Case Studies

Case Study on HVDT FFT Analysis for Catcon Exhaust System Validation

This case study showcases how iASYS enabled a leading automotive manufacturer to validate its Catcon exhaust system using an advanced HVDT FFT analysis approach. Through the integration of the Orbit test automation system and automated FFT-based vibration analysis, the solution optimized Powertrain testing automation by improving accuracy, reducing test time, and ensuring reliable detection of resonance frequencies. By standardizing vibration testing and data analysis, iASYS helped the customer enhance NVH performance, prevent Catcon fatigue, and establish a repeatable, future-ready validation framework. This transformation not only improved automotive powertrain testing efficiency but also demonstrated the versatility of iASYS’s automotive testing solutions for engines and battery testing solutions for e- mobility.

Standardizing Vibration Analysis for Reliable Catcon Durability Validation

Use case: – Hot Vibration Durability Testing (HVDT) with FFT-based vibration analysis to identify resonance frequencies and critical vibration points in catalytic converter exhaust systems.

Goal: – To enable accurate, repeatable, and automated vibration analysis that improves fault detection, reduces test time, and ensures durable Catcon performance under real-world conditions.

Challenges:- Identifying dominant resonance frequencies in complex vibration data, synchronizing DAQ hardware with analysis tools, managing large FFT datasets, and enabling real-time, multi-domain analysis.

Solution:- iASYS implemented Orbit-E Host with integrated DAQ modules and analysis applications to automate HVDT execution, perform real-time FFT and order analysis, and streamline data logging and export.

Results :- Reduced test time and manual effort by 60–70%, increased fault detection efficiency by over 70%, improved NVH performance, and established a standardized FFT-based validation methodology for future durability projects.

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high-fidelity real-world load reproduction across a wide operating envelope.