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| Automotive Competence |
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Right on Target –
Testing Concepts and Solutions
in the Automotive Industry
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(pdf, 600 KB)
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Vehicles and their components are becoming increasingly complex. Therefore, increasing amounts of data are generated in the course of development.
With its solutions Werum supports the automotive industry in handling the deluge of data. Werum‘s test data management systems form the infrastructure to efficiently manage, archive and keep measurement, test and control data available for investigating. These solutions are based on established platforms and complemented by specific customized functions. Werum has a long and proven record in the industry, and has many international car manufacturers as its customers.
Werum has successfully implemented numerous projects for a large variety of wind tunnels, test stands and test fields and cooperates with consortiums where suitable.
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| Efficiency in Test Management
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Test station, test stands, large test rigs or large-scale test fields are all key components in developing vehicles. They must meet the latest requirements of efficiency, comfort, environmental friendliness, conservation of resources and technology. Like anybody else involved in the development process, the designers and operators of such test systems have to meet increasingly high demands.
Wind Tunnel Control Center in Ingolstadt/Germany
Source: Audi AG
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They are expected to deliver the best possible results in terms of time, flexibility and costs. They opt for solutions based on standard tools that can be adjusted to varying requirements. |
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| Platforms, Applications and Industries
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Werum identifies, parameterizes and configures the required basic functions in accordance with the customer’s requirements. They are combined to a product-based solution – complemented by product-specific adjustments. Users get the best of two worlds. On the one hand, Werum’s HyperTest offers them a standardized platform with product character, which is not only marked by stability and a wide range of functionalities, but is also widespread and easy to maintain. On the other hand, they benefit from the advantages of a customized solution tailored to their specific needs.
Operator control room for climate wind tunnel
Source: Audi AG
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The tasks of any test station, test stand, large test rig or test field are quite similar when it comes to data management. Independently of the range of application and industry, they require comparable functions and properties. The solutions implemented by Werum range from a measuring system for vehicle components, for example, to a wind tunnel control system and a control unit for a rocket engine test bed. The basic functions of these platforms comprise data recording and distribution, test bench automation, test bench control systems and data and information management.
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Werum has successfully completed a large number of projects related to vehicle development in the automotive industry.
These projects are based on the WTCS (Wind Tunnel Control System), HyperTest and the TBAF (Test Bed Automation Framework) platforms.
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Platform components form the basis for custom solutions
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| Data and Information Management in Test and Control Environments
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Many professionals in the automotive industry attach great importance to the efficient handling of test data in the vehicle development stage. Companies measure and acquire more and more data within ever shorter periods of time and are forced to record growing numbers of parameters. To keep the data understandable and interpretable, more and more additional information is needed – like the characteristics and type of sensors used, applied test procedures, configuration of the unit under test or the relevance of the individual measurement for the overall project. Powerful data management solutions ensure that all data are searchable without losing time and are identifiable in their context. For this application, Werum has developed the HyperTest platform.
With HyperTest the user prepares automated test data evaluations and reports without endless searching. The solution incorporates the customer’s specific tools for the interpretation of the measured data.
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| Control Systems for Automotive Wind Tunnels
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Together with its partner S.E.A. GmbH, Werum has developed the WTCS (Wind Tunnel Control System) platform for measuring and control systems in wind tunnels. This solution is used in different types of automotive wind tunnels – such as those used in aerodynamic, aeroacoustic, climate or energy and environmental applications. Depending on the customer’s specific requirements, WTCS incorporates various subsystems of the wind tunnel like six-component balance, fans, model positioning or air conditioning devices. As a result, the user benefits from a homogeneous control environment for the subsystems, with user-friendly editors to parameterize the subsystems for the measuring and testing tasks at hand. Test sequence controls in WTCS make sure that the defined tests are run in a coordinated way and that all connected systems work together properly. WTCS records all the required configuration and operation details and measured values for the subsequent evaluation of the tests. The system visualizes and saves this data and optionally stores it in the connected HyperTest test databases. Here the data is available for further investigation or processing. HyperTest delivers automated standard reports, provides data in individual formats and enables individual data selection profiles. With the help of their specific tools the customers can further process the results of their search.
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| Data Management for a Brake Booster Test Stand
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Connected to a brake booster test stand, HyperTestmanages information about individual units under test, descriptions of the tests to be carried out, test requests and test results. The user parameterizes every test through web-based dialogs and transmits the information to the corresponding test system. There the test is carried out in accordance with the specified parameters and test definitions. Once the test is completed, the test system transfers the results and status data to the data management system. As a result, the integrity and traceability of the tests and results is ensured at all times.
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| Universal Measuring System for Mechanical Component Test Benches
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For this task, Werum has implemented a measuring system, which is applied at different test benches for mechanical steering components. Depending on the specific task and test bench, the system records a number of measuring channels that the user can configure freely. It visualizes the data and checks in real time whether the individually configured limit values are complied with. To record and distribute the values the measuring system uses core functions of the TBAF platform. A key feature is the wide range of scalability: users configure the application in accordance with the measuring task at hand. They determine what sensors they want to use and define activities, conditions and limit values. Users describe and configure the test procedures and sequences.
Control room of the Energy and Environmental Test Center, Munich
Source: BMW AG
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The system runs the tests automatically – typically long-time fatigue tests or cycle tests. It makes calculations and evaluations online and initiates the pre-defined activities when limit values are exceeded or fault conditions occur. Measured values are stored in data systems together with the pertaining configuration information. If requested by the user, the solution visualizes the current status via user-defined displays.
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| Higher-Level Control Systems for Several Wind Tunnels and Climate Test Chambers
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Based on the control system functionalities of WTCS, Werum has designed and implemented higher-level control systems for large test centers with several wind tunnels and test chambers. They allow for a detailed insight into the ongoing activities at every test stand at any time. With their help the systems can also be operated unattended.
WTCS is an integrated control system and in this constellation test stands may be integrated as logical units just like subsystems.
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| Test Management in the Wind Tunnel
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A HyperTest-based AERO database manages the data of aerodynamic surface and force measurements taken in a wind tunnel. It makes aerodynamic calculations and reports and administers descriptive information about vehicles, orders and measurement parameters. The platform compiles all vehicle data with aerodynamic relevance and offers integrated tools for queries and data search. This data is stored in HyperTest together with all associated meta-information. So the test results together with the related test conditions remain interpretable at any time. |
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| Test Data Management in Vehicle Testing
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HyperTest has also proven its value as a data management system for endurance tests. It archives data and information from field trials and ensures that they can be located without losing time. The platform manages the vehicle configuration and routes and compiles the logging data. This ensures that users can make reliable evaluations for their test runs, even in the face of increasing data volumes. Various user groups analyze data from specific viewpoints. Comprehensive analyses like x-t logs and classifications are also conducted automatically by HyperTest. | |
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| Measuring Equipment Management
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A German car manufacturer uses the measuring equipment management, a HyperTest module, to set up test stands and test vehicles in the run-up to tests. HyperTest provides information about the availability, calibration status and the place of storage or usage of measuring equipment at all times. No time is wasted for inquiries. A warning function identifies devices with due calibration. History views enable the user to follow up the calibration and use of measurement equipment. That makes it easier to provide evidence during audits.
Control room of the Energy and Environmental Test Center, Munich
Source: BMW AG
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| Instrumentation setup management
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An add-on to HyperTest manages the measuring points on vehicles. The system describes measuring points and assigns them to test vehicles. It documents various setup stages of the vehicle and the related measuring points with their properties – which makes planning easier. Moreover, the persons in charge and the users can quickly be identified for every measuring point. This transparency enhances efficiency in planning tests. HyperTest derives assembling instructions for those who install the devices and documents the setup phases. When combined with the measuring equipment management, information is provided on the entire signal chain for the purposes of test documentation.
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| Customers / References
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Audi |
Wind Tunnel Control |
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 Details
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Smart |
Information Management |
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Toyota Motorsports |
Wind Tunnel Control |
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Volkswagen |
Control Center "Autonomous Driving" |
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Details |
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Volkswagen |
Drive Recorder for Test Vehicles |
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Efficiency in Test Management