Modular and automated test system for sim racing pedals

Asetek SimSports

Case introduction

Asetek is a Danish company known for its liquid cooling solutions for computers, which set new standards for performance and efficiency. Since then, Asetek has expanded into sim racing with Asetek SimSports®, offering high-end racing wheels and pedal systems designed to meet the demands of the most dedicated sim racing enthusiasts and professionals.

Asetek SimSports® contacted us in the fall of 2022 for assistance in developing a new test system. Their existing system was unable to test all the required functions and suffered from recurring system failures, resulting in significant downtime. This became a high-priority challenge as Asetek was preparing to outsource production to Malaysia and China, making test validation and quality assurance more critical than ever. This was because Asetek did not want to scale production internationally until the process included automated testing to ensure consistent production quality and minimize the risk of operator errors.

Challenge

Asetek had an existing test system that was unable to test all the required functions and resulted in frequent downtime. At the same time, they wanted to outsource production, placing high demands on test automation and quality assurance.

Result

A stable and user-friendly test system with shorter cycle times, increased test coverage, and improved quality assurance, enabling Asetek to outsource production to Malaysia and China while maintaining full control of their test data.

Technology

Development of a modular and automated test system with electric actuators, sensors, and integration with WATS Test Data Management for global data collection and analysis.

“We’ve greatly valued the collaboration and exchange of ideas with GPower throughout the process. Most importantly, we’re extremely satisfied with the modular test system they delivered. Both the compact tester and fixture work exactly as we had hoped and even exceed our expectations. The new tester significantly reduces cycle time while performing more tests.”
– Lasse Wachmann, Senior Test and Validation Engineer, Asetek SimSports.

Test system requirements and specifications

In addition to Asetek’s requirements for the production test system to be user-friendly for operators and capable of testing all required functions, the system also needed to be able to:

Test the entire pedal range by automatically actuating the pedals using electric actuators capable of applying more than 500 N of force
Calibration of pedal travel
Validate LED strips using light sensors
Test connections to other external accessories

Automation strengthens both development and product quality

Asetek also had a requirement regarding data collection, with the purpose of comparing their production in Denmark, Malaysia, and China, respectively. For this part of the project, WATS Test Data Management is used. A system that provides a complete overview of global production data. WATS ensures that Asetek’s test data is easily accessible and that they can quickly act on deviations in production based on the right data foundation.

The mechanical solution has been carefully designed to significantly reduce changeover time. The test system’s quality assurance now enables us to outsource production to both China and Malaysia, which was the primary objective of the project.

– Lasse Wachmann, Asetek SimSports

At GPower, we were responsible for, among other things:

GPower’s software and hardware solutions are far ahead of the competition. In addition to addressing our immediate needs, GPower kept our future production scalability in mind throughout the project. We clearly see GPower as our test partner for the future.
– Thomas Ditlev, VP, Global R&D, Asetek.