TimesEV
TimesEV
TimesEV
TimesEV
TimesEV
TimesEV
More
    HomeEV ProductsBatteriesAdvancing EV Testing: High-Frequency Simulation Tables Revolutionize Automotive R&D

    Advancing EV Testing: High-Frequency Simulation Tables Revolutionize Automotive R&D

    In the realm of automotive research and development (R&D), hydraulic simulation tables play a crucial role in conducting tests on various components, ranging from vehicle internals like transmissions and suspensions to interior elements such as seats and headrests. However, as the automotive industry increasingly focuses on electric vehicles (EVs), engineers are faced with new design challenges that traditional test and simulation equipment cannot adequately address.

    Auto EV India Expo

    According to Kevin Oliverio, the hydraulics department manager at Element Materials Technology based in Warren, Michigan, most vibration testing for automotive suspensions and components typically operates up to around 50Hz. However, EV battery components require a significantly higher threshold. Frequencies ranging from 50 to 150Hz are necessary to simulate a capacitor’s ability to withstand vibration and evaluate the durability of soldering bonds. Furthermore, by conducting higher frequency tests reaching up to 150Hz, automakers and battery designers can precisely evaluate the charging and discharging rates in various circumstances. Oliverio explains that this level of testing provides feedback equivalent to the experience of a vehicle’s battery during both motion and stationary periods.

    Element began testing battery components on a conventional simulation table for a major automotive original equipment manufacturer (OEM) approximately seven years ago. Recognizing the direction the auto industry was heading, Element expanded its testing capabilities by incorporating another simulation table. Through the use of battery cyclers, the company could observe a battery cell’s response over time. This led Element to enclose the table in an environmental chamber, equipped with fire suppression and venting systems. As the auto industry continued pushing the boundaries of EVs, Element aimed to stay ahead by incorporating high-frequency testing.

    The upgraded high-frequency Moog MAST (Multi-Axis Simulation Table) can assess vehicle components, including batteries and electronics, for vibration and durability, replicating data collected during testing on proving grounds. The foundation of Moog’s high-frequency shaker table is a six-leg hexapod, initially developed for flight simulators. The hexapod features two equilateral triangular frames stacked with a 30° offset. Moog actuators connect each apex of the top triangle to the corresponding apexes below the lower triangle. The new table designed by Moog engineers can reach frequencies of up to 200Hz. Some EV battery packs on the market consist of as many as 2,500 batteries, weighing 450kg or more. The high-frequency Moog MAST features an impressive table size of 2,300 by 2,000mm and an actuator peak force of 53kN. It has the capability to accommodate a system payload weighing up to 600kg. Similar to conventional systems, the Moog MAST at Element offers six degrees of freedom, enabling movement in the x, y, and z axes, as well as rotational movements (pitch, roll, and yaw). Oliverio emphasizes that without simulation technology like Element possesses, OEMs lack real-time data on battery testing and often rely on generic specifications.

    Element has combined the high-frequency table from Moog with the company’s motion control software and the Moog Test Controller to conduct EV battery pack testing in unprecedented ways. Using the test controller and a power spectral density profile, Oliverio and his team can subject a large battery pack to vibration testing before the OEM places the vehicle on the road, identifying potential issues. This allows Element to engage with vehicle manufacturers during the early stages of the design and development process. The insights gained at this early stage can then be applied to automotive specifications and use cases. Oliverio notes that customers now turn to Element to advance their testing further, replicating data collected from proving grounds or validating an EPA model using the new high-frequency shaker table.

    Himanshu Vaibhav
    Himanshu Vaibhavhttps://www.timesev.com/
    Himanshu Vaibhav is a distinguished Technology Journalist associated with ELEtimes.com and TimesEV.com. With expertise in researching, writing, and editing, he demonstrates a deep understanding of technology, particularly in the EV industry. His continuous updates on EV, Automotive, and E-mobility industries reflect his commitment to staying at the forefront of emerging trends.

    Related Post

    Most Popular

    Best Picks

    WISE Testing Solutions: Comprehensive Products and Services for Vehicle Development and EV Battery Testing

    WISE Testing Solutions Pvt. Ltd., a privately held company registered as a limited company, aims to provide a comprehensive range of products and services...

    Anton Paar: Revolutionizing EV Battery Testing with Standardization Initiatives

    Anton Paar, a distinguished company specializing in the development, production, and distribution of precision laboratory instruments and process measuring systems, alongside delivering customized automation...

    Exploring the Challenges and Testing Methods for Electric Vehicle...

    Aimil Ltd. is an esteemed organization celebrated for its exceptional expertise spanning multiple domains such as electric vehicle battery testing (both electrical and mechanical),...

    “The core idea behind u-blox has always been to...

    u-blox develops some of the world’s leading IoT communication and GNSS modules, chips and services supporting the industrial, automotive and consumer markets. Recently Andreas...

    PRAGYATMIKA: Empowering EV, Automotive, and E-Mobility with Cutting-Edge Technology...

    PRAGYATMIKA stands out as a leading provider of effective technology solutions for the EV, automotive, and e-mobility sectors. Their comprehensive services go beyond technological...

    Jean-Louis CHAMPSEIX, VP, Head of Corporate Sustainability, emphasizes :...

    ST addresses twofold imperatives - i.e. making technology itself more sustainable, and using technology to become more sustainable. ST is one of the largest...

    Exploring the Impact of Aarjay International’s Testing & Automation...

    Aarjay International is widely recognized for its outstanding expertise in delivering comprehensive test and automation solutions. Their wide range of services encompasses electronics and...

    Future of High Voltage EV: Wide Band Gap Semiconductors

    Article Courtesy: Sterling Gtake E Mobility Limited INTRODUCTION: Wide band gap semiconductors (SiC & GaN) are regarded as the next-generation power semiconductor for automotive applications...

    Motor Control and Human Interface Technologies from Virtual Forest...

    Forests are a vital part of human existence thus it relies upon them how to conserve the forests and maintain the ecological balance. Over...

    Must Read