Performance testing system integrated with Mikrotron high-speed cameras opens up a new concept of automotive safety standards (Part 1)

By incorporating high-speed EoSens® GE GigE Vision® cameras from Mikrotron into its WheelWatch ™ optical measurement system, AICON 3D System GmbH has set a new standard for monitoring contactless wheel movement in testing. Experimental dynamics of the vehicle.

The WheelWatch system can be deployed both on the test station as well as on the drive tracks. However, it is also ideal for other motion analyzes such as:

• Check hatches
• Check the opening and closing motion of car windows and trunks
• Vibration analysis of components
• Robot ray used in measurement
• Machine control
• Error analysis in the production line (eg welding process)
• Movement of components in a wind tunnel or air chamber
• Impact analysis
• Materials, structural analysis
• 6D positioning and alignment

With a maximum speed of nearly 500 frames per second, the Mikrotron EoSens GE camera uses a 1.3 megapixel CMOS sensor, resulting in 1280 x 1024 pixel resolution with 90 dB dynamic range. As a result, the WheelWatch system can capture sharp, high-contrast images for analysis (car quality / performance), even at driving speeds of up to 155 mph. including accurate measurement of wheel parameters such as track, camber* tilt, spring movement, ground clearance and steering angle.

*Camber is the angle of incline or inclination of the wheel (front or rear) from the vertical seen from the front (or back)

WheelWatch is used in the prototype testing phase in automobile research and development. Before a series of cars could be mass produced at any production facility, the prototype was fully tested on millions of miles. Careful and accurate inspection of how the wheels operate is part of this process in case of the worst possible cases.

So how do manufacturing engineers handle situations when a vehicle is hit or when the road is slippery? Are the manufactured vehicles stable during obstacle avoidance drills or when running at high speeds? Does the wheel well still provide enough space even when the car goes through sudden sharp turns? These are the types of dynamic parameters that WheelWatch can obtain for analysis.

During the test, the Mikrotron EoSens® GE camera was subjected to intense forces such as sudden acceleration, sharp steering control and sudden braking that would damage the standard camera. Equally challenging, the camera is expected to operate in driving tests lasting several hours.

Unexpectedly, Mikrotron EoSens® – perfecting the fanless design, shockproof and vibration in rugged metal housing – has accomplished the task, achieving lasting stability through hundreds of tests.

Productivity and Quality Office