In todayās automotive industry, where innovation drives competition, testing solutions must be as precise and adaptive as the systems they validate. From advanced driver-assistance systems (ADAS) to electric vehicle (EV) technologies, modern vehicles demand rigorous testing to meet safety, performance, and sustainability standards. Custom test rigs have become the cornerstone of engineering excellence, enabling manufacturers to overcome complex challenges and drive innovation. At Hadfield Services Ltd (HSL), we specialise in making bespoke test rigs that empower automotive engineering teams to meet the demands of a rapidly evolving industry.
1. Tailored Solutions for Complex Systems
Off-the-shelf testing solutions often lack the flexibility needed to handle the nuances of todayās automotive systems. Custom test rigs bridge this gap by replicating exact operational scenarios, ensuring accuracy and reliability. HSLās expertise lies in developing tailored solutions for intricate engineering challenges, enabling clients to achieve:
- Enhanced system performance validation: Custom rigs ensure components such as wiring harnesses, ECUs, and sensors function seamlessly under real-world conditions.
- Streamlined prototyping workflows: Bespoke rigs allow iterative testing during the development phase, enabling quick adjustments and reducing time-to-market.
- Future-proof integration: From EV battery systems to ADAS calibration, our rigs adapt to the cutting-edge technologies shaping the automotive sector.
Case Study: Revolutionising ECU Programming with the CAP Rig
One of HSLās most impactful innovations is the Common Architecture Programmer (CAP) rig, developed to solve inefficiencies in ECU programming. Before the CAP rig, programming a single ECU manually took 30 minutes, requiring a skilled software engineer. HSL designed a fully automated system that programs four units simultaneously in just 6.5 minutes, complete with full traceability, diagnostic logs, and self-diagnosis features.
This solution not only improved efficiency but also democratised the process by allowing operators without advanced programming expertise to handle tasks previously requiring specialised skills. The CAP rig has been so effective that it was adopted by international clients who purchased multiple units to implement globally.
2. Efficiency through Innovation: Automating Testing for Superior Results
In manufacturing, efficiency is key. Time saved during testing can translate into significant cost reductions and faster delivery to market. HSLās custom test rigs bring automation, precision, and reliability to automotive engineering processes. Our designs ensure:
- Optimised workflows: By automating repetitive tasks, our rigs reduce manual intervention and minimise errors.
- Integrated diagnostics and traceability: Real-time data logging ensures that all tests are documented, enabling quick resolution of issues and seamless audits.
- Robust performance: Built to withstand rigorous use, our test rigs offer consistent, high-quality results, even in demanding environments.
Case Study: LIN Programming Unit for End-of-Line Testing
HSL developed a bespoke LIN Programming Unit for end-of-line testing of key systems, designed to handle both LIN 1.2 and 2.0 standards. The rig ensures secure programming via server connections, with no sensitive data stored locally. This innovation improved both the security and efficiency of key programming processes, reducing cycle times while maintaining strict quality control standards.
Key features included:
- Full Programming Traceability ā logs of every action taken during the process.
- Self-Diagnostic Capabilities ā automatic identification of issues within the system.
- Automation ā drastically reduced operator intervention, allowing for efficient batch processing.
This rig transformed the client’s operations, reducing programming time by over 60% and improving overall system reliability.
The rise of electrification, automation, and connectivity in vehicles presents unprecedented engineering challenges.
3. Building Rigs for Emerging Automotive Technologies
Custom test rigs are critical for validating these advanced systems, ensuring they perform reliably under diverse conditions. HSL is at the forefront of developing rigs that address these emerging needs:
- EV Battery Testing: Our rigs support validation of high-voltage components, battery management systems, and thermal control solutions, ensuring safe and efficient operation.
- ADAS Calibration: Custom rigs facilitate precise testing of LiDAR, radar, and camera systems, critical for autonomous and semi-autonomous vehicles.
- Integrated System Testing: HSLās solutions enable comprehensive validation of interconnected vehicle systems, ensuring seamless compatibility and performance.
Whether itās custom test rigs for advanced validation or innovative production aids that streamline manufacturing, Hadfield Services Ltd is committed to making life easier for our clients. We thrive on tackling complex challenges and delivering solutions that combine precision, innovation, and reliability. Our partnership with the automotive industry is defined by our ability to anticipate its evolving needs and respond with excellence.
If youāre looking for bespoke solutions that redefine engineering standards, contact us today to learn how we can help overcome your biggest challenges.
For media inquiries or more information, please contact Hadfield Services Ltd atĀ [email protected].
What do you think?
Custom solutions like these truly highlight the importance of innovation and adaptability in automotive engineering. Itās fascinating to see how Hadfield Services tackles complex challenges with tailored test rigs.