Test bench automation at ATESTEO: Faster, more efficient, safer testing

The mobility industry is constantly on the move – be it through new technologies, sustainable drives or innovative business models. Companies must continuously innovate in order to remain competitive. ATESTEO, a leading provider of drivetrain testing, is constantly setting new standards with its in-house developed automation software PDES. PDES enables ATESTEO to operate its own test benches worldwide efficiently, cost-effectively and safely, regardless of the type of test bench. Whether component tests, NVH tests, environmental simulations, endurance tests, efficiency or function tests.
At the DAKKS accredited ATESTEO calibration laboratory, the complete calibration process is automated, monitored and analysed by the PDES automation system.

Customised solutions for individual requirements

The requirements for modern automation platforms go far beyond pure measurement and control. PDES was developed to be able to quickly adapted to the specific requirements of each customer project. With modular hardware and software components, configurable interfaces and scalable functions, the software can be perfectly integrated into existing processes and adapted to future test requirements. ATESTEO customers profit from a customised solution which seamlessly integrate their devices and systems and make the tests efficient and reproducible.

Focusing on adaptability and efficiency

Whether customised user interfaces, the integration of complex controller structures or the integration of simulations into existing test sequences – the PDES development environment provides all the necessary tools. This tool chain is highlyvaluable if the test project needs to be expanded or adapted during the test run. New requirements, changed test parameters or additional measurement systems can be integarted without longer interuptions to the test process. This saves time and helps implement changes immediately.

Real-time capability and system performance

PDES offers exceptional real-time performance, enabling precise and deterministic control and regulation of even the most demanding test processes. The system captures and processes large amounts of high-frequency sensor data in real time without compromising stability or response speed.

“The combination of high performance and computing power is essential for demanding applications – such as rest bus simulations, realistic integration and validation of control units, or complex online analyses such as classifications and FFT. This capability enables precise early damage detection and the automated, timely shutdown of the test run.”

Robert Voigt, Head of Drivetrain Testing at the Alsdorf site

Data management and analysis

PDES not only manages and stores large amounts of data in an efficient, structured and secure manner, but also follows industry standards which guarantee that the measurement data is readable for a long time. The integrated analysis tools make it possible to run automated standard evaluations as well as generate custom reports. Thanks to seamless interfaces for data export, the measured information can be transferred to external systems and post-processed for further analysis.

Safety and monitoring

PDES utilises state-of-the-art error detection techniques and automated safety protocols to ensure the highest safety standards. In the event of deviations from defined standard values, alarm messages are triggered immediately so that tests are interrupted at an early stage and damage to the test specimen is prevented. In the event of a fault in the automation, an additional PLC (programmable logic controller) acts as a redundant safety system to ensure maximum operational safety.

‘With the ATESTEO Testing Cockpit, all test benches worldwide can be monitored remotely in real time. This service is also available to ATESTEO customers, giving them a comprehensive overview of the testing process at any time and from anywhere.’

Andreas Olf, Operation Testing Manager at ATESTEO

More about the Testing Cockpit

Find out more about the Testing Cockpit in the blog post or on the Testing Cockpit page.

The key benefits of PDES at a glance

  • Independent modules:
    Open, modular system with high flexibility and standard interfaces (EtherCAT, CAN-FD, XCP, ASAM MCD3, MQTT, …).

  • Realtime kernel:
    Stable and scalable real-time environment with high system performance. Guaranteed response times, no delay or jitter, synchronised data acquisition with high sampling rates.

  • Project editor:
    Setup and definition of all project channels, highly dynamic controllers (PID, fuzzy, …), extensive online filter library.

  • Layout editor:
    Customisable dashboards and interfaces allow interaction during test sequences. Extensive graphical object library with online curves and diagnostic options.

  • Programming language P5CL:
    Proprietary programming language with full access to all project parameters. Modern code editor with syntax highlighting, code completion, live syntax checking and variable monitoring.

  • Sequence generator:
    Intuitive graphical tool for easy creation and management of test sequences.

“PDES is the result of decades of development and stands for intelligent test bench automation made by ATESTEO! With PDES, we operate our in-house test benches worldwide efficiently, safely, and economically, regardless of test bench type or test requirements.”

Horst Frantzen, Head of Software Products ATESTEO

About the Author: ATESTEO

With over 200 test benches in Germany, the USA and China, along with representations in Japan, ATESTEO is the leading specialist for drivetrain testing combined with component validation, vehicle measurement technology, and engineering services. The company is among the top partners of the automotive and automotive supply industries around the globe—also in e-mobility testing.