Auto Tier1Mobile Testing Made Easy: The Smart Approach to a Testbench in a Box

Long story short

When space is limited but rigorous testing is required, a mobile testbench offers a flexible and transportable solution. Instead of relying on fixed test benches, containerized vessels provide adaptability across different operational environments. However, this flexibility introduces challenges related to operator comfort, thermal management, vibration control, and compliance with transport regulations. Through simulation-driven optimization, various design configurations are evaluated, ensuring an optimal balance between these often-conflicting requirements.

“Simulation-driven optimization allows us to balance thermal management, vibration control, and operator comfort, ensuring an efficient and reliable mobile test facility.🔧🌡️🏗️”
Aaron Wittouck – Simulation Expert @ CTRL Engineering

Navigating the Constraints of Container Designs

Traditional stationary test facilities require dedicated space inside manufacturing halls, which can be costly and inflexible. A mobile setup can be a solution but must address several key engineering challenges. The confined space of a shipping container necessitates precise component placement while maintaining compliance with weight distribution regulations. Thermal stability is crucial, as both operator and equipment generate heat, which is further influenced by external weather conditions. Effective vibration control is required to prevent interference with sensitive measurements. Additionally, ensuring a safe and ergonomic working environment for the operator under varying climatic conditions is essential.

A Simulation-Driven Approach towards Optimized Designs

To address these challenges, design constraints covering placement restrictions, operator requirements, and equipment-specific needs were first defined. These constraints were incorporated into an optimization algorithm that systematically evaluates different design configurations. By utilizing mechanical and thermal simulation models, the algorithm identifies the most effective design based on transportability, energy-efficient cooling, and vibration control. Advanced simulation tools such as Siemens HEEDS, Simcenter3D, and MATLAB played a pivotal role in refining the optimization process.

Geometrical design constraints, including component dimensions, spacing requirements, accessibility for maintenance, and designated operator areas, were initially established. Multiple potential layouts were generated and assessed for compliance with spatial and operational boundary conditions, enabling the evaluation of both long container layouts and stacked configurations.

Thermal simulations analyzed the temperature impact on both the operator and equipment by considering factors such as solar radiation, heat dissipation from components, and air circulation. The air inside the container was dynamically meshed, adjusting to different component placements. Boundary conditions, including airflow paths and external convection, were applied to ensure accurate thermal predictions. Ventilation placement was automatically optimized to maintain cooling efficiency, preventing temperature spikes in constrained areas like the operator’s workspace.

Structural analysis focused on modal behavior, assessing how the testbench frame and container walls responded to different vibration excitations. This evaluation helped identify parameters that could be adjusted to shift natural frequencies away from critical operating ranges, ensuring structural stability. Weight distribution was also carefully assessed, as strict regulations govern load balance on public roads. Feasible layouts were evaluated for compliance, and if necessary, ballast placement was calculated to correct imbalances.

By integrating all these simulations into a continuous optimization loop, design solutions were identified that met all constraints while minimizing cooling power requirements. This resulted in a robust, energy-efficient mobile test facility optimized for real-world deployment.

A Winning Formula: How Engineering Optimizations Improve Mobile Testing

Through simulation and optimization, multiple feasible testbench layouts were identified that met all engineering constraints. Each layout strategically positioned components to achieve optimal weight distribution, minimal thermal load, and effective vibration isolation. CFD simulations confirmed that internal temperatures remained within acceptable limits, reducing cooling power requirements. Vibration analyses verified that sensitive measurements would not be affected by excessive movement. These findings establish a solid foundation for constructing a mobile test facility that is both efficient and adaptable, ready for deployment in diverse industrial settings.

Why it matters to you?

Engineering projects frequently present multiple design alternatives, each with trade-offs and constraints. By leveraging simulation and optimization techniques, different configurations can be analyzed early in the process, ensuring that the best-performing solution is selected. If an engineering challenge involves multiple potential designs, the right combination of optimization and simulation can help evaluate and compare alternatives, leading to well-informed decisions. This approach minimizes development risks, optimizes resource allocation, and accelerates time to market, ensuring a final design that efficiently meets all functional, regulatory, and operational requirements.