lifespan simulation

During the lifetime simulation, several test specimens are usually tested in parallel under continuous operation. Very often, the assemblies are exposed to different temperatures (e.g., from -40 to +120 degrees Celsius) in climate chambers during the tests. Crucial for these validation tests is that the measured quantities are recorded continuously and reliably over days and weeks. The data is evaluated, analyzed, and logged by the operator.

For these requirements, we have developed an optimal system with our own hardware components over the years.

For several years now, we have been supplying systems for electric mobility. Due to the high voltage range of up to 1000 volts and currents of several hundred amperes, further requirements have arisen.

While, for example, a control unit for comfort electronics can still be tested with very simple replacement loads or even original loads, this is no longer possible for the testing of inverters - the power electronics between the battery and the electric motor -.

For the emulation of the electric motor, we can offer a patented electric machine emulator. This is specially designed for lifetime testing, which has a very positive effect on our customers' investment volume, especially in this complex test environment.

Requirements we meet:

• Safe, failure-free operation of the test system over days and weeksn

• Hardware and software designed for parallel testing

• Hardware and software that can also capture very fast signals in real-time

• Software that allows test plans to be duplicated across multiple test stations

• Parameterizable data acquisition

• Handling of very large data volumes with adapted evaluation software

• Clear visualization of all ongoing tests

• Control of temperature cabinets

• Remote maintenance capability

Electronic control units for automotive applications require comprehensive validation to ensure that the device functions properly over the years under harsh environmental conditions. During validation, the inputs and outputs of the device to be tested must be stimulated and the operation continuously monitored.

IRS offers lifetime test systems to simulate all vehicle components. Our system communicates with the test specimen and monitors all relevant signals for the development and validation process:

• Simulation of real load conditions

• Diagnostics via CAN (FD), LIN, FlexRay

• Independent operation of multiple DUTs in parallel

• Continuous monitoring of all signals

• Standardized hardware and software platform