Innovative method for capturing load data in customer use

Auto Tech Outlook | Wednesday, May 03, 2023

High-accuracy accelerometers provide a simplified load assessment

method Vehicle tests can be time-consuming and expensive on account of the large number of sensors required for comprehensive measurement data acquisition. The Kempten-based monitoring specialist, monalysis, has therefore developed a method that allows these tests to be carried out far more cost-effectively than before. The durability transfer process is based on high precision accelerometers from ASC and is used by MAN Truck & Bus SE among others.

Stay ahead of the industry with exclusive feature stories on the top companies, expert insights and the latest news delivered straight to your inbox. Subscribe today.

The preparation and execution of a vehicle test, with a fully equipped test vehicle, is very complex. The application, calibration and setup of various measuring points alone usually takes several weeks. "The costs of this sensor work also include the investments in sensors and the measurement data acquisition, as well as personnel costs for the permanent technical support of the measurement campaigns," says Benedikt Mundl, to explain the expenditure involved. At monalysis, Benedikt Mundl is responsible for the test drives and he travels around the world to this end.

The tests generate meaningful data to provide manufacturers with important information about the load behavior of their vehicles.

"This kind of acquisition of load data from a large number of vehicles in actual customer operation would be desirable from the point of view of vehicle developers, but the high costs involved tend to make it unfeasible", explains Michael Städele, General Manager of monalysis GmbH.

Tests allow trucks to be adapted to regional road conditions

The requirements for robustness vary greatly from country to country and depend on the conditions of use in any given region. "Different load situations apply to motorway journeys than when driving on an unpaved mountain pass", says Benedikt Mundl.

 The aim of the monalysis studies is therefore to identify as easily as possible the various regional and use-dependent loads and stresses on a wide range of vehicles, so that MAN can take the lessons learned into account in the development of its trucks.

New procedure reduces burden and costs

Monalysis is a spin-off from the Kempten University of Applied Sciences in Allgäu, Germany, and since its founding in 2011 has already carried out numerous vehicle tests with MAN. In order to reduce the burden and costs of vehicle testing, the analysis experts developed an innovative measurement method. The “durability transfer method” makes it possible to drastically reduce the number of sensors from several hundred to just a few, for measuring, for example, acceleration on the chassis or body longitudinally, laterally and vertically. From these relevant indicators, the load and stress behavior can be derived in different vehicle areas using deep learning algorithms. "From the accelerator values recorded we can therefore draw conclusions about the load behavior on the whole vehicle or on individual components such as chassis, frame, components or the cab", explains Michael Städele. Due to the significant reduction in the number of measurement points and independent measurement data collection, any customer vehicle may be used as a test vehicle in the future.

In addition, the durability transfer method can also be used to assess and categorize the road quality. If vertical vehicle accelerations are recorded, they may be used to assess the road quality of a particular road segment.

 In order to obtain meaningful measurements, the sensors used must be extremely reliable. "We tested models from different manufacturers intensively before opting for the ASC accelerometers," recalls Benedikt Mundl. "In addition to the high quality and excellent value for money, also decisive for us were the recommendations of companies that have already used ASC sensors and have been very satisfied with their performance."

ASC sensors meet the high requirements of the test engineers

For the test drives on MAN trucks, monalysis uses 5521MF (Medium Frequency) triaxial capacitive accelerometers from ASC. They cover measurement ranges from ±2 to ±200 g and have a wide frequency response of 0 Hz to 7 kHz (typically ±3 dB). This makes the sensors particularly suitable for measuring low and medium frequencies. Due to its robust design, the ASC 5521MF also has a high resistance to repeated impact loads up to 6000 g and can operate with high accuracy and reliability at temperatures of up to +125°C.

Individual solutions can also be developed on request

Due to their wide frequency response and excellent impact resistance, the ASC accelerometers are used by many automotive industry companies for fatigue strength testing. This includes vibration tests, shock tests and test-to-fail investigations for material cost optimization.

Through many years of collaboration with the key international players in the automotive industry, the ASC sensor specialists know exactly what their requirements are. At ASC a wide range of sensor solutions have been developed to enable test and measurement engineers to perform their demanding tests under optimum conditions. The accelerometers are not only ideal for strength tests but are also very well suited for test bench applications, modal analyses, driving comfort measurements and crash and driving dynamics tests.

In addition to capacitive analog accelerometers, ASC also manufactures digital accelerometers, yaw rate sensors, tilt sensors and inertial measurement units (IMUs). Since most customers require sensors for very highly specialized applications, ASC often develops bespoke solutions. This extends from the adaptation of individual components such as cables or connectors to modifications of existing sensors. In addition, the sensor specialist is developing and manufacturing more and more digital sensor solutions, so that it is also able to offer suitable solutions for future innovative applications.

High-quality "Made in Germany" sensors

All ASC sensors are developed, manufactured and calibrated at the Pfaffenhofen headquarters. As a result, the paths between development department, production and laboratory are very short. With many of its competitors, by contrast, only the development department remains in Germany, with production mostly taking place in Asia. Development and manufacturing in Germany not only give ASC the advantage of maintaining complete control over all processes and guaranteeing high product quality, but also mean that it can offer a comprehensive range of services. For example, ASC can recalibrate sensors (as per DIN EN ISO/IEC 17025:2005), as they must be regularly "re-adjusted". Customers can also return defective sensors for repair.

Further test operations planned

Benedikt Mundl is very satisfied with the sensors and the service of ASC. The engineer will therefore soon be using the sensors on other vehicles, too. This will provide further insight into vehicle load and stress behavior worldwide, and into the quality of the roads. 

More in News

The automotive industry is changing, and technological advancements are transforming how dealerships function. While these innovations present significant opportunities for growth and increased efficiency, they also bring unique challenges. Dealerships need to understand and navigate these challenges in order to succeed in an increasingly digital landscape. Adapting to Rapid Technological Changes One of the most significant challenges facing automotive dealerships today is the rapid pace of technological change. New software, platforms, and tools are consistently emerging, making it difficult for dealerships to keep up. The integration of advanced technologies, such as customer relationship management (CRM) systems, inventory management solutions, and digital marketing tools, requires dealerships to adapt their business processes continually. To effectively navigate this challenge, dealership leadership must prioritize ongoing training and development for their staff. By investing in training programs that focus on new technologies, dealerships can ensure their employees remain proficient and confident in using modern systems. Additionally, staying informed about industry trends and participating in relevant workshops or conferences can help dealership employees understand best practices and innovative solutions that are on the market. Balancing Technology and Customer Experience While technology can enhance operational efficiency, dealerships must maintain a strong focus on the customer experience. The implementation of sophisticated systems, such as online purchasing options and virtual showrooms, can sometimes lead to a disconnect between customers and sales personnel. A common challenge is striking the right balance between automation and the personal touch that customers expect when making significant purchases, such as vehicles. To address this challenge, dealerships should strive to create seamless digital experiences while preserving meaningful interactions with customers. This involves encouraging staff to utilize technology to enhance their engagement with customers rather than replace it. For instance, sales representatives can leverage CRM tools to gather insights about a customer's preferences and tailor their approach accordingly. By blending automation with human interaction, dealerships can offer a more personalized service that fosters trust and cultivates long-term relationships. Overcoming Integration Issues As automotive dealerships adopt new technologies, integrating these systems with existing infrastructure can pose a significant hurdle. Different platforms may not always communicate effectively with one another, leading to data silos and inefficiencies. For example, a dealership might have separate solutions for inventory management, accounting, and customer outreach, making it challenging to have a unified view of operations. To minimize integration issues, dealerships should carefully evaluate the technology solutions they invest in. Opting for platforms that offer easy integration capabilities or are specifically designed for the automotive sector can alleviate many of the common pitfalls associated with technology adoption. Furthermore, involving IT professionals during the selection and implementation process can help identify potential compatibility issues beforehand. Providing a clear roadmap for implementation and encouraging collaboration among teams can also facilitate a smoother transition when integrating new technologies. ...Read more
 Automotive companies are at a critical turning point due to rapid technological advancements, changing consumer demands, and increasing environmental concerns. To navigate this evolving landscape, innovative ideas must emerge from automotive engineering services. This innovation is driven not only by the immediate needs of consumers but also by the necessity to shape a sustainable future proactively. A complete paradigm shift for the traditional automotive engineer, this is a new form of automotive engineering that mingles the latest understanding in electric powertrains with advances in battery technology and infrastructure for vehicle charging. There is one new invention in innovative engineering services: research and development constitute part of operations, and effective collaboration can now occur between automotive companies and technology firms to create leading-edge solutions that improve and enhance the performance and sustainability of the vehicle. Increased Complexity Requires New Approaches to Design and Testing: The increased complexity of increasingly complex vehicle systems, including advanced driver assistance systems, connectivity features, and autonomous driving, will require new approaches in design and testing. New simulation tools and software will allow the engineer to model scenarios and assess performance to save development time and costs, meaning faster go-to-market strategies while maintaining safety and reliability. The processes of manufacturing vehicles need to have a reduced automotive footprint as well as production processes. New sustainable materials and manufacturing methodologies are being developed and tested through innovative engineering services, such as additive manufacturing and closed-loop recycling systems. Using these manufacturing means allows companies to reduce waste and energy usage significantly - at least in terms of set global sustainability goals. Digital technologies are changing the face of the automotive market. Big data analytics, AI, and the IoT are transforming vehicle design, manufacturing, and servicing. By harnessing these technologies, automotive engineering services can improve processes, enhance quality control, and provide personalized customer experiences. Predictive maintenance now comes front and center as it is powered by data analytics. Using data analytics, manufacturers can predict flaws before they appear to maximize the vehicle's life. Workforce development is one of the most significant solutions that can be helped by it. A workforce that can adapt to new tools and methodologies is required for the speed at which technologies change. Innovative training programs and partnerships with learning institutions are in great demand to prepare the next generation of engineers. A continuous learning culture with adaptability will enable automotive engineering services to stay ahead of industry changes. ...Read more
The automotive industry is continually evolving to enhance security and safety for drivers, passengers, and pedestrians. Modern vehicles are now provided with advanced technologies designed to reduce accidents and improve protection. For instance, blind spot detection systems monitor hard-to-see areas around the vehicle and alert drivers to nearby cars. Advanced Driver Assistance Systems (ADAS) combine various technologies to help prevent accidents or lessen their impact. Features such as automatic speed regulation maintain safe distances on highways, while emergency braking systems detect potential collisions and can intervene to avoid or mitigate the severity of accidents. Autonomous driving tech uses sensors, cameras, radar, and AI to represent a significant leap in automotive safety. While fully autonomous vehicles are still in testing, semi-autonomous driving capabilities are available. Cybersecurity has become a critical concern as cars become more connected and reliant on software. Modern vehicles have advanced cybersecurity measures to protect against hacking and unauthorized access. Automakers collaborate with cybersecurity firms to develop robust security protocols and regularly update software to address emerging threats. Biometric authentication is an emerging technology that enhances vehicle security by using unique biological characteristics for identification. Features like fingerprint scanners, facial recognition, and iris scanners are being integrated into vehicles to provide secure and convenient access. Airbag technology has seen significant advancements, with modern systems designed to offer better protection in various crash scenarios. Dual-stage airbags, which deploy with varying force depending on the collision's severity, and curtain airbags, which provide head protection in side impacts, are now standard in many vehicles. Pedestrian airbags, which deploy from the hood to cushion the impact for pedestrians in a collision, are being introduced to enhance pedestrian safety. The systems can provide alerts or take corrective actions, such as slowing down the vehicle, to prevent accidents caused by impaired driving. The systems maintain road safety by continuously monitoring drivers' behavior. The latest advancements in automotive safety and security are transforming the driving experience, making it safer and more secure. Technologies such as ADAS, autonomous driving, enhanced cybersecurity, biometric authentication, advanced airbag systems, and driver monitoring are at the forefront of this transformation. They will undoubtedly contribute to a significant reduction in road accidents and enhance the overall security of vehicles. The future of automotive safety and security promises a safer, more innovative, and more connected driving environment. Biometric systems can customize vehicle settings based on the driver's preferences, adding a layer of personalization and security. ...Read more
In recent years, the automotive industry has witnessed a transformation in marketing strategies, driven by technological advancements and changing consumer behaviors. The rise of digital platforms, data analytics, and innovative advertising methods has allowed automotive brands to engage with their audiences more effectively than ever before. These advancements not only enhance brand visibility but also provide invaluable insights that drive sales and customer loyalty. What Role Does Data Analytics Play in Automotive Marketing? Data analytics has become a cornerstone of automotive marketing, allowing companies to gather and interpret vast amounts of consumer data. By analyzing trends and customer preferences, automotive brands can create personalized marketing strategies that resonate with their target audience. Top auto tech companies leverage machine learning algorithms to predict consumer behavior, enabling them to tailor advertisements and promotions. As a result, customers are more likely to engage with content that aligns with their interests and needs, leading to higher conversion rates. The emergence of customer relationship management (CRM) tools has revolutionized how car manufacturers and dealers interact with potential buyers. These tools help in tracking customer journeys, from initial inquiries to post-purchase follow-ups, ensuring that every touchpoint is optimized for maximum engagement. As a result, automotive marketing is no longer about broadcasting messages; it is about creating meaningful interactions that foster brand loyalty. How Is Social Media Changing the Landscape of Automotive Marketing? Social media has rapidly become a vital component of automotive marketing strategies. Social media platforms offer brands an opportunity to connect with consumers in a more casual and engaging environment. Automotive companies utilize these platforms not only for advertising but also for storytelling and building brand identity. Influencer partnerships, user-generated content, and interactive campaigns are just a few examples of how brands are leveraging social media to enhance their marketing efforts. With the rise of video content, brands are increasingly using these platforms to showcase vehicles through immersive experiences such as virtual test drives and behind-the-scenes looks at the manufacturing process. These dynamic formats capture the attention of potential buyers and can drive significant engagement. Moreover, social media allows for real-time feedback, enabling companies to adapt their strategies quickly based on consumer reactions and trends. The impact of advancements in automotive marketing extends beyond merely promoting vehicles. It is now about creating a holistic experience that starts well before a consumer steps into a dealership and continues long after the purchase. By utilizing technology, automotive companies can develop stronger relationships with customers, leading to long-term loyalty and enhanced brand reputation. As the industry continues to evolve, it will be crucial for automotive brands to stay ahead of technological trends. The integration of virtual reality (VR), augmented reality (AR), and artificial intelligence (AI) into marketing strategies promises even greater opportunities for engagement. These technologies will allow potential buyers to visualize their dream cars in innovative ways, making the shopping experience not only more engaging but also more informative. ...Read more