Development of a new type of overall vehicle test rig for motorcycles with the RENK automation system RDDS

My dissertation is dedicated to the development of an innovative motorcycle test rig that is designed to precisely replicate real driving conditions in a laboratory environment. The challenge is to accurately measure the complex vibrational and motional dynamics of motorcycles, as conventional test rigs are often only of limited use. The test rig should avoid dangerous or inefficient driving manoeuvres that would be necessary in real testing. By simulating real driving conditions, a safer and more efficient test environment is created that provides valuable insights without the risks and limitations of real-world driving tests.

The dissertation aims to provide a solid foundation for the development and validation of such test rigs and to support future developments in vehicle testing.

The development of the new motorcycle test stand began with the creation of a comprehensive concept that formed the basis for all subsequent steps. This concept was realised in hardware and rated a success by the project partners. The test rig prototype was then further developed in Dresden to further optimise its functions and performance.

A major advance was the integration of advanced driver actuators into the existing test system. We were looking for a modular system in which both software and hardware can be expanded as required and costs are manageable and transparent. RENK played a key role in this, in particular by sponsoring an academic licence for the RENK Dynamic Data System (RDDS). RDDS enabled the integration of readily available industrial electronics and provided the basis for precise control of the driving robot. The choice of Beckhoff TwinCAT as the real-time environment ensures reliable computing power and offers extensive expansion options via interfaces such as CAN bus and EtherCAT. An outstanding feature of RDDS is the ability to use Simulink models directly in the real-time environment, which allowed the control algorithms developed on digital twins to be efficiently transferred to the real system. For this test rig, an MBS model was created in VI-Motorcycle, which can be controlled by ADAMS/Controls in Simulink. This allowed the Simulink algorithms for switching and control to be tested and further developed at the desk before they were integrated into the real test rig control (TwinCAT / RDDS).

Maximilian Stanglmayr has extensive experience in the development and optimisation of test rig systems, especially in the field of motorcycle technology. During his time as a research assistant and project manager, he worked intensively on the design and implementation of complex test rig solutions. He was continuously active in the development of a complete motorcycle vehicle test rig, starting with the design phase and simulation and continuing through to realisation. In this context, he was responsible, among other things, for programming the automation software, integrating systems for measurement data acquisition and analysis, and realising and expanding the prototype test rig.

Of particular note is his role as the operator of the RENK Dynamic Data System (RDDS). Maximilian Stanglmayr successfully integrated RDDS to optimise the automation and adaptation of the test rig.