The efficient operation of powertrain test benches in research and development is strongly influenced by the state of “health” of the functional test object. Hence, the use of Early Damage Detection Systems (EDDS) with Unit Under Test (UUT) monitoring is becoming increasingly popular. An EDDS should primarily avoid total loss of the test object and ensure that damaged parts are not completely destroyed, and can still be inspected. Therefore, any abnormality from the standard test object behavior, such as an exceeding of predefined limits, must be recognized at an early testing time, and must lead to a shutdown of the test bench operation. With sensors mounted on the test object, it is possible to isolate the damage cause in the event of its detection. Advanced EDDS configurations also optimize the predefined limits by learning new shutdown values according to the test object behavior within a very short time.
In this paper, the expectations on an EDDS and its general structure are presented and discussed. The advantages and disadvantages in test bench operation are analyzed and compared with measurement results. Based on the analysis of various test series, it will be shown that shutdowns of the test bench initiated by the EDDS are an effective damage prevention for the UUT. Avoiding major damage to the usually very valuable test objects leads to lower testing costs and increased efficiency of the test bench operation in general. Combining the additional features of an EDDS with conventional damage prevention methods, such as the automated compliance with test-relevant limits and regular analysis of lubricants and coolants, significantly increases the UUT safety.