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New test rig components for faster development and validation

16.05.2019

Numerical simulations have massively accelerated product development over the past few decades. A variety of scenarios can be tested in a short time and the number of necessary prototypes has been steadily reduced. Nevertheless, physical tests will not lose significance. Numerical models must be validated and approval testing must be carried out. In the project “Digitization in Testing Technology”, scientists from the Fraunhofer Institute for Structural Durability and System Reliability LBF have developed tunable test rig components and a mechanical hardware-in-the-loop approach.

The Results will present at the Automotive Testing Expo in Stuttgart, May 21-23, 2019 in hall 8, booth 8052.

What is the optimal combination of real and virtual world? The research team from Darmstadt developed tunable components and a mechanical hardware-in-the-loop interface.


Prototype of a mount with tunable stiffness.

Photo: Fraunhofer LBF/Raapke


Prototype of a mechanical hardware-in-the-loop interface.

Photo: Fraunhofer LBF/Raapke

Tunable components allow continuous adjustment of mechanical characteristics. For example, mounts with tunable stiffness enable testing of a test specimen under different boundary conditions or the implementation of tunable vibration absorbers.

If tunable rubber mounts are used as a development tool, with stiffness and damping adjustable independently of each other, it is possible to forgo the first bearing prototypes. This makes it possible to provide the mount manufacturer with optimized specifications at an early stage of development.

Mechanical hardware-in-the-loop interfaces can be used to simulate more complex boundary conditions in experiments, especially in the field of NVH development. The interface behaves equivalent to a underlying numerical model in a wide frequency range.

For example, an adaptive shock absorber can be tested for different combinations of top mount and chassis without carring out any modifications to the testing bench.

»The transfer of numerical simulation methods into the physical world of testing makes it possible for development processes to be drastically accelerated and costs to be reduced. Furthermore, our technologies and test rig components offer new possibilities for validation of numerical simulation models. Models can be validated for different operating points with less effort«, says Jan Hansmann, research associate and project manager at the Fraunhofer LBF.

Next, the research team from Darmstadt wants to work on the series-production implementation, which requires close cooperation with industrial partners.

Wissenschaftliche Ansprechpartner:

Jan Hansmann, jan.hansmann@lbf.fraunhofer.de

Weitere Informationen:

http://www.lbf-jahresbericht.de/en/services/project-overview/vibration-technolog... Fuzzy control systems, Pareto optimization, genetic algorithms
http://www.lbf-jahresbericht.de/en/services/project-overview/reliability/structu... hardware-in-the-loop testing environment

Anke Zeidler-Finsel | Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF

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