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The suspension system of the chassis is not only a critical component of the vehicle but also directly affects the driving experience, handling performance, and ride comfort. As the automotive industry moves towards electrification and intelligence, semi-active and active suspension technologies are rapidly developing and being widely adopted. However, to successfully apply semi-active and active suspension technologies in actual vehicle production, rigorous testing and validation are essential.

VCARSYSTEM's Solution

VCARSYSTEM’s comprehensive Suspension HIL testing system supports a full range of active and semi-active suspension systems—including air suspension, CDC dampers, electromagnetic damping, hydraulic suspension, and linear motor suspension—and supports a flexible range of testing modes, such as standalone HIL mode and system integration mode (full-vehicle four-post test bench, suspension four-post test setup). It accurately replicates complex real-world operating conditions, enabling thorough validation of suspension system performance via precise closed-loop control. This delivers robust technical support for the research, development, verification, and optimization of active and semi-active suspension systems, ensuring a seamless transition to real-vehicle testing.

HIL SYSTEM

VCARSYSTEM offers Hardware-in-the-Loop (HIL) testing solutions that cover the entire scope of automotive electronics, including modules for new energy powertrain systems (BMS/VCU/MCU), automotive driving systems (ACC/LKA/AEB, etc.), chassis electronic control systems (EPS/ESP/SBW/EPB/EHB/EMB), traditional powertrain systems (EMS/TCU), as well as body electronics and intelligent cockpits. It provides comprehensive HIL testing services to help customers accelerate product launch timelines.

VCAR EM

VCAR EM, developed by VCARSYSTEM for HIL platforms, is an engineering configuration tool that enables comprehensive HIL project setup. The software facilitates GPIO signal configuration, bus communication configuration for CAN/CAN FD, LIN, Ethernet, board hardware configuration, simulation model import, signal mapping, real-time host multi-task allocation and management, and project compilation. It also supports multi-task distribution management and multi-device daisy-chaining configuration, meeting diverse testing scenario requirements.

VCAR EA

VCAR EA is an automated testing software independently developed by VCARSYSTEM. It provides excellent support for editing and managing test cases, executing and evaluating them, and generating test reports, through dedicated interfaces and testing tools. Additionally, in response to the evolving demands of testing, VCAR EA supports the creation of user-defined steps to meet personalized requirements, making it widely used in the automotive testing field.

ADVANTAGES

High-Precision Simulation Capability

- Ensures suspension performance validation is highly consistent with real-world operating conditions, enhancing the credibility of test results.
- A high-bandwidth real-time computing platform delivers millimeter-level road surface input simulation and dynamic load control accuracy, supported by comprehensive built-in vehicle models for high-precision hardware-in-the-loop simulation.

Self-Developed Board Capability

- Reduces equipment cost and improves compatibility, with robust customizability to meet diverse test needs quickly.
- All boards are proprietary designs, with voltage/PWM input boards integrating multiple acquisition functions, CAN communication boards supporting three protocols (CAN, LIN, FlexRay) with abundant channels, and single boards enabling multi-type signal acquisition.

Built-In High-Speed Data Acquisition

- Provides accurate, real-time test data to support precise suspension performance analysis and optimization.
- A proprietary VCARSYSTEM high-speed measurement system (max. sampling rate ≥2 MHz, resolution ≥16-bit) captures high-fidelity suspension dynamic parameters, with a custom PSI5 signal board supporting five communication protocols for high-speed, stable data transmission.

Multi-Suspension Type Compatibility

- Eliminates the need for extensive reconfiguration across test setups to reduce test preparation time and costs.
- Flexible, configurable interfaces accommodate all types of active and semi-active suspension architectures.

Highly Integrated & Portability

- Expands application scenarios and improves operational efficiency, lowering the barrier to equipment adoption.
- The system features high integration and a lightweight design, allowing for easy movement and on-vehicle installation.

Cost-Effective Software & Customization

- Reduces procurement and operational costs, shortens delivery cycles, and meets personalized test needs of different customers.
- It offers abundant optional configurations with short procurement cycles, a single software license for multi-user access, and secondary development support without additional licenses or external software purchases.

Efficient Model & Test Management

- Dramatically reduces test preparation time and manual configuration effort, minimizing reliance on specialized technical personnel.
- By automating interface generation and supporting flexible workflow customization, it accelerates test iteration cycles and ensures consistent, repeatable test execution across projects.

FUNCTIONS

Full-Dimensional Suspension System Function Validation

Covers full-dimensional performance validation of the suspension system, including pitch control during braking/acceleration, height adjustment, automatic leveling, vehicle body vertical control, and lateral/longitudinal cooperative control, enabling comprehensive verification of suspension performance under real working conditions.

Real Road Condition & Dynamic Scenario Emulation

Accurately reproduces various road excitation inputs and dynamic vehicle loads, providing high-fidelity operating conditions for the verification of suspension dynamic response characteristics and durability.

Signal Acquisition & Multi-Protocol Communication

Implements multi-type signal acquisition and multi-protocol communication via self-developed hardware boards, supports automatic configuration of signal and interface model mapping, and fully adapts to signal interaction requirements in all suspension test scenarios.

Height Sensor PSI5/PWM Signal Emulation

Supports full-spectrum emulation of height sensor PSI5 (covering all versions 1.3/2.1/2.3) and PWM protocols, with flexible configuration of baud rate, cycle period, check modes, operating voltage, synchronization signals, multi-operation modes, current and initialization parameters to meet suspension height sensing test requirements.

Acceleration & IMU Signal Emulation

Supports emulation of multiple types of vehicle body attitude signals, including acceleration signals via CAN/PSI5 protocols and IMU signals via CAN/SPI protocol. It also supports signal emulation of preview sensors including camera, mmWave radar and LiDAR, fully matching the test requirements for attitude sensing and preview control of suspension control systems.

Full-Scenario Fault Injection Testing

Enables injection of a full range of fault scenarios into the suspension test system to verify the operational safety and fault tolerance of active/semi-active suspension systems under fault conditions.

M-Script Driven Automated Testing & Interface Configuration

Supports multiple test modes, automatically generates communication interface modules via M-script based on dbc/ldf files and hardware interface definitions, with built-in Override function, to simplify the automated test workflow and improve test consistency.

Software & Model Lifecycle Management

Integrates host configuration, test management and automated test software, supports Simulink physical model import and secondary development without additional authorization restrictions.

Integrated Measurement, Calibration & Diagnosis

Has a built-in measurement and calibration library, enabling direct measurement, calibration and full-function diagnosis of the suspension controller without relying on external professional software.

ASSOCIATED PRODUCTS

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