Measurement data management in vehicle development and operations – with Kistler software

For bus manufacturers all over the world, integrated management of measurement data plays a critical part in development work: they use data loggers to record every detail about their vehicles. The MaDaM measurement data management software from Kistler continuously stores and organizes the data, which can then be visualized and comprehensively evaluated with additional solutions from the Kistler portfolio such as jBEAM.

The ongoing transformation in the automotive industry is impacting vehicles of every type, including buses and commercial trucks. These changes are not limited to electrification of the power train and alternative propulsion concepts: increasing use of software as an instrument to generate value is an equally important trend. Daimler Buses relies on holistic measurement data management from Kistler for its vehicle trials and development work, and the company also uses this technology for information exchange with customers such as municipal transport providers and travel companies.

As the European market leader, Daimler develops and manufactures state-of-the-art buses at multiple European sites and also in Turkey. Daimler Buses launched a fully electric variant of its popular Citaro city bus (the eCitaro) back in 2018; the hybrid version had already been on the market for some time. Software solutions such as MaDaM, jBEAM and jBEAM Cluster from Kistler play a key part in ongoing development and fleet management for these and many other models. As long ago as 2016, the Daimler subsidiary introduced MaDaM from Kistler for its bus business in response to the constant increase in data volumes, enabling it to make optimal use of the data. MaDaM is a 100 percent plug-and-play solution that can be used not only in vehicle trials and development work, but also for after-sales activities in collaboration with end customers.

Vehicle developers benefit from big test data

Because MaDaM is so flexible, it allows users to record many different types of measurement data and store it in vast quantities. Categories include vehicle dynamics parameters such as velocity and rotational speed, parameters for subsystems such as doors, and diagnostic data for individual components. Efficient indexing and organization make it fast and easy to locate and evaluate the data – in the form of load spectra, for example. Johannes Wübbeling, a software engineer at Kistler's Chemnitz facility, explains:

When we were developing the architecture for MaDaM, we deliberately decided against the ASAM ODS standard for managing measurement data: even though it’s commonly used, it imposes strict requirements for data formats, search fields, and so on. With our software, customers are free to define their own data model. MaDaM’s sustained success in a highly complex and wide-ranging project like this one shows that we were right to opt for greater flexibility."

Johannes Wübbeling, software engineer at Kistler


To date, Daimler Buses has recorded more than three million measurements with MaDaM – and around 2,000 new ones are added every day. Many users from different departments feed in data from over fifty sources, in six different file formats. Measurements usually begin as soon as the engine is started; in buses, they are handled by data loggers installed as standard, but these loggers can also be retrofitted on vehicles if required. For typical applications such as endurance tests that run for at least a year with changing weather conditions, MaDaM automatically generates and transmits reports at regular intervals.

However, the advantages of holistic measurement data management are not limited to vehicle testing: this approach also delivers outstanding benefits when new drive types need to be assessed. For example, it becomes easy to compare fuel consumption between hybrid and conventional buses in regular service. Electric buses support features such as smart onboard power supply: daily usage can be documented in various levels of detail, and the data can be supplied to the operators as well as the Federal Ministry of Transport and Digital Infrastructure.

Efficient data evaluation – even including data mining

Alongside flexibility and high performance, critical advantages for customers include the visualization and evaluation options offered by jBEAM. Also, both MaDaM and jBEAM are highly versatile systems that feature extensive functional scope. Users can quickly locate measurement data for use in automated reporting. These benefits open up almost unlimited possibilities for development and vehicle testing. Recording measurement data also yields advantages in operation: during regular bus services, for example, specific performance parameters (such as battery consumption on electric vehicles) can be accurately monitored and any potential irregularities or faults can be analyzed rapidly and effectively.

Kistler maintained regular dialog with the customer in the course of a close working relationship, and this played a key part in the ongoing development and specification of the solution. Wübbeling emphasizes the value of a collaborative working style: "This project taught us a lot about the application-based approach to developing our solutions. In that regard, dialog with customers and joint development work on the software were especially valuable aspects." Endurance tests, in particular, generate enormous volumes of measurement data that can be analyzed with the help of data mining algorithms to detect recurring patterns. MaDaM and jBEAM have the processing capacity and performance scope needed to handle applications such as these: on the hardware side, the Kistler solutions are now based on as many as five servers.

For passenger cars and buses alike, it is not yet possible to foresee what the drive technologies of the future will look like because development is proceeding at such a dynamic pace. Fuel cells could well play a major role – especially in the coach segment, where range is a highly critical factor. As multiple types of drive technology become available, complexity will inevitably increase: ever greater volumes of data will be generated during development and operation, so the management of measurement data is bound to become an even more crucial factor in the future.

Daimler Buses relies on MaDaM and jBEAM to further develop of its electric city buses.
On the road to success with IEPE and MEMS accelerometers for the ISTAR research aircraft – on the ground and in the air.
KiTraffic Statistics delivers precise WIM data for a railway bridge in central Austria
Advanced fastener testing with ANALYSE systems for reliable zink flake coatings in the automotive and wind turbine industries
How Yuchai achieves more precision, transparency and resource efficiency for its production of engines conform to China VI
A high precision measuring chain with dynamometer, laboratory charge amplifier and software enables objective comparison tests.
SRA: Find the best spot and the ideal sensor layout for direct enforcement of overloaded vehicles.
At Estudio de la Pisada in Valencia, a 3D force plate helps podiatry experts to develop treatments and orthoses for patients and athletes.
Two IEPE accelerometers deliver key data for propulsion validation and optimization of flight characteristics even in the stratosphere
Capturing micro-vibrations with a dynamometer leads to improved satellite technology
Zero defect despite high volumes: this is the way quality assurance with Kistler test automation systems works for zinc die casting parts
A digitally driven brake force measurement system makes the life of service technicians for train maintenance much easier
Inside "The Atmosphere" at MARIN, 100 of our pressure sensors capture wave impacts under varying environmental conditions
How MAN Energy Solutions is using sensors from Kistler to make its gas turbines fit for the future
Measurement technology dedicated to the discipline and biomechanics of pole vault enables high performances
How does a digital measuring chain for piezoelectric sensors work as part of a complex vehicle test stand?
Convincing test results: The Ohio Department of Transportation goes on to apply Lineas from Kistler for traffic monitoring.
Precision is the key to top performance: how measurement technology from Kistler supports the development team at EMUGE-FRANKEN
Quality assurance solutions by Kistler like ComoNeo ensure highest accuracy at TSP Precision Tooling in Shanghai.
Kistler supports Ceratizit in the development of HDT. This enables complex geometries to be produced with just one tool.
Process monitoring systems and cavity pressure sensors from Kistler help to reduce the amount of scrap drastically
How measurement technology from Kistler contributes toward boosting high-end powertools' quality
How the ANALYSE system from Kistler is enhancing safety and transparency in the field of fastening technology
Turkey opts for weight enforcement with WIM technology from Kistler
For the next manned flight to the moon: safety that can be measured
Segregation of good and bad parts every 1.5 seconds: process monitoring with Kistler enables high quality for over 5 million parts per year.
In order to achieve excellent quality for its components and medical devices, Tessy Plastics chose sensors and solutions from Kistler.
A renowned manufacturer of electrical appliances trusts testing and sorting systems by Vester to improve its quality.
NFL's Jaguars boost their fitness levels with Kistler.
By using process monitoring from Kistler, not only the assembly of electric fuses is validated, but even the function of the sensors itself.
How to determine the fitness level of an athlete efficiently? A practical report on the Quattro Jump force plate system from Kistler.
Thanks to precise Weigh in Motion technology from Kistler, Hungary's roads are sustainably protected against overloaded vehicles.
Bang&Clean relies on Kistler's precise measurement of ignition processes and pressure wave propagation
Sartorius applies the process monitoring system ComoNeo from Kistler and thereby increases the process quality during injection molding
The Dortmund Technical University tests the new MicroDyn 9109AA cutting force dynamometer from Kistler and breaks new ground for developing its micromachining processes.
The ZF company operates a software-controlled Kistler fastener test bench with an integrated vibration unit.
BIG Daishowa, headquartered in Osaka, Japan, is one of the leading producers of tool holders for the machining industry. Each year the company produces over half a million collet chucks. Their products are developed using, among other resources, Kistler’s cutting force measuring device.
Enhanced quality and efficiency in mobile crane manufacture – thanks to the test stand for torque tools by Kistler
The world’s largest provider of rail transport technology relies on Kistler’s measurement expertise. Thanks to the only crash wall of its kind in the world, the impact forces of the trains and their components can be precisely measured and analyzed.
In the development of cooling lubricants, Blaser Swisslube relies on Kistler's measurement expertise.
Applus IDIADA relies on DTI in-dummy technology from Kistler for Test Device for Human Occupant Restraint (THOR).
Road safety is a central topic in vehicle development. Through accurate measurements, Kistler helps increase the chance of survival in crashes.
Kistler makes progress in vehicle development possible
Kistler Sensor Correvit® SFII measures world record
Kistler sensors deliver a maximum in data quality under any conditions.
Kistler pressure sensors enabled the Rosetta space probe to fly for 6.4 billion kilometers.
Since the end of 2015 FC Basel is using Kistler force plates to reduce the dropout of young talents.
Kistler makes the difference in the crucial sports moments with its Performance Analysis System for Swimming.
Determination of Pump Efficiency with Kistler KiTorq Measuring Flange System
Piezoelectric Measurements with CompactRIO™
Quality Assurance in the Automotive Industry
How Brose improves the quality of its two-component production and automatically separates defective parts
The Kistler Group pursues a growth policy that is both ambitious and sustainable – and strategic acquisitions are one of its core elements. ‘Strategic’ means that Kistler deliberately selects companies which can achieve more together with Kistler than they ever could by continuing alone. The takeover of Dr. Staiger Mohilo & Co. GmbH in 2006 enabled Kistler to grow jointly with the acquired company...
After a ten-year voyage, the Rosetta space probe's Philae landing module finally touched down on the surface of comet ‘Chury’.
HEWI and its Customers Benefit from Cavity Pressure Technology
End-to-end process monitoring for critical medical moldings
Cavity pressure measurement eliminates short shots at Fischer GmbH & Co KG of Sinsheim/Germany
Max 25 MB