Severe tests for greater security

Before security systems such as the electronic stability program ESP can go into serial production, they have a long development and testing phase ahead of them. They are subjected to extreme conditions on Bosch proving grounds to ensure that they will work perfectly in every situation.

New car models are optimized in cooperation with manufacturers and their security systems adjusted to match the features of each model.

Testing worldwide
Bosch has seven major proving grounds around the world:

• Boxberg (Germany)
• Vaitoudden (Northern Sweden)
• Flatrock (USA)
• New Carlisle/Indiana (USA)
• Baudette (USA)
• Juvincourt (France)
• Memanbetsu (Japan)

Vaitoudden way up in the North of Sweden and Baudette near the Canadian border are typical winter courses, where icy cold and slippery conditions are the decisive test factors. Boxberg and New Carlisle, on the other hand, are our testing courses for temperate climates.

The test sites exchange a lot of information with each other and benefit from the very contrasting experiences they have with security systems in different climates and on different types of courses.

Only experienced engineers become testers

Only engineers can become Bosch test drivers. They must have enormous experience with security systems. That is the only way to guarantee that vehicle reactions are assessed correctly, so that the tested systems can be optimized.

During test drives, the car trunk is often filled with additional measuring instruments. A laptop is placed on the co-driver's seat to display the measured data in color graphics immediately: e.g. the front wheel steering angle, brake pressure, revolution rate and much more.

The aim is always to improve system performance.

For instance, the Bosch engineers who perform the tests drive round tight corners at high speed until the ESP is activated to keep the car on track. Or they make an emergency stop from 100 km/h on a highly slippery surface, activating the ABS anti-locking brake system. The measured and recorded data are used to optimize security systems for different vehicle models until the best possible protection is achieved.

Variety of test courses at Boxberg

The Boxberg proving ground 90 km north of Stuttgart is used to test vehicles and systems to their limits on an area of 94 hectares.

• The high speed oval is 3 km long and permits speeds of up to 200 km/h without risk to other traffic.
• ESP is tested on the extremely swerving handling course.
• The running gear and electronics must prove their quality on poor, uneven road conditions with large potholes and Belgian cobblestones.
• The circular driving dynamics course has a diameter of 300 m for tests of every kind in dry and wet conditions.
• Braking systems are tested on various wet braking surfaces – from good grip to highly slippery.
• Launch behavior in wet and icy conditions can be tested on extreme uphill gradients.
• Driving through up to 1 m of water tests the functions of the on-board electronics.

Garages and offices at the Boxberg proving ground provide support in test preparation and vehicle maintenance.

Its central location in Europe, the large variety of test scenarios and a professional all-round service make the Boxberg proving ground the first choice for many vehicle tests.

Skidding in Vaitoudden

Kings enjoy driving fast too: His Majesty King Carl XVI Gustaf of Sweden personally opened the new winter proving ground in the northern Swedish town of Vaitoudden, driving faster than anyone else on the ice.

This state-of-the-art winter proving ground covers an area of 500 hectares. Test driving takes place both on land and on the several kilometers of ice provided by the frozen Uddjaur lake. The icy cold provides ideal test conditions for brake control systems.

The facility is regarded as one of the world’s most modern winter proving grounds. One major advantage is that workshops are directly on site, so that engineers can implement test results in the vehicles straight away. The course provides a range of road surfaces, such as black ice, snow and heated asphalt. Every test has the appropriate course: Handling courses, test courses for ABS (anti-locking brake system) and ASR (drive slip control system), several hills and one dynamic surface.

Up to 400 Bosch employees from the Chassis Systems Division spend the winter in Vaitoudden at temperatures that often fall below minus 20 degrees Celsius. But the new Arjeplog test course has not only improved the quality of brake systems: The Swedish King praised the investment Bosch is making in an area of low economic activity. The proving ground has generated many jobs, he said.