Professional Documents
Culture Documents
w
w
w
.
A
u
t
o
m
o
t
i
v
e
T
e
s
t
i
n
g
T
e
c
h
n
o
l
o
g
y
I
n
t
e
r
n
a
t
i
o
n
a
l
.
c
o
m
M
a
r
c
h
2
0
1
2
U
K
I
P
M
e
d
i
a
&
E
v
e
n
t
s
L
t
d
Join us on our visit to the dyno
gurus UK HQ to nd out why it
is a major player in the market
Aerodynamics
Is CFD blowing away wind tunnels?
Seven experts debate the future
Ford aims for new generations in new
markets with the EcoSport, the rst
One Ford car to be developed in South
America, and the rst to be built in India
www.AutomotiveTestingTechnologyInternational.com
Could Quebecs new crash
test facility be the most
accurate in the world?
Transport Canada
Euro 6
The 2014 regulations are fast
approaching. Be prepared with
the latest technology
Froude Hofmann
Chris Biggs
The junior exec against which
all others are judged. The 2012
model features great advances
BMW 3 Series
The return of the facility test.
In this issue: can Germanys
ATP retain ve-star status?
ATP
Chevrolets global
vehicle line director
has taken big steps
to improve small cars
EcoSport EcoSport
LMS SCADAS
Flexibility. Performance. Precision.
The quality leader for fast, single-run data acquisition
Fit-for-purpose frames for lab, eld, or autonomous
recording applications
Scalable platform, from 8 to hundreds of channels
Lab-Mobility: mix-n-match all types of LMS SCADAS
systems
Optimally tuned for noise, vibration, acoustic and
durability testing
More information on www.lmsintl.com/scadas
Leading partner in
Test & Mechatronic Simulation
Take your mind
off the deadline
Ad AutoTTI SCADAS January.indd 1 23/01/12 13:44
CONTENTS CONTENTS
008 Ford EcoSport
This SUV is a milestone for Ford. We
attended the cars unveiling in New Delhi,
one of the companys key target markets
COVER STORY
004 BMW 3 Series
Major advances in a major international
product. Find out how the new 3 Series has
been developed for a new world
012 Automotive Testing Expo India
Indias foremost auto testing event takes place
in Chennai, March 6-8. Read our taster of the
exhibitors and technology on show
WHATS NEW
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012 001
030 Euro 6
With Euro 6 implementation a mere 30
months away, now is the time to invest in
emissions testing technology
036 Aerodynamics
A panel of experts debate: are CFD advances
making wind tunnels redundant?
042 Interview: Chris Biggs
Chevys global vehicle line director reveals
how the brand is making a fresh start in
the world of small cars, with an eye to
international penetration
048 Smash lab
Transport Canadas new crash test facility in
Blainville is claimed to be the most accurate
and reliable in the world and you can use it
056 Site visit: Froude Hofmann
Discover how Froude Hofmann earned its
stellar reputation in dynamometer technology
FEATURES
008
030
048
042
PRODUCTS AND SERVICES
061 Innovative powertrain testing systems
065 Frequency domain technique for simulation
068 Virtual preparation for Le Mans
070 Testing in Arctic conditions
072 Lab-to-line test systems
074 Euro 6 emissions challenges
077 Products and services directory
It looked so promising: a cheap
sorry, very cheap car for
a massive population enjoying
increasing wealth and keen to
join the motoring world. At about
US$1,900 for a new car, how
could it fail? I was among those
impressed by the ethos of the Tata
Nano, its pared-down features, and
how so much could be had for so
little. Indeed, Ive been itching to
drive one.
Sadly, not so many shared
my enthusiasm, with sales
considerably lower than expected.
Curiously, the problem was its
remarkable price, which gave rise
to an image of being a poor mans
car. The alternative of buying
a more prestigious but older
car was nding favor. Happily,
a higher specication, improved
dealerships, and attractive
nancing are creating a rise in
demand, though time will tell if the
production capability of 250,000
units a year will be reached. It just
goes to show that logic has no
place in the automotive sector.
However, keen to get in on the
strengthening rupee, many other
manufacturers are developing cars
created with India and other new
markets in mind. And the great
news is that they have access to
a growing number of Indian
proving grounds and test facilities,
due to massive investment by the
likes of NATRiP, which has nalized
six facilities around the country.
For track work, there is the Kari
Motor Speedway, and even time
on the shiny new Buddh
International Circuit can be
negotiated. Meanwhile, Maruti
Suzuki is investing millions in an
R&D center in Haryana that will
become its global research hub,
complete with tracks, and Daimler
Indias commercial vehicle division
is also investing heavily in test
tracks near Chennai.
India is now one of the most
exciting automotive markets in
the world, and big events such
as Automotive Testing Expo India
and Auto Expo are giving glimpses
into the potential of this area.
A prime example is the modern,
youthful Ford you see on this
issues cover. Forward-thinking
design, great quality, dynamics
worthy of the blue oval badge,
and made in India.
I just hope they make it
expensive enough.
Adam Gavine
CONTENTS
014 Read
A weighty problem
016 Theodore
EMC is not as easy as ABC
018 10 questions: Mustang
Donald Ganzhorn, chief engineer of
Mustang Dynamometer, discusses being
a social techie and growing concerns
020 Ask Alex
Our resident automotive lawyer
considers the toughest test of a vehicle
020 Recall roundup
The latest vehicle roundup news
from the rst quarter of 2012
022 Proving ground news
Keith Read brings you proving
ground news from around the world
027 Facility test
The return of the regular facility test scores.
ATP scored the full ve stars back in 2003:
can it retain the honor?
096 Testbed legends
A tribute to the Mercedes-Benz NAFA,
a clever car that conceived a smart generation
REGULARS
FREE reader enquiry service available at
www.ukipme.com/recard/temcard_mag.html
Editors note
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012 002
The views expressed in the articles and technical papers are those of
the authors and are not necessarily endorsed by the publisher. While
every care has been taken during production, the publisher does not
accept any liability for errors that may have occurred. ISSN 1751-0341.
This publication is protected by copyright 2012. Automotive Testing
Technology International USPS 018-628 is published quarterly in
February, April, September, and December by UKIP Media & Events Ltd,
Abinger House, Church Street, Dorking, Surrey, RH4 1DF, UK. Annual
subscription price is US$88. Airfreight and mailing in the USA by agent
named Air Business Ltd, c/o Worldnet Shipping USA Inc, 155-11 146
th
Street, Jamaica, NY11434. Periodicals postage paid at Jamaica, NY11431.
US Postmaster: send address changes to Automotive Testing Technology
International c/o, Air Business Ltd, c/o Worldnet Shipping USA Inc, 155-11
146
th
Street, Jamaica, New York, NY11434. Subscription records are
maintained at UKIP Media & Events Ltd, Abinger House, Church Street,
Dorking, Surrey, RH4 1DF, UK. Air Business is acting as our mailing agent.
Printed by
William Gibbons & Sons Ltd,
26 Planetary Road, Willenhall,
West Midlands, WV13 3XT, UK
published by
UKIP Media & Events Ltd
Subscriptions US$88
Contact us at:
Automotive Testing Technology International
Abinger House, Church Street, Dorking,
Surrey, RH4 1DF, UK
Tel: +44 1306 743744
Fax: +44 1306 742525
Editorial fax: +44 1306 875824
Email: testing@ukipme.com
Editor
Adam Gavine
Chief sub editor
Alex Bradley
Deputy chief sub editor
Nick Shepherd
Proofreaders
Aubrey Jacobs-Tyson,
Frank Millard
Head of production/logistics
Ian Donovan
Deputy production manager
Lewis Hopkins
Production team
Carole Doran, Cassie Inns,
Robyn Skalsky
Art director
James Sutcliffe
Design team
Louise Adams, Andy Bass,
Anna Davie, Andrew Locke,
Craig Marshall, Nicola Turner,
Julie Welby, Ben White
Contributors
John Challen, Brian Cowan,
Alex Geisler, Dave Gorschkov,
Graham Heeps, Nick
Kurczewski, Peter Lyon,
Mike Magda, Jim McCraw,
John Miles, Keith Read,
Michael Scarlett, Satnam
Singh, Dean Slavnich, Richard
Stobart, Chris Theodore,
Adam Towler
CEO
Tony Robinson
Managing director
Graham Johnson
Sales & marketing director
Dominic Cundy
Editorial director
Anthony James
Publication manager
Jason Sullivan
International sales
Rob Knight
Circulation manager
Suzie Matthews
070
www.moog.com/test WHAT MOVES YOUR WORLD
85% OF TOP AUTOMOTIVE MANUFACTURERS RELY
ON A MOOG ADVANCED TEST SOLUTION.
Leading-edge automotive testing solutions allow test professionals to market new designs faster, manage increased
regulatory pressures and maintain cost efciencies through rapid, reliable and versatile testing. Our unsurpassed
expertisecombined with close customer collaborationmake Moog a leader in providing both simple and complex
structural and performance test solutions.
Ready to master the automotive test solutions that put you in the drivers seat?
Contact us at test@moog.com or download our free white paper on the automotive tests
of the future at http://info.moog.com/h2il
2
0
1
2
M
o
o
g
I
n
c
.
A
l
l
r
i
g
h
t
s
r
e
s
e
r
v
e
d
.
T
o
p
a
u
t
o
m
o
t
i
v
e
m
a
n
u
f
a
c
t
u
r
e
r
s
l
i
s
t
e
d
i
n
A
u
t
o
m
o
t
i
v
e
N
e
w
s
D
a
t
a
B
o
o
k
,
G
l
o
b
a
l
S
a
l
e
s
R
a
n
k
i
n
g
s
.
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
33
BMW embraced new markets and new
approaches to testing in the development
of its premium sedan
WORDS BY JOHN CHALLEN
004
BMW
WHATS NEW
WHATS NEW
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
Given the breadth of BMWs
product portfolio, the fact
that, every year, the 3 Series
sedan accounts for one-fth of the
companys global sales is an
impressive one. It is also the reason
why more time was spent on, and
more attention paid to, the seventh
generation of the car, otherwise
known as F30, than ever before.
F30s lengthy development period
(four years from when work rst
started to production) was used to
consider new approaches to testing.
Martin Sautter, responsible for small
vehicle architecture and integration
at BMW, reveals that many elements
of the program were tweaked in a bid
to increase efciency, mirroring one
of the key aims of the vehicle itself.
We had a very small number
of mule vehicles, but a lot of new
systems, he explains. Using
experience from previous test
005
procedures we were able to reduce
the number of these initial vehicles
to just ve. Our new philosophy is
putting the money into fewer but
more state-of-the-art mule vehicles
for initial evaluations.
It was at this early stage in
proceedings that the decision was
taken to concentrate more on virtual
test methods much earlier in the
program than BMW would typically
expect to. We made a lot of
WHATS NEW
006
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
simulations, and one of the main
challenges was to get the results
of the hardware testing on the
prototypes to interact closely with
the virtual evaluations we had done
previously, says Sautter.
This was the focus of the
different teams that we put together;
we had to have engineers that work
on the hardware working together
with the simulations team much
more closely than they have before.
The new process we devised is called
integrated validation and testing,
thereby bringing results from the
virtual world together with the real
data we get from hardware testing.
Sautter says that this fresh
approach to simulation helped to save
BMW a lot of time and money on
prototype vehicles, but neglects to
put a gure on the nal bill. BMW
applied the same philosophy from its
F30 mules to its prototype vehicle
range, which arrived 30 months prior
to SOP. The 200, more mature,
models were also fewer than in a
standard BMW program, despite the
fact that the development map took a
different direction. The standard
facilities were visited test sites
around Munich, the Nrburgring, the
USA and Scandinavia but evaluation
in Asia become a major priority.
We had a major focus on China,
more than for any other BMW
development program in the past,
reveals Sautter. China is a very
big market for us, and therefore
we undertook some specic testing
on the trafc conditions, which are
very different to what we have
experienced in the past, and how
our customers there use the car in
Chinese megacities. With Sautter
expecting China to be one of the top
three markets for the new 3 Series,
it was important to have a greater
presence than with previous test
programs. BMW conducted two
years of continuous development in
China using an unspecied number
of the 200 prototypes, ne-tuning
everything from fuel compatibility
to dynamics to crash behavior.
The ofcial literature about the
new 3 Series details an emphasis
on sporting prowess, elegance, and
comfort. Sautter explains that focus
was placed on certain areas of the
cars underpinnings early on in the
program to achieve these goals.
For F30, we concentrated on driving
dynamics, for which we developed
a very stiff, but very lightweight,
body-in-white, he says of the car
benchmarked against the Mercedes
C-Class, Audi A4, Lexus IS, and the
Inniti G37. We used this to carry
out the main test and renement
work for the cars new damper
system. F30 has linear dampers,
which give very good ride comfort
and sporty behavior, as well as a very
good chassis. Familiar facilities were
used to hone the new variable
dampers, namely ATP Papenburg,
and the Nordschleife.
F30 is bigger than its predecessor,
but clever material choice means the
car is lighter in some cases by up
to 50kg (110 lb). One of our top
priorities was to cut weight because
we had made the car bigger to gain
more interior space and to integrate
the head-up display, recalls Sautter.
We added a lot of metal, so we had
to compensate with lightweight
options. We used a lot of ultra-high-
strength steel in load areas, and in
the C-pillar we have hot-formed steel.
These were areas where we used a lot
of simulation work to optimize the
body. For the exhaust, we used a new
high-strength steel, which enabled
us to make the system lighter, and
we also used some aluminum parts.
Sautter states that more simulation
work did help to save time and
money, but that physical testing was
still essential. We carried out some
fatigue testing on the test track and
also on rigs, where we devised
specic tests for the new materials
that we were using, he explains.
And, he says, despite streamlining
on manpower by using more and
more simulations, the project still
had 1,000 dedicated test engineers
at its peak.
One of our top priorities
was to cut weight because
we had made the car bigger
to gain more interior space
ABOVE: The F30
is larger than its
predecessors. This is
partly because interior
space is critical to
success in China
BELOW: The
dashboard is angled
7 toward the driver
for a focused feel
Need for speeds
The new 3 Series features the rst appearance in
its class of an eight-speed automatic gearbox,
which indicates one place where the savings made on
development vehicles was offset.
The main challenge was the cost of getting a gearbox
designed for a 5 Series [to t] into a 3 Series, admits
Sautter, who adds that from a testing point of view, the
biggest hurdle was on the software side, getting the
parameterization right. We had to work very closely
with the supplier to ensure that all the software features
work, which meant intensive application and testing.
This also meant [doing similar work] for the whole range
of 3 Series engines, and that is when you need a lot of
competent people and engineers doing their jobs.
measure and predict with condence
QuantumX by HBM The new generation of data acquisition systems
Professional test and measurement is the key to success in the automotive industry. Heres the data acquisition system
which delivers results you can trust and offers maximum exibility and the highest reliability in your test stands:
QuantumX by HBM.
_ Universal data acquisition system, supporting all common transducer and bus technologies
_ New: Autonomous data recoder module for failsafe acquisition of measurement data.
Data recording and evaluation without a PC connection
_ Worldwide exclusive APM technology: Advanced Plug and Measure for immediate setups of your measurement
_ Small, compact, light-weight, expandable up to innumerable channels.
Reliable. Universal. Flexible.
See all the benets at: www.hbm.com/quantumX
XXL performance in mini format.
Americas: HBM, Inc. 19 Bartlett Street Marlboro MA 01752 USA Tel. (800) 578 4260 Email info@usa.hbm.com
Asia: Hottinger Baldwin Measurement (Suzhou) Co., Ltd. 106 Heng Shan Road Suzhou 215009 Jiangsu China
Free hotline: 4006217621 (only in China) Tel: +86 512 682 47776 Email: hbmchina@hbm.com.cn
Europe: HBM GmbH Im Tiefen See 45 64293 Darmstadt Germany Tel. +49 6151 8030 Email: info@hbm.com
qx_Ad1104_215x275_en_art110627.indd 1 26.07.11 12:17
008
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
WHATS NEW
The all-new EcoSport will be the driver
for Fords growth in India and beyond
WORDS BY SATNAM SINGH
EcoSport EcoSport
The EcoSport is the latest
One Ford global product set
to expand Fords footprint
in the worlds fastest growing auto
markets, including India. The car
which will be sold in nearly 100
markets worldwide will be
produced at ultra-modern assembly
plants in India and Brazil, and other
markets yet to be announced.
The new EcoSport reects our
commitment to serve our customers
with the cars and trucks they truly
want and value, says Alan Mulally,
president and CEO of Ford. India
is an increasingly important auto
market, and EcoSport will play
a key role in Fords aggressive global
plan to achieve a 50% increase in
worldwide sales by the middle of
the decade to eight million vehicles
a year. Asia-Pacic and Africa is
expected to deliver 60-70% of that
target. He also assures that the
Ford
model will be launched in India
with a high level of localization.
The EcoSport is the second of
eight products Ford plans to bring
to India by the middle of the decade.
We are investing US$142 million
in setting up the platform for
manufacturing EcoSport at our
Chennai plant, reveals Michael
Boneham, president and managing
director of Ford India. The compact
SUV ts in the current product
009
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
WHATS NEW
range between the Figo small car
and the Fiesta B-segment sedan in
the Indian market. Its compactness
is likely to make it a success on the
crowded Indian roads. With the
road presence of a larger vehicle,
EcoSport is small enough for the
city, yet strong and rugged enough
for trips to the mountains or
countryside. The new model will
eventually be sold in nearly 100
markets around the world.
Ford is also bringing EcoBoost
powertrain technology to India for
the rst time, in the form of its
newest and smallest ever EcoBoost
engine. With only three cylinders
and 1 liter of displacement, the
latest EcoBoost engine will provide
fuel-efcient power for the EcoSport
as fuel economy plays a key role
for the success of any model in the
Indian car market. Despite its small
capacity and size, the engine delivers
ABOVE: The cars
lines were penned at
Fords design center
in Camaari, Brazil,
which is now part of
a global network of
Ford design studios
collaborating on new
global products
performance to rival a traditional
1.6-liter petrol engine, with less
than 140g/km of CO
2
. The EcoBoost
engines feature direct injection,
turbocharging, and other
technologies, and replace larger
engines with no loss of performance
and with lower fuel consumption.
This new engine will also be
made available in Ford models
in China, Europe, North America,
and other regions.
010
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
Developed at Fords Dunton
Technical Centre in the UK, this
direct-injected EcoBoost engine
features a new compact, high-
performance turbocharger design.
The extremely fast response of the
turbocharger and its ability to reach
nearly 250,000rpm results in
virtually no turbo lag and peak
torque of 170Nm from 1,300-
4,500rpm.
Ford has made certain
innovations in the engine to suit the
Indian conditions. The EcoBoost
engine also features an exhaust
manifold cast into the cylinder head,
which lowers the temperature of the
exhaust gases and in turn enables the
engine to run with the optimum fuel-
to-air ratio across a wider rev band.
An advanced split cooling system
reduces fuel consumption by
warming the engine more quickly
and unique to the 1-liter engine
cast iron has been selected for the
block, reducing the amount of energy
needed for warm-up by up to 50%
The 1-liter EcoBoost is one of the most
technically advanced and efcient engines
Ford has ever designed and produced
Joe Bakaj, vice president of global powertrain engineering at Ford
over aluminum. Intelligent ancillaries
such as a variable air-conditioning
compressor and oil pump also reduce
demand on the engine improving
economy and emissions and
special coatings for engine
components and intricate
development of engine geometry
result in minimal frictional losses.
Like its larger capacity siblings, the
1-liter EcoBoost engine will use twin
independent variable camshaft
timing (Ti-VCT) to further improve
performance and economy. Ford has
also employed an all-new camshaft
actuator to speed up response times
without sacricing durability.
Ford believes these innovations
combined with optimized engine
mounts will deliver a truly rened
performance feel, perfected during
447,000 miles of tests including
224,000 miles of durability trials and
6,000 miles of environmental testing.
Fitted with a long list of innovative
technologies, the 1-liter EcoBoost is
one of the most technically advanced
ABOVE: The cast-iron
EcoBoost engine is
light and lean ideal
for the emerging
markets Ford is keen
to penetrate
WHATS NEW
and efcient engines Ford has ever
designed and produced, says Joe
Bakaj, vice president of global
powertrain engineering at Ford.
This new engine demonstrates
Fords laser focus on improving fuel
economy without compromising
performance. It will be an engine
that not only surprises and delights
our customers but also offers them
great value in the lower cost of
ownership.
Ford believes that this
combination of attributes will make
the EcoSport appealing in growth
markets such as India and Brazil.
EcoSport is the rst One Ford
product to be designed and
developed in South America by
a global team, marking that regions
increasing importance in Fords
worldwide product development. The
creativity behind the EcoSport was
sparked in Brazil, a nation dominated
by compact cars that has become one
of the worlds key emerging markets
as India is fast becoming.
sentinelEX
I N T E G R AT E D D AT A A C Q U I S I T I O N S I G N A L C O N D I T I O N I N G S Y S T E MS
U N R I VA L E D P E R F O R MA N C E
U N R I VA L E D S I M P L I C I T Y
SentinelEX, VTI Instruments 4th generation of Smart dynamic and static
data acquisition instrumentation, builds upon a proud legacy, established in
the 1980s, by continuing to deliver trusted solutions to the marketplace.
Part of the largest worldwide install-base of precision data acquisition instru-
mentation, these innovative products are truly the gold standard for physical
measurements, delivering unmatched condence and performance.
FPGA-based synthetic instrument customization
Corporate wide cloud data management and access
Flexible open architecture hardware and software designs
Exceptional analog measurement and excitation performance
Comprehensive health monitoring and run-time self-calibration
Precision distributed measurement synchronization and control
SentinelEX Series solutions are the perfect t for a broad range of applica-
tions including noise, vibration and harshness (NVH), temperature, strain,
voltage, parallel high-speed acquisition, and pyroshock.
DOWNLOAD COMPLETE SHORTFORM TODAY AT :
http://www.vtiinstruments.com/SentinelEX.aspx
R E L I A B L E D A T A F I R S T T I M E E V E R Y T I M E
High-Speed
Modal or GVH
Shock Testing
Vibration Testing
Order Analysis
Rotating Machinery
Acoustics
Temperature Monitoring
Structural and Fatigue
012
WHATS NEW
their products domestically.
There is also an invaluable
free-to-attend technology
workshop on each morning
and afternoon of the show
featuring speakers from
around the world who will
be sharing their knowledge
of the latest automotive
testing techniques.
The inaugural event in
February 2010 welcomed
nearly 4,000 visitors from
Indias car and component
manufacturing industry.
As N. Prabu, deputy manager
of engineering at Renault
Nissan said in Hyderabad,
From a vehicle
manufacturers perspective,
its great to have the
equipment suppliers all
under one roof.
Why not pay a visit? Entry
is free, and the experience is
invaluable. To register, simply
visit www.testing-expo.com/
india and ll in your details.
and AVL, Automotive Testing
Expo India 2012 is a must-
attend event for any automotive
test engineer.
Highlights for visitors will
include: the announcement
of an agreement between
Olympus, TRL, and Xcitex
that will see the companies
pool their strengths to deliver
turnkey impact test facilities;
the launch of Honeywells
completely digital TMS 9250
digital telemetry torque
measurement system; and the
CT-1000, which its developers,
Control-Tec and Drew
Technologies, claim is the
ultimate data acquisition and
telematics system. In addition,
Automotive Test Systems is set
to reveal plans for its facilities
in Chennai, including setting up
an NVH lab with a state-of-the-
art listening studio and a tire
test lab that will provide the
tire industry and OEMs in India
with an opportunity to test
Expo highlight
The TRL/Olympus/Xcitex
stand will incorporate a
regular live impact sled test
to showcase the quality of
all the components of the
system: a TRL sled, Olympus
cameras, and Xcitex motion
analysis software.
Activated from a central
control booth, the working
4m sled will be red on
a regular basis. Visitors can
follow the entire workow
sled setup, control, and
operation, review the quality
of the video footage, and
perform detailed 3D motion
analysis at the stand,
demonstrated and discussed
by experts from each of the
partner companies.
Following a tremendously
successful launch in
Hyderabad in 2010, this years
Automotive Testing Expo India
is set to be an even bigger event.
For 2012 the show, which takes
place on March 6, 7, and 8,
moves to Chennai, one of the
main automotive manufacturing
regions of India and home to
BMW, Caparo, Ashok Leyland,
Nissan, Daimler India, Ford
India, Hyundai Motor
Engineering, Hindustan Motors,
Mahindra & Mahindra, and
many more.
Over 120 exhibitors will
display technology covering
every aspect of automotive test
and evaluation, including test
simulation, NVH analysis,
engine and emissions testing,
vehicle dynamics testing, and
materials testing.
With exhibiting companies
such as MTS Systems, Horiba,
National Instruments,
Automotive Test Systems,
India insight
One of the worlds fastest-growing automotive markets is home to one
of the industrys fastest-growing events: Automotive Testing Expo India
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
1310 Kalamazoo Street
South Haven, Michigan 49090
Phone: 269.639.7229 Fax: 269.639.7306
Developers of Engine and Powertrain Testing Accessories
WWW.APPENGINC.COM
Dynamometers
-Small Engine Dynamometers
-Gasoline/Diesel Dynamometers
-Types of Dynamometers
-New and used Dynamometers
Engine Handling
-Dynamometer Risers
-Engine Handling Carts
-Engine Cart Receivers
-Small Engine Test Stands
-Engine Handling Accessories
Drive Line Components
-Torsional Couplings (Voith
Kusel)-Driveshafts
-Driveshaft Guards
-Flange Adapters
-Flywheel Systems
Fuel Systems
-Diesel Fuel Systems
-Fuel Supply Systems
-Fuel Measuring Systems
-Fuel Tempering Systems
Cooling Systems
-Engine Coolant Cooling
-Engine Oil Cooling
-Oil Tempering Systems
-Combination Systems
-Dynamometer Cooling Systems
Actuator Systems
-Standard Duty Throttle Actuators
-Heavy Duty Actuators
Froude Hofmann
Blackpole Road, Worcester, WR3 8YB, United Kingdom
sales@froudehofmann.com| Tel: +44 (0) 1905 856 800
ADVANCED FLEXI BI LI T Y, ADVANCED SI MULATI ON, ADVANCED ENGI NEERI NG
FROUDE HOFMANN has developed and supplied the ultimate in vehicle chassis and powertrain testing
technology with its multi -vehicle test system able to exceed emission standard accuracy and correlation,
while achieving the flexibility to test the latest innovations in driveline technology in motorcycles,
electric vehicles and 4x2 or 4x4 medium duty vehicles. The four rollers are each independently
controlled by separate motors and accurately synchronised to provide through the road simulation. The
ability to test hybrid and kinetic energy recovery systems is enhanced with the flexibility to test Traction
Control Systems, ABS brake systems, cornering simulation and collision avoidance systems . Combined
with Froude Hofmanns vDriver
TM
real world road simulation package and automated robot driver, testing
technology has been re-engineered to a new advanced level of accuracy, repeatability and flexibility.
www.froudehofmann.com
FROUDE HOFMANNENGI NEERI NGSUCCESS
THE ULTIMATE IN ADVANCED VEHICLE POWERTRAIN TESTING
FROUDE HOFMANN has developed and supplied the ultimate in vehicle chassis and powertrain testing
technology with its multi-vehicle test system able to exceed emission standard accuracy and correlation, while
achieving the flexibility to test the latest innovations in driveline technology across a range of applications
from motorcycles to electric vehicles and 4x2 or 4x4 medium duty vehicles. The ability to test hybrid and
kinetic energy recovery systems is enhanced with the flexibility to test Traction Control Systems, ABS brakes,
cornering simulation and electronic driver assistance systems, such as collision avoidance. Combined
with Froude Hofmanns vDriver
TM
real world road simulation package and automated robot driver, testing
technology has been re-engineered to a new advanced level of accuracy, repeatability and flexibility.
resized.indd 1 09/02/2012 15:56
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012 014
No one can deny the enormous strides
that auto makers around the world,
specically those in the massive US market,
have made in designing and producing
engines that are far more fuel-efcient than
those of 25 or 30 years ago. Driven by the
twin demands of diminishing oil reserves
and the need to reduce climate-damaging
emissions, engineers have all but surpassed
themselves with their achievements to
date and the encouraging prospects
for future models.
But there is a problem, a big problem.
And its particularly serious in the USA,
where gas prices are still incredibly low
compared with fuel costs in Europe and many
other major vehicle-using territories. Despite
great improvements in engine fuel efciency,
actual mpg gures in the USA are nowhere
near as good as they should be because
not being too bashful about it cars have
become more muscular and obese.
Its taken an economist at the Michigan
Institute of Technology (MIT), which is
renowned for its work in the automotive
sector, to highlight the statistics that show
two key facts. One, when gas prices are too
low, customers demand big, powerful, and
thirsty automobiles; and two, auto makers
have given in to this demand with little or
no apparent regard for the consequences.
So who is the whistle-blower? His name
is Dr Christopher Knittel, who joined the
faculty at MIT last year having taught
previously at UC Davis and at Boston
University. Knittel received his BA in
economics and political science at the
California State University, Stanislaus,
an MA in economics at UC Davis, and a PhD
in economics at UC Berkeley. And, because
he is a research associate at the National
Bureau of Economic Research, his views
clearly carry (without being facetious)
a lot of weight.
In a powerful presentation entitled
Automobiles on Steroids he points out that
between 1980 and 2006 the average fuel
economy of autos sold in the USA improved
by just over 15%. But the average curb
weight of those vehicles increased by
26% and horsepower shot up by 107%.
However, if Americans were today driving
cars of the same size and power that was
typical in 1980, the CAFE for the nations eet
of autos would have jumped from an average
of 23mpg to about 37mpg, well above the
current CAFE of around 27mpg. The 10mpg
discrepancy comes, says Knittel, as a result
of most of the technological progress in fuel
efciency having to compensate for the
increased weight and higher horsepower.
It has, therefore, in effect been wasted.
In terms of the environment, he points
out that with the transportation sector
producing more than 30% of US greenhouse
gas emissions, turning the full improvement
in fuel economy would have produced
notable environmental benets. Indeed,
had cars in the USA remained at roughly
the same weight and power as those of 1980,
Actual mpg gures in the USA are
nowhere near as good as they
should be because cars have become
more muscular and obese
A WEIGHTY PROBLEM
OPINION
the country would already be boasting a eet
average economy some 1.5mpg better than
the CAFE target of 35.5mpg set by President
Obama for achievement in 2016.
Interestingly, Knittel does not hold the
auto industry entirely responsible for the
wasted benets. Quite the opposite. He
praises the development and introduction
of turbocharging and efcient fuel-injection
systems that have replaced carburetors.
He points out that most vehicles now have
multiple camshafts that enable a smoother
ow of fuel-air mixture into the engine and
exhaust gases out. He applauds variable-
speed transmissions, dual-clutch
developments and gearboxes with six,
seven or eight ratios that optimize
engine performance.
Whats more, he says that because there
has been no [government] incentive to direct
these innovative technologies toward
reducing overall fuel consumption, he can
nd little fault with the auto makers. He
cites the 30% reduction of gas prices (when
adjusted for ination) as counter-productive
and believes that raising gas taxes is the
best way to reduce automotive emissions.
Knittel has this message to all auto
manufacturers: now is the time to shift
your focus to making vehicles more efcient
for the sake of overall efciency not
performance. It can be done without
sacricing weight or performance.
That, of course, is a message long-
advocated in Europe and, in many cases,
comprehensively adopted. Former F1 race car
designer Gordon Murray has been telling us
for many years that the fastest, easiest and
cheapest route to cutting fuel consumption
and reducing CO
2
emissions is to cut the size
and weight of our cars.
Surely its time now for the US authorities
to listen to Murray and Knittel and act.
Keith Read spent many years as
communications manager at MIRA before
becoming an industry commentator
OPINION
The issue of EMC is something that we
all need to understand. Im no expert
on EMC, but it is an important part of the
vehicle development process.
As a mechanical engineer, I dont trust
anything I cant see, and todays complex
automobiles require us to control things
we cant see or suffer the consequences.
Five decades ago, the worst that could
happen with electromagnetic interference
might be poor AM radio reception. Now
the consequences can be catastrophic.
EMC design and testing in the automotive
arena have come a long way, but it is clear
that the state-of-the-art must improve
rapidly. The current state is to manage EMC
at the component, systems, and vehicle level.
Electrical components must be designed
to minimize electromagnetic emissions and
maximize immunity to external emissions
(from other vehicle components or the
external environment).
Today there are few analytical, physics-
based tools to simulate EMC using both
circuit simulation and electromagnetic
theory. That leaves the bulk of the work
to testing compliance at the component,
systems, and vehicle levels, including
wiring harnesses.
Things get even more difcult as hybrids,
PHEVs, and BEVs become more prevalent.
With the addition of high-power, high-
voltage electronic devices, complexity
grows exponentially. I experienced this
rst hand while conducting Car of the
Year judging: starting up a new BEV, the
right rear passenger window decided
to lower itself!
Whether this was due to a software
error, bus communication problems, or
electromagnetic interference, Ill never
know. One thing is certain: my experience
demonstrates how critical EMC will be
in this brave new world.
Toyotas unfortunate experience
last year with unintended acceleration
demonstrates the high stakes associated
with failures we dont understand.
Imagine the potential consequences
with the advent of autonomous vehicles.
Product liability attorneys will have a eld
day making manufacturers prove that
something unexplained cant happen.
Its only a matter of time before sunspots are
blamed for vehicle failures in plaintiffs suits.
EMC must be taken seriously. This is
a mysterious subject that Automotive
Testing Technology International will allow
readers to understand better. As they say,
an ounce of prevention
GM sells MESA
UK facilities report boom
LONDON Three UK proving
grounds have reported booming
business with record turnover.
MIRA saw revenue increase in
2011 to almost US$64.5 million
from US$57 million in 2010
itself a record year.
A big increase in defense
contracts has, says MIRA CEO
Dr George Gillespie, helped to
boost earnings. We have a
forward-looking order book of
US$30.5 million. In the sectors
we serve were not seeing any
signs of a double-dip recession
just continued growth.
Bruntingthorpe Proving
Ground started 2012 by winning
the MIA Business Excellence
Award for services to the
high-performance engineering
industry as well as planning
consent from its local authority
to develop an innovation park
(pictured above) within its
670-acre site a former USAF
Cold War airbase.
Bruntingthorpes managing
director, Dave Walton, said, Our
new, ultra-modern development
will bring opportunities and
commercial benets to what is
a thriving industry one that
is contributing greatly to the
national economic recovery.
Millbrook also reported a
record year in 2011. Neil Fulton,
head of sales and marketing,
said, All areas did exceptionally
well, especially vehicle test and
durability, and powertrain and
emissions. We have seen
powertrain test labs running
around the clock and an
unprecedented number of
vehicles on our tracks. In 2011,
there was 75% more track-based
vehicle activity than in 2010.
Fulton also revealed plans
to upgrade the emissions and
vehicle safety facilities.
DEARBORN Sue Cischke
has retired after a 35-year
career in the automotive
industry. Since joining Ford
in 2001, Cischke has served
as the companys top
environment and safety ofcer
and was appointed group VP
of sustainability, environment,
and safety engineering. But it
was at Chrysler that she started
her career and held various
key positions,
including general
manager of
scientic labs
and proving
grounds.
Its been an honor to work
35 years in the auto industry
and dedicate my career to
delivering ever-safer and
more efcient vehicles to
our customers, she said.
Aberdeen Test Center
www.atc.army.mil
ACTS
www.acts.de
Arctic Falls AB
www.arcticfalls.se
Arctic Testing Services
www.arctictesting.
Arjeplog Test Center
www.arjeplogtestcenter.com
ATP Papenburg
www.atp-papenburg.com
Bosch
www.bosch.us
CERAM
www.ceram-mortefontaine.fr
Cooper Tire and Vehicle
Test Center
www.tvtc.us
Dayton T. Brown
www.daytontbrown.com
Deance Testing
and Engineering
www.deancetest.com
IDIADA
www.idiada.com
Gerotek Test
Facilities
www.gerotek.co.za
Keweenaw Research Center
www.mtukrc.org/school.htm
Magna Steyr
www.magnasteyr.com
MGA Research
www.mgaresearch.com
Michigan Proving Ground
www.testprofessionals.com
Millbrook
www.millbrook.co.uk
MIRA
www.mira.co.uk
Nevada Automotive
Test Center
www.natc-ht.com
PMG Technologies
www.pmgtest.com
Prodrive
www.prodrive.com
Prototipo
www.prototipo.org
Smithers Winter
Test Center
www.wintertesting.com
Southern Hemisphere
Proving Ground
www.shpg.co.nz
Southwest Research
www.swri.org
TNO Automotive
www.automotive.tno.nl
Transportation Research
www.trcpg.com
P
R
O
V
I
N
G
G
R
O
U
N
D
S
MESA General Motors
has nally sold off the
last 3,200 acres of the
Mesa Proving Ground in Arizona
for US$265 million. The land
will be developed for housing.
Mesa was opened in 1953
to complement GMs Milford
Proving Ground in Michigan
the industrys rst dedicated
automobile test facility, dating
from the early 1920s and
provide year-round hot-weather
testing. GM sold the rst 1,800
of the sites 5,000 acres in 2004.
In July 2009, the General
joined the US Army at its Yuma
Proving Ground, Arizona,
opening a new hot-weather test
facility there. The auto maker
signed an agreement to
co-develop and administer
the site with the Army.
Despite defense cuts, the
Yuma Proving Ground was the
US Armys busiest test center in
2011, clocking up 2.77 million
direct labor hours, which
accounted for 30% of the
Armys total test workload.
YPG spokesman Chuck
Wullenjohn said the record-
breaking feat was largely due
to a huge increase in vehicle
testing done by the Combat
Automotive Division, which
accumulated 1.07 million labor
hours, a 6% increase on 2010.
He expects the level of testing to
remain steady this year: There
arent going to be any huge
increases or decreases.
Proving ground directory
MORE GROUNDS ARE LISTED AT
WWW.AUTOMOTIVETESTINGTECHNOLOGYINTERNATIONAL.COM
If you would like your facility to be included in the Automotive Testing Technology
International proving grounds directory, please contact Jason Sullivan on:
+44 1306 743744, or email: jason.sullivan@ukipme.com
Former Chrysler proving ground manager retires
KIKUGAWA Yamaha is reviving its plan to build a fth test
facility in Japan. Work on the Kikugawa proving ground
which was due to start in 2009 and be completed toward the end
of 2012 but fell victim to the recession will start soon but with
a reduced budget.
The facility will cover 121 acres its largest in terms of area and
feature a 1.18-mile closed course. This is shorter than the originally
planned 1.86-mile track. Yamaha will use the test facility to develop
its high-performance and small-displacement motorcycles intended
for developing markets. It will be far from a conventional, at race
speed track as it will incorporate dusty and hilly sections to
simulate real-world conditions.
Yamaha revives fth test facility
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
022
INDIANA Half a mile long
and visible from space, the
Studebaker arboreal sign at its
former proving ground now
owned by Bosch is causing
some concern. The 5,000 red
and white pine trees, planted by
the Civilian Conservation Corps
in 1938 some 12 years after
Studebaker opened the site,
have survived without a
maintenance budget. But thats
about to be put right with the
help of a US$2,500 endangered
places grant to preserve and
maintain the sign.
Tree time at Studebaker
Bigger and better
than ever before
Noch grer,
noch besser
Cooling performance
beyond limits
Bowman heat exchangers are
renowned worldwide for their high
performance cooling efficiency and
operational reliability. Thats why
theyre already the first choice for
many OEMs and Motorsport teams.
And with a comprehensive product
range plus full technical advice,
product support and rapid ex-stock
delivery, you can have complete
confidence when you specify
Bowman heat exchangers for your
test house cooling facility.
Bowman test house equipment
includes:
Charge Air Coolers
Hydraulic oil coolers
Exhaust Gas Heat Exchangers
Fuel Coolers
Header Tank Heat Exchangers
In Line Plate Type Heat Exchangers
Stainless Steel Heat Exchangers
For maximum cooling performance
beyond limits, choose
Bowman Heat Exchangers.
Quality without compromise.
SHPG offers the automotive
industry the opportunity to
develop seamless cold climate
R&D programmes through state
of the art counter-seasonal cold
climate testing during the Northern
summer months - June August.
JUNE - AUGUST WINTER TESTING
southern hemi sphere
Contact SHPG for all your winter testing requirements. Southern Hemisphere Proving Grounds Ltd. PO Box 350,
Cardrona RD.1, Wanaka, New Zealand tel: + 64 3 443 0344 email: admin@shpg.co.nz www.shpg.co.nz
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
074
From 2014, current
proposals for Euro 6
would apply limits
on particle number (N/km)
emissions for both gasoline
direct injection and diesel
light-duty vehicles, and
reduced diesel NOx limits.
In the case of diesel
vehicles, compliance with
the particle number limits is
exclusively via tting diesel
particulate lters. Particularly
in the case of gasoline direct
injection (GDI) engines,
Cambustions DMS500
fast-response particulate
analyzer offers crucial insights
and assistance with particle
emissions compliance.
The reduced NOx limits
that apply to diesel vehicles
are likely to require some
form of aftertreatment such
as selective catalytic reduction
(SCR). The highly variable
nature of engine-out NOx
poses some difcult control
problems in urea dosing.
Since the air and fuel ows
in a ring engine can change
rapidly, the extra insight into
engine operation offered by
fast-response gas analyzers
has proved valuable in meeting
emissions legislation in a
cost-effective and timely way.
The Cambustion fast
NOx analyzer offers NO
and NO
2
measurement with
a response time as fast as
2ms. This gives aftertreatment
engineers the opportunity
to obtain high-frequency
data about engine-out NOx
during transients, which
can be used to rene the
SCR dosing model.
The problems of GDI
particle emissions are
essentially those of mixture
preparation and AFR control.
The former is particularly
difcult at cold start, while
the latter remains an issue on
throttle transients throughout
the drive cycle, where the air
and fuel ows change rapidly.
Legislated systems measure
cycle particle emissions
correctly, but are less
effective in a development
environment, where their
slower response time reduces
their usefulness for transient
calibration work.
Cambustions DMS500
is specically designed to
system (only power and
compressed air are required
for operation), and integrating
with existing test-bench
equipment via AK or analog
connections, the DMS500 can
add instant particle number
capability to a facility, with the
added advantage of particle
size and mass measurements,
should the project require it.
Since the standard
DMS500 is capable of raw
exhaust gas sampling, it allows
development in test cells
where CVS tunnels are not
available. A typical application
is strategy and calibration
development to reduce particle
number emissions. In this
application, the instrument
can run unattended under
control of the test bench,
allowing a mapping process
to be completed efciently.
Parameters affecting particle
emissions include injection
timing, split injection, valve
timing, ignition timing, and
EGR, with the DMS500s
fast response time allowing
efcient optimization.
Gasoline particulate lters
(GPF) are another potential
solution to reducing particle
number emissions from
gasoline vehicles. Unlike
a DPF, a GPF never reaches
very high ltration efciencies,
since higher exhaust
temperatures mean the
soot load on the lter never
becomes signicant. In this
case, the DMS500 is used
upstream of the GPF to reduce
input soot concentration,
and downstream to measure
GPF performance.
5
0
6
O
N
L
I
N
E
R
E
A
D
E
R
E
N
Q
U
I
R
Y
N
U
M
B
E
R
Euro 6 emissions
challenges
The latest fast-response gas analysis technology could be a useful
tool for those preparing for changes in emissions legislation
Cambustion
Tel: +44 1223 210250
Email: sales@cambustion.com
Web: www.cambustion.com
ABOVE: Cambustions DMS500 offers
a fast-response particulate number
LEFT: Fast-response emissions
analyzers for transient cycle
development
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
measure transient engine
particulate in a test cell
environment. Measuring
particle size, mass, and
number enables the DMS500
to be used as a development
tool for a variety of standards.
The DMS500 offers the best
response time available (10Hz
data, 200ms T
10-90%
) in an
engine exhaust particle
number instrument. This
allows the resolution of
features that are not revealed
by certication systems,
such as the effects of AFR
uctuations, or spark and
injection strategy.
Featuring a fully integrated
sample handling-and-dilution
248.373.9097 |sales@oriontest.com | www.oriontest.com
Announcing Our New Location in Pune, India
DETROIT, USA TORREON, MEXICO POZNA, POLAND PUNE, INDIA
Test & Assembly Systems
for Electronic, Mechanical,
Hybrid and Hydraulic/Fluid
Components
Production Testers
Laboratory & PV/DV Testers
Assembly Stations
Tooling & Fixtures
Custom Software
See us at the
Chennai Expo
Booth No. 3081
World Headquarters, Auburn Hills, Michigan
Durability and Performance
www.hbm.com/ncode | info@hbmncode.com
Analyze vast amounts of measured
data with specialized functionality
for fatigue and durability testing.
Predict fatigue up-front using
nite element analysis to optimize
designs and reduce costs.
Learn from and share all your test
data in a secure, web-based
environment for automated data
storage, analysis, and reporting.
The most complete range of advanced products for when failure is not an option
Signicant new technologies introduced for
physical test and CAE durability
www.hbm.com/ncodewebinars
Now available
in nCode 8:
RAC0687_VB-ATTI-fp-feb12-p.indd 1 24/01/2012 14:21
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
ACS
Tel: +1 608 663 1590
Email: acs-us@acscm.com
Web: www.acscm.com
Global standardization of test facilities
507
As automotive
companies continue
to expand their global
footprint, ACS provides design and
construction management, as well
as system integration services,
to deliver standardized testing
facilities throughout North and
South America, Europe, and Asia.
ACS delivers functional test
facilities through its Integrated
Project Delivery model. The project
teams accomplish this by tapping
into their knowledge of building
design and construction, and
combining it with expertise in
industry regulations, testing
technology and applications, and
the ability to fully integrate building
and test systems. By partnering
with its US-based clients, ACS
helps meet clients needs to create
equivalent, standardized test
facilities around the world.
ACS leverages its expertise in
the design of test facilities and
equipment to help clients meet
complex test requirements, design
for future test needs, meet
regulations, and increase cell
utilization. ACS works with clients
to determine the best way to help
them achieve their goals. This
could involve conceptual design;
equipment specication, selection
and procurement; fabrication of
custom equipment; facility
integration; construction
management; and commissioning,
operations and management
services.
508
Torsional vibration
analysis is a vital
part of the drivetrain
development process. The
vibrations caused by processes
occurring inside the engine do
not just impair the level of driving
comfort, but can also have
noticeable effects on individual
components, even going as far
as destroying them completely.
Targeted data acquisition
reveals the starting points for
component and construction
optimization, as well as the
sources of interfering vibrations
and noises. PikesPEAK
is the broadband, modular
measuring system for high-speed
measurements and torsional
vibration analysis by AFT Atlas
Fahrzeugtechnik. It offers up to 30
analog channels with sampling
rates that can be individually
congured up to 500kHz. The
measuring system allows the
CAN-based 4Measure modules
(temperature, voltage, current,
strain gauge, active sensors) to be
integrated. A module can simply
be plugged into the PikesPEAK
housing and incorporated into the
complete measuring system. This
makes the modules much easier
for the user to operate.
Technical highlights include:
a multiprocessor architecture
with 1GHz PowerPC and FPGA;
a high-speed engine speed
module with a resolution of
<0.1ns as the basis for a speed
sensor with digital (TTL) output;
and a high-speed analog module
with a sampling rate of 500kHz
per channel and extended
voltage range.
AFT Atlas Fahrzeugtechnik
Tel: +49 2392 8090
Email: info@aft-werdohl.de
Web: www.aft-werdohl.de
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
AOS Technologies AG
Tel: +41 56 483 3488
Email: info@aostechnologies.com
Web: www.aostechnologies.com
S-VIT F3 breaks barriers
077
Precision for torsional
vibration analysis
509
The new S-VIT F3 by
AOS Technologies
offers high specs such
as: up to 700fps at HDTV-image
resolution (720p); up to 2,100fps
at 512 x 512; and a maximum
frame rate of 6,000fps at 270 x
270. The powerful, easy-to-operate
control software is compatible with
third-party control networks and
allows users to download the
image data directly in popular
data formats like MPEG-4.
The new S-VIT F3 includes
features from earlier S-VIT
cameras such as: shock-
resistance up to 100G; a built-in
battery for best image protection;
and a compact design with a small
footprint to t into tight spaces.
The S-VIT F3 offers input
and output control lines for
a simple integration to larger
camera systems. The camera is
compatible with other high-speed
cameras. Specially designed
accessories such as lens cages
increase the value of the camera
even further.
Full-scale car crash tests and
sled tests, as well as rollover
tests, are typical applications
in which the S-VIT F3 proves its
performance, reliability, and
exibility.
Despite its feature set and
performance, plus its Swiss made
precision, the S-VIT F3 is offered
at an attractive and highly
competitive price.
Take cutting-edge wind tunnel technology. Add a 180 mph rolling road.
And build in the best in precision data acquisition capabilities. When we
created the worlds rst and nest commercially available full-scale testing
environment of its kind, we did much more than create a new wind tunnel.
We created a new standard in aerodynamics.
1 8 0 M P H WI T H O U T M O V I N G A N I N C H
+1 704 788 9463 I NFO@WI NDSHEARI NC. COM WI NDSHEARI NC.COM
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
079
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
510
Time in the wind tunnel
is always at a premium,
so Brel & Kjr has
developed dedicated tools to help
engineers assess noise source
distribution rapidly and efciently.
A new foldable half-wheel
microphone array gives improved
precision due to its optimized
structural geometry, while saving
considerable transport, setup, and
cabling headaches.
The numerically optimized
microphone positioning minimizes
ghost images by suppressing
undesirable side
lobes in the data, while a built-in
reference camera helps document
the measurements. It joins a
comprehensive array suite from
Brel & Kjr, and is engineered to
safely acquire reliable data in the
tough conditions of wind tunnels
and test tracks.
For wind-tunnel measurements,
rened beam-forming software
has been developed with industry
partners. This software improves
beam-forming spatial resolution
by a factor of three using
deconvolution methods, for
precise independent noise source
identication making it a detailed
tool for ranking contributions from
component combinations such as
door pillars and mirrors.
One-button operation initiates
automatic calculation, retaining
the single-shot operation and
then post-processing the data to
achieve the dramatic accuracy
improvements. Results are simple
to display and export using
drag-and-drop operation, and
as part of Brel & Kjrs well-
established PULSE platform, the
software is versatile and fully
backwards-compatible.
D2T Powertrain Engineering
Email: sales@d2t.com
Web: www.d2t.com
511
D2T Powertrain
Engineering is
launching a new
version of its MORPHEE automation
system. It has been designed to
adapt perfectly to component
testbed applications, in addition
to countless applications for
engine test-benches and
powertrains.
With 2,500 licenses, 10,000
users, and 12 million bench-
rotation hours per year, MORPHEE
is a worldwide standard. This new
version works in Windows 7 and
offers excellent component testbed
performance. It allows the
integration of MATLAB SIMULINK
simulation models on the testbed
and can rotate in real time at
frequencies up to 10kHz. This
functionality, along with its usual
characteristics, makes MORPHEE
an ideal system for new
applications battery test-beds,
for example.
Currently, a battery testbed
often performs relatively simple
operations: charge/discharge
testing, capacity testing, and
resistance measurements.
However, these test beds will be
increasingly used to ne-tune the
battery management system and
for this reason, they integrate
advanced simulation
functionalities. MORPHEEs
user-friendly characteristics
allow this type of bench to
evolve easily toward simulation.
Brel & Kjr
Tel: +45 7741 2000
Web: www.bksv.com
Rened wind-tunnel technology
512
DEWETRON-RLD test
instruments guarantee
synchronous
measurement of all signal types.
The universal analog inputs
are well-suited for voltage,
current, bridge, ICP sensors,
thermocouples, Pt100 to Pt1000,
and charge measurements. As
well as analog data, video, GPS,
CANbus, FlexRay, digital status
information, and counters are
also acquired. Most popular
enhanced sensor systems such
as KistlerRoaDyn 2000 wheels
or GeneSys INS/GPS platforms
are supported, and can even be
hardware synchronized to
DEWETRON-RLD instruments.
For managing simple sensors,
a powerful sensor database
and TEDS support are integrated.
DEWETRON-RLD systems offer
high-quality analog inputs with
22-bit resolution and anti-aliasing
lters. Other practical functions
include sensor balance and shunt
calibration for bridge/strain gauge
inputs. The systems can ash test
all inputs for errors and the
overload display shows the status
of all recorded signals at a glance.
Complete instrument and sensor
set-up can be carried out ofine
through an XML le. RLD systems
are of dual-use in vehicles, or
at test rigs. Results of road
measurements are exported to
RPCIII format and provided to
the test-rig controller. The RLD
systems real-time analog output
is used to support the control loop
with measurement feedback.
Export functions for analyses and
reports in Excel, DIAdem, FlexPro,
and Matlab are included.
The typical RLD conguration
is the DEWE-501 with 64 analog
inputs, four CAN, two Ethernets,
and a number of DIO counters.
It is easily expandable to
128 analog channels and
eight CAN.
DEWETRON
Email: info@dewetron.com
Web: www.dewetron.com/rld
Road load data systems
for durability testing
MORPHEE becomes more open
Roads to every testing destination
SignalCalc
Dynamic Signal Analyzers
SignalStar
Vibration Control Systems
SignalForce
Shakers & Amplifiers
Now there is one trusted name
you can turn to for proven test and
measurement solutions. For over
25 years, Data Physics has been
driven by its customer needs to
develop, internally and through
acquisition, a full range of power-
ful technologies for noise and
vibration applications.
Roads to every testing destination
Powered by
Solutions to Test and Measurement challenges from
people who are driven by them.
Roads to every testing destination
of
25
Test & Measurement
INNOVATION
Y
E
A
R
S
1984 - 2009
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
081
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
Dytran Instruments
Tel: +1 818 700 1818
Email: info@dytran.com
Web: www.dytran.com
Accelerometers for ride quality
and vehicle dynamics studies
Imtech
Tel: +49 40 6949 2527
Email: zentrale@imtech.de
Web: www.imtech.de
Mobile combustion air-conditioning unit
513
The mobile combustion
air-conditioning unit
ComCon is used for
the research and development of
combustion engines. It realizes
the stipulation of intake air under
standard conditions, as well as
special conditions of intake air on
engine testbeds. The following
engine intake air parameters can be
conditioned: pressure, temperature,
and relative humidity. The unit fulls
the following demands: AK-
specication of mobile combustion
air-conditioning units for engine
testbeds, VDI/VDE guidelines,
DIN-standards, and equipment
safety laws.
The advantages of the Imtech
ComCon are: it is a mobile unit with
easy handling and plug-and-test
installation; it offers continuous
control; it has an additional
temperature sensor for the intake
air; it has tailor-made software for
the dynamic control loops; and it
has a user-friendly operator level.
The main focus of application is
simulation of different pressure
values of intake air with high
repeatability of measurements
and short-term availability.
The Imtech ComCon
is available in different air-mass
ows from 1,000 to 3,000kg/h.
The unit can simulate temperature
range from +15C to +35C
(accuracy 1 K); humidity range
from 15 to 75% rH (accuracy
3%); and pressure range from
900 to 1,100 mbar (accuracy
1 mbar).
515
Dytran Instruments
has recently expanded
its DC MEMS
accelerometer offerings to include
new models designed for use in tilt
measurements, crash test, and
other low-frequency vibration
measurements.
Included in the new models now
available from Dytran is the 7503A
series, a family of low noise,
triaxial DC MEMS accelerometers.
Offered with a choice of seven
different measurement ranges
from 2 to 200g, these high-
precision variable capacitance (VC)
sensors combine an integrated VC
chip. The sensors offer a low -nd
frequency response down to DC,
with an upper frequency range
between 400 and 2,500Hz with
differential output. Units are rugged
to 5,000g shock and operate from
+9 to +32 VDC power.
In addition to the 7503A series,
Dytran has released the 7600B
series, a family of high-precision
VC accelerometers designed for
use in crash test and ride-quality
applications. Available in six
models, with ranges from
5-200g, the Dytran 7600A series
incorporates a MEMS capacitive
sensing element and an advanced
ASIC to simulate piezoresistive
bridge operation, as well as
an integrated VC accelerometer
chip. Units use the same power
supply as traditional piezoresistive
and strain gauge sensors, allowing
them to operate as standalone
differential output or in place
of piezoresistive bridge-
type accelerometers.
Moog
Email: test@moog.com
Web: www.moog.com/test
Hydraulic simulation table
514
Moog, a leader in
high-performance
systems and products
for automotive and aerospace
testing, has designed and
manufactured a hydraulic
simulation table based on the
companys latest line of hydraulic
test actuators. This offers more
capability than a conventional
orthogonal system, which is a table
moved by actuators mounted on
its base and sides. The hydraulic
simulation table is a six-legged
hexapod with two equilateral
triangular frames set one above
the other, offset at 30. Each apex
of the top triangle is connected to
the two apexes below it via Moog
hydraulic test actuators with
hydrostatic bearings.
The table gives a frequency of
response up to 100Hz and can
handle payloads up to 680kg
(1,500 lb). Auto-makers and test
houses can use this table to
replicate real-world road
conditions that strain automobile
components such as axles;
engines; interior and exterior
assemblies; seats, steering column
assemblies; cooling module
systems; truck and tractor cabs;
and aftertreatment systems.
As our customers use the
simulation table for more tests,
some features clearly emerge
as key advantages. Firstly, higher
delity means a more realistic
test, says Tobe Ehmann, Moogs
product line sales manager for
test and simulation. Secondly,
compared to classic orthogonal
systems, the hexapod form factor
of the Moog Simulation Table has
a smaller footprint, just one-third
the size of classic systems, which
creates more oor space.
Steve Panter, operations
manager of Exova, purchased such
a table last year, and says:
A lot of damage occurs within the
range from 50 to 80Hz when a
company does testing analysis.
With a lower performance
simulation table, results are often
ltered down to 40Hz, so any
damaging events beyond that point
are not captured. The Moog
hydraulic simulation table allows
those events to be included in the
scope of testing, and broadens the
value of the testing process.
Moog designs and manufactures
the servo valves, actuators, test
controllers, and software used
in the hydraulic simulation table.
(888) 665-2677 | www.eyesolarlux.com
EYE Lighting International of North America, Inc., a division of Iwasaki Electric of Japan
APPLIED OPTI
The air conditioning system is the single largest auxiliary load on a
vehicle by nearly an order of magnitude. EYE Applied Optix Solarlux
full spectrum lamps faithfully simulate the natural environment within
your emission test chamber to help ensure the most accurate and
repeatable SC03 STFP testing. Results will be so close to real life, the
car will believe its out on the open road.
Is AC Robbing
Your MPG?
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012 083
LaVision
Tel: +49 551 9004-0
Email: info@lavision.com
Web: www.lavision.de
EGR-rate examination inside
engine cylinders
KMT Kraus Messtechik
Tel: +49 8024 48737
Email: info@kmt-gmbh.com
Web: www.kmt-gmbh.com
Flat and exible transmitter
for torque measurement
Filter Weighing
Solutions
The easy way to determine
particulate matter on Filters.
A range from Manual
to Robotic Weighing
www.mt.com/filter
For Videos and Webinars please join us at:
516
LaVisions ICOS (Internal
Combustion Optical
Sensor) product family
provides a series of new techniques
for the measurement of quantitative
engine-relevant values inside
engine cylinders, such as air/
fuel-ratio, temperature, or the
EGR-rate. All systems are
applicable in gasoline, as well
as in diesel experimental, or
production engines.
The newest trends in
recirculated exhaust gas
management are based on
variable valve timings to control
the EGR-rate. The new LaVision
ICOS-EGR system can precisely
measure the cycle-resolved
EGR-rate directly inside the
cylinder. Both internal and external
EGR-rate components
are determined. Cyclical variations
of internal and applied external
EGR-rates at different engine
conditions can be analyzed easily.
When using multiple probes in
different cylinders simultaneously,
the EGR distribution between the
cylinders can be analyzed exactly.
LaVisions ICOS-systems do not
need any complex gas extraction
systems. The robust and
easy-to-handle optical probes are
designed to be used directly inside
the cylinder without modication.
The probes are available as
spark-plug probes or small
non-ring probes, which can be
used in typical pressure transducer
threads or glow-plug adapters for
diesel engines.
517
The new TEL1-PCM
Flex transmitter
electronics from KMT
couple the efciency of the existing
TEL1- PCM transmitter with new
exibility. With a maximum overall
height of less than 2mm, the rotor
electronics unit is extremely at.
Mounted on a exible, foil
substrate, its space-saving design
enables it to be easily applied to
rotating shafts or similar machine
parts. The rotor electronic includes
the sensor supply, signal
processing and transmitter for
the contactless data transmission
of the measured signal.
The low-prole TEL1-PCM
Flex is also ideally suited for
applications involving high
rotational speeds. The
supplementary onboard inductive
power supply ensures continuous
and reliable measurements from
the rotating shaft.
Today, it is more important than
ever to have reliable, detailed
information about torque, vibration,
or other feedback signals by
metering the different types of
applications. The TEL1-PCM Flex
telemetry system helps you to
capture this data even from
rotating applications. A very small
rotor electronic, installed directly
on the shaft ,captures, conditions
and transmits the measuring data
to an inductive powerhead
(pick-up). After this, the
information can be reproduced on
the output of a stationary decoder.
Because it is easy to install and
can be powered inductively or with
a battery, it is a real all-rounder for
measurements on rotating
machinery. There is no easier way
to run wireless data transmission.
AUTOMOTIVE TESTING EXPO CHINA 2012
Abinger House, Church Street,
Dorking, Surrey, RH4 1DF, UK
Tel: +44 (0) 1306 743744
Fax: +44 (0) 1306 877411
email: dominic.cundy@ukipme.com
www.testing-expochina.com
Our business partner in China is:
Mr. Wilko Fong
Reliable International Exhibition Services Co Ltd
Rm.1702, Bldg.6, SOHO New Town,
No. 88 Jianguo Road, Chaoyang District,
Beijing 100022, P.R. China
Tel: +86 10 85898181 Fax: + 86 10 85898180
Email: wilko_fong@reliable.org.cn
September 18-20, 2012
The Shanghai Everbright Convention &
Exhibition Center, Shanghai, China
Chinas ONLY automotive test, evaluation
and quality engineering trade show
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
085
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
520
OAK Racing, through
its Onroak Automotive
division, is active as a
chassis designer and manufacturer
in the LMP1 and LMP2 classes.
The design ofce, led by Nicolas
Clmenon, relies on RUAGs AWTE
wind tunnel to test its prototypes.
We performed two wind-tunnel
campaigns at the end of 2011 to
adapt our cars to the new ACO
rules for LMP1 and LMP2,
explains Clmenon. Typically,
after the installation of the model,
which is specically built for these
tests, the wind tunnel is run 12
hours-a-day for four to ve days.
RUAG provides a dedicated
customer room, where the results
are shown in real time, continues
Clmenon. These are analyzed
immediately before the next change
on the model is performed.
We have been working with
RUAG since 2008 and have
performed 12 test campaigns.
We have always found an excellent
correlation between the wind-
tunnel results and the observations
on the track, adds Clmenon.
Racelogic
Web: www.velocitybox.co.uk
Accurate slip angle measurement
518
UK-based electronics
company Racelogic
has recently made
a huge breakthrough in vehicle
dynamics testing technology, with
the launch of a GPS data-logger
that enables you to measure slip
and pitch/roll angles with low
latency at 100Hz.
The new VBOX 3i Dual Antenna
(VBOX3i SL) uses two antennas
placed a xed distance apart (along
the vehicle for pitch and across for
roll). By utilizing both the GPS and
Russian GLONASS constellations,
RMS accuracies of up to 0.04
for slip and 0.028 for pitch can
be achieved.
The system is so accurate that
you can even measure the small
effect a side wind has on the slip
angle of a moving vehicle a feat
that even the best inertial systems
struggle to replicate.
Racelogics managing director,
Julian Thomas, says: If you need
to measure slip angle, then the
VBOX 3i SL easily outperforms
a single antenna inertial system,
for around half the price. Its our
best VBOX to date.
The VBOX 3i SL is quick to set
up and simple to operate, while
519
Southern Hemisphere
Proving Grounds (SHPG)
in New Zealand is the
worlds leading provider of
June-to-September winter
testing facilities and services.
SHPG offers the strategic
advantage of mid-season winter
tests, helping shorten development
cycles from 12 to six months.
Through the opportunity to conduct
three winter tests within one
calendar year, SHPG represents
a strategic advantage in the quest
to rush new products to market.
SHPG strives to keep its
products and services in line with
ever-advancing OEM technologies.
New developments at SHPG
include climate-controlled heated
and refrigerated split-friction
gradient pads. These facilities offer
stable and controlled friction for
testing traction and drive controls.
Other new developments include
a multi-million dollar, ber-optic
data and telecommunication
system, fast-charging capabilities
for electric vehicles, a higher
speed heated ABS facility, and
a dedicated 180m ice-at.
SHPG runs 24/7 through the
months of June to September,
and is equipped and capable of
meeting the most demanding
cold-climate testing challenges.
Cotta gearboxes are rugged and reliable platforms
for R&D testing of automotive components.
Applications include dyno resolvers, axle,
transmission, and driveline test stands. Choose from
our available models or have us design one for your
application. Built and tested by craftsmen, backed
by over 100 years of experience, and covered by an
excellent warranty. Need speed? Contact Cotta.
The speed you need.
Beloit, Wisconsin, USA
Cotta.com/HS | sales@cotta.com | (608) 368-5600
Industrial and Specialty Transmission Experts. Speed Reducers, Speed Increasers, Multi Range, Planetary, Right Angle
RUAG
Tel: +41 41 268 3801
Email: aerodynamics@ruag.com
Web: www.ruag.com
OAK Racing tests in RUAG
wind tunnel
Southern Hemisphere Proving Grounds
Email: admin@shpg.co.nz
Web: www.shpg.co.nz
Counter-seasonal test facilities
being exible enough to be used
for many different kinds of tests.
A useful feature is that you can
translate the slip angle to any point
on the vehicle, in real time.
BOOTH
1976
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
521
SINGLE
Temperiertechnik
offers a portfolio of
high-quality temperature-control
systems based on water or oil as
the transfer medium, heat transfer
units, water-to-water chillers, as
well as customized solutions.
The company provides
high-performance temperature
control of test benches for vehicle
technology applications. SINGLE
temperature-control technology
operates with liquid media with
a wide performance range and
maximum temperatures of
between -40C and +350C.
These liquid media help maintain
and control constant temperatures
or specic temperature proles on
test benches. SINGLE
temperature-control systems
control the media temperature, the
ow and/or operating pressure,
and create realistic conditions
involving serial operation or
excessive loads for safety checks.
SINGLE also has an enhanced
service package, working with a
network of more than 30 sales and
service points, with technology and
manufacturer certications that
meet European Pressure Equipment
Directives and comply with
standards such as UL and regional
directives to CSA and GOST.
SINGLE Temperiertechnik GmbH
Tel: +49 7153 30090
Web: www.single-temp.de
Temperature-control systems
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012 087
523
VPCs iSeries connectors
offer solutions for low
I/O small connector
needs in industries including
automotive and aerospace. With
high density in compact sizes, the
iSeries connectors iCon, i1, and
i2 Micro iCon offer consistent
performance up to 10,000 cycles.
They are capable of discrete wiring
and PCB mounting.
VPCs innovative QuadraPaddle
technology means the connectors
can offer signicant signal points
in a small footprint.
iCon mates up to 320 signal
contacts in two modules, with
myriad variations when hybrid
options are needed, including
coax, power, pneumatic,
thermocouple, and ber optic.
i1 holds a single iCon module
in each connector, offering up
to 160 signal points and various
hybrid congurations.
i2 Micro iCon is a solid-state
module receiver, available in 168
signal and 120/12 signal and
micro-power/coax congurations.
i2 has a 0.8in footprint, enabling
impressive horizontal stackability
and drop-in replacement of 156-pin
ZIF connectors.
VPC
Web: www.vpc.com/iSeries
Innovative connectors
522
Cotta has developed
a high-speed
transmission for use in
test stand applications. Designed
originally for testing aircraft
components, Cottas SN2105
compact transmission is nding
increased application in automotive
testing. The SN2105 features
a nominal power rating of 200HP
and over-speed ratios up to 5.5.
The single-input/single-output
transmission features a cast-iron
case and parallel shaft design with
single-stage gearing. Featuring
a standard output speed of
18,000rpm, Cotta believes the
SN2105 is a candidate for the
most cost-effective, true high-
speed test stand transmission
on the market.
The company also manufactures
industrial and specialty
transmissions, available as speed
increasers and decreasers, for use
in a wide range of non-aviation
applications, including automotive
testing. Transmission models are
available in a wide range of output
speeds, up to 80,000rpm.
Modied-standard and custom
models are also available.
Cotta Transmission Company
Email: sales@cotta.com
Web: www.cotta.com
Compact high-speed test
stand transmission
expert. independent. sustainable.
www.aeieng.com
+1.608.236.1231
TEST FACI LI TY TYPES
Al ternati ve Fuel s
Al ti tude Test Labs
Anechoi c/Pass-by
Cl ean Manufacturi ng
Contai neri zed Test Cel l s
EMI /EMC Test Labs
End- of-Li ne Test Cel l s
Hybri d/Batter y Dri vetrai n Labs
Smar t Gri ds
Hydrogen Test Faci l i ti es
NVH/ser vo-hydraul i c Test Labs
Test Tracks
Envi ronmental Chambers
Engi ne & Chassi s Test Cel l s
Emi ssi ons Test Faci l i ti es
Europe
US
South America
India
China.
Thousands of facilities
designed.
Turnkey or design/bid/build
delivery.
Sustainable, LEED -certified
technical center resum.
Engineering led master-
planning
Product-independent
consultancy.
Are you planning an extraordinary event? If so, fascinate your customers, employees and VIP-
customers with something special: 780 ha site, 2 steep curves and 75 kilometres of diferent types
of tracks. Combine this with a driving safety training or a product presentation and you get the
thrill your customer will not forget. Further on there are conference rooms, catering and an
eventmanagement if you like to be supported by our event-team.
Book something special: +49 4961 975 330 or www.atp-papenburg.de
On one of the worlds biggest and most impressive proving grounds
Get ready for it!
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012 089
524
Todays automotive
test facility users
and operators face
increasing pressure to generate
better data in less time to compete
successfully in the face of shrinking
development budgets. Delays due
to poor test coordination and data
acquisition inefciencies simply
cannot be tolerated as the need to
continually reduce the cost per
datapoint is relentless. Furthermore,
increased operational costs such as
energy are pressuring test facilities
to nd ways to reduce testing times
and increase testing throughput.
Jacobs is one of the largest
engineering and technical services
companies in the USA. It provides
engineering, construction,
operations, maintenance, and
technical support services for
customers to design, construct,
commission, operate, and maintain
technical facilities and systems
throughout Europe, Asia, and North
America. Jacobs understands the
need to maximize data productivity,
accuracy, and security. Its latest
software, Test SLATE, provides an
integrated test facility control and
data acquisition environment that
provides drag-and-drop ease for
conguring new test sequences,
incorporating new measurement
systems, or improving data
visualization/analysis on the y.
In a motorsport wind tunnel, for
example, Test SLATE automates
wind and rolling road speeds, yaw
angle, wheel ride height settings,
and other vehicle-specic controls
for maximum test efciency. Test
SLATE provides self-optimizing test
sequence automation for maximum
data quality in minimal time and is
eld-proven for monitoring facility
and test article onboard data
parameters at more than 20 million
samples per second while
comparing these with user-dened
alarm limits for health and safety.
Jacobs Technology
Tel: Tennessee (+1 931 455 6400), Michigan (+1 248 633 1440) or Germany (+49 89 3090 7160)
Web: www.testslate.com or www.jacobstechnology.com
Test automation software
EnUrga Inc.
1291-A Cumberland Avenue,
West Lafayette, IN 47906
P: +1-765-497-3269,
F: +1-765-463-7004,
E: sales@enurga.com
CONTRACT TESTING
OF FUEL INJECTORS
AND NOZZLES
OPTICAL PATTERNATION
DROP SIZE AND VELOCITY
HIGH SPEED IMAGING
525
nCode, the brand of
durability, test, and
analysis products
offered by HBM, has introduced
new methods for assessing the
durability of adhesive bonds in
lightweight vehicle structures in
version 8 of nCode DesignLife.
nCode DesignLife 8 uses a fracture
mechanics-based method requiring
relatively minor modications to
a typical vehicle body nite element
model. Adhesive bonding is
increasingly used in the
development of lightweight vehicle
bodies. In addition to improving
structural rigidity, it provides
a means of joining high-strength
steels, aluminum alloys, and
dissimilar materials, with good
durability against fatigue compared
with more traditional methods such
as spot-welding and seam-welding.
The implemented method
provides a safety factor
assessment of each joint
HBM-nCode
Tel: +44 114 254 1246
Email: info@hbmncode.com
Web: www.hbm.com/ncode
Methods for assessing durability of adhesive bonds
by comparing the calculated
maximum strain energy release
rate with the threshold required for
crack growth. The theoretical basis
of the method was developed as
part of a project conducted by the
Volvo Group and the testing and
software implementation were
carried out as part of the Bonded
Car collaborative research project,
the partners including Jaguar Land
Rover, Coventry University, and
Warwick University.
November 13-15 2012
Novi, Detroit, Michigan, USA
Showcasing the next generation of powertrains,
advanced batteries and testing solutions for EVs
2011 Show: 170 exhibitors + over 2,700 attendees
2012 Show (anticipated): 250+ exhibitors + over 3,500 attendees
BOOK NOW
EXHIBITION SPACE LIMITED
www.thebatteryshow.com
info@thebatteryshow.com
IN PARTNERSHIP WITH:
@TheBatteryShow
The EV Charging Show
CO-LOCATING WITH:
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
091
526
Tire designers and
researchers appreciate
the benets of
integrating electric actuation into
mechanical testing systems.
Electric systems do not require
hydromechanical infrastructure,
so there is no uid to manage or
pumps to keep cool. They typically
operate more efciently and
maintenance is simpler.
For these reasons, MTS is
incorporating more electric
actuation into its tire testing
systems. The benets of electric
systems, however, diminish
when it comes to dynamic tire
characterization. This is why MTS
has adopted a thoughtful approach
one that addresses customer
needs for efciency and simplicity
without sacricing performance.
For example, the new Flat-Trac
CT Plus Tire Force & Moment
Measurement System trades its
tire hydraulic drive for an electric
permanent magnet motor that
increases capacity and response.
This improves performance,
enabling more accurate
simulations. The system retains
servohydraulic actuation to provide
the power density required for
simulating dynamic tire motion.
On the other hand, rolling
resistance measurement involves
lower speeds and forces, so
electric actuation is a natural
t. That is why new MTS RRsi
systems feature a highly
efcient, fully electric design
that actually expands testing
capabilities by allowing slip
and inclination angles.
Contact MTS today and learn
how its new tire test systems
balance electric and servohydraulic
technologies to deliver optimal
testing efciency and enhanced
performance.
527
Race Technologys latest
addition to its product
line-up, the Speedbox-
INS, is now shipping to customers.
The Speedbox-INS is a unique
sensor system that combines
advanced proprietary GPS and
a precision six-axis inertial system.
The Race Technology system
differentiates itself from the
competition in terms of ease of use,
accuracy, and price. Initial customer
applications include chassis
development for on- and off-
highway vehicles.
The Speedbox-INS is specically
designed to become the system
of choice for automotive industry
testing. Its unique design means no
calibration or initialization phase is
needed, improving productivity and
ease of use. Fitment on standard
vehicles is quick, easy, and secure,
enabling it to be used by
technicians as well as engineers.
High accuracy, low latency
output of vehicle attitude, heading,
gradient, velocity, acceleration,
and distance make the system an
ideal choice for applications such
as stability testing, brake testing,
fuel economy testing, chassis
development, and much more. The
headline accuracy gures include
one-tenth of a degree for roll and
pitch, and two-tenths
of a degree for yaw measurements.
The sensor and new rmware are
available as an upgrade to existing
Speedbox customers.
MTS
Email: info@mts.com
Web: www.mts.com
Tire testing evolution
Race Technology
Email: sales@race-technology.com
Web: www.race-technology.com
Unique sensor system
Contact us: ttc@ul.com | ulttc.com U
L
a
n
d
t
h
e
U
L
l
o
g
o
a
r
e
t
r
a
d
e
m
a
r
k
s
o
f
U
L
L
L
C
2
0
1
2
Your Plastics Testing Experts.
Advanced technology: sophisticated compounding
and fully automated test specimen production
Unequalled capacity: testing of all major
applications from standard plastics to engineering
and high performance thermoplastics and
selection from over 200 different tests
Uncompromising quality: ISO/IEC 17025 accredited
adherence to the strictest industry standards
Extensive expertise: over 60 years of experience
The Fast Track to Success.
UL Thermoplastics Testing Center.
AZ Automotive Testing Technology 183x80.indd 1 31.01.12 11:53
INVINCIBLE LED HIGH SPEED LIGHTING FOR CRASH TEST
CREATIVITY of New Technol ogy
PASSION of Engi neeri ng
TRUST on Product
LED Advantage
No IR and UV emissions
Cold temperature operation
Much longer life time(30,000h) than Metal Halide(HMI)
No time to warm up
Flicker free in high speed imaging
LED lighting heat dissipation
Energy Efciency
Applications
Frontal, Side & Rear Impact, Sled, Car to Car, Roll-Over Tests,
Pedestrian Test, Air Bag (Deployment, Dynamic) Test, etc.
VISOL, Inc
#601 Gwangmyeong Techno-Town, 626-3, Cheolsan-dong, Gwangmyeong-si, Kyonggi-do 423-829 KOREA
Tel : +82-2-2612-2111 Fax : +82-2-2612-0660 www.visol.co.kr E-mail : international@visol.net
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
093
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
528
The engineers at
Mustang Advanced
Engineering are seeing
a higher demand than ever for
automated end-of-line testing
solutions. It has never been more
important to test each product
thoroughly as it comes off the
production line in a controlled and
consistent environment that
provides repeatable results.
MAE is an industry leader in the
design, manufacture, and
installation of advanced end-of-line
test stands for automotive,
heavy-duty, and off-road vehicle
production and quality assurance
testing applications. The
companys dedicated mechanical
and software engineers work to
develop custom solutions for their
customers by providing intelligent
system designs coupled with
outstanding technical expertise
and world-class customer support.
From a high-throughput tester
that can control each wheel
independently, such as the
MAE-AC-4000 (pictured), to
custom designs for lawnmowers
and snowmobiles, MAE provides
the advanced engineering
technology manufacturers need.
When automation is combined
with a controlled testing
environment that gives repeatable
results, you develop a level of
condence in your product that is
no longer a luxury, its a necessity.
Build, test, and deliver products
that are more reliable and more
thoroughly tested, and youll gain
customers for life.
Mustang Advanced Engineering
Tel: +1 888 468 7826
Email: sales@mustangae.com
Web: www.mustangae.com
Automated end-of-line testing
529
Fuel injector and
exhaust-doser
designers have a
constant need to characterize the
spray formed. The critical
parameters that affect the
performance of fuel injectors and
dosers are the surface area density
of the drops, spray angles, spray
pattern, and velocity.
The surface area density is
particularly relevant as the local
fuel or urea evaporation rate is
correlated to this quantity more
than the local drop size, the local
mass ux, or the local velocity.
There are several instruments
that characterize these different
parameters. For example, drop
sizes and/or velocities in sprays
can be obtained using a phase
doppler interferometer or a laser
diffraction instrument, while
surface area densities and spray
angles can be obtained using the
SETscan optical patternator. In
many cases, all these instruments
are not available to the company
that is developing fuel injectors
and dosers.
Therefore, outsourcing of these
core functions is very attractive
during the design stages,
particularly because it relieves
the organization from having the
in-house expertise to operate
these instruments. It is also
anticipated that in future,
outsourcing of the quality audit of
nozzles would provide for a more
economical production line and
a better return on investment. In
conclusion, outsourcing of spray
characterization is seen
as a growth industry in the
automotive sector.
EnUrga
Tel: +1 765 497 3269
Email: sales@enurga.com
Web: www.enurga.com
Outsourcing of spray
characterization
Swiss quality, precison, efficiency, competence
and flexibility: This is what you can expect at
RUAGs premium aerodynamic testing facility.
Whether you are looking at outsourcing a full
aerodynamic development or just obtaining
high quality wind tunnel test data: With our
competent and highly skilled personnel in
combination with our state of the art equip-
ment we can offer the solution. Why dont
you put us to the test and experience the
difference?
Too much drag? RUAG wind tunnel testing helps you do better.
RUAG Aviation
Aerodynamics Department P.O. Box 301 6032 Emmen Switzerland
Legal domicile: RUAG Switzerland Ltd Seetalstrasse 175 P.O. Box 301 6032 Emmen Switzerland
Tel. +41 41 268 38 01 Fax +41 41 268 38 97 aerodynamics@ruag.com www.ruag.com
P
R
O
D
U
C
T
S
A
N
D
S
E
R
V
I
C
E
S
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
094
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
094
Accurate Technologies AB .........................................87
ACS Inc .....................................................................17
Afliated Engineers Inc .............................................88
AFT Atlas Fahrzeugtechnik GmbH .............................38
Application Engineering Inc .......................................12
Arctic Falls AB ...........................................................95
ATP - Automotive Testing Papenburg ........................88
Automotive Testing Expo China 2012 .......................84
Automotive Testing Expo Europe 2012 .........21, 23, 24
Automotive Testing Technology International
Online Reader Enquiry Service ..............................96
Berndorf Band GmbH ........................Inside Back Cover
Brel & Kjr ................................... Outside Back Cover
Cambustion Ltd .........................................................35
Cotta Transmissions .................................................85
D&V Electronics Ltd ..................................................60
D2T ...........................................................................29
Data Physics Corporation ..........................................80
Dewetron GmbH ........................................................82
Dytran Instruments ...................................................67
EJ Bowman Ltd .........................................................73
EnUrga Inc................................................................89
EYE Lighting International of North America .............82
FAIST Anlagenbau GmbH ..........................................55
FGB - Fertigungsgeratebau A Steinbach GmbH.........86
Froude Hofmann .......................................................13
HBM - Hottinger Baldwin Messtechnik .......................7
High Speed Vision GmbH ...........................................52
IMMI ..........................................................................52
IMTECH Deutschland GmbH & Co KG ........................19
Jacobs Technology Inc ..............................................59
KMT - Kraus Messtechik GmbH ................................84
LEMO SA ...................................................................55
LMS International ............................. Inside Front Cover
Luminys Systems Corp..............................................59
MAHA AIP GmbH & Co KG .........................................67
MCE Stahl- und Maschinenbau GmbH & Co KG.........44
Memmert GmbH & Co KG ..........................................69
Messring Systembau MSG GmbH .............................63
Mettler Toledo AG ......................................................83
Millbrook Proving Ground ..........................................47
Moog ...........................................................................3
MTS Systems Corporation ........................................64
Mustang Advanced Engineering ................................71
nCode........................................................................75
NV Solutions Ltd ........................................................69
Orion Test Systems and Engineering .........................75
PCB Piezotronics .......................................................18
PCO AG .....................................................................17
Peak Solution GmbH .................................................44
Race Technology Ltd .................................................26
Racelogic ..................................................................76
Re-Sol LLC ................................................................47
RUAG Schweiz AG .....................................................93
Seoul Industry Engineering Co ..................................71
Single Temperiertechnik GmbH .................................32
Southern Hemisphere Proving Ground ......................73
Teamtechnik, Machinery & Equipment GmbH ...........15
The Battery Show 2012 ............................................90
Toyota Motorsport GmbH ..........................................41
UL International TTC GmbH .......................................91
Virginia Panel Corp ....................................................26
Visol Inc ....................................................................92
VTI Instruments ......................................................... 11
Windshear Inc ...........................................................78
INDEX TO ADVERTISERS
530
Recent months have
seen the UK government
introduce a plug-in van
grant to stimulate the market for
ultra-low emission light commercial
vehicles. The approach is
technology neutral, ensuring any
vehicle that complies with the
criteria of the scheme will be
eligible for the subsidy providing
plenty of opportunities for
manufacturers and vehicle
conversion teams to embrace the
grant with different technologies.
Eligible vehicles will emit less
than 75g/km CO
2
, reach a speed
of at least 50mph, and have
a minimum range of 60 miles
between charge for fully electric
vans and a minimum 10-mile
electric range for hybrid vehicles.
However, signicantly for
manufacturers looking to register
their vehicles for the scheme,
relevant electrical and crash safety
standards must also be met.
Such validation and certication
work requires specialist expertise,
which is limited to test
organizations with experience in
alternative propulsion vehicles. The
team at Millbrook was the rst to
certify an electric van to European
Whole Vehicle Type Approval and
is part of a consortium advising
the European Commission on
hybrid test procedures, as well
as a member of the Low Carbon
Vehicle Partnership in the UK.
With more than 40 years of
testing experience and almost
a decade specializing in electric
and hybrid vehicles, Millbrook
Proving Ground ensures accurate,
repeatable, and safe test
schedules for ultra-low emission
technologies. By working closely
with government and
manufacturers, Millbrook is
advancing the development of
the vehicle and infrastructure
solutions to ensure the light
commercial market is supported
with ultra-low carbon alternatives
for the future.
Millbrook
Tel: +44 1525 404242
Email: info@millbrook.co.uk
Web: www.millbrook.co.uk
Millbrook assists with electric van grantY
O
U
R
S
.
S
E
F
O
T
O
:
GIVE US A CALL: +46 929 47 47 00
SEND US A FAX: +46 929 47 46 99
SEND US E-MAIL: info@arcticfalls.se
VISIT US ON: www.arcticfalls.se
27 COLD CHAMBERS VEHICLE TESTING WORKSHOPS
EFFICIENCY CIRCULAR TRACK
HANDLING TRACK CONFIDENTIALITY
COMFORT TRACK
SHORT HANDLING
ARTIFICIAL LAKE TWIST HUMP
SAFETY
TYRE TESTING FREQUENCY SWEEP TRACK COBBLE STONE
WASHBOARD SPLIT FRICTION TRACK
ELECTRIC VEHICLE TESTING ICE TRACK ON LAND
SERVICE 24/7 HILL TRACKS
HANDLING ROAD
5PROVING
GROUNDS
IT IS IMPORTANT in testing to have
good conditions and good service. We also ensure
that personnel are well provided for, with quality
accommodation and good food. There is a risk they will not
want to go back home... Our mindset is that most things are possible,
and we love a challenge!
You are welcome to visit us to explore our state-of-the-art proving grounds.
TESTBED LEGENDS
096
www.AutomotiveTestingTechnologyInternational.com
MARCH 2012
A
t
r
i
b
u
t
e
t
o
h
i
s
t
o
r
y
s
m
o
s
t
f
o
r
w
a
r
d
-
t
h
i
n
k
i
n
g
c
o
n
c
e
p
t
c
a
r
s
,
w
h
i
c
h
h
a
v
e
f
o
r
m
e
d
t
e
s
t
b
e
d
s
f
o
r
t
e
c
h
n
o
l
o
g
i
e
s
o
f
t
h
e
f
u
t
u
r
e
Urban congestion, highway tailbacks, and
a lack of parking are nothing new. Indeed,
in 1981 Mercedes-Benz developed the
Nahverkehrsfahrzeug (short-distance vehicle,
or NAFA for short), a small vehicle designed for
the urban landscape and short journeys.
At the time, Mercedes was known for large,
luxury cars so this concept attracted a lot of interest
and skepticism. However, the NAFAs principles,
if not its boxy design, can be appreciated and seen
in many vehicles today.
Reality check
With a length of 2.5m and
a height and width of 1.5m,
the NAFA raised more than
a few eyebrows. However,
with four-wheel steering
(the rears were electric-
powered and could turn up
to 15) and a tight turning
circle of 5.7m, the car could
easily be maneuvered
around town, and even
parked with its nose to the
curb. This was a major point
of interest when the Smart
Fortwo was launched,
though only the front
wheels could be steered.
Even where the gap to other
vehicles on each side of a
parking space was small,
two forward-sliding doors
permitted convenient entry
and exit. A similar setup can
be seen in the Peugeot 1007.
The NAFA weighed a mere
550kg, which meant that
a light and economical
powertrain could be used.
The concept featured a 41hp
one-liter, three-cyclinder
petrol engine mated to an
automatic box. Engine
advances in the period until
the Smarts launch meant
that it made production with
an even smaller 599cc
boasting 61bhp over
100bhp per liter!
In 1998 engineers in
Mercedes-Benzs Advanced
Passenger Car Development
converted the two-seater
NAFA to electric drive. The
researchers considered the
pilot operation of up to 100
electric NAFA cars in Berlin,
but the batteries storage
capacity proved inadequate
for continuous service.
However, in 2011 there was
a successful trial of 100
electric Smarts in the UK,
and in 2012 production
versions will hit showrooms.
Lest Mercedes takes all the
credit, the Smarts design
was also in large part down
to the vision of Nicolas
Hayek, founder of Swatch
watches, who had a vision
of an affordable, fun car for
the masses. After an initial
agreement with Volkswagen
fell through, Hayek
approached Mercedes,
which saw the ideal
opportunity to progress its
earlier work with NAFA.
ABOVE To aid ingress
in tight parking spaces,
the doors slid forward
and the mirrors folded
in automatically
FAR LEFT: The angular
design has dated badly,
but its principles were
way ahead of their time
LEFT: Swatch input saw
the Eco Sprinter concept
appear in 1996, before
being rened to become
todays Smart Fortwo
Mercedes-Benz
NAFA
To request a free subscription to Automotive Testing Technology International go online to:
www.automotivetestingtechnologyinternational.com
FREE ONLINE READER ENQUIRY SERVICE ALSO AVAILABLE
subscribe now
MARCH 2012
www.AutomotiveTestingTechnologyInternational.com March 2012
UKIP Media & Events Ltd
Join us on our visit to the dyno
gurus UK HQ to nd out why it
is a major player in the market
Aerodynamics
Is CFD blowing away wind tunnels?
Seven experts debate the future
Ford aims for new generations in new
markets with the EcoSport, the rst
One Ford car to be developed in South
America, and the rst to be built in India
www.AutomotiveTestingTechnologyInternational.com
Could Quebecs new crash
test facility be the most
accurate in the world?
Transport Canada
Euro 6
The 2014 regulations are fast
approaching. Be prepared with
the latest technology
Froude Hofmann
Chris Biggs
The junior exec against which
all others are judged. The 2012
model features great advances
BMW 3 Series
The return of the facility test.
In this issue: can Germanys
ATP retain ve-star status?
ATP
Chevrolets global
vehicle line director
has taken big steps
to improve small cars
EcoSport
EcoSport
The NAFA study, while
not very warmly received
at the time, certainly did not
fall into oblivion. In fact, it
spawned one of the most
relevant cars of our time.
The principles of the NAFAs
design entered into the design
of the A-Class Mercedes-Benz,
the prototype of which debuted
in 1996, and it strongly
inuenced the Smart Fortwo,
introduced in 1997 as the smart
city coupe. The comparatively
high seating position, the low
waistline, and large glazed
surfaces made for an optimal
all-round view. NAFA showed
that small didnt have to mean
Smart thinking
spartan, and it featured
automatic transmission,
air-conditioning, and power
steering, all of which went
into the Smart. The only
fundamental changes were
that the car went from being
front-driven to rear-wheel-
drive, and volume production
necessitated conventional
doors rather than electric
sliding doors.
... steel belts from Berndorf Band!
Fast ...
... faster ...
Berndorf Band GmbH
A-2560 Berndorf, Austria
Phone: (+43)2672-800-0
Fax: (+43)2672-84176
band@berndorf.co.at
www.berndorf-band.at
Steel belts from Berndorf Band have
been used for automotive testing
applications for many years.
It began with tyre test belts, leading
to the construction of wide rolling
road belts for wind tunnel testing.
Speeds of almost 300 km/h and the
need for extremely accurate running
properties place exceptionally high
demands on steel belts.
Berndorf Band is the leader in the
development and manufacturing of
high speed belts. This results in
signicant advances in the quality and
performance of our products.
HEADQUARTERS: Brel & Kjr Sound & Vibration Measurement A/S DK-2850 Nrum Denmark
Telephone: +45 77 41 20 00 Fax: +45 45 80 14 05 www.bksv.com info@bksv.com
Local representatives and service organisations worldwide
B
N
1
1
0
5
1
1
www.bksv.com/beamforming
NORMAL beamforming
REFINED beamforming
REFINED BEAMFORMING
No time for
uncertainty
Rened beamforming yields
three times better spatial resolution
for non-coherent sources
Ideal for wind tunnel testing
SINGLE-SHOT
BEAMFORMING
MEASUREMENTS
ALL FROM ONE PARTNER
Brel & Kjr has the worlds
most comprehensive range of
sound and vibration test and
measurement systems
12-003_BN1105-11_Windtunnel_Refined Beamforming_215x275.indd 1 30-01-2012 11:04:39