APPLICATION REPORT

WheelWatch
From test bench to test track
ika relies on WheelWatch

Test drive at the Institute of Automotive Engineering (ika) of

RWTH Aachen University
Ever since cars have been built, engineers have worked on the
design and development of various chassis components to
enhance vehicle comfort and at the same time improve active
safety. The Chassis Division at the Institute for Motor Vehicles
(ika) of the RWTH Aachen University is also committed to these
working principles. Since 2013 the ika has successfully deplo-
yed WheelWatch for their examinations of the driving dynamics
of vehicles.
Ready for measurement: vehicle fitted with WheelWatch
In cooperation with car manufacturers and their suppliers, the Institute
for Motor Vehicles (ika) of the RWTH Aachen University focuses on
specific issues, making an acknowledged contribution to finding solu-
tions to present-day challenges. Its engineers master all steps of chas-
sis development: from design and simulation through to detail design,
prototype construction as well as functional and endurance testing in
test drives and on different test benches. fka Forschungsgesellschaft
Kraftfahrwesen mbH Aachen is a research institute founded by ika. For
more than 30 years it has been conducting research for international
OEMs and suppliers, and offers consulting, construction, simulation,
design, prototyping and experimental testing from a single source.
Both institutes work closely together.
To further develop the measurement technology used, an optical high-
speed measurement system was required which could provide all im-
portant measurements for determining axle parameters such as track,
camber inclination and shifts in the coordinate system of a vehicle.
WheelWatch system components
The system had to be appropriate both for test track
and test bench, as well as for any other measuring
tasks required. Today, ika uses the AICON measure-
ment system WheelWatch for these tasks.
Non-contact measurement of high
speed wheel motion on the test track
The impact of different types of bearings on both ax-
les and wheel positions as well as drivability is for ex-
ample one of the questions that can be answered by
an effects analysis. To do so, a variety of maneuvers
are driven where for example the vertical dynamics
are examined through straight exits on bad roads. To
measure the lateral dynamics, standardized driving
maneuvers such as the VDA (German Automobile In-
dustry Alliance) lane change (according to ISO 3888-
2) are performed, but also open-loop maneuvers such
as stationary circle and sinusoidal steering.
To do so, an axle is fitted with the WheelWatch
system. A camera is mounted on each wheel to be
measured which simultaneously captures the fender
as a stationary reference system and the wheel as
a second rigid body. Specially coded measurement
targets on the bodywork identify the vehicle coordi-
nates system. The wheel is signalized with an adapter
in lightweight construction (CRP).
Lane change maneuvers on the test track
The complete setup including referencing, wheel axis calibration and
system setup takes less than one hour per vehicle axle.
In addition to the WheelWatch system, the test vehicle has more
measurement equipment on board: for example, sensors which record
forces and acceleration; a steering robot and centrifugal platforms are
often also deployed. The different sensors are connected via various
interfaces (such as CAN, Ethernet, analog) to the data acquisition
system and measurement data are synchronously merged and stored
centrally, in real-time or post-processing, according to need.
WheelWatch setup on the test bench
Kinematic analysis on the test bench
The kinematics and elastokinematics of vehicles and axis modules are
measured on the kinematic and compliance test rig of ika: wheel be-
havior, wheel loads, track, camber inclination, longitudinal, lateral and
vertical forces as well as the shifting of wheel contact points are some
of the values recorded. The analyses also address the question of the
impact which individual components have on the axle. A loaded con-
dition of the vehicle is simulated, i.e. the vehicle is placed in a defined
spring travel position. The tests are performed with a mechanical wheel
replacement system and WheelWatch.
Parallel to the measurement, ika also works with WheelWatch on the
test bench with its own recording system of forces and travels. A
Exemplary presentation of results of the wheel center positions X, Y, Z
when driving through a pot hole
measuring computer controls the test bench. The 6D
data (X, Y, Z, 3 rotations) captured by WheelWatch
are sent in real time via the Ethernet interface to the
central data recording system. Extensive post proces-
sing is therefore not required. This makes the work
with WheelWatch and the integration of the system
into more complex measuring processes simple and
convenient.
New system - new comfort
Thomas Horrmann, manager Benchmarking and
Function Development, supervises the work with
WheelWatch. He is extremely happy with the de-
cision in favor of AICON: We have integrated the
WheelWatch system very well into our existing testing
environment. The fast setup allows us to save 30%
time compared to our previous measurement system.
WheelWatch makes test drives much easier to im-
plement; now we can determine absolute track and
camber angles, and not only relative values as before.
Whats more, the new system is very stable.
WheelWatch is the system with the highest available
accuracy for static and dynamic vehicle parame-
ter monitoring on the market. In driving tests, the
system impresses with its robustness and reliability
in data acquisition even under harsh environmental
conditions. WheelWatch is part of AICONs modular
MoveInspect Technology system concept that can
be adapted to any individual measurement task. The
system will therefore also be used in the future for the
measurement of other components and parts. For the
ika and fka research teams, the WheelWatch system
has proved itself today as a long-term solution for
universal measurement tasks.
WheelWatch measurement on the kinematic and
compliance test rig
We thank the Institute for Motor Vehicles (ika) of
RWTH Aachen University and fka Forschungsgesell-
schaft Kraftfahrwesen mbH for their kind support!
AICON 3D Systems GmbH
Biberweg 30 C | D-38114 Braunschweig
tel. +49 (0)531 58 000 58
www.aicon3d.com | info@aicon.de