Driving simulator
An automotive driving simulator moves structures weighing many tonnes with high dynamics, and all cables run through energy chains. Break monitoring reports chain damage early and switches the system off automatically if necessary.
Driving simulator at a glance
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Automotive driving simulator: detecting chain breaks
In the solution example, four energy chains, each 14.80 metres long, carry all the lines for power, control, networking, pneumatics and cooling water, a total of 90 kilograms per metre over 20 metres of travel. The installation uses the P4.1 series e-chain with plain bearings made of high-performance polymers and new chainflex cables. For EC.B break detection, a rope is tensioned through the e-chain; it registers every change in length and reports it to the EC.B sensor. Chain breaks are thus detected early, and the system can shut down automatically.
The example comes from the automotive industry, with break detection and cable monitoring as use cases. At its Technology Center in Sindelfingen, Mercedes-Benz runs a 22-tonne driving simulator with a 360° screen and a twelve-metre rail. It is used for vehicle dynamics, operating concepts, driver assistance systems and autonomous driving. The system moves at up to ten metres per second. After ten years of trouble-free operation with one system, igus replaced all cables and chains and added break monitoring to further increase plant safety and availability.
Automotive driving simulator: frequently asked questions
How does break monitoring work on a driving simulator?
A rope tensioned through the energy chain registers every change in length and reports it to a sensor. With the igus EC.B break detection in the Mercedes-Benz driving simulator, chain breaks are detected early in this way. The system can then shut down automatically before cables or equipment are damaged. This increases safety during operation.
How are cables routed in an automotive driving simulator?
In energy chains that keep power, data and media moving with the system. In the Mercedes-Benz driving simulator in Sindelfingen, all lines for power, control, networking, pneumatics and cooling water run through four chains, each 14.80 metres long. That amounts to 90 kilograms per metre. The chains consist of several bands so that the weight is distributed evenly.
What does modernising a driving simulator involve?
At Mercedes-Benz, it meant replacing all cables and energy chains and adding new break monitoring. igus replaced the existing P4 series profile rollers with the P41.80 e-chain and the old cables with chainflex cables. The guide trough was still in very good condition, so only its damping profiles were renewed. igus handled design, supply and installation from a single source.
What loads act on an automotive driving simulator motion platform?
High dynamics and large masses. The Mercedes-Benz driving simulator moves 22 tonnes at up to ten metres per second, and the computer calculates vehicle behaviour more than 1,000 times per second. The energy chains carry 90 kilograms of cables per metre. igus therefore uses chains with maintenance-free plain bearings made of high-performance polymers, together with break monitoring.
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