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Inertia dynamometer testing needs to evolve. They need to allow the test engineer to embed the test in a vehicle environment: Developing or adaptation of the braking system as a mechatronics/software integration. Having access to advanced real-time control systems to simulate vehicle modules and vehicle dynamics. And a relentless pace to assess more conditions, scenarios, and manoeuvres, way before going to the proving ground (if at all). Since dynamic torque output (as a direct effect of changes in the coefficient of friction) changes during and between braking events, having the actual brake in the control loop avoids the requirement (and risks) of attempting to model all the complexities and nuances of the brake corner. After presenting the key elements and architecture of the test environment, this paper uses examples with full-scale inertia dynamometer testing with selected manoeuvres of the SAE J2707 block wear cycle. The test cases and examples include several matrices to a) compare the Vehicle Dynamics Model control to the native dynamometer control system, b) assess the effects on torque output when changing the vehicle mass and weight distribution, c) determine the sensitivity and responsiveness of the intelligent test bench to changes in brake balance, d) and assess the response to changes in certain parameters (battery power, regenerative torque, and state of charge) of the electric machine within the intelligent test bench. By quantifying and visualizing the dynamic interactions between the vehicle dynamics simulation and the inertia dynamometer, the test engineer can understand the value, relevance, and fidelity of simulation tools. Only then, test methods, programs, and laboratory test architectures can commence the migration to smarter test platforms and realize the benefits of new technologies.
Link Engineering Co: Mr. Carlos Agudelo, Mr. Barry Purtymun, Mr. Matias Blanc; Dspace Inc: Mr. Simon Roechner