Influence of internal loads on the accuracy of durability tests of a vehicle on a test rig

Durability prediction of suspension systems in vehicles has always been a critical parameter in quest of more performant, efficient, and safe cars. Since the experiments with fully instrumented vehicles on the road are very expensive, tests are typically performed in a laboratory environment. Using time waveform replication (TWR), the control signals for the actuators are computed for the test rig setup. A commonly used techniques in TWR is based on linear frequency domain modelling using averaged frequency response function. This paper presents different simulation scenarios to explore possibilities of considering extra targets in the process. It illustrates the advantages and drawbacks of adding internal loads. Different types of sensors have been integrated into the numerical model. The influence of additional sensors on durability indicators has been compared using the RMS and the pseudo-damage of signals over time. The results show an overall beneficial effect of the extra target signals on TWR target reproduction quality.