Design and Implementation of Novel Testing System for Intelligent Tire Development: From Bench to Road

Intelligent tire technology significantly enhances vehicle performance and driving safety by integrating sensors and electronics within the tire to facilitate the real-time monitoring of tire-road interactions. However, its testing and validation face challenges due to the absence of integrated bench and road testing frameworks. This paper introduces a novel, comprehensive testing system designed to support the full lifecycle development of intelligent tire technologies across both laboratory and real-world driving scenarios, focusing on accelerometer and strain-based sensing. Featuring a modular, distributed architecture, the system integrates an instrumented wheel equipped with multiple embedded tire sensors and a wheel force transducer (WFT), as well as vehicle motion and driving behavior sensors. A robust data acquisition platform based on NI CompactRIO supports multiple-channel high-precision sensing, with sampling rates of up to 50 kHz. The system ensures that data performance aligns with diverse intelligent tire sensing principles, supports a wide range of test parameters, and meets the distinct needs of each development stage. The testing system was applied and validated in a tire vertical load estimation study, which systematically explored and validated estimation methods using multiple accelerometers and PVDF sensors, compared sensor characteristics and estimation performance under different installation positions and sensor types, and culminated in a product-level assessment in road conditions. The experimental results confirmed the higher accuracy of accelerometers in vertical load estimation, validated the developed estimation algorithms and the intelligent tire product, and demonstrated the functionality and performance of the testing system. This work provides a versatile and reliable platform for advancing intelligent tire technologies, supporting both future research and industrial applications.