Road load data acquisition (RLDA) is gaining strategic importance in the validation of electric powertrains, where new load characteristics—such as high instantaneous torque, reduced damping, and altered vibration spectra—challenge conventional durability assessment methods. In this context, Hottinger Brüel & Kjær (HBK) has introduced Fusion RX, a data acquisition platform designed to capture and process vehicle load data under real operating conditions.
RLDA systems acquire mechanical and structural data from instrumented vehicles during on-road and proving-ground testing. Sensors installed across key subsystems—including chassis structures, suspension components, and e-drive interfaces—record time histories of loads, accelerations, and strains. These datasets form the basis for generating laboratory test profiles and for validating simulation models used in the development of electric drivetrains.
For electric motors and integrated e-axles, the availability of accurate load data is particularly relevant. Unlike internal combustion engines, electric machines deliver peak torque from standstill and operate across a wide range of speeds with different excitation frequencies. This can result in distinct fatigue mechanisms affecting bearings, shafts, and gear meshes. RLDA enables engineers to capture these effects under real driving conditions and replicate them in accelerated durability tests.
HBK positions Fusion RX as a response to evolving constraints in vehicle development, including reduced prototype availability, increased system complexity, and compressed validation timelines. Electrified platforms, often integrating motor, inverter, and transmission into compact assemblies, require synchronized multi-channel measurements to ensure correlation between mechanical loads and electrical operating states.
Operating environments for RLDA remain inherently challenging. Data acquisition must be reliable across diverse conditions—from smooth highways to rough off-road terrain—where shock loads, temperature variations, and electromagnetic interference can affect signal integrity. Modern systems must therefore handle high channel counts and large data volumes while maintaining measurement accuracy and robustness.
Fusion RX is designed to support continuous vehicle-level data acquisition and seamless integration with downstream analysis tools. The resulting datasets can be processed into load spectra suitable for bench testing. For example, torque and vibration data recorded at the electric motor shaft during dynamic driving cycles can be translated into equivalent stress profiles for endurance testing of bearings or gear stages, reducing the need for repeated physical road tests.
More broadly, RLDA platforms are contributing to the convergence of physical and virtual validation processes. High-quality load data improves the fidelity of simulation models, enabling earlier detection of potential failure modes and reducing development iterations. This is particularly critical in electric motor engineering, where compact designs and high power densities leave limited margins for error.
 is gaining strategic importance in the validation of electric powertrains, where new load characteristics—such as high instantaneous torque, reduced damping, and altered vibration spectra—challenge conventional durability assessment methods.){kind=link}