Simulation Table for Vehicle Component Battery Testing

11 June 2012

Moog Industrial Group, a division of Moog Inc. and a leader in providing high-performance testing systems to the automotive and aerospace markets, has been selected by Fraunhofer LBF, German Institute for Structural Durability and System Reliability Research, to deliver a complete test system to be integrated with a climatic chamber and battery-testing safety system. The test system consists of a Moog High Frequency Hydraulic Simulation Table and real-time controller, includingMoog operator test and application software.

Automotive manufacturers and independent testing laboratories utilize Moog’s high frequency simulation tables to replicate real-world structural loads and vibrations in applications such as drivetrain components, interior and exterior assemblies, seats, steering column assemblies, batteries and cooling systems. One of the main test applications for which Fraunhofer LBF intends to use the system is the development and testing of electric car batteries and power management systems.

The test system is rated for frequencies up to 200 Hz as compared to standard Moog Hydraulic Simulation Table limited to frequencies up to 100 Hz. The Moog High Frequency Hydraulic Simulation Table has the ability to test specimens by using higher frequencies in simulated operating environments, allowing Fraunhofer LBF to assess the behavior of test specimens under the most extreme and realistic conditions.

The test system will aid Fraunhofer LBF in the evaluation of electric car battery performance in order to assist the automotive industry with research and development for batteries and electric vehicles. During testing, the batteries will undergo drive simulation and vibration tests to measure the performance and durability aspects under ‘real’ circumstances. A virtual model will simulate power consumption and measure the charge and discharge of the batteries during a car ride. All power consuming car parts will be included in the test, such as the electric motor, power steering, wipers, windows, lights, audio, heating, etc.

Project Leader Dr. Chalid el Dsoki of the Center for the System Reliability- Electro Mobility of Fraunhofer LBF comments: “We were searching for a long-term partner with extensive experience in providing high-performance testing systems and an interest in surpassing with us the state of the art. Moog fulfilled these conditions and was able to reach frequencies of up to 200 Hz in combination with specific mass and stroke specifications.

The high-frequency simulation table allows us to simulate the conditions that occur at higher frequencies and temperatures compared with conventional simulation tables. This increases the value of our testing process and provides a unique testing capability in Germany. Another important advantage of the system is that it combines high performance and flexibility with a small laboratory space requirement (footprint).”

Along with the simulation table, Moog will supply a 6-channel Automotive Test Controller and Moog Integrated Test Suite software, including the software modules Replication and Runner for system identification, iteration and play-back drive files. The controller features a modular PLC for an easy interface with the climatic chamber and overall battery test control and safety system.

The Moog High Frequency Hydraulic Simulation Table consists of six hydrostatic actuators that allow for 6 degrees- of- freedom (DOF). A very stiff table is connected to the actuators via a push-pull-rod that has hydrostatic bearings to limit the play and improve the accuracy of the system. The actuators are mounted in actuator joint blocks on a stiff and compact base platform. The base platform is to be anchored into a heavy seismic mass to compensate for its motion. Fraunhofer intends to dedicate a completely new building for the test rig and will integrate a climatic chamber around the test rig to be able to test the batteries under specific environmental conditions.

“Moog is very pleased to have this opportunity to work closely with the renowned Fraunhofer LBF Institute on this innovative project. Fraunhofer's decision to select Moog was based on the clear benefits of the High Frequency Hydraulic Simulation Table and we are delighted that this test system will play a major role in their testing and further development of electric car batteries.” said Thomas Hale, Market Development Manager Test Europe at Moog.