RPC Connect software and FlexTest controllers will be integral to establishing the testing ecosystem needed to support the hybrid simulation and connectivity demands of Durability 4.0.
Virtual Testing will yield useful loads, motion and damage information on vehicle components and systems very early in the development process, before the availability of physical components. (Above) Full vehicle model coupled to a virtual Model 329 Spindle-coupled Road Simulator (ADAMS/Car 329 model).
Hybrid simulation techniques like HSRC integrate physical testing and virtual models to enable objective analysis and testing earlier in development. (Above) Virtual tires and digital roads combine with Model 329 Spindle-coupled Road Simulator as part of a full-vehicle durability test.
Servo-Hydraulic Innovation: MTS DuraGlide™ Actuators employ innovative rod coating and finishing technologies to achieve new levels of durability, performance and reliability.
Servo-Electric Innovation: ePost™ Tire-coupled Road Simulators employ energy-efficient MTS linear electric actuators to meet durability testing requirements across a full range of passenger car and trucks.
Durability 4.0MTS Systems is pioneering a new generation of durability testing tools to help auto manufacturers realize significant time and cost savings in the face of rising expectations for product quality and complexity. Engineered for maximizing durability test throughput and achieving new levels of operational efficiency, these next generation tools will usher in a new era of innovation on the durability testing timeline: Durability 4.0.
The Durability Testing Timeline
The durability testing timeline starts at Durability 0.0 when most testing was done on the proving ground.
Durability 1.0 (1960-80) signifies the transition to more controlled and repeatable laboratory testing, using early 4-posters and emerging Remote Parameter Control (RPC) iterative methods and techniques.
Durability 2.0 (1980-2000) is characterized by advancements in analog controls and the advent of multiple degree-of-freedom (DOF) time history replication. This era saw widespread deployment of 4DOF spindle-coupled road simulators and RPC® software (versions I-III).
Durability 3.0 (2000-2020) marks the introduction of FlexTest digital controls and Windows-compatible RPC Pro and cRPC Pro software, further advancing multi-DOF time history replication and enabling 6DOF road simulators and MAST systems.
The emerging era, Durability 4.0 (2020 - ) will usher in the use of virtual and hybrid simulation, vehicle and lab connectivity tools and test hardware innovations to realize new levels of productivity, efficiency and reliability.
Integral FlexTest® Controls & RPC Software
Pivotal to reaching key milestones across the durability testing timeline, RPC software and FlexTest controller technologies will be integral to establishing the testing ecosystem needed to support the hybrid simulation and connectivity demands of Durability 4.0.
Foundational to the Durability 4.0 ecosystem, FlexTest controllers feature a modular, scalable architecture for conducting a full spectrum of durability testing. The versatile FlexTest architecture supports MatLAB Simulink Models and offers virtually unlimited calculated I/O capacity. FlexTest controllers run full-featured MTS 793 platform software, which includes a rich, application-specific toolset and support for a growing array of field bus systems, including EtherCat, CANbus and Modbus.
Next-generation RPC Connect software carries forward the legacy of renowned RPC Pro software, while laying a robust, scalable foundation for an evolving simulation toolset. RPC Connect will support powerful hybrid simulation techniques and new data analysis and communications tools for accommodating active and semi-active systems. An intuitive, easy-to-use graphical user interface will increase operator productivity and efficiency.
Virtual & Hybrid Simulation
Durability 4.0 will leverage virtual testing and hybrid simulation to streamline and shorten durability test cycles and generate meaningful component and subsystem test data far earlier in development.
Virtual Testing employs finite element analysis tools, multi-body dynamic analysis tools and RPC iteration techniques to excite vehicle models on modeled test systems. This technique can yield useful loads, motion and damage information on vehicle components and systems very early in the development process, before the availability of physical components.
An industry leader in hybrid simulation, MTS has proven two approaches for integrating physical testing and virtual models to perform objective analysis and testing, well before the availability of pre-production prototypes.
Hybrid System Response Convergence (HSRC) employs an offline, iterative process to generate accurate test loads by surrounding physical test parts with virtual components and generic inputs; for example, using virtual tires and digital roads as part of a full-vehicle durability test.
Mechanical Hardware-in-the-Loop (mHIL) employs a real-time, closed loop process to substitute real parts for difficult-to-model components within a virtual simulation; for example, using actual vehicle dampers as part of a virtual handling simulation.
Lab Efficiency Tools
Durability 4.0 will leverage innovative lab connectivity tools to enable close monitoring and analysis of test equipment and infrastructure performance, improving uptime, throughput and overall operational efficiency.
MTS Echo® Intelligent Lab employs a cloud-based or local hub solution to establish the connectivity required to manage critical tests, track test equipment status and monitor lab infrastructure health and performance, from anywhere and at any time. The potential benefits of this connectivity are tremendous, including improved efficiency, better test results and lower operating costs.
MTS Multi-Pump Control Manager (MPCM) provides the ability to monitor and control multiple HPUs as a single system to improve lab operating and energy efficiency and prolong equipment life. An intuitive touchscreen interface enables close monitoring of HPU system fluid demand and precise management of fluid supplies and distribution.
Test Hardware Innovation
Durability 4.0 will leverage an array of MTS hardware innovations to realize additional operational efficiencies, long life and cost savings.
New SWIFT® Evo wheel force transducers feature a high stiffness one-piece design that delivers unmatched precision and long life. Ideal for RLDA or lab-based road simulators, they are easy to install and use and are available in a wide range of sizes. Proprietary multi-axial sensor calibration ensures data and test integrity.
SilentFlo™ 515 Hydraulic Power Units (HPUs) feature high-efficiency motors and improved cooling circuits to achieve significant improvements in energy efficiency - up to 8% - over earlier SilentFlo models. SilentFlo 515 HPUs are easy to operate and maintain with fewer parts, accessible controls, improved filtration and Multi-Pump Control Manager (MPCM).
MTS DuraGlide™ Actuators employ innovative rod coating and finishing technologies to achieve new levels of durability, performance and reliability. The new coating increases actuator rod life expectancy by a factor of ten. MTS SureCoat™ Rod Finishing Technology serves to reduce rod banding and unloaded chatter, while also extending seal life.
TestLine Solutions comprise a versatile set of modular components for creating cost-effective component and subsystem test rigs that can be easly reconfigured as requirements change. Precision-engineered for seamless integration, the TestLine portfolio includes durable load bearing components, MOKOKIT® portal frames, SilentFlo HPUs, MTS DuraGlide actuators, FlexTest controls and RPC software.
ePost™ Tire-coupled Road Simulators employ MTS linear electric actuators to meet the requirements of a full range of passenger car and truck test applications, including Durability, NVH, BSR and Inline Production Quality. Energy-efficient ePost actuators are more economical to operate and maintain than conventional 4-posters and enable a cleaner, more streamlined simulation environment.
MTS RPC software, FlexTest controls and mullti-DOF testing technologies have played unique and pivotal roles throughout the decades-long pursuit of lab-based durability testing that correlates closely with proving ground results. Contact MTS today to learn how the next-generation will leverage new simulation techniques, lab efficiency tools and test hardware innovation to usher in Durability 4.0 - a new era of durability testing productivity, efficiency and reliability.
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