Endurance Testing
Endurance Testing at a Glance
Data Logging for Long-Term Testing and Reliability Verification
Endurance testing is an essential part of vehicle development, used to investigate the behavior of components, electronic control units (ECUs), and complete systems under prolonged stress. The goal is to identify signs of aging and wear, detect intermittent faults at an early stage, and assess system reliability.
As these tests can run for several days, weeks, or even months, they generate large volumes of communication and measurement data that must be recorded continuously and reliably. High-performance data logging is therefore essential for tracking changes in system behavior, analyzing faults, and identifying long-term trends.
Typical Test Setup
Test Setup and Data Acquisition for Endurance Testing
The specific test setup for endurance testing depends on the system under investigation and the relevant stress conditions. The device under test (DUT) is subjected to various operating and load conditions, either on a test bench or directly in the vehicle. During testing, a data logger records communication between electronic control units (ECUs) via bus systems such as CAN/CAN FD or Automotive Ethernet, as well as additional measurements such as voltages, currents, and temperatures. It is essential that all data is recorded in a time-synchronized manner so that any anomalies can be clearly correlated with the corresponding operating conditions of the system under test.
Application
Endurance Testing of Vehicles and Vehicle Systems
Challenge
Continuous Data Recording Over Extended Periods
Interfaces
CAN / CAN FD, Automotive Ethernet, LIN, and More
Bandwidth
Data Throughput: 1–16 Gbit/s Storage Requirements: 1–32 TB
Test Setup and Test Environment
Depending on the validation objectives, testing may focus on individual components such as electronic control units (ECUs), battery systems, power electronics, or electric drives, as well as interconnected systems and even complete vehicles. Testing is carried out under defined operating, load, and environmental conditions, for example on component and hardware-in-the-loop (HiL) test benches, in climate chambers, or directly in the vehicle.
During testing, a data logger records ECU communication and relevant measurements such as voltages, currents, and temperatures in a time-synchronized manner. This allows anomalies to be clearly correlated with the corresponding operating conditions and analyzed in detail.
Test Procedure and Execution
First, the device under test (DUT), operating cycles, load limits, and measurement parameters to be recorded are defined. The system then repeatedly undergoes specified operating and load conditions, such as temperature cycling, power on/off cycles, or varying load demands.
Throughout the entire test, the data logger records bus communication and measurement data with the highest possible level of time synchronization, documenting any faults or anomalies that occur.
During and after endurance testing, the recorded data is analyzed to correlate fault events with the corresponding operating conditions and investigate their root causes.
Data Sources and Interfaces
Während einer Dauerlauferprobung werden Daten aus verschiedenen Quellen erfasst. Neben der Kommunikation zwischen den Steuergeräten sind auch zusätzliche Messgrößen relevant, um den Zustand des Fahrzeugs bzw. der untersuchten Systeme möglichst vollständig abzubilden. Typische Datenquellen und Schnittstellen sind:
- CAN / CAN FD
- Automotive Ethernet
- LIN
- Analoge und digitale Signale
- Diagnoseschnittstellen
Die unterschiedlichen Datenquellen werden im Datenlogger zusammengeführt und möglichst zeitsynchron aufgezeichnet, damit Messwerte und Kommunikationsdaten später eindeutig miteinander in Beziehung gesetzt werden können.
Data Logging Requirements
Endurance tests place particularly high demands on data logging due to high data rates and extended recording periods. Depending on the test setup, data throughput can range from 1 to 16 Gbit/s, with storage requirements of 1 to 32 TB. The data logging system must reliably capture, transfer, and store these large volumes of data without loss throughout the entire test period.
Challenges in Test Operations
Endurance testing places high demands on data acquisition and processing due to extended test durations and large volumes of data. Key challenges include:
- Continuous and reliable data acquisition over extended periods
- Handling large data volumes at high data rates
- Secure and scalable data storage without data loss
- Synchronization and efficient processing of data from multiple sources
Data Analysis and Further Processing
During or after endurance testing, the recorded data is made available for further analysis. Relevant time intervals and events are identified, data from different sources is correlated, and anomalies are systematically investigated. Filtering and automated analysis enable efficient processing of large data volumes, supporting fault analysis and further vehicle validation.
Product Highlight
XORAYA N4000+
High-Performance Data Logger with Flexible Interfaces
The XORAYA N4000+ is a powerful and versatile automotive data logger widely used in vehicle endurance testing, among other applications. With its high channel count and support for numerous interfaces, including HS-CAN/CAN FD, 1000BASE-T1, 100BASE-T1, Gigabit Ethernet, FlexRay, analog and digital inputs, RS-232, and LIN, it offers a wide range of applications. By connecting it with additional data loggers, probes, and storage units in a cascaded configuration, it can be flexibly adapted to different measurement requirements.
- Performance All-Rounder
- Available in Multiple Interface Configurations
- Supports HS-CAN/CAN FD, 1000BASE-T1, 100BASE-T1, Gigabit Ethernet, FlexRay, Analog Inputs, Digital Inputs, RS-232, and LIN
System Examples
Which Products Do We Recommend for Endurance Testing?
The choice of XORAYA products for endurance testing depends on the specific requirements regarding interfaces, data rates, number of measurement points, test duration, and existing test infrastructure. Designed to work seamlessly together, all XORAYA products can be flexibly combined to create customized system solutions. This results in an integrated data logging setup that can be easily adapted to different operating conditions and endurance testing requirements.
Single Data Logger
- Data Logger: e.g., N4000+
- Storage: e.g., ESU
- Software: e.g., Suite
Advanced System
Extended Signal Acquisition in Vehicles or on Test Benches
- Probes: e.g., MultiProbe X1
- Data Logger: e.g., N4000+
- Data Storage Unit: e.g., ASU
- Software: e.g., Suite +
Networked Data Loggers
Integrated Measurement System for Comprehensive Testing Processes
- Probes: e.g., MultiProbe X1 + Probe B12
- Data Loggers: e.g., 2 × N4000+
- Data Storage Units: e.g., 2 × ASU
- Software: e.g., Suite + App
- SDK
Personal Consultation
Do you have questions about this product or a specific application? Our experts will be happy to provide you with personalized, no-obligation advice.
Services & Engineering
We Provide the Right Measurement Solution for Your Endurance Testing Needs
We develop customized system solutions based on our modular product portfolio – tailored precisely to your needs. By intelligently combining and adapting individual components, we create high-performance, scalable end-to-end systems from a single source – from planning through implementation.
Measurement System Design
We design scalable data logging systems tailored to your measurement requirements, with the appropriate interfaces, data rates, and storage capacities.
Vehicle & Test Bench Integration
We integrate your measurement equipment into test vehicles and test benches using tailored installation solutions and validate its functionality.
Cables & Wiring Harnesses
Custom-fit cable assemblies and wiring harnesses ensure signal quality, reliable power supply, and electromagnetic compatibility (EMC) in your specific installation.
Performance & Functionality
Targeted hardware and software modifications enhance our data loggers with additional performance, interfaces, and features.
Software Customization
Customer-specific software features extend the capabilities of our applications and support your individual measurement workflows.
Configuration & Support
From commissioning and user training to maintenance and repair, we provide support throughout the entire lifecycle of your measurement equipment.
FAQ
The following questions address key aspects of data acquisition and suitable data logging systems for vehicle endurance testing.
Why Are Endurance Tests Conducted?
Endurance tests are conducted to investigate the behavior of a system over an extended period under defined operating conditions and to assess its reliability and service life.
In addition, homologation requires extensive driving mileage to be documented for each relevant software and hardware version. This ensures that each system configuration is sufficiently tested under real-world operating conditions and that its functional safety is verified over an extended period of use.
What Data Is Recorded During Endurance Testing?
During endurance testing in vehicle development, a wide range of data is typically recorded to enable subsequent reconstruction and analysis of faults. The relevant signals depend largely on the system under test.
Typical data sources include:
- Vehicle Communication: CAN/CAN FD, Automotive Ethernet, LIN, FlexRay, and other interfaces
- Diagnostic and ECU Data: Fault codes, operating states, and internal measurements
- Measurement and Driving Data: Analog/digital signals, vehicle speed, engine speed, temperature, etc.
- Environmental Data and Metadata: Position, timestamps, triggers, and test events
What Are the Challenges of Data Logging?
In addition to continuous data acquisition, key priorities include storage capacity, data integrity, and reliable data recording over extended periods.
Which X2E System Solution Is Suitable for Endurance Testing?
For endurance testing, a scalable system solution based on the XORAYA N4000+ is recommended. The data logger simultaneously records various vehicle and network data streams and supports data rates of up to 3 Gbit/s. For larger test setups, it can be combined with a XORAYA ASU as a central data storage and aggregation unit.
How Can X2E Systems Be Expanded for Long-Term Testing?
The setup can be flexibly expanded depending on the required number of interfaces, data rates, and storage capacity. Up to four devices can be connected to a single XORAYA ASU. For larger endurance testing setups, multiple ASUs can be combined to create a more powerful system architecture.
Which Software Features Support Long-Term Measurements?
Depending on the system, features such as triggering, filtering, automated recording, live monitoring, data export, and analysis are available.