KU Leuven LMSDPushing the Limits of Measurement Precision in Drivetrain Research

Long story short

KU Leuven’s Laboratory for Mechatronics and System Dynamics (LMSD) researches high-dynamic NVH phenomena in drivetrains. They needed an ultra-precise measurement system, accurate to 0.1 arcseconds, that integrates seamlessly into their real-time research setup. CTRL engineering designed a custom PCB with high-precision signal acquisition and real-time EtherCAT communication, from concept to deployment. The result? A state-of-the-art research tool that takes drivetrain analysis to new levels of accuracy.

What does this mean for you?

High-precision measurements and real-time data processing are critical in automotive research, industrial automation, and other high-tech applications. The ability to design and implement tailor-made solutions ensures greater reliability, efficiency and accuracy: the key factors in pushing technological boundaries.

At CTRL engineering, we specialize in delivering fully integrated engineering solutions, from custom PCB and FPGA development to advanced industrial communication systems. Whether your project requires high-precision measurement systems, real-time data processing, or EtherCAT-enabled solutions, we provide cutting-edge expertise tailored to your needs.

The challenge

High-speed drivetrain research demands exceptional accuracy to capture even the smallest NVH phenomena. LMSD required an encoder measurement system with an unprecedented level of precision. Standard data acquisition solutions introduced too much electrical noise and latency to be reliable. Any compromise in measurement quality would impact research outcomes, making a tailored approach essential. The system had to achieve a measurement accuracy of 0.1 arcseconds to detect even the most subtle drivetrain NVH effects. It also needed real-time EtherCAT communication for immediate data exchange and system control while integrating seamlessly into the existing research environment to ensure compatibility and efficiency.

Our approach

CTRL engineering approached the project with a focus on delivering an optimized, long-term solution. The process began with analyzing the exact requirements for precision measurement and environmental conditions. Based on these insights, a custom PCB was developed, designed for high-resolution signal acquisition with minimal electrical noise, ensuring the required 0.1 arcsecond accuracy.

To enable seamless real-time operation, a custom FPGA-based EtherCAT stack was implemented, transforming the PCB into a fully functional EtherCAT slave device. This allowed the system to synchronize effortlessly with the data aquisition of the existing research setup.

Once the prototype was completed, rigorous validation testing confirmed its accuracy and stability. Fine-tuning both the hardware and FPGA firmware ensured optimal performance under all test conditions. When deployed in LMSD’s research environment, the system can provide the precise, real-time data needed to advance drivetrain research.

“The ability to capture high-speed NVH data with such precision is a major step forward in our research, enabling deeper insights into drivetrain dynamics. 😊🔧🎯”

- Claus Claeys, Research Manager at KU Leuven LMSD

The result

With the custom-engineered solution fully integrated, LMSD now benefits from an ultra-precise measurement system that meets and exceeds the required 0.1 arcsecond accuracy. Researchers can capture high-resolution data with minimal noise and latency, significantly improving their ability to analyze NVH effects in drivetrains. The real-time EtherCAT integration allows seamless control and monitoring, streamlining their research workflow.
This enhanced capability empowers LMSD to push the boundaries of high-speed drivetrain analysis, ultimately contributing to advancements in vehicle performance, efficiency, and noise reduction.