Data recording

Dewesoft is taking a major role in all kinds of data recording applications in automotive industry, especially in development laboratories and test facilities, where the ability to acquire data from all different sources creates major advantage. We are not only talking about standard interfaces like analog, digital, counters, CAN, GPS and video channels, but we have made our effort to support special devices like gyro platform from Genesys or torque wheels from Kistler, everything of course perfectly synchronized with other sources.

Ride handling

Cars and trucks are designed on computers, and built by robots under computer control. But there is no substitute for testing the car with a human being, under a wide variety of road conditions and environments. That's where ride handling tests start. Most vehicle manufacturers have their own test track or proving grounds, where they can put their creations to the test. What normal people would consider subjective criteria like how a car feels under certain conditions must be precisely quantified and then tested over and over again, on every vehicle. Usually the outer ring of the track is for high speed highway tests, while the center contains duplicates of city roads built with a wide array of surfaces, suburban sections, dirt roads, tight loops, and crazy-looking suspension tests

Application reports

Wheel force measurements	Data acquisition system for wheel force measurement Magna Steyr AG, Austria	View
Application Ride handling tests with data acquisition of analog, CAN and Kistler wheel force transducers. Notebook is the base unit for measurement. Measurement challenge In ride handling the most important thing is that all the data sources are completely synchronized with each other. Especially the Kistler wheels since they are standalone device and are tricky to synchronized with the other data sources. DEWESoft does that perfectly. The channel setup and calibration database is automatically loaded into DEWESoft without the need to retype the setup for each channel. The data is exported to Diadem for later processing and comparison with calculated results. Kistler wheel RoaDyn Test setup
Car behavior on standard road	Road behavior on standard road and track PSA Peugeot Citroen, France	View
Application PSA has a wide variety of Dewetron data acquisition units equipped with analog, digital, counter, CAN and video channels. They are used daily for all different kinds of measurements. Either for driving the car on roads, test tracks, rough roads, to see the dynamic behavior to the tests where the car is almost destroyed by jumping into the air and landing on asphalt several seconds later. Measurement challenge Full synchronization of all data sources is the key feature. The engineers are perfectly able to describe the behavior of the car just from analog sensors, but fully synchronized additional video channels make the system unique and gives the engineers the ability to see what is going on with the car in certain stages of the test. Data acquisition in DEWESoft Data acquisition in DEWESoft

Brake testing

With DEWESoft you can acquire and analyze data. But there's more. DEWESoft 7 introduced the automated brake testing sequence, which allows you to acquire and process data for simple and more advanced brake tests in no time. This is ideal for simple brake test users like car magazines or racing teams for comparison measurements or similar tests. It is also ideal solution for homologation authorities and vehicle parts manufacturers (brake system, tyres, ABS systems, ...). On the other hand vehicle manufacturers can use the system in many different ways: R&D, quality control, homologation according to standards and so on.

Road load data

Collecting road load data is a standard application of Dewesoft, being able to acquire data from hundreds of channels of strain gages, force and displacement transducers. The time of acquisition is limited only by the amount of disk space, so we have our customers driving hundreds of kilometers for hours and hours in the worst condition that anyone can imagine. After data collection, first results can be observed immediately, but the data is usually exported in standard format like RPCIII for replay on test stands.

Application reports

Road Load Data acquisition	Road Load Data (durability testing) Ford, USA	View
Application The application is to collect sever road profile data to be later analysed in labs and replayed on the test benches. The data acquisition devices are Dewetron 501 units which can be stacked together for higher channel count. Measurement challenge The challenge of this measurement is to provide in vehicle flexible system for data acquisition of 60-150 channels. Channels are mostly vibration and strain gages. In addition to these channels the data acquisition system must acquire data from wheel force transducers. The setups are loaded automatically from their Excel template and the data is exported to RPCIII format for the replay on the MTS simulator. Road load test Road load test Kistler wheel RoaDyn Playback on MTS simulator
Road Load Data acquisition	Road Load Data acquisition MAN, Germany	View
Application The application is to collect the road load data at test facilities. The purpose of the tests is fatigue test and analysis of components and the whole vehicle. The data is then exported to the test rig application for replay in laboratories. Measurement challenge The measurement challenge is to provide automated solution for simple and flexible setup, easy and reliable data acquisition of many analog channels and straightforward export of data to test rig data format. Trucks used for tests System configuration
Road Load Data acquisition	Measurements on roads and test track Scania, Sweeden	View
Application The truck tests means driving through snow in Finland and through jungle in South America on rough roads, collecting hours and hours of measurements from where the typical load pattern can be determined and the fatigue properties of the vehicle and its component can be found. The system is built into the truck and needs to survive all the pain which truck is going through. Measurement challenge The requirement of this measurement is to provide a flexible high channel count (16-128) reliable system with the possibility to acquire analog bridge, potentiometer, accelerometers, thermocouple, voltage as well as CAN, video and GPS channels. The channels have antialiasing filters and the user needs strong, but yet simple software to operate the system. Test truck Test forrest industry machine

Performance testing

To optimize vehicle performance is crucial to gain advantage over competitors. Just think of a formula one car - initial design is of course a base, but then the fine tuning of this design brings the performance to win the championship. For passenger vehicles, top performance might not be the most important criteria, but we all like to look to the 0-100 km/h number or the slalom test results of the vehicle. On another side, to optimize the fuel consumption becomes the most important issue of these days. DEWESoft plays important role in optimizing the vehicle performance all over the world.

Application reports

Aerodynamic operational stability	Aerodynamic operational stability test equipment Toyota, Japan	View
Application It is important to measure the air flow under the floor of the vehicle in order to evaluate the aerodynamic operation stability of the vehicle. Since it is virtually impossible to recreate the actual road conditions in the wind tunnel, these tests need to be performed using the test track. Measurement challenge The measurement challenge is to acquire data from 32 analog channels, mostly air pressure and additionally gyro system, acceleration, laser and speed data. On top of these the video channels are the most important (again) to see what was actually going on in the course of the test.
F1 team R&D testing	Wheel down-force measurement, Chassis vibration, Suspension testing Renault F1, United Kingdom	View
Application Formula 1 cars are designed for performance. The vehicle telemetry acquires the data on different test tracks all over the world. These data sets are then replayed on so called seven pole test rig, which can simulate the real driving conditions to set up new cars for these conditions. Measurement challenge Formula 1 cars are designed for performance. The vehicle telemetry acquires the data on different test tracks all over the world. These data sets are then replayed on so called seven pole test rig, which can simulate the real driving conditions to set up new cars for these conditions. F1 test car Test setup Test setup

Component testing

Each component to be used in automotive industry must pass strict testing to ensure that it will not be the cause of service when installed in the vehicle. Testing of vehicle components like engines, transmission, brakes, electrical systems, mechanical components is every day's task of DEWESoft software. Wide variety of data sources and a chance for automating the test procedures makes DEWESoft perfect for all kinds of testing.

Application reports

HALT tests and data logging	Testing of automotive LED electronics Philips, Netherlands	View
Application LED diodes are replacing normal car lights due to low power consumption and higher reliability. However they need to pass strict life cycle testing on high and low temperature with high vibration. The test lasts until the light brakes. Measurement challenge These test are lasting days and even weeks on 32-64 channels at 5-10 kHz data rate giving Gigabytes of data. DEWESoft is not only able to handle this amount of data, but could add the video channel to give an idea when the light brakes down. F1 test car Test setup
Tyre testing	Tyre performance testing Pirelli, Italy	View
Application The power without control is nothing - so is the vehicle without the tires. The tire manufacturers are putting lots of efforts in testing their tyres for performance in terms of vehicle dynamics, handling, noise and vibration, braking performance, stability in every possible environmental conditions. The test consists mostly of driving on test tracks as well as working on the test facilities in the labs, which could also give good results and reduces time to market. Measurement challenge The system needs to have the ability of high speed synchronous analog acquisition, it needs to be portable and have the ability to add CAN bus and video channels. With the modularity of Dewetron and flexibility of DEWESoft there is no real competitor in this area. Pirelli Pirelli test track Tire camera shot In house testing DEWESoft in action

Structural testing

When designing the vehicle, all mechanical parts are done with the use of computer and qualified with finite element method to determine natural frequencies of the structures. However, the need to check those method is needed more than ever to produce a closed loop to correct the models that they fit the measurement results. DEWESoft provides DeweFRF add-on software to add the ability to import the geometry models, measure transfer functions with the use of either hammer or shaker excitation and see fascinating animation of the structures on the fly. Data can be easily exported to UFF format for further processing.

Application reports

FRF analysis of the structure	FRF analysis of the structure of the brake drum CIMOS, Slovenia	View
Application CIMOS is a producer of parts for automotive industry. They need a system to control a quality of break drums. The customer was looking for unique solution. Measurement challenge We decided, that we should use DEWE FRF software with suitable A/D card, vibration sensors and excitation hammer. The sensors are mounted on the surface of the product Ð construction, and with the hammer we hit on the defined point on the surface of the construction. The basic princip of this system is, that with the exitation of the construction we get it«s response. From the natural frequencies of the construction in different modes we see, if the product is good or damaged (broken or porous). This system can be used on all kinds of construction, especially where we want to get the response of the construction.

Order tracking

When determining how the structures behave under real operating conditions, order tracking provides the means of seeing the structural response to real life excitation. The rotating parts of the vehicle like engine, shafts or the wheels creates excitation forces on the structure. Did you ever had a car starting to rattle and shake at certain vehicle speed? This car was for sure not tested with DEWESoft and those high vibrations were result resonance frequencies of some elements at certain input frequencies.

By measuring rotating speed and the response (in terms of vibration, noise and others) the Nyquist, Bode and three dimensional FFTs are generated on the fly giving clear picture of the frequencies having a problem.

Torsional vibration

If the acceleration sensors provides information about linear movement, torsional vibration procedure provides the information about angular vibration. Imagine a long shaft going through the vehicle. Like each structure has linear natural frequencies, this shaft will have angular natural frequencies resulting at high angular vibration at certain rotation speed. To check the bending of the shaft, we mount any kind of angular sensor on each end of the shaft and measure the angle difference. The data can be used in order tracking to give a clear indication of natural frequencies.

Combustion analysis

Dewesoft adds the power of acquiring angle based data and calculate parameters of combustion analysis (maximum pressure, MEP, heat release, temperature, knocking, combustion noise and others). The p-v and CA-scope display shows the measurement results while measuring. DEWESoft uses multi-threading technology to use the new multi-core processors for real time calculations.

Another major advantage of CA module is that it can be used with other data sources like CAN bus, video, OBDII and time domain analog signals, all synchronized with engine data.

Application reports

Combustion analyzer	Angle-based and time-based combustion measurements FAW, China	View
Application The customer requires the data acquisition system which can be general purpose, recording data in the time domain with all the goodies of DEWESoft with CAN, video and other automotive interfaces as well as working in the angle domain for combustion analysis. The additional demand is not only to measure the pressure in the combustion chamber, but also needle lift. Measurement challenge DEWESoft with the ability to merge both worlds - time domain as well as angle domain sampling is a perfect tool for such customers. The Dewetron hardware with signal conditioning and 1 Ms/s 16 bit data acquisition card is a perfect base for advanced calculation. Combustion parameters are calculated on line and can be used to give information to engine test beds. Data can be analyzed in post processing, but can be also exported to iFile and other formats for special post processing. Same system can be used on test bed as well as in the vehicles on the test tracks. Tested engine Engine animation Angle sensor Valve lift indication DEWESoft in action

Hybrid testing

Hybrid and electrical cars are more and more common in today's world of energy shortage. With a long tradition in both worlds - automotive and power/energy market DEWESoft is an excellent base for combined testing of electrical and vehicle parameters. DEWESoft has a very powerful and high accuracy power module giving the chance to calculate virtually all power, energy and power quality parameters.

Application reports

MCU monitoring	Monitoring system for Motor Control Unit in Hybrid car Hyundai, Korea	View
Application Application is to acquire and analyze signals from onboard motor control unit in hybrid car engine. The system is used to measure and test 3 phase power supply (voltage, current) to the motor, IGBT switching, short circuit protection, fault output, engine temperatures and DC voltage. Measurement challenge DEWESoft had a job not only to acquire synchronous data from all the different sources but was also used for later analysis and archivation of data. Dewe800 hardware system was used with 16 bit ADC resolution and 1M sample rate. MCU in hybrid car Test setup Dewe800 DAQ system Power supply switching test in DEWESoft

Distributed data acquisition

Lots of customer in automotive industry uses distributed data acquisition simple to have more flexible data acquisition systems. 16 or 32 channels acquisition devices can be used separately, but when there is a need for higher number of channels, those boxes can be combined to act like a single acquisition device.

Active safety tests

The active safety test is currently state of the art solution combining different DEWESoft technologies. The idea is to measure distance and position between two vehicles during driving with two centimeter accuracy and update rate of several hundred Hz.

The clock from GPS provides exact timing between two vehicles and Genesys ADMA platform gives position and speed information. The wireless LAN sends the data to the master vehicle, where we can see the difference between vehicles during driving. The system is used to check the new active safety radar systems, but just imagine the advantages if such system would be in each vehicle driving on the street.

Welding

The support of high speed camera from Photron is a good base to use DEWESoft in welding applications. The Photron camera has the ability to acquire several seconds of video data with up to 100000 frames per second. Additionally the high precision measurement of analog data (voltage, current) is perfectly synchronized with video data. Only the combination of both is enough to determine the quality of welding.

Crash tests

All vehicles must be checked for crashes. DEWESoft with the support of high speed data acquisition cards as well as high speed cameras is perfect software to perform such tests.