Mercedes-Benz accelerates vehicle development with the latest EtherCAT measurement technology
Beckhoff Automation Co., Ltd. Press release: November 13, 2024 Mercedes-Benz accelerates vehicle development with the latest EtherCAT measurement technology ~Highly accurate and flexible measurement technology optimizes tuning of next-generation vehicles~
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Mercedes-Benz’s test bench renewal for next-generation vehicle development. Beckhoff has renovated the test bench that utilizes EtherCAT, TwinCAT, and the high-precision measurement terminal “ELM series” in the development of next-generation vehicles for
Mercedes-Benz. As a result, the company’s chassis performance evaluation process has been significantly optimized, making advanced analysis of vehicle characteristics possible. High-precision test bench essential for pursuing drive characteristics Mercedes-Benz strives to improve the quality of its chassis, which define the characteristics of its vehicles and the personality of its brand. At the Mercedes Technology Center (MTC) in Sindelfingen, Germany, axle inspections are carried out using four state-of-the-art test benches. The testing process proceeds by placing the vehicle on a jack and applying a load to the axle. The reaction to the force, displacement, and torque applied to the vehicle is measured with an accuracy of 0.1 mm. The test results are compared with approximately 90 parameters using a digital twin, which plays an important role in ensuring the high driving performance of the development vehicle. Uwe Lochner of Mercedes-Benz’s chassis analysis team emphasizes the importance of precision: “Understanding the characteristics of a vehicle with a high degree of precision is essential to maintaining brand identity.” Background of the renewal of the old system and benefits of the new system The control system of the old test bench, which has been in use for many years, was developed by Daimler. It was built on the basis of “Hydromat”. However, issues such as difficulty in procuring parts became apparent, and system integrator DynoTec Prüfstandstechnik (hereinafter referred to as DynoTec) was outsourced to design and implement the new system. The new system maintains the modular concept of the test bench, but with the need for more efficient and flexible control, EtherCAT is introduced to replace long analog signal lines with digital signals and improve data logging. Accuracy has been significantly improved, and at the same time, control quality has also been improved. Beckhoff’s open automation platform also ensures compatibility with equipment from different manufacturers, improving maintainability and reducing system costs. The deciding factor was Beckhoff’s high-precision measurement terminal Beckhoff’s EtherCAT measurement terminal was a decisive factor in the system renewal. The ELM3xxx series of high-precision measurement terminals can acquire data on vehicle vibration, displacement, torque, etc. with high precision and high resolution. In this system, up to 136 measurement channels each Records synchronously at 5ksps. Additionally, it can be expanded up to 10ksps if needed for a total data rate of 680ksps. Additionally, the compact modular structure allows for flexible and space-saving data logging. Thanks to EtherCAT’s high-speed
communication capabilities, all measurement data is acquired in real time, enabling live monitoring on the PC and immediate transfer to the database. The high-speed communication and high-precision measurement enabled by EtherCAT significantly improves test bench control quality and enhances reliability. The introduction of Beckhoff’s open control platform also provides increased flexibility and scalability, providing a foundation for future innovations.
https://prcdn.freetls.fastly.net/release_image/27362/42/27362-42-69521d5cbd8948bd36a4f7613bb600de-1000×667.png A control panel that houses the ELM3xxx series of high-precision measurement terminals. Compact and high-performance measurement technology enables space-saving data logging. (Photo provided by Mercedes-Benz)
https://prcdn.freetls.fastly.net/release_image/27362/42/27362-42-ff99580f85a25f753317ccc16b7cbe98-3500×1969.png Thanks to EtherCAT’s high-speed communication capabilities, all measurement data is acquired in real time and the measurement results are visualized in detail using the TwinCAT HMI. (Photo provided by Mercedes-Benz) Future direction of system development Mercedes-Benz and Dynotech plan to implement Beckhoff’s automation software feature TwinCAT Analytics Logger in future test bench developments. This enables real-time data logging and storage across multiple test benches for centralized management and rapid analysis of test data. “With Beckhoff’s scalable control platform, we have confirmed that we can handle a variety of projects with a standardized system,” said Dinotech’s Walter Selg, expressing his confidence in the success of this project. Masu. Read the full article here:
