Overview
W5 Engineering partnered with Aurora to execute a comprehensive Road Load Data Analysis (RLDA) campaign to validate structural performance under real-world operating conditions.
The objective was to capture, correlate, and analyze mechanical loads experienced by the system using a synchronized network of:
- Strain gages
- Accelerometers
- Displacement sensors
- DEWESoft data acquisition
This enabled Aurora to translate real-world inputs into quantifiable engineering data for validation, durability assessment, and model correlation.
The Challenge
Aurora required a robust RLDA solution capable of accurately capturing complex loading behavior:
- Multi-Axis Load EnvironmentReal-world loading introduced combined effects:
- Bending
- Torsion
- Dynamic vibration
- Correlation Across Sensor TypesRequired precise time alignment between:
- Strain (structural response)
- Acceleration (dynamic excitation)
- Displacement (system-level movement)
- High-Fidelity Data Under Dynamic ConditionsNeeded to capture:
- Transient events
- Frequency-dependent behavior
- Peak load cases
- Deployment ConstraintsInstrumentation had to be:
- Durable
- Low-profile
- Non-intrusive to system operation
W5 Engineering Solution
W5 delivered a complete RLDA measurement and validation framework, from sensor placement to data interpretation.
1. Strain-Based Load Measurement
W5 implemented a targeted strain gage strategy to quantify structural loads:
- Placement at critical load paths and stress concentration regions
- Use of:
- Uniaxial gages for directional strain
- Rosette gages (0°/45°/90°) for principal strain analysis
- Outputs enabled:
- Conversion of strain → stress and load estimation
- Identification of peak load conditions and fatigue drivers
2. Dynamic Input Characterization (Accelerometers)
To capture real-world excitation:
- Integrated IEPE accelerometers at key locations
- Ensured proper mounting for accurate frequency response
This allowed:
- Identification of vibration modes
- Detection of transient shock events
- Correlation between input excitation and structural response
3. Displacement & Deflection Tracking
W5 deployed displacement sensors to measure:
- Relative movement across interfaces
- System compliance under load
This provided:
- Validation of mechanical tolerances
- Insight into deflection-driven strain behavior
4. DEWESoft DAQ Integration
A synchronized DEWESoft data acquisition system formed the backbone of the RLDA effort:
- Simultaneous acquisition of:
- Bridge-based strain channels
- IEPE accelerometer inputs
- Analog displacement signals
- Configuration included:
- High sampling rates for dynamic capture
- Precise time synchronization across all channels
- Real-time monitoring during testing
- Signal integrity ensured through:
- Shielded cabling
- Proper grounding strategy
- Calibration verification
5. Road Load Data Analysis (RLDA)
W5 translated raw data into actionable engineering insights:
- Time-domain analysis
- Peak strain and load identification
- Event-based evaluation
- Frequency-domain analysis (FFT)
- Identification of dominant vibration frequencies
- Resonance detection
- Cross-channel correlation
- Linking acceleration inputs to strain response
- Understanding cause-and-effect relationships
- Load case extraction
- Defining representative load cycles for durability testing
- Supporting downstream simulation and replication
Results
W5 Engineering enabled Aurora to:
- Accurately quantify real-world load conditions
- Correlate structural response with dynamic inputs
- Identify critical load cases and stress drivers
- Generate high-quality datasets for model validation and durability analysis
Key Outcomes
- Full RLDA dataset with synchronized multi-sensor inputs
- Clear understanding of load paths and structural behavior
- Identification of peak and fatigue-relevant events
- Data ready for simulation correlation and test replication
Why W5 Engineering
W5 goes beyond instrumentation—we deliver engineering clarity:
- Deep expertise in strain-based load measurement
- Proven capability in dynamic system analysis
- Seamless integration of multi-sensor DAQ systems
- Ability to translate data into actionable validation insights
Applications
W5 RLDA solutions support:
- Vehicle and mobility platforms
- Aerospace structural validation
- Defense systems testing
- Industrial equipment durability analysis
From Data to Decisions
W5 Engineering helps you move from raw signals to validated performance.
If you need to understand how your system behaves in the real world—we’ll measure it, analyze it, and help you act on it.
