Firmware Update: Data Logger, Test Drives

Firmware and diagnostics during test drives in commercial vehicle development

When commercial vehicles have reached a sufficient level of maturity, physical models are used to create prototype vehicles that are deployed in various test environments, routes and duty cycles. The aim of these test drives is to optimise driving behaviour, functions and calibrations under real operating conditions such as load, terrain, climate and usage profiles.

During the test drives, the ECUs and their firmware continue to undergo a continuous development process. New software and calibration versions must be regularly installed on the vehicles. At the same time, diagnostic data, error codes and measured values are read out from the vehicle, analysed and used for further adjustments. Especially in commercial vehicle programmes, multiple prototypes and long test phases result in large and evolving data sets. The vehicle is continuously monitored and iteratively optimised.

Key challenges for firmware updates during test drives

Frequent flashing of new firmware and calibration levels on commercial vehicle prototypes
Wireless access to diagnostic and flash functions while driving
Reading out error codes and diagnostic data during operation and test driving
Recording and evaluating large amounts of data via data loggers over long operating periods
Traceability of software versions and changes within the test fleet

DSA supports OEMs with the ODX front-loading tester PRODIS.OFT for firmware updates of commercial vehicle prototypes during test drives. In conjunction with WDI-2 as a wireless diagnostic and flash interface and DT-4 for continuous data acquisition while driving, update, diagnostic and analysis processes can be efficiently combined across different vehicles, routes and test scenarios..

PRODIS.OFT enables reproducible flash and test sequences, structured evaluation of diagnostic data and continuous monitoring of the vehicle status. This speeds up calibration adjustments and supports efficient, iterative optimisation commercial vehicle prototypes under real-world operating conditions.