release and acceptance, examining error-case behavior, concept validation, mechanical endurance tests, and measuring the unit under test. dSPACE provides highly dynamic turn-key test benches, that enable hardware-in-the-loop (HIL) test cases to access the electronic control unit (ECU) even when it is not possible only by its electric interfaces.
When it is not possible to access the ECU only by its electric interfaces, mechanical access is needed. This is also essential for tasks such as:
- Applying mechanical loads to electric drive
- Physically stimulating the integrated sensors for mechatronics ECUs
- Mechanically stimulating human-machine interfaces
With HIL technology it is possible to test and integrate ECUs and vehicle buses. The reference values for the load machines are provided in real time by real-time simulation models. Through suitable I/O interfaces, closed-loop operation between the test bench components, the ECUs and the simulation is achieved. By coupling the test bench with a HIL simulator realistic load scenarios for the electronic and mechanical components can be created. Different load machines are used for different requirements and applications: rotary drives, spindle actuators, highly dynamic linear motors, etc.
Applying mechatronic test benches is common within the following areas:
- Steering systems, such as:
- Electric power steering
- Superposition steering
- Controlled electric pumps, e.g., fuel and hydraulic
- Mechatronic ECUs with integrated sensors and actuators, such as:
- Gear control units with integrated speed sensors
- Parking brake ECU with integrated inclination sensor
- ESP with integrated rotation rate and acceleration sensor
- Pedal actuation for testing electric brake boosters
- Force feedback control in driving simulator applications
