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Use Cases
Use Cases

Harmonized system simplifies tests of mechanical loads

The optimization of hybrid and electric vehicles does not only extend to the electric drivetrain, but also includes all vehicle components. The aim is to save weight in order to achieve maximum performance and energy efficiency. At the same time, the vehicle must be permanently stable and safely designed for the planned service life. For this reason, chassis components are also tested and continuously improved with regard to mechanical stress. Measurement modules from CSM and telemetry measurement technology from AXON are used to measure the fatigue strength of parts of the wheel suspension.

Tie rod and axle guide in vehicle
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Simulation and validation

The control arms and track rods are part of the unsprung masses and have a significant influence on driving dynamics and ride comfort. The expected forces that occur during various driving situations are predicted in simulations during development and must then be validated in road tests and on the test bench. To validate the simulations, the forces acting on the axle geometry are determined.

Measurement Task

Measurement of forces on control arms and tie rods as well as measurement of spring travel, steering angle and speed.

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What should be considered?

To measure the durability the acting forces as well as the suspension travel, steering angle and speed must be measured. For a simple application, all measured variables are recorded in parallel with one measurement system. Data is collected during different driving situations as well as on the test bench. The measurement system used should be able to be used in all test scenarios in order to avoid long conversion times and to enable simple comparison of the data obtained.

Component-specific requirements

Tie rods and control arms are very stable components, which means that only low strain values are to be expected in normal driving situations. The measurement technology used must therefore be very high-resolution in order to record very small signal values. However, since very high values can occur during misuse tests, such as driving over a curb, the measurement technology must offer sufficient dynamics. In addition, when measuring rotating parts, there are difficulties in transmitting the values as the sensors have to be attached to the shaft.

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Combine all data in one measurement system

Components from the Vector CSM E-Mobility Measurement System are used for the measurements. The tensile/compression load in the tie rods is measured using strain gauges. Depending on the geometric design of the axle control arm, strain gauges are used to measure individual strains, bending or tensile/compressive loads.

Measurement setup for measuring the fatigue strength of the tie rod and axle control arm

Automatically adjusted in the measurement module

All strain gauges are connected to a STG6 pro BS20 strain gage measurement module. Quarter bridges are added directly in the sensor cable to form half bridges. The strain gauge is simply added to the full bridge in the measurement module, eliminating the need for further wiring and allowing a wide range of strain gauge resistance values to be supported. Thanks to the extremely low input voltage range of up to ±0.3 mV/V, very small measurement signals can be precisely recorded. The measurement data rate of up to 20 kHz per channel allows the detection of rapid load changes.

Measurements on rotating parts

Telemetry systems for recording torques from AXON Systems GmbH, a long-standing partner of CSM, are used for the measurements on the drive shaft. With the solution from AXON, the data from a rotating strain gauge measurement point for torque measurement are transmitted without contact. For this purpose, the strain gauge measurement point is connected to a rotor electronics unit, which is installed on the drive shaft and provided with a multi-layer protective coating so that environmental influences do not affect the measurement results. The data is transmitted wirelessly to a stator unit, the antenna of which is placed in a ring around the axle. The antenna of the stator unit can be freely shaped and thus flexibly adapted to the conditions at the installation site with little installation space. The control unit generates the necessary supply voltage for the sensors on the rotor unit and forwards the recorded measurement data.

Simply merge signals for analysis

The CSM measurement modules are connected to an XCP-Gateway via EtherCAT®. The XCP-Gateway synchronizes the measurement modules via the Precision Time Protocol (PTP) better than 1 μs and converts all signals to XCP-on-Ethernet. The data from the AXON telemetry system is integrated into the measurement chain via CAN, bundled in the XCP-Gateway and also forwarded via XCP-on-Ethernet. The collected data can be recorded either with a data logger or a measurement computer. The subsequent data evaluation can be carried out with Vector CANape or vMeasure.

Fatigue strength measurement on tie rod and axle control arms in the systematics of the Vector CSM E-Mobility Measurement System
Durability measurement on tie rod and axle control arms in the systematics of the Vector CSM E-Mobility Measurement System
AXON telemetry system
The AXON telemetry system installed in the vehicle. Thanks to the flexible antenna, the axle has sufficient space for demanding test drives. (Photo: AXON Systems GmbH)
AXON torque measurement flanges
In addition to sensors installed on the axle, AXON also offers torque measurement flanges for acquiring acting forces. The entire measurement technology is also suitable for harsh environmental conditions, such as off-road driving tests. (Photo: AXON Systems GmbH)
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Suitable measurement technology for high requirements

With the components of the Vector CSM E-Mobility Measurement System and measurement technology from AXON, all required measurement variables can be acquired precisely with a standardized system. Thanks to the compact and robust design, the measurement modules and telemetry systems can be installed close to the measurement point and used both in road tests and on the test bench.

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