Beyond the test rig: efficiency challenges demand development partners

The pressure on vehicle emissions has been heating up, with automotive companies facing closer regulatory scrutiny and tighter standards. It has become more important than ever for developers to optimise their systems. In this regard, engineering and testing facilities play a pivotal role. Driveline engineering consultancy Drive System Design (DSD) aims to offer comprehensive development centres for automotive companies to fine-tune their driveline efficiency, and its ambitions have gone global. North American addition The company is based in the UK but has been working to expand into North America. "Four years ago we decided to establish a technical presence in North America, starting off in the Metro Detroit area, to offer the same consulting capabilities to North American customers as we currently do in Europe," explained Jon Brentnall, President of Drive System Design Inc in North America. Brentnall and his team have spent the past four years building up the brand and establishing a growing customer base. The company is now opening a new testing facility in Michigan, which will initially house a loaded transmission efficiency test rig. Over the course of the year it will add a hydraulic test stand for hydraulic valve body development and a tilt rig, which provides enhanced lubrication flow analysis capability. "The business in North America is following the same path that’s been successful in Europe, which has been to become a one-stop shop engineering supplier for torque transfer systems," Brentnall told Greenstreetsoftware.info. That includes designing, building and testing capabilities. Last year, DSD worked with around about 20 customers, with similar expectations for this year. This group ranges from automotive OEMs and off-highway OEMs to automotive Tier 1s and a commercial truck transmission manufacturer. It also has a programme for a large military tracked vehicle transmission, and another for rocket vehicle gearbox systems. Automotive work accounts for the bulk of DSD's work in Europe but is expected to contribute between 30% and 50% to the business done out of North America. "Although the rig is primarily centred around passenger car transmissions, it does lend itself to being a useful test facility for other markets. We are also involved in aerospace and military programmes. We have found that automotive technology paves the way, and the military and the aerospace folk have the chance to jump on the back of it," he added. A holistic approach Designers face a host of challenges when it comes to improving system efficiency. One of the biggest struggles for customers stems from trade-offs as they seek to balance efficiency against NVH and durability. For DSD, a holistic approach works best. At the same time, the wide variety of projects in which it has been involved has become a crucial asset. "We have seen many products now, especially on hybrid EV drives. We are pretty tuned in to all of the calibration knobs that you can turn to help dial down frictional losses," said Brentnall. A typical customer may only work on one or two new products a year, but at DSD they see more like ten to 15. From pure testing to development partner Behind any of its test rigs, the real focus for DSD is to offer a development service rather than just pure testing. It boasts a team of capable engineers that are familiar with and have often designed the products going onto the test rigs themselves. "It is of much more interest to us to secure early or prototype products so we can find and solve issues as they occur," Brentnall explained. "This is where we try to differentiate. Otherwise the typical model is to just hire a test rig for a specific time slot and it comes with a technician. There is not much in the way of engineering support for product development." Most of DSD's projects start with some form of concept phase. "With much of our work we become involved before even the hardware exists. We are conceiving the products and the technology. Ultimately, it will result with us producing a design, building the prototypes and putting it on test," he added. Another type of project may involve a customers with a design close to release stage, seeking a review and possible fix of any mistakes. "This is easy because we act as a fresh set of eyes," Brentnall noted. Other projects come in where the prototype hardware has already been built and the company is essentially looking for a development partner. At that point, DSD can step in and write the test plan and the test procedure for the customer. With today's focus on real-world emissions and efficiency challenges, facilities like these - whether in Europe or North America - have become a substantially more important piece of the overall puzzle.

Beyond the test rig: efficiency challenges demand development partners

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