In today’s rapidly evolving automotive landscape, the journey from concept to road-ready vehicle is longer and more intricate than ever before. As vehicles grow smarter, cleaner, and more connected, the processes of testing and validation are being fundamentally reshaped. Stricter regulations, rising consumer expectations, and accelerating technological advancements are redefining how OEMs and suppliers approach quality, safety, and performance—turning automotive validation into both a strategic imperative and a competitive edge.
Testing Tomorrow’s Tech Today
As the automotive sector pivots swiftly towards electrification, ADAS, and autonomy, Gurgaon-headquartered Automotive Test Systems (ATS), which supports automotive regulatory requirements and consumer safety through state-of-the-art testing solutions, is positioning itself as a key enabler in India’s transition.
Speaking to Mobility Outlook, S Ramanathan, Managing Director of the company shared how it is expanding its infrastructure and partnerships to stay ahead of evolving vehicle technologies and regulatory demands.
The company is setting up what could be India's first private test facility for high-powered e-axles—capable of handling 400–450 kW motors with high torque loads—primarily for heavy-duty applications like electric trucks. Located in Bengaluru, the facility is slated to go live imminently, marking a significant milestone in India's vehicle testing landscape.
In parallel, ATS is ramping up its capabilities in ADAS validation. Collaborating with institutions like IIT Hyderabad, NATRAX in Indore, and GARC in Chennai, the company is working on test toolchains critical for ADAS as its adoption expands from passenger vehicles to commercial trucks starting next year.
Recognising that ADAS is intrinsically linked with vehicle dynamics, the company is taking a systems-level approach—addressing not just sensors and software, but also steering, braking, and powertrain interfaces, he said. It recently set up a dedicated lab in partnership with MdynamiX, equipped with state-of-the-art simulators including Driver-in-the-Loop (DIL) and Vehicle-in-the-Loop (VIL) systems—among the first such facilities in India accessible to both private and public stakeholders.
More than a developer, “ATS views itself as a testing and validation catalyst, offering infrastructure that enables manufacturers to align with emerging norms even before regulations take effect. Through collaborations with TUV Rheinland, GARC, and NATRAX, it supports customers end-to-end—from early validation to homologation readiness—ensuring India’s automotive ambitions are backed by world-class testing capabilities,” Ramanathan explained.
Digital Twins & Real-World Replays
According to Ramanathan, virtual validation plays a pivotal role in modern automotive development, in terms of compressing timelines and reducing cost—without compromising accuracy. As vehicles grow more complex, testing begins not on a track, but on a screen. Development starts with computer-aided engineering (CAE), where digital models—of components or entire systems—are built and tested in virtual environments that mimic real-world driving conditions. From bustling cities to rural roads, entire landscapes can be digitally recreated, he noted.
Initially, the process relies on Software-in-the-Loop (SiL) simulations, where electronic control units (ECUs)—like those for ADAS or ESP—are validated virtually. Engineers can run the software in these virtual ECUs to test full functionality before flashing it onto physical hardware, catching errors early and speeding up development cycles.
The next stage is Hardware-in-the-Loop (HiL), where physical components—such as a steering system—are tested in sync with virtual vehicle models. Real-world forces are fed back into the hardware using actuators, allowing engineers to observe system response in near-real driving conditions. Inputs can be generated by a simulated driver or real-world data captured from specific traffic scenarios using AI-enabled loggers.
Whether it's validating the dynamics of a steering system or simulating a camera response in a complex urban setting, ATS integrates all this seamlessly—bringing the digital and physical worlds together to ensure components perform flawlessly when they finally hit the road, he mentioned.
Putting EVs To Test
As electric vehicles (EVs) become mainstream, ensuring their reliability and endurance is crucial. ATS is at the forefront of this shift, offering end-to-end testing—from motor and battery evaluation to full vehicle durability simulations, Ramanathan said.
In its Bengaluru facility, ATS operates advanced electric motor test benches that assess everything from performance metrics to back-EMF (electromotive force - the voltage generated within the motor's armature windings, opposes the applied supply voltage and limits the armature current) characteristics. These setups allow engineers to integrate and fine-tune motor controllers, while also running Motor-in-the-Loop (MiL) and HiL simulations to evaluate motor behaviour in real vehicle conditions.
Battery testing is equally comprehensive. From charge-discharge cycles to safety-critical tests like nail penetration and drop impact, the company helps validate battery systems under extreme conditions.
To ensure vehicle durability, ATS employs electric actuators—supplied by eMpulse USA—that replicate real-world driving forces. Whether it’s simulating potholes or speed bumps, these systems apply repetitive load inputs to test structural integrity and predict component wear over time.
Safety Validation
Safety validation has entered a new era, and ATS is pushing the boundaries with advanced robotic testing solutions for ADAS systems. Leveraging small, Wi-Fi-controlled electric vehicles and high-precision robotic systems, the company recreates real-world driving scenarios—including potential accident situations—with exceptional accuracy.
Elaborating the procedure, Ramanathan said that using robotic platforms from AB Dynamics (UK) and STAHLE (Germany), the company enables fully autonomous test runs where even gear shifts and steering are executed robotically. Vehicles can be programmed to simulate unpredictable events—a pedestrian crossing abruptly, a sudden vehicle cut-in, or emergency braking—helping validate crucial ADAS features like lane-keeping assist and autonomous emergency braking.
These fully instrumented vehicles and dynamic targets allow repeatable, high-fidelity testing in controlled environments. By simulating real-world hazards in a safe, precise, and programmable manner, ATS ensures ADAS technologies are robust, reliable, and ready for deployment in the unpredictable world of real roads.
Through the seamless integration of virtual simulations and real-world testing, ATS delivers a comprehensive validation ecosystem—ensuring that vehicles, from fuel-agnostic drivetrains to advanced driver assistance systems, meet the highest standards of performance, safety, and reliability well before they take to the road, Ramanathan capped off.
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