INDUSTRY 4.0 MONITORING FOR AUTOMOTIVE TESTING

casestudy

In 2018 the UK automotive sector was valued at £82 billion and employed 823,000 people.

As the trends towards automated, low carbon and electrical vehicles increase the requirements of modern testing and certification are critical. In this customer application we explore how one of the UK’s largest automotive test companies is meeting these new challenges helped by the adoption of the cutting edge Rotronic Monitoring System (RMS).

Automotive Test and Validation

In 2017 the Worldwide Harmonised Light Vehicle Test Procedure (WLTP) was introduced.  This lab test required the assessment of fuel consumption as well as CO2 and pollutant emissions from cars during
• Test cycles based on real-driving data
• Test cycles based on a variety of driving phases
• Test cycles using both heaviest and lightest power-train configurations

Facilities that provide these tests and have access to suitable test tracks are increasingly in high demand. Prior to testing cars must be preconditioned at specific environmental
conditions and during lab testing these conditions are replicated.

WLTP

The Application

In order to meet ongoing quality demands and compliance to the latest Vehicle Emissions Regulations (WLTP), our client required a solution to improve and enhance their monitoring capability in several key test areas. Latest standards required more frequent ambient measurements as well as five-minute rolling averages. Engine testing is undertaken in multiple soaking areas operating at different temperatures, ranging from -20 °C to +50 °C, requiring numerous temperature and humidity sensors monitoring different parts and areas of the test vehicles.

The Challenge
It is no longer practical to use a range of different monitoring platforms for every specific application. For the automotive industry the growth of the latest 5G and electric car technology provides new validation and testing challenges, a monitoring platform must be able to adapt to meet these new requirements easily. For our client the system had to be centrally managed with all data accessible from anywhere on site. Reporting, alarming and a clear audit trail were vital. Already having experience with a range of hardware and software it was clear that the system had to utilise standard IT infrastructure and software platforms.

car
Rolling road for vehicle testing

Hardware Integration and Standardisation

Investing in a monitoring system traditionally locked customers in to one supplier. Where possible, RMS has been designed to support Industry 4.0 open integration and interoperability. As such, RMS software is built as a standard web service. All data sits on a standard SQL database. Industrial device interoperability is never easy, RMS provides
options via simple APIs for many applications and analogue input modules for existing analogue hardware. When a robust and secure integration solution for digital hardware is required it can be professionally integrated using our RMS-Convertor module.

The result is that end users can add supported 3rd party devices with a few clicks. These devices benefit from secure data backup and auto-recovery of data in the event of any system downtime, as well as all the normal charting, reporting and alarming features RMS offers.

Project Overview

Our client engineers favoured Red Lion E3 modules, a proven industrial I/O device from Red Lion Controls. The E3 range includes 16 channel thermocouple devices, ideal for automotive testing. Integration was achieved in partnership with Rotronic R&D. Using a trial Red Lion E3 device Rotronic was able to fully integrate the unit. Final testing was undertaken by the client to confirm that the devices performed as required.

A key feature was that the Red Lion E3 modules have the ability to daisy chain Ethernet devices. Therefore, using a single port the 16x channel Red Lion module was networked along with a high accuracy humidity and temperature RMS LAN logger to every engine test cell providing a robust, elegant solution for this industrial application.

Millbrook

Product Focus – Rotronic Monitoring System (RMS)

High accuracy and high frequency multi parameter monitoring including temperature, humidity, pressure and dew point.
• On premise or cloud software solution
• Support for wired and wireless data loggers
• No local end user software required just a web-browser
• Full historic record and summary reporting
• High accuracy and high frequency ambient temperature and humidity monitoring
• Ability to calculate and record 5 minute rolling averages with alarms
• Extensive support for 3rd party devices and data streams

Read the case study from Red Lion on this project here; https://www.redlion.net/resources/millbrook-technology-park-case-study 

Contact us to discuss your monitoring requirements be they GxP, Industrial or Commercial.

Dr Jeremy Wingate
Rotronic

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