Picture of C. SAP2000 - Vehicle Driving Robots

C. SAP2000 - Vehicle Driving Robots

Quick overview

Robot Driver for Manual and Automatic Transmission Vehicles.

Robot driver for Manual and Automatic Transmission Vehicles for computer controlled driving of cars on test stands. Humanlike drive style and highest grade of repeatability used for emission tests, mileage accumulation and climate tests, etc. Different levels of systems and different interfaces are available.


Fields for application such as 

  • Exhaust Emission Tests
  • Fuel Economy Tests
  • Running Losses Tests
  • Mileage Accumulation & Durability Tests
  • Climatic Tests
  • Transmission & Power Train Tests
  • Acoustic Tests
  • EMC Tests
  • Correlation Measurements
  • R & D Studies

Will be accomplished by robots with an extreme degree of reproducibility in temperatures ranging from –40°C to +80°C.

  • Optimization of consumption and exhaust gas parameters demands extremely high reproducibility of driving style. AUTOPILOTS will achieve deviations in the distance driven which are < ± 1m with a 17.86 km long emission cycle, as well as standard deviations of only 0.05% for consumption measurements.
  • Quick and easy installation of the driving mechanism in the vehicle, plus a learning cycle where, independent of any test and at one go, it will learn all the control parameters fully automatically, guarantee short setup and pre-run times, along with simple operation.
  • Versatile interfaces with roll test beds and host computer systems will enable complete integration into the entire test cell.
  • The modular design of the AUTOPILOTS makes it possible to offer various configurations, including stand-alone actuators, enabling for example the running of tests on transmission or engine test beds parallel to those on roll test beds using the identical actuators and regulators.
  • This allows correlating component tests with tests made on the vehicle.
  • An additional application for the AUTOPILOTS arises when they are supplemented by steering systems, so that they can be used for field driving tests on proving grounds or on flat belt test beds.


Quick Installation With universal attachement less than 10 minutes
Single Operator Control Component weight about 16kg. Handy terminal user guidance and text in clear
Universal Actuator Unit Installation on driver seat. No modifications to the vehicle. The actuator unit is temperature proof from -40°C up to +80°C and designed for endurance tests. Minimum self warm up. Aerodunamically neutral design for climatic measurements.
Mobile Units AUTOPILOT systems are assignable to several test stands. Different actuator units can be operated on one test cell.
Praxis Oriented Software Teach-in of the gear positions with commands in dialog (check list). Comfortable user interface with simple operation. Drive cycles can be defined without programming experience.
Learn Cycle Once per vehicle type an self learn cycle has to be performed. This cycle is independent to the drive cycle to run. During this automated learn cycle the AUTOPILOT learns all relevant parameters that are required to drive the vehicle and any drive cycle.
Continual Learning od Clutch Behavior Correct start point over the whole test period. Compensation of wear & tear during the complete ensurance test. Automatic adaptation to the true bite point of the clutch.
Constant Control Algorithm During Test Drive Ideal driver for correlation, research, development, and quality control.
Highest level of safety Safe non-energized basic positions. The clutch pedal is disengaged and the accelerator pedal is released. Emergency-off button on actuator unit. 24V technique on actuator unit. Skid monitoring on the wheels (Wheel drum slip monitoring and compensation). Gear shifts forces may be programmed. Safety tolerance band monitoring (speed errors). Permissible repetitions of a shift process may be preset. Speed and engine speed monitoring
Data Managers Local data managers for vehicle data, drive sycles, shift tables. Networking capable.
Support of various transmission types

Automatic trasmission:

  • Standard
  • Triptronic®
  • column shifter (optional)

Manual trasmissions:

  • Standard, sequential, each with/without clutch
  • SeleSpeed®
  • Smart®
Integration Digital interface to emission benches with digital outputs and inoputs. Optionally different interfaces for host computer communication: AK+SCPI (serial or TCP/IP) Bit parallel + analog
Drive Cycles Directly accessible standard drive cycles. Drive cycle files can also be created as ASCII files in different file formats. Instructions from host computer systems can be executed in different operational modes. Drive cycles can contain additional data as road gradient commands, sub cycles, control commands, etc.
Human driving style Speed control algorithm with human driving style. Choice if different human driver models for emission tests. Highly accurate and repeatable control.
Automated modes

Closed loop control modes for:

  • Vehicle speed
  • Engine speed
  • Throttle traces
  • Clutch traces
  • External unit as intake manifold pressure, force/torque, etc.
  • Reproduction of recorded tracks with max. 10Hz
Manual Modes Different manual operation modes to drive and operate the vehicles via keyboard or handy terminal

Actuator unit SAP2000:

  • Total Weight ca. 33kg
  • Component Weight max. 16kg
  • Motor Voltage 24V
  • Operating Temperature -40°C ... +80°C


  • Accelerator
  • Brake
  • Clutch
  • Shift (X+Y)
  • Ignition key (optional)

Power controller 19" unit, 2x3 RU, power consumption 600Watt, 115/320VAC, voltage selector

Computer system

Industrial - PC system with plug in boards

System extensions (exact)
  • Gear stick release mechanism
  • Shift force measurement
  • Pedak force measurement
  • Column shifter
  • Keyboy SBE to acurate ignition key
  • Keyboy SBX to acurate ignition key
  • Steering wheel ficture
  • Adapter to column shifter (N-D Positions only)
  • Adapter for hard link to gear stic (screwed connection)
  • Vehicle motion switches

Host computer communication:

  • AK++ SCPI (serial or TCP/IP)
  • Bit parallel + analog

  • Windows GUI
  • Vehicle datd stack module
  • 19" - cabinets
  • Opto coupler module for digital I/O's
  • Vehicle engine speed measurement
  • 5th wheel sensor to measure roller surface velocity
  • Data acquisition and monitoring
  • Correlation package: All components permanently installed in vehicle
  • Custom modifications
System Configurations and complete packages A wide range of options allows to configure the system exactly to the purpose of its application, as a non-supervised fully automated endurance testing with automated refueling. Different system packages, including versiong with reduced control features or reduced volume of functions are available for different applications and requirements.


Accelerator + + + +
brake + + + +
clutch + + + +
Gear shift arm left-hand Drive + + + +
Gear shift arm right-hand Drive 0 0 0 0
Gear shift steering-column shift 0 0 0 0
Keyboy SBE + 0 0 0
Keyboy SBX (emergency-off function) 0 0 0 0
Truck Adapter 0 0 0 0
Accelerator pedal switch + - - -
Data memory module drive mechanism 0 0 0 0
Gear shift lever release 0 0 0 0
Gear shift force measuring unit 0 0 0 0
Hand-held Terminal + + + +
Learning via universal self-learn cycle + + - -
Selectable driving styles + 0 - -
Manuel driving mode + + + +
PID controller - - + -
Event recording + + + 0
Breaking via chassis dynamometer + + + 0
Road gradient output to chassis dynamometer + + + 0
Graphics cycle protocol + + + 0
Hybrid motor support + + + +
WINDOWS user interface WIN32 + + + +
Analog input for MAP/tractive effort + + + 0
Adapter for steering-column shift N-D 0 0 0 0

E = Emission Test + standard
M = Mileage Accumulation/Durability Testing 0 optinal
MP = Mileage Accumulation with PID Controller - not possible
ACT = Actulator

Optional Hardware

  • Shift arm for steering-column shift
  • Shift lever release
  • Shift force measurement
  • Ignition switch actuation SBX Keyboy with custom-design clam for positive interlocking with spring-loaded rest function (emergency-off function)
  • Ignition switch actuation SBE Keyboy with universal device for claiming onto igniton key
  • Vehicle position sensor

Optional Software

  • Communication with host via V24/RS232 interface or TCP/IP
  • Bit-parallel I/O interface host
  • Network support
  • Integration of fueling process into the test procedure
  • Cold-driving program, consisting of special chill start and starting-assistance program
  • System intergration via AK protocol, RS232, or TCp/IP SCPI protocol, TCP/IP ASAM-GDI

Call for pricing

Additional information

Manufacturer: Stähle