TOYO Corp.’s vehicle-in-the-loop simulator for electric and autonomous vehicle design and test

TOYO Corp.’s vehicle-in-the-loop simulator for electric and autonomous vehicle design and test

June 14, 2022

Toyo Tech Corporation

TOYO Corporation’s vehicle-in-the-loop simulator (ViLS) tests and validates the next generation of electric vehicles (EVs) and autonomous vehicles, ensuring their successful development, manufacture, and production.

The ViLS allows automotive engineers to perform a wide variety of vehicle, environmental, and road testing under real-world conditions but in a more cost-effective and safer lab-controlled setting. The TOYO ViLS supports the CASE paradigm which refers to the new automotive technology fields of “Connected" cars,” “Autonomous/Automated” driving, “Shared,” and “Electric”. These areas define the future of transportation and are enthusiastically supported by the automotive industry. The TOYO ViLS is designed from the ground up. The company integrates best-in-class comprehensive components into the solution. Among them are Rototest Energy chassis dynamometers, Advanced driver assistance systems (ADAS), and True Sim, a professional grade driving simulator co-developed by TOYO and Iwane that features augmented reality functionality.

After a multi-month technical assessment of the ViLS with one of the automaker’s EVs, they established that the ViLS met both their current and evolving needs. They needed dynamometers capable of coping with the high-torque forces generated by EVs and observed that the Rototest system met this stringent requirement. They moved forward and submitted an order for two complete ViLS systems. The order is the largest one ever secured by TOYO for the ViLS with a valuation in the multi-millions of dollars. The customer worked closely with TOYO’s U.S. subsidiary TOYOTech through all phases of the procurement cycle. And delivery and deployment of the platforms are expected to occur before the end of the year.

Some key advantages of the TOYO solution include:

  • Portable and short setup time (15 to 20 minutes per hub)
  • Supports high-torque force
  • 4-wheel independent control dynamometer system requiring only a flat surface and power
  • Allows for steering control and feedback during a running test
  • Uses a low-inertia drive motor unit
  • Allows for a quick acceleration test by eliminating tires
  • Allows for a 4-quadrant test (forward, reverse, power running, and regeneration)
  • Allows for a running resistance test, also simulating hill conditions
  • Available in different variations covering from single-axle (2WD) vehicles to dual-axle (4WD) vehicles
  • Available in application-specific models such as a low-noise model for the NVH test (45dBA or less at 62mph/100kmh) and an environment test model (covering down to -95 °F/35°C)
  • Allows for system customization with different options, such as:
  • A blower that generates headwinds according to the simulated running speed
  • Interface to link external control systems such as a driving simulator or hardware-in-the-loop simulator

The automaker’s key test requirements for the TOYO ViLS include support for:

  • Advanced driver assistance system software modules
  • High torque force tests
  • Acceleration tests
  • Adaptive cruise control tests
  • Steering control and feedback tests
  • Emergency and regenerative braking tests

CASE encompasses many technology fields including automotive, compute, wireless communications, networking, sensors, radar, and artificial intelligence to name just a few; TOYO possesses core competencies and decades of experience in many of these areas. As the adoption of the CASE methodology reaches critical mass in the global automotive industry, TOYO is there to drive this vision forward with innovative test solutions such as the ViLS.