Software Development and Controls Engineering

Test Control Software, Automation & Instrumentation

Bring motion, measurement, environmental conditions, and process control together in one synchronized test environment.

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Modular Add-ons for Your Test Setup

HEXaDRIVE® provides the controlled motion at the core of the test. Simtec extends the platform with integrated technologies for control, measurement, environmental simulation, and process automation, creating a test environment configured around the specific test task.

The modules integrate with HEXaDRIVE® as part of a coordinated test system and cover functions ranging from centralized test control and real-world motion acquisition to environmental simulation, fluid and gas handling, and measurement technology. Simtec also integrates individual modules into customized test benches and existing laboratory environments.

HEXaCONTROL

HEXaCONTROL is the central control and data acquisition system for integrated test setups. It brings test-system parameters, measurement data, and connected process functions into one central control environment. Motion, environmental conditions, and test-object parameters are controlled, monitored, and recorded within the same test sequence. EtherCAT communication, flexible system interfaces, and test profile import functions support the integration of measurement systems, external equipment, and application-specific test processes.

MDAS / Motion Data Replay

The Motion Data Acquisition System (MDAS) captures real-world movement for controlled reproduction in the laboratory. Its 6-DOF sensor system records three linear accelerations and three rotational rates at the relevant measurement point, for example inside a vehicle. Recorded data can be transferred to HEXaDRIVE® and used as the basis for the corresponding motion profile, with a washout filter converting the measured motion into movement within the platform’s available motion envelope.

ESD – Environmental Simulation Dome

The Environmental Simulation Dome (ESD) adds controlled environmental conditions directly to dynamic motion testing. The lightweight carbon-fiber, double-shell chamber is mounted directly on the HEXaDRIVE® platform and can reproduce programmable temperature, ambient-pressure, and humidity profiles. Depending on the configuration, temperature ranges from –30°C to +60°C, pressure from 60 to 110 kPa absolute and relative humidity from 10 to 95% can be simulated and coordinated with the motion profile.

Climate Chamber

Simtec climate chambers add controlled temperature conditions to dynamic component testing. Available configurations cover temperatures from –30°C to +40°C, with an optional range up to +60°C, and integrate directly with the motion system. Corrosion-resistant materials and a quick-exchange specimen carrier support demanding test procedures, while dried compressed-air flushing reduces condensation and icing during temperature changes.

Liquid Temperature Control System

The Liquid Temperature Control System conditions fluids within the test setup or directly inside the test specimen. A controlled circulation circuit with stainless-steel heat exchangers heats or cools the fluid according to the required test profile and coordinates the fluid temperature with motion and other test conditions. Fuel-temperature configurations provide programmable conditioning up to 60°C, 6 kW heating power, temperature gradients up to 20 K/h, and an accuracy of ±1 K.

High Precision Dosing

High Precision Dosing controls the extraction and injection of liquids and gases at defined volumetric flow rates during the test. Liquid dosing reproduces processes such as consumption or controlled media transfer, while N₂ injection simulates gaseous flow and outgassing conditions. N₂ configurations cover flow rates from 0 to 100 SLPM at operating pressures of 4–6 bar. HEXaCONTROL coordinates the dosing process with the running test profile.

Measurement Technology

Application-specific measurement technology captures the physical parameters required to evaluate the test object and the test process. Simtec configures the measurement setup with sensors for parameters such as pressure, temperature, flow, force, strain, or acceleration according to the validation task. HEXaCONTROL integrates the measurement channels and records actual values together with corresponding set values, motion data, and other simulated conditions.

In-Process Storage Tanks

In-process storage tanks provide controlled buffer storage for fluids within automated test setups. Integrated pumps collect, transfer and recirculate test media, while fill-level monitoring, overfill protection, and secondary containment support controlled fluid handling throughout the test process. The system also supports automated emptying and refilling of the test specimen and separate storage circuits for different test fluids.

Built Around Your Test

A complex validation task rarely depends on one parameter alone. Motion, temperature, pressure, media conditions, measurement signals, and test-object behavior may all need to change together within the same test sequence.
Simtec combines the technologies required to create these conditions, control the process, and capture what happens. HEXaCONTROL provides the central test environment, while measurement systems, environmental simulation, and process technologies are integrated according to the specific validation task.
Existing sensors, customer equipment, and laboratory infrastructure can also be connected through defined interfaces. The result is not a fixed package of accessories, but a coordinated test environment built around the test itself.

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Testimonial

“Simtec’s simulators bring real-world conditions into a controlled environment.“

Gavin Grolms

The German Aerospace Center (DLR)

Test Systems References

Review our successfully deployed test rigs at global OEMs and research labs validating tomorrow’s technologies under strict laboratory control.

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