Intelligent breakage monitoring in 22-ton automotive driving simulator

The simulator is primarily used for testing and validating driving dynamics, operating and display concepts, vehicle assistants and autonomous driving. The vehicle's control equipment is connected to the driving simulator's computer control system via data lines. The computer calculates the car's driving behavior over 1,000 times per second and issues the corresponding commands to the mechatronics. It moves the system at a maximum speed of ten meters per second (36 km/h). With a 360° screen, the fast electric drive and the twelve meter long rail for the “air-bearing movement”, the system is one of the most powerful in the automotive industry. All the necessary cables for the power supply, control system, network technology and pneumatic and cooling water hoses must be safely routed and protected. The most efficient solution was sought here.

Energy chains act like an umbilical cord: they ensure the supply of energy, data and media and are constantly in motion. In the energy chains used, 90 kilograms per meter are distributed over four chains. The length of each chain is 14.80 meters and the travel distance is designed for 20 meters. In order to further increase system safety and availability, those responsible decided to install new P4.1 series energy chains including intelligent breakage monitoring. Should an unforeseen problem arise in real operation, especially in such a highly dynamic application, this can be detected directly with the unique i.Sense EC.B breakage detection system from smart plastics. As a result, chain breakages are detected at an early stage and high accident costs for the entire system are avoided.