Case Study : Brake Test Simulation Integration

The Problem

Automotive manufacturers already have very sophisticated simulations of real-life vehicles. They have been able to simulate actual driving conditions and responsiveness of the driving experience prior to building prototypes, but it was not quite like the real thing. Would the new components and designs provide the right driving experience? The challenge was to integrate parts of real assemblies like brakes into the feedback of the simulators. It would also allow test drivers to experience the genuine feedback of the assembly in real-time without having to build the vehicle.

The Solution

The solution was to build and program a motion control machine that would, in real-time, transfer the pedal position of the driving simulator and simultaneously transfer back the response of the actual pedal assembly. The system could pass back actual position as well as the force on the assembly within milliseconds. This way the driver can experience the actual feedback of the brake assembly and not a computer generated simulation.

The Results

The motion control system allowed prototyping of brake assemblies to validate design and performance criterion in a fast and effective method. It allows developers of the products to receive immediate feedback and allow testing and validation of the products from test drivers months before actual integration into a product.