Sebastian Feldmann and Matthias Wiedenmann, Aalen University, Germany

Conventional Pedelec Test Benches Fail To Replicate The Biomechanical Complexity Of Human Pedaling, Producing Damage Patterns That Differ From Field Failures. This Paper Presents The Proceedings Of The Development Of A Hardware-In-The-Loop Control Concept For A Biomechanic Pedelec Testbench Integrating A Digital Twin Of Both Rider And Environment, Finalized In The Year 2020. The Rider Model Generates Physiologically Realistic Torque Profiles Including Phase-Shifted Left-Right Actuation And Standing Pedaling With Radial Bottom Bracket Loads. Unlike Conventional Approaches Prescribing Fixed Trajectories, Vehicle Dynamics Emerge From Rider-Specimen-Environment Interaction. Validation Through 20,000 Km Endurance Testing Demonstrates Reproduction Of Field-Relevant Failure Modes Including Micro-Cracks And Pitting Unattainable With Traditional Protocols.

Biomechanical Control, Torque Actuation, Pedal Force Simulation, Real-time Control, E-Bike Testing