Vehicle EMC testing
Vehicle EMC testing is a critical process that assesses how well a vehicle can function within its electromagnetic environment, ensuring it does not experience interference from external sources or disrupt other devices.
This testing is increasingly important as modern vehicles become more complex, incorporating numerous electronic components such as advanced driver-assistance systems, infotainment, and navigation technologies. Given this complexity, rigorous vehicle EMC testing is essential to confirm that these systems operate reliably under various electromagnetic conditions.
The testing process consists of two main components: emissions testing and immunity testing. Emissions testing measures the electromagnetic energy radiated by the vehicle, identifying any potential interference that could affect nearby electronic devices. It ensures compliance with established regulatory standards regarding electromagnetic emissions.
In contrast, immunity testing evaluates the vehicle’s resilience to external electromagnetic fields, determining how well the vehicle can withstand interference from devices like mobile phones and radio transmitters. This dual approach is vital for ensuring that vehicles operate safely and effectively in real-world environments filled with electromagnetic sources.
Beyond regulatory compliance, vehicle EMC testing enhances overall vehicle safety and performance. As vehicles increasingly rely on advanced technologies, the risk of electromagnetic interference rises. Effective vehicle EMC testing helps identify and mitigate issues that could lead to malfunctions or safety hazards, ensuring all electronic systems function as intended. For instance, reliable communication between vehicle systems is crucial for safety features to operate correctly.
Additionally, thorough vehicle EMC testing contributes to the overall quality and reliability of vehicles. Manufacturers who invest in comprehensive testing reduce the risk of recalls and enhance customer satisfaction by ensuring their vehicles perform well in diverse electromagnetic environments. This proactive approach not only safeguards the brand’s reputation but also builds consumer trust in the safety and technology of their vehicles.
Stationary vehicle EMC testing system
The stationary vehicle EMC testing system is a comprehensive performance test system, mainly used for vehicle electromagnetic compatibility (EMC) and electromagnetic interference (EMI) testing. It has the following features and advantages:
Testing environment
The vehicle EMC testing system can be set up in the anechoic chamber or reverberation chamber, providing a testing environment that isolates interference.
Measurement capability
Equipped with professional measurement instruments, it can comprehensively measure vehicles’ EMC and EMI indicators.
Simulation of road loads
Adopting an adjustable drum load system, it can simulate the loads under actual driving conditions, providing a real working condition environment for testing.
Multi-drive axle support
The load system can be designed for 2WD, 4WD or more drive axles according to the number of drive axles of the model, adapting to the testing needs of different models.
Flexible installation
The drum load system can be stationary or mobile. The stationary design is integrated into the rotary table or floor, while the mobile type adopts a modular design and can be pushed into the anechoic chamber for testing.
Independent control functions
Each load machine unit can be independently controlled for torque and speed to simulate different road loading conditions.
High-precision measurement
The load machine adopts advanced control technology with high-precision torque and rotational speed measurement capability and good repeatability of test results.
Electromagnetic shielding performance
The vehicle EMC testing system adopts special shielding technology, which can meet the Class 5 requirements of CISPR 25 standard and ensure the electromagnetic compatibility of the test environment.
Additional functions
Optional accessory equipment such as the self-driving robot, exhaust emission system, windward system, etc. can be used to simulate more realistic test scenarios.
Customized design
DynoEquip can provide customized vehicle EMC testing solutions according to customers’ specific needs.
The stationary vehicle EMC testing system functions
Simulated driving conditions
- The load machines allow the vehicle to operate under simulated driving conditions such as acceleration, deceleration, and constant speed.
- This simulated environment helps to reproduce actual electromagnetic conditions that may be encountered during normal vehicle operation.
Measuring electromagnetic interference
- During the vehicle EMC testing, the vehicle’s electromagnetic emissions and immunity to electromagnetic interference are measured and evaluated.
- This evaluation helps to ensure that the vehicle complies with relevant EMC regulations and standards.
Ensuring Compliance
- Comprehensive vehicle EMC testing using the load machines helps to verify a vehicle’s EMC compliance, which is an important aspect of the overall vehicle development and certification process.
- Compliance with EMC regulations and standards ensures that the vehicle’s electrical and electronic systems function properly and do not interfere with other electronic equipment or systems.
The stationary vehicle EMC testing system configuration
Chassis dynamometer
- This is the core component of the vehicle EMC testing setup and can operate the vehicle under simulated driving conditions.
- It can simulate various driving conditions such as acceleration, deceleration, and constant speed.
Measurement equipment
- Specialized test and measurement equipment is used to monitor and evaluate the electromagnetic emissions and immunity of vehicles.
- These instruments are capable of performing comprehensive EMC measurements and analyses to assess a vehicle’s compliance with applicable regulations and standards.
Controlled environments
- The vehicle EMC testing is typically performed in a shielded, controlled environment to minimize external electromagnetic interference and ensure measurement accuracy.
Mobile vehicle EMC testing
The mobile vehicle EMC testing system is a highly specialized solution designed for evaluating the electromagnetic compatibility of vehicles efficiently and flexibly. Its modular structure allows for easy assembly and transportation, making it adaptable for various vehicle types and sizes. Equipped with heavy-duty load-bearing universal wheels, the system can be effortlessly maneuvered into an anechoic chamber, which is essential for minimizing external electromagnetic noise and reflections that could interfere with test results.
At the start of the testing process, an adjustable bracket is placed in the designated support position within the chamber to stabilize the vehicle during testing. After securely positioning the vehicle, engineers connect various systems, including a power cable to energize the vehicle’s electronics, a communication fiber for real-time data transfer, and a pneumatic pipeline to manage air pressure needs for systems like active suspension or braking. This comprehensive setup ensures that all vehicle functions are operational and accurately reflect real-world conditions.
Once all connections are established, the vehicle is secured in place using a ratcheting harness. This mechanism prevents any movement during testing, which is crucial for maintaining the stability necessary for accurate results. With the vehicle firmly secured and operational, the vehicle EMC testing can commence.
During the testing phase, engineers perform a series of assessments to measure emissions from the vehicle’s electronic systems and its immunity to external electromagnetic interference. Emissions testing quantifies the electromagnetic energy emitted by components such as the engine control unit (ECU) and infotainment systems. This evaluation helps identify potential sources of interference that may affect the vehicle’s performance or disrupt nearby electronic devices.
Simultaneously, immunity testing evaluates how well the vehicle’s systems withstand external electromagnetic fields, ensuring reliable operation even in environments with significant electromagnetic activity, such as urban areas filled with electronic devices. By exposing the vehicle to various frequencies and field strengths, engineers can gauge its resilience and ensure that it complies with industry standards.
The mobile vehicle EMC testing system has the following features:
Individual units
Each load machine unit is an individual unit and can be modularized for assembly.
Torque or speed control
Each load machine unit can be independently torque or speed-controlled to simulate road loads.
Suitable for full vehicle testing
Can be used for full vehicle testing in either the anechoic chamber or reverberation chamber.
Customized design
Customized design according to user requirements.
Adaptation to different wheelbases
The spacing of the multi-axis load machines is adjustable to adapt to the testing of vehicles with different wheelbases.
Configuration options
Can be configured with the automatic driving robot, exhaust emission system, vehicle windward system, etc.
Shielding technology
Unique shielding technology is adopted to meet Class 5 requirements of CISPR 25.
High-precision control
The torque-speed control of the load machine is highly accurate and repeatable.
Flexible installation
The load machine can be embedded in a turntable or installed under a raised floor.
Robust and reliable
The vehicle mounting device is integrated with the load machine body, making it robust and reliable.
The mobile vehicle EMC testing system usually consists of the following components:
Anechoic chamber
This is an environment used to conduct Electromagnetic Compatibility (EMC) and Electromagnetic Interference (EMI) testing. In the anechoic chamber, the test product will be subjected to controlled electromagnetic fields to simulate different operating conditions.
Drum load machine system
This is the equipment used to test the dynamic performance of vehicles. It consists of load-simulating drum units that are used to simulate the loading of the vehicle at different speeds.
Measuring instruments
Instruments used to measure various parameters of the vehicle such as speed, acceleration, emissions, etc.
In addition, the specific configuration of the load machine system will be determined by the parameters of the product to be tested. For example, vehicle cooling systems, wheelbase adjustment systems, automated driving robots, vehicle flat tire devices, exhaust emission systems, and real-time control systems may be included in the load machine system.
The mobile vehicle EMC testing system key technology description
Road load simulation load machine
Motor type
The load machine adopts an induction asynchronous servo motor.
Control method
A four-quadrant inverter is used for control to realize the speed and torque control of the load machine.
Integrated design
Each set of load machines and frequency converters is integrated into a single unit body, which is completely shielded. In addition, the cables between the frequency converter and the load machine are very short, thus significantly reducing electromagnetic radiation.
Communication
Dynamic control of the load machine and feedback of the measured parameters is achieved through fiber optic communication between the controller and each frequency converter.
Drum
The rotating drum is an important component of the vehicle EMC testing system used to simulate road friction.
Drum
The drum is a component of the testing system, usually made of metal. It has a surface with a certain roughness to simulate the friction of the road surface. The vehicle’s tires come into direct contact with the drum, creating friction.
Hard chrome coating
The surface of the drum is usually coated with hard chrome. This coating is abrasion and oil-resistant and increases the life of the drum.
Assembled construction
Drums are usually assembled. Before precision machining, the drum needs to be stress-relieved to ensure stability and performance.
Support and dynamic balancing
The drum assembly is supported at both ends by heavy-duty grease-lubricated spherical roller bearings. After assembly, dynamic balancing is also required to ensure that the drum operates without vibration or imbalance.
Drum braking system
When the vehicle enters the vehicle EMC testing system, the drum braking system brakes the drum so that the vehicle can enter the test position. This system uses pneumatic brakes. When the brake system is on, the brake applies to the drum and when the brake system is off, the brake automatically releases. In addition, the system has a brake position detection function. If the brakes are not reset, the testing system will not start and the user will be prompted to reset the drum brakes.
Vehicle fixtures
High strength heat resistant ratchet harness
This is a type of harness with high strength and heat resistant properties, usually made of special materials. It is used to connect the vehicle to the hooks on the steel frame of the vehicle EMC testing system.
Connection
One end is connected to the hook on the steel frame of the testing system, and the other end is connected to the hooks on the front and rear ends of the vehicle. This connection is realized by a ratchet mechanism, which facilitates the fastening of the vehicle.
Withstand tension:
Each ratchet harness can withstand up to 10 tons of pulling force. This means that it has enough strength to keep the vehicle stable.
Flat tire detection device
The flat tire detection device is an intelligent safety system for detecting whether a flat tire has occurred on a vehicle. When the vehicle has a sudden tire blowout during testing or driving, the device immediately triggers the following operations:
Stopping operation
The system will immediately shut down the vehicle’s power system to prevent further movement.
Vehicle stop
At the same time, the flat tire detection device will automatically trigger the braking system to bring the vehicle to a quick stop to reduce the potential danger.
Windward system
When the vehicle is tested in an anechoic chamber, a windward cooling system is required to keep the vehicle’s position fixed. The vehicle EMC testing system offers two different windward systems: mobile and recessed. Specifically:
Mobile windward system
This system utilizes a mobile fan. The cooling air is directed to the front of the vehicle using an air guide to maintain the cooling effect.
Embedded windward system
This system embeds the fan inside the load machine. The fan is mounted underneath the raised floor of the radio anechoic chamber and directs the cooling air to the front end of the vehicle using an air guide.
Both systems have their own advantages and application scenarios, and the choice depends on the needs of the test and the characteristics of the vehicle.
Exhaust emission system
To deal with exhaust emissions from fuel or hybrid vehicles, we use the following measures:
Exhaust emission unit
This is a key component that is used to discharge the vehicle’s exhaust gases into the environment. It usually includes catalysts, oxygen sensors, and other filtration devices to reduce the emission of harmful substances.
High-temperature resistant bellows
This is the component that connects the exhaust pipe to the exhaust emission device. Since exhaust pipes generate high temperatures, the bellows need to be heat-resistant to ensure a safe and effective connection.
Quick Connect
This is a convenient connection system that allows for quick connection of the tailpipe to the exhaust pipe of the vehicle. This helps in maintenance and replacement.
Exhaust emission treatment in an anechoic chamber
This is the pipe that directs the exhaust emissions from the vehicle to the environment. An anechoic chamber may be a laboratory or testing facility used to study exhaust emissions and other related issues.
Autopilot robot
The self-driving robot uses pneumatic actuators to control the vehicle’s throttle and brake pedals. In the control room, the operator can manually control the travel of the pneumatic actuators to accelerate and decelerate the vehicle. This system can be automated or switched to manual mode to give the operator more flexibility in controlling the vehicle.
Real-time control system
The real-time control system uses a quad-core embedded microprocessor and adopts the fastest and most stable communication method, EtherCAT, which writes the control program of the load machine into the real-time controller, thus realizing real-time dynamic control without perturbation. The upper computer is only used for data display, processing, saving, and triggering command sending. In addition, the real-time control system can control each wheel load machine independently or master-slave control. This system is also capable of simulating road loads such as ramp resistance.
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