Simulation Testing

Why is simulation necessary before launching a product?

An electric vehicle might function perfectly in a factory, but will it maintain its performance after years of traveling on rough roads? An electronic device might operate reliably in an office, but will it remain accurate when working in an environment of high temperatures, high humidity, or constant vibration? Or how will an aircraft device react when subjected to low pressure and temperatures of tens of degrees below zero Celsius at an altitude of tens of thousands of meters?

Testing a product directly under all real-world conditions is almost impossible. It's costly, time-consuming, and many scenarios cannot be consistently replicated.

That's why simulation testing has become an indispensable part of the product research, development, and validation process. By recreating operating conditions in a testing laboratory, businesses can evaluate the performance, durability, and safety of a product before it is put into use.

 

What is Simulation Testing?

Simulation testing is the process of simulating real-world operating conditions or extreme scenarios in a controlled environment to evaluate the performance of a product, component, or system.

Unlike functional testing, which only checks whether a product works, simulation testing aims to answer the following questions:

• Does the product operate reliably under harsh conditions?
• Is the design capable of withstanding the load over the long term?
• How will components react to vibrations, high temperatures, or high humidity?
• What weaknesses need to be improved before mass production?

This allows engineers to detect risks early and optimize designs right from the development stage.

 

Why is simulation testing becoming increasingly important?

Product development cycles are getting shorter while quality requirements are becoming increasingly stringent. Businesses no longer have much time for trial and error with physical prototypes.

Simulation testing helps to:

• Reduce product development time.
• Reduce the number of prototypes that need to be manufactured.
• Detecting errors right from the design stage.
• Saves on field testing costs.
• Assessing difficult or hazardous conditions that are virtually impossible to replicate in reality.
• We provide support for certification according to international standards.

Not only large corporations, but increasingly more businesses in the automotive, new energy, electronics, and aerospace sectors are investing in simulation testing labs to proactively manage their R&D activities.

 

Common simulation test groups

Environmental Simulation

This is the most widely used test group today.

Reproducible simulation devices:

• High temperature.
• Low temperature.
• Thermal cycle.
• Humidity.
• Rain.
• Dust.
• Slightly salty.
• UV rays.
• Elevation.

This allows engineers to assess a product's performance in a variety of climatic conditions without having to wait for specific seasons or bring the product to each geographical area.

 

Simulation of vibration and mechanical shock

In reality, vehicles and equipment are constantly subjected to vibrations, impacts, and mechanical loads.

Systems such as the Electrodynamic Shaker , Road Simulator , or Shock Test System help to recreate:

• Vibrations occur when the vehicle is in operation.
• Oscillations on rough roads.
• Collision during transportation.
• Repeated loads cause structural fatigue.

This is a critical test group in the automotive, aerospace, rail, and defense industries.

 

Load and life simulation

Some tests are not intended to recreate the environment but to simulate long-term usage.

For example:

• The door has been opened and closed hundreds of thousands of times.
• The battery's charge-discharge cycle.
• Material fatigue testing.
• Testing the durability of the hinges.
• Continuous load testing.

These tests help predict product lifespan and identify potential failure points.

 

Simulation of electrical and electromagnetic conditions

For electrical and electronic products, the testing laboratory can simulate:

• Electrostatic Discharge (ESD).
• Voltage surge.
• Conducted interference.
• Radiation interference.
• Power supply oscillations.
• Low blood pressure.

These tests help assess the device's ability to operate stably in a complex electromagnetic environment.

 

Simulating special operating conditions

Some industries require the recreation of very specific conditions, such as:

• Low pressure in aviation.
• A vacuum environment for space devices.
• Tilt and oscillation on a ship.
• Icy and snowy conditions.
• Strong winds.
• Solar radiation.

These tests help ensure the product remains safe to operate under real-world operating conditions.

 

Applications of Simulation Testing in various fields

Automotive

Simulation testing is applied at all three levels:

• Vehicle Level Test.
• System Level Test.
• Component Level Test.

The simulations include:

• The road is bad.
• Climate.
• Vibrate.
• Impact.
• Electric vehicle batteries.
• Suspension system.
• ADAS Camera.
• Electronic controller.

Air

Aerospace equipment is subjected to conditions that cannot be replicated in a normal environment.

Simulation testing helps to simulate:

• Elevation.
• Pressure.
• Extremely low temperatures.
• Vibrations during takeoff and landing.
• EMC.
• Fireproof.

Many tests are performed according to RTCA DO-160 or MIL-STD.

New energy

For lithium-ion batteries and energy storage systems (ESS), simulation testing focuses on:

• Charge-discharge cycle.
• Aging is accelerating.
• Thermal Runaway.
• Overheating.
• Vibrate.
• Impact.
• Climate conditions.

Electronics and home appliances

Electronic devices are tested under the following conditions:

• Temperature.
• Humidity.
• EMC.
• Fall.
• Vibrate.
• The opening and closing cycle.
• Continuous operation.

Railways and ships

Electrical and mechanical systems are evaluated based on:

• Anti-vibration.
• Corrosion resistant.
• Ability to withstand a marine environment.
• Load cycle.
• EMC.

 

Commonly applied standards

Depending on the industry, simulation testing may follow these guidelines:

• IEC 60068 – Environmental testing.
• ISO 16750 – Electrical and electronic equipment for automobiles.
• RTCA DO-160 – Aviation equipment.
• MIL-STD-810 – Environmental testing.
• IEC 62133 – Lithium batteries.
• IEC 62619 – Industrial batteries.
• ISO/IEC 17025 – Competence of testing laboratories.

 

Simulation Testing – The stepping stone between design and the actual product.

Simulation doesn't completely replace real-world testing, but it significantly reduces the time and cost for businesses during product development. More importantly, simulation testing provides engineers with data to understand the limitations of their design, allowing them to improve the product before mass production or field testing.

In the context of rapidly developing technology, Simulation Testing is not only an evaluation tool but also a platform for businesses to improve their R&D capabilities, shorten development cycles, and increase competitiveness in the market.

 

GPower Vietnam – Partnering with businesses in simulation and testing solutions.

Each product faces different operating conditions. To build an effective testing process, businesses need to select the right equipment, the right methods, and the right standards.

GPower Vietnam provides Simulation Testing solutions for various sectors such as automotive, aerospace, new energy, electronics, railways, and shipbuilding . We support businesses from consulting and laboratory design to providing environmental testing systems, vibration testing, mechanical shock testing, EMC testing, battery testing, and measurement and data acquisition solutions according to international standards.