Turnkey Test Stand for Powersports Vehicle Durability Simulation

Maximizing Field Reliability Through Advanced Vehicle Durability Simulation

Discover how ACS engineered a turnkey R&D durability test stand that transforms traditional validation methods for heavy machinery. By replacing costly, time-consuming field trials with high-fidelity laboratory vehicle durability simulation, this custom solution enables repeatable, high-stress vehicle durability testing in a controlled environment. Read the full case study to see how the integration of advanced controls and flexible hydraulics delivers a new standard in precise off highway testing.

The Challenge

In the fast-paced development of heavy equipment, a leading manufacturer faced the critical challenge of verifying the physical dynamics of their next-generation off-road products and individual components. Traditionally, validating these rugged machines required driving expensive prototype vehicles for hundreds of hours across punishing, real-world field environments globally. This legacy validation method was not only cost-prohibitive and time-consuming, but it also limited the team’s ability to repeatedly capture high-stress failure data in a controlled manner. To streamline operations, the manufacturer needed a flexible powersports vehicle durability simulation solution to execute comprehensive testing inside a controlled laboratory setting.

The Solution

ACS partnered closely with the client to engineer and deliver a comprehensive, turnkey R&D durability test stand solution engineered specifically for rigorous off highway testing. To achieve the accuracy required for high-precision vehicle durability simulation, the ACS team integrated an intricate array of mechanical-hydraulic mechanisms paired with customizable control systems. This architecture allowed the team to run exact powersports vehicle durability simulation routines, precisely replicating the extreme stress, shock, and wear-and-tear of real-world ground profiles.

On the automation and controls front, ACS developed a dedicated test automation system for durability testing anchored by a high-performance Allen Bradley PLC housed in a main electrical control cabinet outside the physical test enclosure. Operator interaction with the complex test sequences is managed seamlessly through an intuitive Human-Machine Interface (HMI) application located on a dedicated test PC in the secure control room. Inside the cell, individual mechanical loading points were engineered for rapid adjustments, creating a highly adaptable test automation system for durability testing capable of handling diverse component and full-vehicle dimensions.

The Outcome

By collaborating with ACS from initial concept to final validation, the client successfully transitioned from unpredictable field trials to a highly repeatable laboratory environment. The client installed the entire turnkey R&D test stand into a specialized, environmentally controlled room at their facility to further simulate the punishing field conditions experienced by off-road machinery around the globe.

The advanced vehicle durability simulation capabilities provided by the new test stand allow the manufacturer to accelerate their engineering cycles, lower prototype development costs, and capture precise physical data on component fatigue. Ultimately, the successful delivery, Factory Acceptance Testing (FAT), and Site Acceptance Testing (SAT) executed by ACS provided the client with a powerful, versatile asset that redefines their approach to heavy-duty vehicle durability testing and ensures product reliability for years to come.

Key Features

• Turnkey R&D durability test stand designed for advanced off highway testing
• High-fidelity vehicle durability simulation utilizing client-specific ground profiles
• Multi-vehicle flexibility optimized for powersports vehicle durability simulation
• Dedicated test automation system for durability testing featuring Allen Bradley PLC integration and custom HMI control
• Flexible mechanical loading points to accommodate various off-road machinery components
• External HPU and electrical cabinets to maximize enclosure safety

ACS Services

• Concept development and comprehensive 3D modeling/design
• Full turnkey engineering and control systems integration
• Rigorous Factory Acceptance Testing (FAT) and final Site Acceptance Testing (SAT)