Validating Automatic Emergency Brake Systems

An estimated 32% of all truck accidents involve rear-end collisions. To address this harsh reality, MAN Truck & Bus has made innovative safety systems a top priority and is working to optimize the active safety systems in its trucks and buses.

One area where MAN is making great strides is with its emergency braking systems.

Current industry standards require emergency braking systems to pass intensive tests before they go into production, but tests with a real truck are time consuming, expensive, hard to reproduce, and risky.

While tests on a real vehicle are still necessary, they aren’t enough to satisfy the demands on reliability and safety. Complex, highly-networked systems, such as emergency brake systems and GPS cruise control, require intensive systematic validation within the electronic control unit (ECU) network. This is why MAN uses hardware-in-the-loop (HIL) test benches for its system tests.

In partnership with dSPACE, MAN has developed a solution to validate automatic emergency braking systems that consists of a camera-in-the-loop setup with innovative radar-camera data fusion integrated with a hardware-in-the-loop test bench.

“With the dSPACE system, we can evaluate the response behavior, from the emergency braking triggered by the sensor system up to the displayed warning in the instrument cluster and compare the run times,” said Burak Kilickiran, System Test Engineer, MAN Truck & Bus. “Using the Cognex camera to analyze the image on the HMI, we can test the entire system chain in just one run”.