An automotive research institute and testing company: dual tracks across R&D and testing
Test line digital twin with remote commissioning, plus a configuration-based CAN/LIN durability test bench software platform.
On one side, an automotive design institute's R&D prototyping test line; on the other, an automotive thermal management measurement and control company's component durability testing business — their shared need: test data must be trustworthy and reproducible, and commissioning and maintenance must no longer depend on people being physically present.
Customer background
On one side, an automotive design institute's R&D prototyping test line; on the other, an automotive thermal management measurement and control company's component durability testing business — both share the same need: test data must be trustworthy and reproducible, and commissioning and maintenance can no longer rely on people being physically present.
Challenges
- Test line commissioning depended on engineers being on site — travel costs and schedule pressure both high
- Test data scattered across individual machines, impossible to reproduce or trace back
- Durability duty cycles are complex (multi-step constant / cyclic / cyclic with gradient); manual recording is unreliable
- Many test customers and machine models; software was rewritten for every model change, making delivery unsustainable
Our solution
The solution is delivered along two main tracks — the R&D-side test line and the testing-side durability test benches:
- R&D side · unified OPC UA collection of multi-brand equipment data
- R&D side · 1:1 3D digital twin refreshing at ~20ms, mapping the physical test line with real-time equipment status color-coding
- R&D side · high-precision personnel positioning and unauthorized-access alarms, safeguarding test safety
- R&D side · remote commissioning / programming / maintenance (multi-channel 3G/4G/Ethernet access) — travel turned into remote work
- R&D side · PROFINET + IO-Link vibration diagnosis (built-in FFT)
- Testing side · automatic execution of multi-step duty cycles (constant / cyclic / cyclic with gradient), synchronized control of program-controlled instruments and PLCs
- Testing side · TDMS high-speed recording + database dual channel, reducing data gaps caused by any single recording chain
- Testing side · deep parsing of CAN/LIN automotive buses (LIN SDF files, DBC messages)
- Testing side · switching machine models changes configuration, not code — configuration-based design supporting batch delivery to multiple customers and models
Results
- A substantial share of on-site commissioning moved to remote completion — travel and schedule both reduced
- Test data recorded automatically and traceable; report preparation efficiency improved
- Test bench software has been delivered in volume to multiple automotive thermal management component companies, covering compressors, ECUs and other models
Technology stack
Project boundaries and replication conditions
- Project boundaries：The implemented scope covers OPC UA collection, 3D linkage, personnel positioning and remote maintenance on the MALS test line; multi-step duty cycles, TDMS recording and CAN/LIN parsing for compressor durability testing
- Applicability conditions：R&D prototyping lines, durability benches and multi-model testing scenarios; equipment control boundaries and safety interlocks must be definable
- Replication prerequisites：Before replication, clarify equipment control boundaries, safety interlocks, protocol / vehicle-model files, sampling requirements and remote-access approvals
- Not disclosed：Travel substitution rates, reporting efficiency or benefit figures not confirmed with the customer are not disclosed
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