KS-R2R: Innovative Test Rig System for comprehensive test and application of drive trains and its components

摘要

The test rig system KS-R2R ("Road to Rig"), developed by Kristl, Seibt & Co GesmbH (KS), enables comprehensive testing and application of drive trains and their components while the test specimen experiences the same stresses as on the real road. The test bench uses a highly dynamic control loop with a frequency of 10kHz, incorporating chassis and wheel/tyre models whilst linking the frequency converters. These features yield a realistic and reproducible simulation of the wheel speeds (including wheel slip), the wheel torques and their correct distribution (left-right/front-rear) as well as all occurring oscillations. Due to the innovative and unique structure of the system, KS-R2R can be used comprehensively for all conceivable applications within drive train testing. The test bench facilitates component, whole drive train and even complete vehicle testing, supporting the original brake systems and Advanced Driver Assistance Systems. With the help of a patented inertia compensation method the dyno's effective moments of inertia are highly dynamically adapted to the current demands. Synchronous and asynchronous machines can be used as required. The operator of the test bed is able to manipulate all available vehicle and road parameters without the need for changing control parameters or the mechanics of the system. As a result, KS-R2R enables highly reproducible testing and application of all kinds of vehicles using any desired set of (simulated) tyres and loading conditions on freely defined or generated test tracks (with the aid of appropriate systems). As an additional benefit, the systems reduce the required set-up times, leading to a considerable reduction in costs.