Efficient Automation of Homologation Tests for Active Aerodynamic Components

Wind Tunnels are complex and cost-intensive test facilities. Thus, increasing the test efficiency is an important aspect. At the same time active aerodynamic elements become increasingly important for the efficiency of modern cars. For homologation, such active aero-components pose an extra level of test-complexity as their control strategies, the relevant drive cycles and their aerodynamics in different positions must be considered for homologation-relevant data. Often, these active components are time-consuming manually adjusted during between test runs as the vehicle is not incorporated in the test automation architecture. Even if so, designing a test sequence stepping through the individual settings for each component of a certain vehicle is a tedious task during the test session. Thus, a sophisticated integration of the wind tunnel automation system with a test management system, which supports the full homologation process is one aspect of a solution. The other is the integration of the vehicle’s active aero components as controllable assets into the wind tunnel automation system. We present an architecture of a comprehensive set of software modules enhancing the capabilities of an automation system in such a way that highly-automated homologation tests of active components become possible with minimal manual actions during the test. This includes a fully traceable test process from the vehicle components to be tested to the results of each step within an automatically generated test run, during which the active components’ parameters are varied in such way, that all test requirements for the active components are satisfied. Finally, the results of each distinct step are transferred back to the test requirements, from which in combination with control characteristics and market-specific drive cycles the relevant homologation data of the active aero components can be obtained.